Fireproofing Composition Water Repellency and Strength
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Solution Overview
Problem
Spray applied fire resistant materials (SFRMs) have low in-place density and porosity, leading to water and chemical intrusion, which damages the underlying substrate and reduces their fire-resistant properties, and existing additives like superplasticizers and silica fumes can decrease strength and adhesion when used in SFRMs.
Innovation Solution
A fireproofing composition comprising a binder, latex polymer, and silicone, which is applied as a slurry that foams and is sprayed onto substrates, enhancing water repellency and physical strength by at least 10% and 5% respectively, compared to compositions without these additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water repellent additives are incorporated into SFRMs, then water resistance improves, but application methodology compatibility deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the SFRM composition by incorporating specific water repellent additives (silanes, siloxanes, or wax emulsions) at controlled concentrations (0.1-5% by weight). This allows the material to achieve enhanced water resistance while maintaining compatibility with spray application methodology through proper formulation adjustments.
2Ease of operation
If superplasticizer is added to SFRM, then workability improves, but physical strength decreases
Solution Approach 1:
The patent adjusts the water-to-cement ratio and superplasticizer dosage parameters to achieve optimal workability without compromising strength. By controlling these parameters within specific ranges, the formulation maintains both sprayability and structural integrity after curing.
3Strength
If silica fume filler is added to SFRM, then physical strength increases, but set time decreases and adhesion reduces
Solution Approach 1:
The patent controls the silica fume content within specific limits (5-20% by weight of cement) and adjusts water dosage accordingly. This parameter control ensures that while physical strength is enhanced, the set time remains acceptable for spray application and adhesion properties are maintained through proper mix design.
4Strength
If Class C fly ash is added to SFRM, then shrinkage reduces and physical strength increases, but adhesion decreases
Solution Approach 1:
The patent limits Class C fly ash content to 10-30% by weight of cement and adjusts the water-to-cement ratio to compensate for its effects. This controlled formulation approach maintains adhesion to the steel substrate while achieving the benefits of reduced shrinkage and enhanced strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition significantly improves water repellency and physical strength of SFRMs, reducing water penetration and maintaining structural integrity while preventing damage from moisture and chemicals, thereby enhancing the fire-resistant properties of the substrate.
Implementation Method 1
introducing an amount of gas into the slurry in the length of hose at a flow rate and pressure sufficient to cause the slurry to foam
Implementation Method 2
The fireproofing composition contains a binder, latex polymer(s), at least one silicone and water. The resulting compositions surprisingly exhibit reduced water permeability
Data Source
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AI summary
The present disclosure relates to water repellent coating compositions, kits and methods of applying the same, for use as fireproofing materials. The water repellent spray applied fire resistant material contains latex polymer(s), such as a vinyl acetate/ethylene copolymer, a silicone, such as methoxy-functional polysiloxane, or both to reduce or eliminate the effect of water damage to the SFRM and underlying substrate.