Emirates pilot training expansion Fireproofing Al Garhoud, Dubai: Ibtikar applied Hempafire Pro 315 Solvent Intumescent Coating across 1,200 m² of structural steel to achieve a 120-Minutes fire rating, completed in March 2024.
Project Type Solvent Intumescent Coating
LocationAl Garhoud, Dubai
Area1,200 m²
Fire Rating120-Minutes
MaterialHempafire Pro 315
CompletionMarch 2024
The Emirates pilot training expansion is an Solvent Intumescent Coating project located in Al Garhoud, Dubai, UAE, where Ibtikar delivered professional structural steel fireproofing and passive fire protection solutions for Emirates Airlines. Covering approximately 1,200 m² of steelwork, the project was completed in March 2024 using Hempafire Pro 315 via airless spray fireproofing, selected to provide reliable protection in accordance with the specified 120-Minutes fire-resistance requirement.
Ibtikar’s scope included the application of the fireproofing system to primary and secondary structural steel members such as columns, beams, connections, and other critical steelwork. Our team strictly managed surface preparation, primer compatibility, coating application, and dry film thickness (DFT) verification at every stage. All fireproofing activities were executed in accordance with approved project requirements, manufacturer recommendations, and applicable UAE passive fire protection and Civil Defense requirements.
Through controlled application and systematic quality inspections, Ibtikar delivered a durable, fully compliant, and properly documented fireproofing system engineered to preserve the structural integrity of the building during fire exposure.
Explore more Ibtikar projects or contact our team to learn about our structural steel fireproofing, intumescent coating, and passive fire protection services across the UAE and GCC.
Primary and secondary structural steel members — columns, beams and connections — are protected against fire exposure to maintain load-bearing capacity for the required fire-resistance period, in line with the project's passive fire protection strategy.
A reactive intumescent coating system is applied to prepared steel surfaces. Under fire exposure, the coating expands to form an insulating char layer that slows the rate of heat transfer to the substrate, delaying loss of structural strength.
Dry film thickness (DFT) is measured throughout application against the specified coating build-up. Each stage is documented with inspection records, culminating in a final walk-through and sign-off prior to handover.
A layered coating system builds up fire resistance on the steel substrate. Products and film thicknesses are project-specific — see the technical documents below.
Prepared structural steel, cleaned and profiled to the specified surface standard prior to coating.
A compatible primer system protects the substrate and provides adhesion for the intumescent coating. Thickness per specification.
The reactive fireproofing coating, applied to the dry film thickness specified for the project's required fire-resistance rating, from 60 up to 120 minutes. Under fire exposure it expands to form an insulating char layer.
A protective topcoat is applied where specified, for UV resistance, weathering or a decorative finish.
Each layer depends on the one beneath it — primer adhesion determines how well the intumescent coating bonds to the steel, and the specified dry film thickness is what delivers the certified fire-resistance rating. Products and film thicknesses are project-specific: always confirm against the data sheets and the approved project specification before application.
Surface preparation and primer sign-off come first for a reason — an intumescent coating applied over contaminated or incorrectly primed steel can fail to adhere, and that is found out long after the steel has been closed in. The DFT records are the evidence: the fire-resistance rating is only as good as the film thickness actually achieved on each member, which is why the readings are taken point by point and kept with the handover file.
1,200 m²Protected Area
120-MinutesRequired Fire Rating
Solvent Intumescent Coating Coating System
CompletedProject Status
Approved 100%Inspection Status
Fire Proofing Material
CE-Marked Passive Fire Protection Optimised for R30/R60 Steel Sections. High-build single-coat application up to 1,600 µm DFT, backed by Certifire and Applus+ approvals.
Source: Hempafire Pro 315 Product Data Sheet (Hempel), cross-checked against a UK distributor listing for pack size. Rated up to 90 minutes overall — the data sheet describes it as optimised for R30/R60 fire resistance, with R90 achievable depending on the specific project's steel section and loading.
A temperature-banded overcoating interval table was not published in the data sheet checked — it states drying/overcoating details are covered in separate Hempel Application Instructions. Confirm exact recoat windows with Hempel before specifying.
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Fire Proofing Material
Tough, UV-Stable Finish Coat With a 4-Hour Handling Time. Two-component polyurethane designed to speed up recoat schedules over primed or fireproofed steel.
Source: Hempathane Fast Dry 55750 Product Data Sheet (Hempel), cross-checked against a UK distributor listing for pack size. This is a two-component polyurethane finish topcoat, not a fire-resistance product — it is typically applied over a certified fireproofing or anti-corrosive system rather than tested for fire resistance itself.
Maximum service temperature is 120°C (248°F) under dry exposure. Figures are at 20°C (68°F) — confirm with Hempel for other site conditions.
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A track record of fireproofing delivered across the UAE's industrial, commercial and infrastructure sectors.
Dedicated focus on passive fire protection and intumescent coating systems for structural steel.
Documented dry film thickness inspection and quality checks at every stage, issued as a signed inspection report.
Technical guidance from specification and system selection through to inspection, handover and authority submission.
What type of fireproofing was used on this project?
This project used a Hempafire Pro 315 intumescent coating system, specified to deliver a 120-Minutes fire-resistance rating on exposed structural steel.
How is intumescent coating applied to structural steel?
Steel is first cleaned and primed, then the intumescent coating is applied in controlled passes — by spray, brush or roller depending on the product and site conditions — to build up the specified dry film thickness.
How is the required fire-resistance rating determined?
The required rating is set by the project’s fire strategy and applicable building regulations, based on factors such as building use, height and occupancy. This determines the fire-resistance period the steelwork must achieve.
How is dry film thickness (DFT) inspected?
DFT is measured using a calibrated gauge at multiple points across each member and recorded against the thickness specified for the required fire rating, with results documented for inspection.
What factors affect intumescent coating thickness?
Coating thickness depends on the steel member’s section factor (Hp/A), the required fire-resistance period, and the specific product’s certified performance data.
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