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Development of effective methods for quantificationally characterizing the thermal resistance of the intumescent char layer of fired fire-retardant coating is of interest in many academic researches and industrial applications. In this work, a novel approach is proposed to calculate the thermal resistance of the intumescent char layer produced after the ultra-thin fire-retardant coating exposed to fire. A correlation was established based on the relative thermal resistance of the char layer to that of steel plate and the surface temperature at the back of the coated steel plate under steady-state heat transfer. The thermal resistance of the steel plate was obtained about 0.009 K·m2·W−1 by calculating the heat flux based on the radiation heat exchange involving three-surface enclosure model (flame, steel, and wall). The thermal resistances of the char layers without and with the layered double hydroxide (LDH) were 0.011 K·m2·W−1 and 0.013 K·m2·W−1, respectively. The results show that the external roughness and internal honeycomb structure can increase both the conductivity and the convective thermal resistances of the char layer to protect the steel structures. The porosity of the char layer is between 0.15 and 0.18, and its thermal conductivity is between 0.4 and 0.8 W·m−1·K−1 in the process of fire. Unlabelled Image • A novel method is proposed to calculate thermal resistance of intumescent char layer. • Thermal resistance is used to evaluate heat-shielding performance of char layer. • LDH improves external roughness and internal honeycomb structure of char layer. • Porosity of char layers is obtained to be 0.15–0.18 via SEM images processing. • Thermal conductivity of char layers is 0.4–0.8 W·m−1·K−1 in the process fire. [ABSTRACT FROM AUTHOR]

• An analysis method for SEM images of intumescent fire retardant char layers is proposed. • Foams in an intumescent fire retardant char layer are characterized quantificationally. • Appropriate addition of CaAlCO 3 -LDHs makes the char layer compact and uniform. • Unsatisfactory result image after color transformation is returned to object segmentation. A new characterization method is proposed to investigate the microscopic morphology of intumescent fire retardant (IFR) char layer observed under a scanning electron microscope (SEM). The method consists of object segmentation extracting the object, color transformation improving the recognition of subtle details, and statistical analysis obtaining the features (area, average, and standard deviation) of the object in the SEM images. There is a descending trend in the standard deviation of the foams with the increase of CaAlCO 3 -LDHs (layered double hydroxides) added to the coatings. Specifically, the number of the foams in the IFR coating with 5 wt% of CaAlCO 3 -LDHs addition is increased from 102 (that of the char layer without CaAlCO 3 -LDHs) to 123. Meanwhile, the standard deviation of the foams in the char layer is decreased from 6383.6 to 4304.5, demonstrating that an appropriate addition of CaAlCO 3 -LDHs can improve the foam quality of the IFR coating by making it more compact and uniform, and enhance the thermal insulation of the char layer covered on the substrate surface. [ABSTRACT FROM AUTHOR]