Comparative Study of Fire Resistance and Anti-Ageing Properties of Intumescent Fire-Retardant Coatings Reinforced with Conch Shell Bio-Filler

Conch shell bio-filler (CSBF) was prepared by washing, ultrasonicating, and pulverizing of conch shells and then was applied in waterborne intumescent fire-retardant coatings. The influence of CSBF on fire resistance and anti-ageing properties of intumescent fire-retardant coatings were studied by using different analytical methods. The fire protection and smoke density tests showed that when the mass fraction of CSBF was 3%, the resulting FRC3 coating had the optimum synergistic flame-retardant and smoke-suppression effects concomitant with a flame-spread rating of 10.7, equilibrium backside temperature of 152.4 °C at 900 s, and smoke-density rating value of 10.4%, which were attributed to the establishment of a more dense and stable intumescent char layer against heat and mass transfer. Thermogravimetric analysis indicated that the presence of CSBF increased the thermal stability and char-forming performance of the coatings, and the char residue of FRC3 rose to 34.6% at 800 °C from 28.6% of FRC0 without CSBF. The accelerated ageing test suggested that the incorporation of CSBF reduced the migration and decomposition of the flame retardants and the yellowing, blistering, and powdering phenomenon, thus improving the structural stability of the coating, resulting in better durability of flame retardancy and smoke-suppression performance.