Cementitious Coating for Structural Steel

Certified Cementitious Coating that expand under heat to insulate structural steel — up to 240 minutes of fire resistance, applied by our certified crews to UAE Civil Defense standard.

Approved

Approved by UAE Civil Defense and trusted by contractors

Mechanism

What it is and how it works

Cementitious fireproofing is a cement- or gypsum-based mortar sprayed onto structural steel. Unlike intumescent paint it does not react or expand — it protects by sheer thickness and very low thermal conductivity, holding the steel below the temperature at which it starts to lose strength.

  • Up to 240 minFire resistance achieved
  • 10–50 mmTypical applied thickness
  • 3 gradesLow, medium and high density

What it is

  • A sprayed mortar, not a paint A cement or gypsum binder with lightweight aggregate — vermiculite or perlite — and reinforcing fibres, applied wet and left to cure into a solid layer.
  • Passive protection with no reaction Nothing activates and nothing expands. The cured material simply resists the passage of heat, from the first minute of the fire to the last.
  • Built for concealed steel The finish is textured and utilitarian, which suits ceiling voids, risers, plant rooms and any structure that sits behind cladding.

How it protects

  • Low thermal conductivity Lightweight aggregate traps air throughout the layer. Heat moves through it slowly, so the steel behind heats slowly.
  • Moisture release Water held in the matrix absorbs heat as it drives off, suppressing the steel temperature through the early stage of a fire.
  • Thickness does the work The rating is a direct function of applied thickness against the section factor of the member — more steel surface per unit mass means more material.
  • It stays where it is put Reinforcing fibres and tested bond strength keep the layer attached under fire, vibration and site impact.

Specification

Fire ratings and coating thickness

Fire rating Typically required in Relative applied thickness
60minutes Warehouses and single-storey industrial frames Lowest
90minutes Multi-storey commercial buildings and car parks Moderate
120minutes High-rise cores, hospitals and schools High
180minutes Transfer structures and plant rooms Very high
240minutes Petrochemical and engineered process structures Maximum

Thickness shown is relative, not a specification. Applied thickness is set by the section factor of each member and the critical steel temperature, read from the certified thickness schedule of the tested system — fire ratings come from ASTM E119 / UL 263 or EN 13381-4, not from the bond-strength tests. Send us your steel schedule and we will return the thickness per member.

Range

Systems we apply

On site

How we apply it

  1. Step 01

    Surface preparation

    • Steel clean and dry, mill scale and loose rust removed
    • Primer must be one the system has been tested with
    • Bonding agent or metal lath where the tested design calls for it
  2. Step 02

    Mixing

    • Wet-mix or dry-mix according to the system
    • Water ratio controlled — over-watering cuts density and bond strength
  3. Step 03

    Spray application

    • Pump-applied in successive passes to build the specified thickness
    • Corners, cleats and connections worked by hand
  4. Step 04

    Thickness and density

    • Thickness measured to ASTM E605 across each member
    • Density and bond verified against the tested design
  5. Step 05

    Curing and protection

    • Protected from rain, frost and impact while curing
    • Any damage repaired before handover and inspection

Each stage carries a hold point — work does not proceed until the previous stage is signed off. Thickness and density are recorded member by member and issued as an inspection report for Civil Defense submission.

Applications

Where Cementitious Coating is used

Cementitious fireproofing is used as passive fire protection on structural steel — beams, columns and connections — to delay structural collapse and hold escape routes open during a fire.

Cementitious fireproofing is the system of choice wherever structural steel needs a high fire rating and physical durability, and the finish will not be on show.

Structures and surfaces

  • Structural steel Beams, columns, bracing and connections carrying load in commercial and industrial frames.
  • Metal decking and soffits Composite floor soffits and profiled decking protected from below.
  • Concrete elements Reinforced concrete where the cover to the rebar needs supplementing.
  • Transfer structures Heavy transfer beams and trusses, where long durations are specified.

Industries and buildings

  • Industrial and process plant Refineries, power stations and manufacturing facilities needing 180 to 240 minutes.
  • Commercial buildings Concealed steel above ceilings, in risers and in plant rooms of offices and hotels.
  • Infrastructure Tunnels, car parks and transit structures, where durability matters as much as the rating.

Portfolio

Recent fireproofing work

A record of steel protected, inspections passed, and deadlines met across the Emirates.

Why us

Why contractors specify Ibtikar

  • Certified applicators

    Manufacturer-trained crews using our own spray equipment. The people on your site are ours, not subcontracted labour.

  • UAE and GCC

    Offices in Dubai, Abu Dhabi, Sharjah, Ras Al Khaimah and Umm Al Quwain — plus a Saudi operation, so we mobilise across the region without travel loading the price.

  • Approvals already in place

    Dubai, Abu Dhabi and Sharjah Civil Defence, plus ADNOC, CMW, PGC and Tawazun. See our approvals

  • Documented handover

    Dry film thickness recorded member by member, issued with material certificates and test reports, ready for authority submission.

FAQs

Answers on curing time, retrofits, documentation, and Civil Defense approval scope.

  • Yes, but it requires a protective topcoat to withstand weathering.
  • Water-based intumescent paints are low in VOCs and environmentally friendly.
  • Intumescent paint is a fire-resistant coating that swells when exposed to high temperatures, forming an insulating char layer that protects the underlying material from fire. It is commonly used on structural steel to maintain its integrity during a fire.
  • Intumescent paints are used on structural steel, wood, and other substrates in commercial, industrial, and residential buildings to provide fire protection.
  • Intumescent paints are lightweight, aesthetically pleasing, and provide long-lasting fire protection without adding significant bulk to structures.