Passive fire protection (PFP) systems play a vital role in protecting industrial facilities by maintaining the structural integrity of steel during hydrocarbon fire events. However, ageing fireproofing systems can become vulnerable when their protective topcoat deteriorates, allowing moisture to penetrate the fireproofing layer and initiate corrosion beneath the surface.

At the ADNOC Gas NGL Plant, the existing PFP system had experienced significant deterioration due to prolonged moisture ingress caused by cooling water exposure. This resulted in progressive under-film corrosion, localised steel degradation, and compromised long-term asset protection. The rehabilitation programme required a solution that would restore certified fire resistance while eliminating the root cause of future corrosion.

Our Solutions

POSCO executed a comprehensive passive fire protection rehabilitation programme, replacing the deteriorated fireproofing system with a modern, high-performance solution designed for long-term durability.

The project involved the safe removal of damaged fireproofing, abrasive blast cleaning of exposed steel, repair of corroded structural members, and reinstatement of a vermiculite-based passive fire protection system. To prevent future moisture ingress, the restored fireproofing was sealed with CAFCO Topcoat 200ME, an advanced elastomeric, water-repellent coating engineered to protect passive fire protection systems in demanding industrial environments.

The completed system restored certified hydrocarbon fire protection while significantly improving resistance to moisture, corrosion, and long-term environmental exposure.

Highlights

• 2-hour hydrocarbon fire resistance rating achieved
• Up to 30 years expected system service life
• Comprehensive fireproofing rehabilitation across structural steel, vessels, platforms, and pipe racks
• CAFCO Topcoat 200ME water-repellent protective system applied
• Structural steel repaired prior to fireproofing reinstatement
• Project delivered over a 2025–2028 execution programme

Results Delivered

The rehabilitation programme successfully restored the integrity of the facility's passive fire protection system while significantly improving long-term asset reliability.

Key project outcomes included:

• Certified 2-hour hydrocarbon fire resistance restored.
• Elimination of moisture ingress that previously accelerated corrosion.
• Enhanced protection of structural steel against long-term deterioration.
• Improved operational safety and emergency response capability.
• Extended service life with reduced maintenance requirements.
• Reduced long-term operational and financial risks associated with fire system degradation.

Why Posco?

Effective passive fire protection goes beyond achieving a fire rating. It requires a complete understanding of how moisture, corrosion, structural integrity, and coating performance interact throughout an asset's lifecycle.

POSCO delivers integrated fireproofing rehabilitation solutions that combine structural repairs, certified passive fire protection systems, and advanced protective coatings to maximise both fire safety and asset longevity.

Our expertise enables industrial operators to restore compliance, improve plant reliability, and protect critical infrastructure against both fire and corrosion using internationally recognised systems and best practices.

Technologies Deployed

Vermiculite Passive Fire Protection System

High-performance cementitious fireproofing designed to maintain structural steel integrity during hydrocarbon fire exposure.

CAFCO Topcoat 200ME

Advanced elastomeric topcoat providing a durable, water-repellent barrier that prevents moisture ingress and protects the underlying passive fire protection system.

Abrasive Blast Cleaning

Surface preparation carried out to industry standards, ensuring optimal coating adhesion and long-term system performance.

Structural Steel Repair

Targeted repair and restoration of corroded structural members prior to reinstating the passive fire protection system.

Project Images

Looking to Upgrade Your Passive Fire Protection Systems?

Whether you're rehabilitating ageing fireproofing systems, protecting critical process facilities, or implementing certified passive fire protection for new infrastructure, POSCO delivers engineered solutions that enhance safety, extend asset life, and ensure long-term operational reliability.

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