Abstract: A unique intumescent composition containing a high weight % solids content of approximately 58%, from a particular mix of solid ingredients including a mineral filler, ceramic fibers, a binder, an expandable graphite, and a solid thickener. The solids are mixed in approximately a 42% liquid carrier solution comprising water, a defoamer, and a dispersant. The resulting intumescent composition is an inert, inorganic, intumescent coating that can be coated or laminated onto paper, wood and/or OSB to act as a fire shield. The product also can also be coated onto steel, aluminum foil, kraft paper, fiberglass or any combination of the foregoing to provide a fire-shielding facer for manufactured insulation boards, sheetrock, polyisocyanurate boards, polystyrene boards, or other construction boards. The product provides excellent structural support to the resultant char after a fire in order to further protect the substrate from deterioration.

Abstract: An intumescent coating composition, coating process for structural panels, and a method of installing the coated and notched structural panels that decreases the fire safety (FSR) rating effectively to meet applicable fire safety approval standards for commercial structures. The intumescent composition comprises sodium silicate, cenospheres, water, and sodium tetradecyl sulfate, and may further comprise either magnesium hydroxide, zinc borate, and amorphous silica, or mineral fibers. The intumescent composition may be applied to wood products, including lumber and any manufactured wood products such as wood structural panels (plywood, OSB, or composite panels), for protection against high temperatures and long periods of heat exposure. The coated panels are notched about their peripheral edges. During installation, the notched, coated panels are installed side-by-side to the framing so that the panels' notches form widened recessed seams, and the seams are then filled with a fire resistant caulk.