Intumescent flame-retardant coating (IFRC) provides a protective barrier to heat and mass transfer for the most efficient utilization of a wide variety of passive fire protection systems at the recent development. This article highlights the fire-resistance, physical, chemical, mechanical, and thermal properties of the IFRC using a Bunsen burner, furnace, Scanning Electron Microscope, freeze-thaw stability test, Instron Micro Tester, and thermogravimetric analysis (TGA) test. The five IFRC formulations were mixed with vermiculite and perlite for the fabrication of fire-resistant timber door prototypes in this research project. Additionally, the best fire-resistance performance of the fire-rated door prototype was selected and compared with a commercial prototype under the fire endurance test. An inventive fire-rated door prototype (P2), with a low density of 636.45 kg/m3, showed an outstanding fire-resistance rating performance, resulting in temperature reduction by up to 54.9 °C, as compared with that of the commercial prototype. Significantly, a novel fire-rated timber door prototype with the addition of formulating intumescent coating has proven to be efficient in preventing fires and maintaining its integrity by surviving a fire resistance period of 2 h.

Intumescent flame-retardant binder (IFRB) offers a great advancement for the most efficient utilization of a wide variety of passive fire safety system at the recent development. This article highlights the fire-resistance and thermal properties of the IFRB using Bunsen burner and thermogravimetric analysis. The five IFRB formulations were mixed with vermiculite and perlite for the fabrication of fire-resistant timber door prototypes. Additionally, the fire rated door prototypes were compared under 2 hours fire test. The prototype (P2), with a low density of 637 kg/m3 showed the superlative fire-resistance rating performance, resulting in temperature reduction by up to 58.9 °C, as compared with that of prototype (P1). Significantly, an innovative fire rated timber door prototype with the addition of formulating intumescent binder has verified to be effective in stopping fires and maintaining its integrity by surviving a fire resistance period of 2 hours.