How Fire Testing Standards Put Structural Steel to the Test

Navigating fire code complexity

Navigating fire testing standards and certification set by different organizations and referenced by building codes can be challenging. Different regions require specific fire ratings, and these evolve as materials and building designs advance.

That complexity underscores why rigorous testing and certification remain important. Substituting test data or assuming equivalence between standards is unacceptable. Ensuring that coatings have been tested to the correct regional standard, and that the test applies to the correct structural configuration, is essential.

Inside fire testing protocols

To test PFP coating performance, structural sections are coated and placed in furnaces that follow temperature curves representing how fires progress over time. For most buildings, tests use the cellulosic fire curve, which simulates the gradual heat rise from the burning of cellulose-containing items such as furniture, wood, and textiles.

Tests conducted under restrained and unrestrained conditions simulate how steel behaves when it can or cannot expand freely when part of a structure. Tests also account for different shapes, sizes and assemblies of steel sections, since heating rates vary between freestanding beams and floor or ceiling configurations. Results from these tests define the fire rating, which is a measure of how long a system can protect steel before failure and typically ranges from 30 to 120 minutes.

In most cases, PFP coatings are tested at independent laboratories that follow the procedures established by standards organizations like UL, ISO, and ASTM. Every aspect of the testing environment must be tightly controlled, from furnace temperatures to load conditions.

Evaluating coating suppliers

Even among internationally recognized fire standards, there is no centralized authority that oversees fire testing procedures and certification. The responsibility for quality and accuracy lies with the organizations who manufacture PFP coatings and conduct fire testing. Still, all stakeholders across the value chain play a role in fire safety verification.

For building owners and contractors, working with trusted partners proves important. Suppliers should have documentation that outlines which standards were used in testing, where the testing was performed, and the relevant assessment reports. Contractors should check that the fire ratings apply to the same structural configurations used in the building. Verifying product certifications and testing results with suppliers can help ensure that PFP coatings are applied properly.

Intumescent coatings at work

Intumescent coatings have proven their effectiveness across diverse, demanding environments from train stations and stadiums to industrial and civic projects. In one major airport expansion, an intumescent PFP coating was applied to an intricate double-layer truss roof, providing fire resistance with a smooth, aesthetic finish. In a fast-tracked industrial facility, the intumescent coating allowed steel sections to be fabricated, coated, and shipped on schedule without sacrificing performance.

These examples demonstrate how tested, well-engineered intumescent systems can provide fire protection and support construction efficiency.

Time-intensive and expensive fire testing often requires hundreds of steel sections and configurations. A PFP coating that fails in practice, however, can lead to project delays, rework, failed inspections, and, in the worst case, loss of life.

By insisting on tested and certified PFP systems, owners and contractors not only meet regulatory requirements but also demonstrate leadership in building resilience. Confidence in fire safety begins with confidence in testing.

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This article was originally published on Buildings.com, an EndeavorB2B sister publication.