Assessing the performance of intumescent coatings using bench‐scaled cone calorimeter and finite difference simulations

A method was developed to assess the heat insulation performance of intumescent coatings. The method consists of temperature measurements using the bench‐scaled experimental set‐up of a cone calorimeter and finite difference simulation to calculate the effective thermal conductivity dependent on time/temperature. This simulation procedure was also adapted to the small scale test furnace, in which the standard time–temperature curve is applied to a larger sample and thus which provides results relevant for approval. Investigations on temperature and calculated effective thermal conduction were performed on intumescent coatings in both experimental set‐ups using various coating thicknesses. The results correspond to each other as well as showing the limits of transferability between both fire tests. It is shown that bench‐scaled cone calorimeter tests are a valuable tool for assessing and predicting the performance of intumescent coatings in larger tests relevant for approval. The correlation fails for processes at surface temperatures above 750°C, which are not reached in the cone calorimeter, but are attained in the small scale furnace set‐up. Copyright © 2006 John Wiley & Sons, Ltd.