Flame Security International (FSI) collaborated with UNSW Sydney to develop FIRECOAT, an innovative fire-retardant paint designed to protect homes, buildings, and infrastructure from the devastating effects of bushfires. The project involved extensive research, testing, and commercialisation efforts, resulting in a product now available across Australia, including at Bunnings stores and the US is soon to follow. FIRECOAT is also being evaluated and used by Transport for NSW in a cost-saving exercise which may be implemented across their extensive network. The collaboration has transformed fire safety and has won several accolades, including the AFR 2024 Research Commercialisation Award and the ‘Problem Solver’ People’s Choice award at the Shaping Australia Awards.
Challenge
Australia is one of the most fire-prone countries in the world, facing frequent and intense bushfires. Traditional building materials often fail to withstand these extreme conditions, leading to significant loss of property and lives. FSI aimed to address this issue by developing a fire-retardant coating that could be applied to various construction materials, offering enhanced protection against fire. However, the company needed advanced research capabilities and extensive testing to bring this vision to life.
"Australia’s bushfire challenges are immense, and the damage caused by these fires is both heartbreaking and costly. The core problem we aimed to address with FIRECOAT was creating a solution that could effectively prevent buildings from becoming fuel for these devastating fires. Our goal was to provide a protective barrier that could make a real difference when every second counts."
Tony Overstead, FSI Founder and CEO
Solution
The collaboration began with Professor Yeoh and his team at UNSW conducting research to develop a polymer-based coating that could withstand extreme heat and flames. After extensive rounds of testing and adjustments, the team identified a unique formulation that creates a dense char layer when exposed to fire. This layer acts as a barrier, preventing flames from penetrating and causing damage to the underlying structure.
FSI and UNSW worked closely to test the effectiveness of the paint, conducting more than 100 tests on different materials. The breakthrough came when the coating withstood a direct flame for over an hour, proving its efficacy. Following rigorous certification processes, FIRECOAT was commercialised and is now available for purchase in Australia and the US soon to follow. Commercial partners are all commercialising FIRECOAT, including Transport for NSW, who are evaluating FIRECOAT Exterior on wooden acoustic panels to avoid high-cost replacements across the network.
"This new paint technology is the world-first paint to pass the stringent Australian standard test (AS 3959) that simulates a bushfire attack. It has been accredited with a BAL-40 rating. The BAL or Bushfire Attack Level rating is the Australian standard for measuring the risk of a home’s exposure to ember attack, radiant heat and direct flame contact. BAL-40 indicates that a building or material has been tested and approved to withstand higher levels of radiant heat (up to 40kW/m²) and ember attack during a bushfire, which provides increased protection against bushfires in areas prone to extreme fire conditions."
Professor Guan Yeoh, UNSW Sydney School of Mechanical and Manufacturing Engineering
Impact
FIRECOAT has demonstrated significant potential in preventing the spread of bushfires. The paint (FIRECOAT Exterior specifically) provides a BAL-40 rating, one of the highest bushfire protection levels, ensuring that structures coated with it can withstand direct exposure to flames for extended periods. In addition to enhancing safety, the product has a broad market application, from residential homes to commercial buildings and critical infrastructure.
The project has also had a profound impact on FSI's growth strategy. The collaboration with UNSW has enabled the company to innovate and expand into new markets, leading to successful product launches and increased industry recognition.
FSI's partnership with Bunnings Warehouse has facilitated the wide distribution of FIRECOAT, making it accessible to homeowners and businesses across Australia. The product's success has positioned FSI as a leader in fire safety solutions and opened the door to further research and development opportunities with UNSW.
"The development of FIRECOAT has been a game-changer not just for our business, but for communities living in fire-prone areas. Seeing our product in homes and knowing it can make a real difference in saving lives and properties is incredibly rewarding. This project has allowed us to expand our impact on a national scale, and we’re just getting started."Tony Overstead, FSI Founder and CEO