MSM Logistic Warehouse Fireproofing Project in UAE

MSM Logistic Warehouse Fireproofing Abu Dhabi: Ibtikar applied Nullifire 804 Intumescent Paints across 13,000 m² of structural steel to achieve a 120-Minutes fire rating, completed in April 2024.

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Project Type Intumescent Paints

LocationAbu Dhabi

Area13,000 m²

Fire Rating120-Minutes

MaterialNullifire 804

CompletionApril 2024

Project Overview

The MSM Logistic Warehouse is an Intumescent Paints project located in Abu Dhabi, UAE, where Ibtikar delivered professional structural steel fireproofing and passive fire protection solutions for MSM Logistics. Covering approximately 13,000 m² of steelwork, the project was completed in April 2024 using Nullifire 804 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.

Location: Abu Dhabi
Project Date: April 2024
Project Type:Intumescent Paints
Surface Area: 13,000 m²
Fire Rating: 120-Minutes
Material:Nullifire 804
Application Method: Spray Fireproofing

Fireproofing Scope & Application

  • Structural Steel Protection

    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.

  • Intumescent Coating Application

    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.

  • Quality Control & Inspection

    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.

Fire Protection System

A layered coating system builds up fire resistance on the steel substrate. Products and film thicknesses are project-specific — see the technical documents below.

  1. Layer 01

    Steel substrate

    Prepared structural steel, cleaned and profiled to the specified surface standard prior to coating.

  2. Layer 02

    Primer

    A compatible primer system protects the substrate and provides adhesion for the intumescent coating. Thickness per specification.

    Primer coating system →
  3. Layer 03

    Intumescent coating

    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.

    Intumescent coating system →
  4. Layer 04

    Topcoat

    A protective topcoat is applied where specified, for UV resistance, weathering or a decorative finish.

    Topcoat coating system →

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.

Project Execution

  1. Stage 01

    Surface preparation

    • Steel surfaces cleaned and prepared to the standard the coating system requires
    • Preparation signed off before any coating is applied, so the system bonds correctly
  2. Stage 02

    Primer inspection

    • Primer film thickness and coverage checked across the steelwork
    • Intumescent application only proceeds once the primer passes
  3. Stage 03

    Intumescent application

    • Applied in controlled passes to build up the specified dry film thickness
    • Spray, brush or roller to suit the product and the site conditions
  4. Stage 04

    DFT inspection and handover

    • Dry film thickness measured at multiple points on each member and recorded against the project specification
    • Final joint inspection on completion, with documentation compiled and issued for handover and close-out

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.

Project Results

13,000 m²Protected Area

120-MinutesRequired Fire Rating

Intumescent Paints Coating System

CompletedProject Status

Approved 100%Inspection Status

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Fire Proofing Material

Nullifire SC802 | 60-Min Water-Based Intumescent Coating

BS 476 & Certifire CF5420 Certified Passive Fire Protection for Internal Structural Steelwork. Optimized single-coat application for 60-minute cellulosic fire resistance.

Fire Resistance Rating Up to 60 Minutes (Internal Steel)
Volume Solids 70% ± 3%
Density / Specific Gravity 1.38 ± 0.02 kg/L
Coverage (Theoretical) 979 g/m² @ 0.5 mm DFT
Max Wet Film Thickness (WFT) 1.0 mm/coat spray, 0.6 mm brush
VOC Content ≤ 16 g/L
Application Method Airless Spray or Brush/Roller
Pack Size & Storage 25 kg Drums (Protect from Frost)

Source: Nullifire SC802 Technical Data Sheet (Tremco CPG), tested to BS 476: Parts 20/21. Your catalog page also mentions a "limited 90-minute option" — this data sheet only confirms 60 minutes, so verify the 90-minute claim before publishing.

Substrate Preparation

  • Steel Preparation: Apply only onto a clean, undamaged, dry, primed steel surface free from contaminants.
  • Substrate Restrictions: Only primers listed in the product's ETA (European Technical Assessment) or on Nullifire's website are pre-approved.

Primer Systems

  • Nullifire's recommended primers are listed in the SC802 ETA and on Nullifire's website. Contact Nullifire technical services for compatibility testing on any primer not already listed.

Airless Spray Application Setup

  • Operating Pressure: 2500–3000 psi (175–210 kg/cm²)
  • Tip Size: 17 to 21 thou
  • Fan Angle: 20°–40°
  • Fluid Line: 10 mm (3/8") ID

Drying Schedule (at 20°C)

Dry Time @ 0.2mm WFT 2 Hours
Dry Time @ 0.5mm WFT 3 Hours
Dry Time @ 1.0mm WFT 4 Hours

Times shown are recoat intervals at 20°C and vary with temperature and humidity — confirm with Nullifire for your site conditions.

Third-Party Certifications & Compliance

  • Certifire CF5420 — third-party approval.
  • Tested to BS 476: Part 20/21 for internal structural steelwork.
  • Cellular beam assessment: YB5.

Technical Documents

📄 Technical Data Sheet (TDS) 🛡️ Safety Data Sheet (SDS) 📊 Hp/A Loading Tables 📜 Nullifire SC801 Brochure

All four links are placeholders. Note: an SC802 Safety Data Sheet is already hosted on your Saudi site (ibtikar-saudi.com) — happy to link that or your own UAE media-library copy once you confirm which to use.

Fire Proofing Material

Nullifire SC804 | Water-Based Intumescent Coating for On-Site Application

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.

Fire Resistance Rating Optimised 90 Min (120 Min Limited)
Volume Solids 69% ± 3%
Density / Specific Gravity 1.38 ± 0.02 kg/L
Coverage (Theoretical) 1,000 g/m² @ 0.5 mm DFT
Max Wet Film Thickness (WFT) 1.0 mm/coat spray, 0.6 mm brush
VOC Content < 0.1 g/L (Ultra-Low VOC)
Application Method Airless Spray or Brush/Roller
Pack Size & Storage 25 kg Drums (Protect from Frost)

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.

Substrate Preparation

  • Steel Preparation: Apply only onto a clean, undamaged, dry, primed steel surface free from contaminants.
  • Substrate Restrictions: Use only primer systems approved per Nullifire's guidance for this product.

Primer Systems

  • Consult Nullifire for the current approved primer list for SC804 — specific primer brands/types were not named in the data sheet checked.

Airless Spray Application Setup

  • Operating Pressure: 2500–3000 psi (175–210 kg/cm²)
  • Tip Size: 17 to 21 thou
  • Fan Angle: 20°–40°
  • Fluid Line: 10 mm ID

Drying Schedule (at 20°C)

Dry Time @ 0.2mm WFT 2 Hours
Dry Time @ 0.5mm WFT 3 Hours
Dry Time @ 1.0mm WFT 4 Hours

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.

Third-Party Certifications & Compliance

  • Tested to BS 476: Part 20/21.
  • Certifire Approval CF5929.
  • ETAG 018 — approved up to Y exposure without topcoat.

Technical Documents

📄 Technical Data Sheet (TDS) 🛡️ Safety Data Sheet (SDS) 📊 Hp/A Loading Tables 📜 Nullifire SC804 Brochure

All four links are placeholders — point them at your own hosted files once confirmed.

Fire Proofing Material

Carbothane 137HS | High-Build Polyurethane Protective Topcoat

Fast-Drying Two-Component Coating for Direct-to-Metal Application in C1–C3 Environments. Outstanding UV and Gloss Retention for Long-Term Exterior Performance.

Fire Resistance Rating N/A — Protective Topcoat
Recommended Environment C1–C3 (No Primer), C4–C5 (With Primer)
UV / Gloss Performance Outstanding UV & Gloss Retention
VOC Content 328 g/L (Part A, as supplied)
Volume Solids Not published in sources checked
Max Dry Film Thickness (DFT) Not published in sources checked
Application Method Not published in sources checked
Pack Size & Storage Not published in sources checked

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.

Substrate Preparation

  • Corrosivity Category: Suitable for direct-to-metal application in C1–C3 environments without a primer.
  • Higher Corrosivity: For C4–C5 environments, apply over an appropriate Carboline primer system.

Primer Systems

  • Specific primer product names/DFT ranges were not published in the sources I could access — confirm the approved primer system with Carboline for your substrate and corrosivity category.

Application

  • Two-component polyurethane, mixed per Carboline's stated ratio before application (ratio not published in the sources checked).
  • Formulated for fast-drying, high-build application with excellent dry times relative to standard polyurethane topcoats.

Drying Schedule

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.

Third-Party Certifications & Compliance

  • No third-party fire or corrosion certifications were found in the sources checked for this specific product — as a topcoat it is typically used as part of a certified system rather than certified on its own. Confirm with Carboline if a specific approval is required for your project.

Technical Documents

📄 Technical Data Sheet (TDS) 🛡️ Safety Data Sheet (SDS) — Part A 🛡️ Safety Data Sheet (SDS) — Part B 📜 Test Certificate

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.

Why Choose Ibtikar

  • UAE project experience

    A track record of fireproofing delivered across the UAE's industrial, commercial and infrastructure sectors.

  • Specialised fireproofing expertise

    Dedicated focus on passive fire protection and intumescent coating systems for structural steel.

  • Professional quality control

    Documented dry film thickness inspection and quality checks at every stage, issued as a signed inspection report.

  • Technical and project support

    Technical guidance from specification and system selection through to inspection, handover and authority submission.

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Frequently Asked Questions

This project used a Nullifire 804 intumescent coating system, specified to deliver a 120-Minutes fire-resistance rating on exposed 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.

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.

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.

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.

Planning a Fireproofing Project in the UAE?

Talk to our technical team about structural steel fire protection, intumescent coatings and passive fire protection requirements.

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