Fireproofing Steel: Requirements, Applications – DTC General Contracting

Steel is one of the most widely used structural materials in modern construction. Its high strength-to-weight ratio, flexibility in design, speed of erection, and durability make it the preferred choice for warehouses, factories, commercial buildings, power plants, and high-rise structures across Saudi Arabia. However, despite its many advantages, steel has a critical weakness: it rapidly loses strength when exposed to high temperatures during a fire.

Fireproofing steel is therefore not optional—it is a fundamental safety requirement. At DTC General Contracting, fireproofing steel structures is a core specialization, delivering compliant, durable, and cost-effective fire protection solutions across the Kingdom.

This article explores fireproofing steel requirements, applications, systems, standards, and best practices, with a strong focus on Saudi Arabia’s construction environment.

1. Why Fireproofing Steel Is Essential

Steel is non-combustible, meaning it does not burn. However, non-combustible does not mean fire-resistant. When exposed to fire:

• At 300°C, steel begins to lose stiffness

• At 550°C, steel loses approximately 50% of its strength

• At 750–800°C, steel may lose up to 90% of its load-bearing capacity

This loss of strength can cause beams to deflect, columns to buckle, and entire structures to collapse—often long before a fire is extinguished.

Key Objectives of Fireproofing

Fireproofing steel structures aims to:

• Maintain structural stability during a fire

• Delay steel temperature rise

• Allow safe evacuation of occupants

• Support firefighting operations

• Reduce property damage and economic loss

• Ensure compliance with fire safety codes and insurance requirements

In Saudi Arabia, where large-scale industrial and commercial projects dominate, steel fireproofing is a critical life-safety system.

2. Fireproofing Steel – Regulatory Requirements

2.1 Saudi Building Code (SBC)

The Saudi Building Code (SBC) mandates minimum fire resistance ratings for structural elements depending on:

• Building occupancy

• Height and floor area

• Fire load

• Use (industrial, commercial, residential)

Steel members must typically achieve:

• 30 minutes

• 60 minutes

• 90 minutes

• 120 minutes or more

2.2 International Standards Followed in KSA

DTC General Contracting applies internationally recognized standards, including:

• ASTM E119 / UL 263 – Fire-resistance testing of building assemblies

• EN 13381 – Fire resistance of structural steel members

• NFPA 251 – Fire tests of building construction materials

• ISO 834 – Fire resistance testing

• UL Listed & FM Approved Systems

These standards ensure predictable fire performance and regulatory approval across industrial and commercial sectors.

3. Fireproofing Steel – Key Requirements

Effective fireproofing depends on several technical and design requirements:

3.1 Fire Resistance Rating

The required fire rating (FRR) depends on:

• Building type (warehouse, hospital, office, refinery)

• Evacuation time requirements

• Structural role of the steel member

• Presence of sprinkler systems

3.2 Steel Section Factor (Hp/A)

The section factor determines how fast steel heats up in a fire:

• Thin sections heat faster

• Larger sections heat slower

Higher section factors require thicker fireproofing.

3.3 Environmental Exposure

Saudi Arabia’s climate introduces additional challenges:

• High temperatures

• Humidity in coastal areas (Dammam, Jeddah)

• Dust and sand exposure

• Industrial corrosion environments

DTC selects fireproofing systems that perform reliably under these conditions.

3.4 Durability and Maintenance

Fireproofing must resist:

• Mechanical damage

• Vibration

• Moisture

• Chemical exposure

Durability is especially critical in factories, refineries, and warehouses.

4. Types of Fireproofing Systems for Steel

DTC General Contracting provides a full range of steel fireproofing solutions tailored to project needs.

4.1 Intumescent Fireproofing Coatings

Intumescent coatings are thin-film paints that expand when exposed to heat, forming an insulating char layer that protects steel.

Key Features:

• Thin and lightweight

• Smooth architectural finish

• Fire ratings up to 120 minutes

• Ideal for exposed steel

Applications:

• Commercial buildings

• Airports

• Shopping malls

• Office towers

• Architectural steel structures

Advantages:

• Aesthetic appearance

• Minimal added weight

• Easy inspection and maintenance

Considerations:

• Higher cost compared to sprays

• Requires controlled application and curing

DTC uses UL-listed and approved intumescent systems suitable for Saudi climatic conditions.

4.2 Spray-Applied Fire Resistive Materials (SFRM)

Spray-applied fireproofing uses cementitious or mineral fiber materials sprayed directly onto steel.

Key Features:

• Economical for large projects

• Fire ratings up to 4 hours

• High thermal insulation

Applications:

• Warehouses

• Factories

• Power plants

• Parking structures

• Oil & gas facilities

Advantages:

• Cost-effective

• Fast application

• Excellent fire performance

Considerations:

• Rough finish

• Requires protection from impact or moisture in exposed areas

DTC applies SFRM using calibrated equipment to ensure uniform thickness and adhesion.

4.3 Fireproof Boards and Encasement Systems

Fireproof boards include:

• Calcium silicate boards

• Gypsum fire-rated boards

• Cementitious boards

Steel members are fully encased within board systems.

Applications:

• Hospitals

• Schools

• Data centers

• Residential buildings

• Clean environments

Advantages:

• Clean installation

• High durability

• Excellent fire ratings

• Good acoustic performance

Limitations:

• Higher labor cost

• Requires space allowance

4.4 Concrete Encasement

Steel encased in concrete provides inherent fire resistance.

Applications:

• Columns

• Structural cores

• Heavy industrial structures

Advantages:

• Extremely durable

• High fire resistance

• Structural enhancement

Disadvantages:

• Increased dead load

• Reduced architectural flexibility

4.5 Flexible Fireproofing Blankets

Flexible systems use mineral fiber blankets wrapped around steel.

Applications:

• Retrofit projects

• Irregular steel sections

• Mechanical rooms

Advantages:

• Lightweight

• Quick installation

• Minimal disruption

5. Applications of Fireproofing Steel in Saudi Arabia

5.1 Industrial Facilities

• Manufacturing plants

• Steel fabrication yards

• Chemical processing units

Fireproofing protects steel against high fire loads and hazardous materials.

5.2 Warehouses and Logistics Centers

Large-span steel structures require:

• Spray-applied fireproofing

• High fire ratings (2–3 hours)

DTC delivers solutions aligned with civil defense approvals.

5.3 Oil & Gas and Energy Sector

• Refineries

• Power plants

• Substations

Fireproofing systems must resist:

• Hydrocarbon fires

• Explosions

• Extreme heat

5.4 Commercial Buildings

• Offices

• Malls

• Hotels

Architectural aesthetics often drive the use of intumescent coatings.

5.5 Healthcare and Education

• Hospitals

• Universities

• Schools

Clean, board-based fireproofing systems are preferred.

6. Installation Methodology – DTC Best Practices

DTC follows strict method statements for steel fireproofing:

1. Surface inspection and preparation

2. Cleaning and rust removal

3. Primer application (if required)

4. Fireproofing material application

5. Thickness verification

6. Adhesion testing

7. Final inspection and approval

Quality control ensures compliance with:

• Approved system data sheets

• Manufacturer recommendations

• Fire authority requirements

7. Inspection, Testing, and Quality Assurance

Fireproofing systems are tested using:

• Wet film thickness gauges

• Dry film thickness measurements

• Density checks (for SFRM)

• Adhesion and cohesion testing

• Visual inspection

DTC maintains full documentation and certification for every project.

8. Maintenance of Fireproofing Systems

Fireproofing is a long-term safety system and must be maintained:

• Repair damaged areas immediately

• Recoat intumescent paint if compromised

• Replace damaged boards

• Conduct periodic inspections

Regular maintenance ensures continuous compliance and safety.

9. Why Choose DTC General Contracting

DTC is a trusted name in steel structure fireproofing in Saudi Arabia, offering:

• Certified fireproofing systems

• Experienced engineering and application teams

• Compliance with SBC, ASTM, UL, EN, and NFPA

• Solutions for industrial, commercial, and infrastructure projects

• Turnkey fireproofing services across KSA

From design to execution, DTC ensures maximum fire safety and regulatory approval.

10. Conclusion

Fireproofing steel is not merely a regulatory requirement—it is a critical investment in life safety, structural integrity, and asset protection. Without proper fireproofing, steel structures are vulnerable to rapid failure during fire incidents.

DTC General Contracting delivers advanced, tested, and reliable fireproofing solutions that meet the demands of Saudi Arabia’s growing construction sector. Whether through intumescent coatings, spray-applied systems, fireproof boards, or concrete encasement, DTC ensures steel structures remain safe, compliant, and resilient under fire conditions.

Web Search Results Referenced

• Fireproofing of Steel Structures in Saudi Arabia – DTC
  Overview of DTC’s certified steel fireproofing services and systems in Saudi Arabia.

• How to Install Fireproofing Paint for Steel Structures in Saudi Arabia
  Step-by-step guide covering proper application methods and compliance.

• Fireproofing Steel: Requirements, Applications, Types – Sherwin-Williams
  Detailed explanation of fireproofing requirements, applications, and system types.

• Steel Structure Fireproofing – DTC
  Explains why steel fireproofing is essential and how it prevents structural failure.

• Steel Construction – Fire Protection (PDF)
  Technical reference covering fire protection principles for steel structures.

• Steel Structure Fireproofing and Fireproofing Paints in Saudi Arabia
  Highlights certified fireproofing paints and applications in KSA.