The effects of zirconium silicate as a fire retardant reinforcement in the mixture of expandable graphite (EG), ammonium poly phosphate (APP), melamine, boric acid, bisphenol A epoxy resin BE-188(BPA) and ACR Hardener H-2310 polyamide amine are presented. Different formulations were developed to study the effects of zirconium silicate on char expansion, heat shielding, char morphology and composition after fire test. The coatings were tested at 950 °C using Bunsen burner for 1 h. The results show state that the zirconium silicate enhanced fire protection performance of intumescent coating. The morphology of the char was studied by Field emission scanning electron microscope (FESEM) after furnace fire test. X-ray Diffraction (XRD) and Fourier transform infrared spectroscopy (FTIR) results showed the presence of graphite, borophosphate; boron oxide and boric acid in the char. Thermogravimetric analysis (TGA) showed that zirconium silicate enhanced residual weight of char. X-ray photoelectron spectroscopy (XPS) analysis showed that 5% zirconium silicate enhanced the carbon content up to 60.87% and lowered oxygen content to 28.09% in the residual char which proved helpful in improving the fire resistance performance of coating. Pyrolysis analysis confirmed that IF5-ZS releases less gaseous products concentration compared to IF-control coating.

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Flake graphite, melamine (Mel) and boric acid (B.A) were purchased from Sigma-Aldrich (M) Sdn Bhd. Malaysia. Ammonium poly phosphate (APP) was provided by Clariant (Malaysia) Sdn Bhd. Acetic acid, sulphuric acid, KMnO4, binder system bisphenol A epoxy resin BE-188 (BPA) and ACR Hardener H-2310 polyamide amine and Zirconium silicate (ZS) were purchased from Mc-Growth chemical Sdn Bhd. Malaysia. The Field emission scanning electron microscope (FESEM) micrograph of Zirconium silicate showed the particle size 22.27 um in Fig. 1. Structural steel A36M was supplied by TSA industries (Ipoh) Sdn. Bhd. Malaysia.

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Enhanced Fire Safety: Reduced Substrate Temperature: The inclusion of 5 wt% zirconium silicate in the IF5-ZS formulation significantly lowered the substrate temperature from 350 °C to 213 °C after 60 minutes of fire exposure. This substantial reduction in temperature enhances the safety and integrity of the underlying materials, providing better protection against fire.

Char Expansion: The zirconium silicate reinforced formulation exhibited a 24.00x increase in char expansion compared to the original coating thickness. This 345% higher expansion compared to the IF-control char indicates a superior ability to form a protective barrier, which is crucial for effective fire retardancy.

Chemical and Thermal Stability:XRD and FTIR analysis revealed the presence of beneficial compounds like boron oxide, borophosphate, graphite, and zirconium silicate, contributing to the material's fire resistance and structural integrity.

Safety and Protection: The significant reduction in substrate temperature and enhanced char formation directly translate to improved fire safety for buildings, vehicles, and other structures, reducing the risk of catastrophic damage and increasing occupant protection.

Cost-EffectivenessBy improving the efficiency of fire retardants, fewer materials might be required to achieve the desired level of fire protection, potentially reducing costs. The extended lifespan and enhanced protection can also result in lower maintenance and repair costs.

Innovation in Fire Retardant Systems:The successful incorporation of zirconium silicate opens new avenues for the development of advanced fire retardant materials. This can lead to further research and innovation in the field, driving the overall progress of fire safety technologies.

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The substrate temperature for each formulation after the fire test (Bunsen burner test) is illustrated in Fig. 2. The temperatures recorded after various time were as follows: IF1-ZS - 336 (30 min), 359 °C(60 min), IF2-ZS - 292 (30 min), 330 °C(60 min), IF3-ZS - 266 (30 min), 292 °C(60 min), IF4-ZS-204 (30 min), 249 °C(60 min) and IF5-ZS - 190 (30 min), 213 °C(60 min). For each formulation of zirconium silicate reinforced in controlled formulation IF-control, the substrate temperature (°C) was reduced by: 8 (1 wt% ZS), 37 (2 wt% ZS), 75 (3 wt% ZS), 118 (4 wt% ZS) and 154 °C(5 wt% ZS). It was noted that the addition of zirconium silicate to IF-control enhanced the char expansion compared to unreinforced or controlled formulation IF-control. The results of char expansion measured (in X times) were: 4.70 (IF-control), 5.40 (IF1-ZS), 7.30 (IF2-ZS), 10.45 (IF3-ZS), 18.75 (IF4-ZS) and 24.00 times (IF5-ZS) from the original coating thickness on the substrate are illustrated in Fig. 3. The best char expansion in this research work was 24.00 times obtained from IF5-ZS coating and it is 334 percent higher compared to the controlled formulation, IF-control coating. IF5-ZS showed excellent results in char expansion and it was able to retain the substrate temperature as low as 213 °C after 60 min of exposure to the fire at 850 °C.

Increasing Fire Safety Regulations:Governments and regulatory bodies worldwide are continuously tightening fire safety regulations, particularly in construction, transportation, and manufacturing sectors. Compliance with these regulations often necessitates the use of advanced fireproofing materials, driving market demand.

Growth in Construction and Infrastructure:The construction industry is one of the largest consumers of fireproofing materials. As urbanization and infrastructure development continue to expand globally, especially in emerging economies, the demand for effective fire retardant systems will increase.

Advancements in Material Science:Innovations such as the use of nano-clay composites and zirconium-based additives in fire retardants enhance the effectiveness of these materials. These advancements attract industries that require high-performance fireproofing solutions, such as aerospace, automotive, and electronics.

Awareness of Fire Hazards:There is growing awareness about the risks associated with fire hazards in residential, commercial, and industrial settings. This awareness leads to increased adoption of fireproofing solutions to protect assets and lives.

Sustainability and Environmental Impact:The development of fire retardants that are not only effective but also environmentally friendly is a growing trend. Materials like zirconium silicate that provide high-temperature resistance without harmful emissions align with sustainability goals, appealing to eco-conscious consumers and companies.