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<p>The widespread use of modern steel structures is challenged by a significant loss of load-bearing capacity at elevated temperatures, particularly above 550–600&#xa0;°C. Intumescent fireproof coatings (IFCs) are an effective protection method. While inorganic coatings such as sodium silicate (SS) offer advantages of non-combustibility and thermal stability, their application is limited by high water solubility and fragile char. This study addresses these limitations by constructing an organic–inorganic hybrid system through in-situ modification of SS with a synthesized polyurethane (PU) prepolymer, facilitated by hydrogen bonding. A flame retardant system comprising melamine (MEL) and piperazine pyrophosphate (PAPP) was incorporated to synergistically enhance performance. The resulting coatings were systematically evaluated for their flame retardancy, water resistance, and formed char structure. It achieved a protection time of 58.6&#xa0;min, exhibited a micron-scale synaptic surface after curing and showed a mass loss of only 12% after 48&#xa0;h of water immersion. This work provides a viable strategy for developing high-performance IFCs with enhanced durability, showing great potential for practical industrial applications.</p> Graphical abstract <p></p>

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A novel sodium silicate-polyurethane hybrid from in-situ polymerization for intumescent fireproof coatings

  • 期刊论文

  • 发表日期：

    2026年4月1日

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  • Zhouya Zhang,
  • Xiaowei Su,
  • Wanen Li,
  • Yujia Wang,
  • Hongfei Li,
  • Shuheng Wang,
  • Xiaoyu Gu,
  • Jun Sun,
  • Sheng Zhang

摘要

The widespread use of modern steel structures is challenged by a significant loss of load-bearing capacity at elevated temperatures, particularly above 550–600 °C. Intumescent fireproof coatings (IFCs) are an effective protection method. While inorganic coatings such as sodium silicate (SS) offer advantages of non-combustibility and thermal stability, their application is limited by high water solubility and fragile char. This study addresses these limitations by constructing an organic–inorganic hybrid system through in-situ modification of SS with a synthesized polyurethane (PU) prepolymer, facilitated by hydrogen bonding. A flame retardant system comprising melamine (MEL) and piperazine pyrophosphate (PAPP) was incorporated to synergistically enhance performance. The resulting coatings were systematically evaluated for their flame retardancy, water resistance, and formed char structure. It achieved a protection time of 58.6 min, exhibited a micron-scale synaptic surface after curing and showed a mass loss of only 12% after 48 h of water immersion. This work provides a viable strategy for developing high-performance IFCs with enhanced durability, showing great potential for practical industrial applications.

Graphical abstract