Abu Dhabi Future School Phase 10 Fireproofing Al Shamkha, Abu Dhabi: Ibtikar applied Nullifire SC804 Intumescent Coating across 3,500 m² of structural steel to achieve a 120-Minute fire rating, completed in March 2024.
Project Type Intumescent Coating
LocationAl Shamkha, Abu Dhabi
Area3,500 m²
Fire Rating120-Minute
MaterialNullifire SC804
CompletionMarch 2024
The Abu Dhabi Future School Phase 10 is an Intumescent Coating project located in Al Shamkha, Abu Dhabi, UAE, where Ibtikar delivered professional structural steel fireproofing and passive fire protection solutions for Abu Dhabi Department of Education and Knowledge. Covering approximately 3,500 m² of steelwork, the project was completed in March 2024 using Nullifire SC804 via airless spray fireproofing, selected to provide reliable protection in accordance with the specified 120-Minute 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.
3,500 m²Protected Area
120-MinuteRequired Fire Rating
Intumescent Coating Coating System
CompletedProject Status
Approved 100%Inspection Status
Fire Proofing Material
BS 476 & Certifire CF5929 Certified Passive Fire Protection for Structural Steelwork. High-build formulation optimized for 90-minute fire resistance, with a limited 120-minute option available.
Source: Nullifire SC804 Technical Data Sheet (Tremco CPG). Rating is optimised for 90 minutes — the 120-minute figure is a limited option, not the primary rating. No single max-DFT figure is published, so coverage is shown at its theoretical reference thickness instead.
Recommended overcoat time is 16 hours. Drying times also vary by temperature (e.g. 1.0mm WFT takes 6h at 10°C, 3h at 30°C) — the figures above are the 20°C reference column.
All four links are placeholders — point them at your own hosted files once confirmed.
Fire Proofing Material
Fast-Drying Two-Component Coating for Direct-to-Metal Application in C1–C3 Environments. Outstanding UV and Gloss Retention for Long-Term Exterior Performance.
Sources: Carboline regional product page (environment, UV/gloss) and the Carbothane 137HS Part A Safety Data Sheet already hosted on your own site (VOC content). Carboline's official TDS PDF is blocked to automated access (robots.txt) — I could not pull volume solids, DFT or pack size from it. If you can download it from your Carboline rep or account, send it over and I'll fill in the rest with real numbers instead of leaving them blank.
Specific tack-free, recoat and full-cure times were not published in the sources I could access for this product — Carboline's official data sheet is blocked to automated fetching. Confirm with Carboline or your TDS copy before publishing exact hours.
The Part A SDS link above is already live on your own site. The other three are placeholders — point them at your hosted TDS / Part B SDS / certificate once confirmed.
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 Nullifire SC804 intumescent coating system, specified to deliver a 120-Minute 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.
TIM Aerospace MRO Hangar Facility