At Element PCC, we specialize in applying complex, high-performance coatings, including intumescent fire protection systems. Recently, we worked directly with Contego’s intumescent coating products and gained critical technical insights not clearly disclosed in the product documentation or marketing materials.

If you are considering working with Contego, here’s what you need to know before you start — including equipment requirements, film build specifications, and why specialized setup is absolutely necessary.

How Intumescent Coatings Work

Intumescent coatings are engineered to protect structural substrates during fire events. When exposed to high temperatures, the material undergoes sublimation — expanding up to 100 times its original dry film thickness (DFT) — creating a carbonaceous char that insulates the substrate underneath.

Contego's intumescent coatings are designed to provide up to two hours of fire resistance, depending on the specific thickness applied and system used.

Unlike conventional paints, the performance of intumescent coatings is dependent entirely on precise material application, correct DFT, and compatible primers and topcoats.

Critical Differences From Conventional Fire Retardants

Earlier generations of intumescent paints often suffered from:

Uneven application
Moisture trapping (leading to substrate corrosion)
Inability to accept topcoats without performance loss

Contego’s modern formula addresses many of these historic problems by allowing properly specified topcoats, reducing dusting issues, and improving expansion uniformity during fire exposure. However, achieving these benefits still depends heavily on application technique and equipment.

Technical Application Requirements

Successful application of Contego coatings requires strict adherence to their technical data sheet (TDS) — plus additional real-world adjustments we discovered through hands-on experience.

1. Specialized Pump Requirements

Although Contego’s TDS mentions the need for an airless sprayer capable of 3300+ PSI, it does not clearly disclose that standard airless sprayers are insufficient.

A specialized high-volume, high-pressure pump with the following specs is mandatory:

Minimum fluid pressure: 3300 PSI sustained (not peak pressure)
Minimum flow rate: 1.5–2.0 gallons per minute (GPM) — NOT the 0.5–1.0 GPM of most residential/commercial pumps
Large-diameter fluid passages and tips to handle the material’s extremely high viscosity (without thinning)

Without this type of pump, the Contego material will not atomize correctly, resulting in uneven film builds, sagging, poor coverage, and serious fire rating failures.

Examples of appropriate pumps:

Graco Xtreme NXT series
Graco King pneumatic sprayers
Titan PowrTwin 8900 Plus hydraulic units (with appropriate tip sizes)

Using standard Graco 390/395, Titan 440, or similar models will result in equipment damage and coating failure.

2. Film Thickness Requirements

Contego must be applied at a much greater thickness than typical paints:

Spray Application: 35 mils wet film thickness per coat
Brush/Roll Application: 25 mils wet film thickness per coat

(Typical latex paint = ~4–6 mils wet.)

Each coat must be carefully measured using:

A wet film thickness (WFT) gauge immediately after application
A dry film thickness (DFT) calculation (WFT × 0.72) after curing

Final dry thickness must match project specifications (or building/fire codes) based on required fire resistance rating.

3. Drying and Recoat Times

Drying times are highly variable based on environment. For example:

Conditions
Surface Dry
Hard Dry
Recoat Time

70°F (21°C), 50% RH

~4.5 hours

~12 hours

Minimum 12 hours

Humidity, airflow, and substrate temperature must be monitored. Recoating too early traps solvents, weakening film strength and compromising fire protection.

Each coat must be 100% dry before reapplication.

4. Primer and Topcoat Compatibility

Contego intumescent coatings are designed to work with a limited set of primers and topcoats.
Primers must be approved by Contego — otherwise, adhesion failure or delamination during fire exposure can occur.

Important:

The primer’s thickness must be measured separately from the intumescent layer.
Only the intumescent layer provides fire resistance.

Topcoats are optional but, if used, must be compatible. Contego maintains a list of approved topcoats (available by request).

5. Testing and Verification

Contego requires performance verification:

Hardness Test: Shore-D gauge, minimum reading of 50
Thickness Test: DFT readings at multiple points across the coated area

Without these verifications, the coating cannot be assumed to meet fire rating requirements.

Real-World Burn Test Results

At Element PCC, we conducted controlled burn tests to validate Contego’s performance.
Two panels were prepared:

Panel 1: Standard latex paint
Panel 2: Contego intumescent coating at correct DFT

Burn Test Outcome:

Latex panel: Immediate substrate degradation within seconds
Contego panel: Charred, expanded surface formed rapidly; substrate remained intact after sustained flame exposure

These results confirmed the importance of correct application, proper equipment, and complete curing to achieve intended fire protection.

Why Specialized Application Matters

Contego’s intumescent coatings are highly effective — but only when applied under controlled, technical conditions.

Summary of Key Points:

Specialized high-pressure, high-volume pump required (NOT a standard airless sprayer)
Strict film thickness and curing timelines
Substrate compatibility and approved primers/topcoats are mandatory
Continuous testing throughout application process

At Element PCC, we have invested in the right equipment, training, and verification procedures to apply Contego coatings correctly — ensuring your fire protection systems are reliable when it matters most.

Contact us today to discuss your specialty coating needs. When fire protection is on the line, precision is everything.

Working With Intumescent Coatings: Contego