STEELPROST

Current methods to provide fire protection of light steel structures include intumescent paints which may be applied on-site or off-site using brushes or spray guns. Common fire resistance time demands are 30, 60, 90, and less commonly 120 minutes, depending on specific applications and treatment required by national legislation (requiring public buildings higher protection than for example industrial warehouses). Such treatments are generally achieved through the preparation of the surface by grit/shot blasting, followed by the application of a primer, and followed by the application of several layers of intumescent coatings. This methodology has a number of drawbacks for a large community of SMEs, including:
- Drying times of intumescent coatings are very long, resulting in very high cost associated to labour (as several layers are required), site disruption (when made on-site in the construction place), and space required for painting (if made off-site prior to sue in the construction site).
- A significant number of cases of SMEs are breaching current legislation as a consequence of uneven application of paint layers, application of fewer layers than required (or no layers in some cases). This shows an ineffective application procedure in some cases, which also results in a considerable waste of paint during the application.
These issues have shown a decrease in the demand of steel in the construction industry, which has been progressively replaced by traditional concrete as a consequence of the overall elevated costs of using steel, affecting a large number of European SMEs in the sector.
The STEELPROST project aims to provide a solution to current surface treatment limitations, by developing a second generation of fire-protective coatings that are: easier to paint on, covering a larger area faster and faster drying. This will be achieved through three core innovations:
- Development of low cost fire-retardant agents using novel tin-based technology, based on non-toxic halogen-free additives (such as zinc stannates, zinc borates, etc.).
- Combination the above fire retardant agents within further additives to confer the paint outstanding adhesion to the metal, and increase abrasion and wear resistance properties (to enable transportation free of damage of steel material after been treated off-site).
- Design and optimisation of a procedure for fast curing of the coating, which can be integrated in the production line of steel structural components, using existing heating source technologies such as infra-red (IR).
The STEELPROST technology is expected to reduce steelwork treatment cost in constructional projects on a 25% for on-site applications and 50% for off-site application. The novel technology will also enable a recovery of the steel market share in construction and provide small coating formulators with an opportunity to compete within their sector.

The overall objective of the project is to develop the STEELPROST paint technology to enable European SME paint manufacturers to recapture a percentage of the European market from imports and enable European SME steel structure manufacturers to recapture roughly a 15% of the market back in 5 years from concrete systems (lost a 30% over the last 10 years), to get to a market share of 35%. To achieve this we will develop a paint technology that would result in total installation (materials, labour costs and other direct costs including machinery amortisation) savings of 25% for on-site application and 45% for the off-site approach by being easier to paint on, covering a larger area faster and by avoiding the need for several coats and drying at a much faster rate.

The scientific objectives are:

- To develop innovative formulations of fire resistant non toxic tin based additives, such zinc hydroxystannate (ZHS), zinc stannate (ZS)
- To enhance the comprehension on the way these functional additives may be used, either in their own physical state (as ultrafine or nano-particulates) or in the form of coated fillers.
- To generate new scientific knowledge on the chemical interaction between fillers, nanoparticles to allow excellent adhesion of the coating and additives for fire resistance, and the mechanical properties (abrasive behaviour) of such surfaces.
- To increase understanding of physical methods and/or technologies for reduction of drying times of coatings and application of multifunctional (primer, topcoat and finishing).

The technological objectives are:

(A) To develop a low cost novel coating with the following properties:
- Can produce a coverage performance of 2m2/l for the on-site manual application and 2.5m2/l for the off-site application
- Fire-resistance able with comply with the grades R90 to R120 and as specified in the standard for fire tests on building materials and structures
- Impact strength to a value of 0.08 kg m/cm according to ASTM D-256.
- Smoke-suppressant properties, 50% lower smoke rating (as measured by optical density) than current coating products, and with 50% reduced emissions of toxic gases, including carbon monoxide
- Good anti-scratch and impact resistance at transport and installation, to enable off-site application, measured as a superficial hardness of maximum 200HV30.
- Very good adhesion to regular ferritic steel substrates
- Water-based solvent or volatile organoclorhide (VOC) content below 50 g/l.

(B) To develop a technology which is able to rapidly and easily apply and dry the coating and can be integrated in the production line of steel structural components:
- Requiring only one application coat
- Drying and hardening in less than 12 hours for on-site case and less than 2 hours for the off-site

fire retardant
intumescent coating
steel structure
Flame retardant
Zinc Stannate
Nano-clay
smoke suppression

The consortium is mainly constituted by four core groups:

- Independent European Association of SMEs: one of the largest Organization at global level concerned with construction steel structures. Role: it will be the coordinator of STEELPROST and will be in charge of ensuring that technical specifications fit SMEs needs and steering project activities to ensure expected ouputs and benefits to their associated companies.

- Research and Technological Development performers (RTD performers): RTDs have been chosen among the most competent and recognized in Europe to ensure a proper delivery of the proposed solution as set in the scientific and technological objectives. Both partners have extensive experience in delivering innovative technologies to enhance competitiveness of SMEs, along Europe.
RTD1 (Spain): Non-profit Research Organization with sound expertise on materials, polymers, coatings, process engineering, and mechatronics. Role: Development of a fast-drying coating and industrialisation of the process.
RTD2 (UK): RTD centre specialised on fire retardant chemistry, polymer formulation and fire testing methodology development of fire-resistance intumescent coatings fire tests. Role: Characterisation of novel fire-resistant coatings, testing (fire, impact, scratch and corrosion resistance).
RTD3 (UK): Development of nano-particles to increase adhesion and mechanical resistance properties of the coatings. Role: Liaise with RTD2 to formulate suitable nano-additives to provide mechanical resistant properties to the coating to be developed.

- Small and Medium Enterprises (SMEs): They constitute the supply chain. Constituted by 3 companies representing the complete supply chain for the supply of the STEELPROST product to the AG Members.
- SME1 (IT): Leading company in providing technical solutions to the construction industry, including the application of fire-protective coatings.
- SME2 (GE): leading specialists in the field of surface treatment, with a relevant position in the fields paint spray guns, automatic spray painting machines and spraying and drying booths.
- SME3 (FR): French company specialized in industrial applications of the infra-red radiation. Their main object is trading infrared heaters through textile machinery builders, paints and varnishes lines manufacturers.
- SME4: constructional steelwork manufacturer.
- SME5: designing and engineering company.