Optimizing Ammonium Polyphosphate–Acrylic Intumescent Coatings with Sustainable Fillers for Naval Fire Safety

This study explores the potential of natural and recycled materials to enhance the fire behavior of eco-friendly intumescent coatings, compared to a traditional ammonium polyphosphate (APP)-based one. To achieve this, cork, halloysite clay, and recycled glass were evaluated as natural fillers and sustainable components within the coating formulation. The aim was to reduce the reliance on synthetic materials and minimize the environmental impact while maintaining fire performance. Fire exposure tests were conducted to assess the in situ char formation and its relationship to the heat source and char foaming process. The results highlighted that all functionalized coatings exhibited suitable intumescent behavior. The best results were evidenced by cork-filled coating that evidenced an intumescent capacity about 40% higher than the traditional ammonium polyphosphate (APP)-based one. This provided valuable insights into the coating's real-time response to fire, determining its suitability for various fire-resistant applications.