Emerging Trends in Fireproofing Metal Construction

Homes burned in the Palisades fire smolder near the Pacific Palisades neighborhood of Los Angeles; Credit: NPR, Josh Edelson/AFP via Getty Images

This year’s fires in Los Angeles serve as a stark reminder of the growing threat of fire in urban and industrial settings. According to the National Fire Protection Association (NFPA), fire departments across the U.S. respond to nearly 38,000 fires annually in industrial and manufacturing facilities, causing more than $1.2 billion in property damage each year. Building on the discussion on Non-Combustible Buildings, dive deeper into the latest fireproofing innovations that are enhancing the safety and resilience of metal structures further highlighting the critical need to protect metal and steel structures. As fire risks intensify, the demand for more efficient, durable, and aesthetically pleasing fireproofing methods continues to grow. Here are some of the emerging trends in steel structure fireproofing technology:

Epoxy intumescent coating offers a powerful solution to insulate structural steel from heat and fire to protect people and assets. (Credit: PPG; Metal Construction News)

Advanced Intumescent Coatings

While intumescent coatings have been around for some time, modern intumescent coatings combine thinner layers with improved fire resistance, minimizing material use without compromising safety. They enable sleek steel designs while offering superior protection. Innovations like water-based formulations reduce VOCs for better environmental sustainability, and nano-enhanced coatings with materials like graphene improve thermal resistance, durability, and longevity of both the coating and the steel it protects.

Sustainable Fireproofing Materials

Sustainability is driving advancements in fireproofing, with eco-friendly solutions like bio-based materials gaining traction. Natural fibers and plant-based resins offer fire protection while reducing carbon footprints. Additionally, recyclable fireproofing systems are being designed for easy removal, reuse, or recycling, minimizing waste and environmental impact.

3D Printing and Prefabrication

Emerging trends in fireproofing metal construction include 3D printing and prefabrication. 3D printing enables precise, custom fireproofing components, tailored to complex steel structures using materials like intumescent composites and insulating foams. Prefabricated fireproofing panels, manufactured off-site, streamline installation, ensure consistent quality, and reduce waste, making them ideal for large-scale projects.

Check out this NEW Fire Resistant 3D Printed Home in Los Angeles.

Smart Fireproofing Systems

As construction embraces smart buildings, smart fireproofing systems are gaining traction. Using IoT sensors, these systems monitor fireproofing materials in real time, detecting temperature, humidity, and structural changes to warn of hazards or material degradation. Smart coatings with temperature-sensitive nanoparticles can signal critical heat levels, improving safety and enabling predictive maintenance, reducing costs by servicing only when needed.

High-Performance Spray-Applied Coatings

SFRM being applied to a building; Credit: Paintworks & Decorating

High-performance spray-applied fire-resistive materials (SFRMs) are an emerging trend, offering improved fire resistance with lighter, easier application compared to traditional sprays. Hybrid coatings that blend intumescent and SFRM properties are also gaining traction, providing dual-temperature protection.

Hybrid Passive and Active Fireproofing Systems

A growing trend in fire protection is the combination of passive and active fireproofing systems. Passive fireproofing includes materials like fire-rated coatings and insulation that inherently resist fire, while active suppression systems, such as automatic fire curtains, water mist systems, or sprinkler integrations, actively combat flames. By combining these two approaches, hybrid systems offer multi-layered protection, enhancing safety and minimizing fire spread in metal structures.

Fire-Resistant Cladding Systems

Credit: Cladco Decking

The evolution of fire-resistant cladding is playing a crucial role in metal construction. New developments include the use of non-combustible materials like fiber cement, aluminum composite panels with mineral cores, and stone wool insulation. These cladding systems provide additional fire resistance, particularly in high-rise and industrial buildings, and help prevent external fires from spreading into the structure.

Global Innovations in Fireproofing

Innovations in fireproofing are not limited to the U.S. In Australia, for example, homes in high-risk fire zones must adhere to the Bushfire Attack Level (BAL) standard, which includes double-glazed windows, fully insulated walls, floors, and ceilings, and fully sealed structures with iron roofs. Additionally, properties must be cleared of trees and shrubs in close proximity to reduce fire hazards.

Flame-diffusing and Ember-resistant Foundation Mesh Screen

One of the most advanced protective measures involves roll-down metal fire doors that can be automatically released and secured with a latch. These doors shield windows and doors from extreme heat and flames, acting as an additional layer of defense in wildfire-prone areas.

Another innovative solution from Australia is the use of stainless steel mesh for fencing and ventilation, such as the Wildfire Defense Mesh. This product prevents embers from entering through vents or gaps, a critical factor in fireproofing homes and buildings. It can also be integrated into rain screens to provide additional protection without compromising ventilation.

Conclusion

As the fires in Los Angeles and elsewhere have demonstrated, fire hazards remain a growing concern, especially in urban and industrial areas. The evolving landscape of fireproofing technologies — ranging from advanced intumescent coatings and hybrid passive-active systems to fire-resistant cladding and global innovations — offers critical solutions to enhance the resilience of metal structures. By adopting these emerging fireproofing methods, builders and developers can not only meet evolving safety standards but also help protect communities from devastating fire events. With continued advancements, the industry is moving toward smarter, more sustainable, and more effective fire protection strategies that will play a crucial role in safeguarding buildings for the future.

Learn More with METALCON

Up Next on METALCON Online

METALCON Online and Metal Architecture Magazine Presents: “Breaking the Cycle of Wildfire Destruction: The Urgent Need for Fire-Resilient Construction” LIVE on Wednesday, May 21 at 1:00 PM EST. In this session, Erla Dögg Ingjaldsdóttir, Owner, Principal and General Contractor + Tryggvi Thorsteinsson, Architect, Principal at Minarc & ERLA Construction will highlight the critical gap between current building practices and the fire resilience needed to withstand these catastrophic events. REGISTER to attend live or to watch later ON DEMAND. This session offers 1 AIA LU HSW credit.

Watch Fire Prevention Webinars ON DEMAND

Share:

More Posts from the METALCON blog:

Metal Construction Industry 101: Dive Into the Emerging Trends of 2025

Metal Construction Industry 101: Dive into the fundamentals of metal construction and get up to date on current and emerging trends is crucial for industry professionals. Explore these topics by watching the recent Metal Construction Industry 101 webinar with experts Todd Miller and Lauren Rubino. Learn why attending the METALCON trade show is essential, especially for future leaders in the industry.

Read More »

AI in Construction: What’s Changed in Just One Year—and What’s Next

AI is no longer a future concept—it’s transforming construction right now. With tools becoming more powerful and accessible over just the past year, the opportunities for innovation and efficiency have never been greater. METALCON 2025 is your gateway to exploring how AI is reshaping the metal construction industry, with expert-led sessions, hands-on tech demonstrations, and real-world strategies to help you stay ahead of the curve.

Read More »

METALCON Launches Veteran Retreat Project with Steel Frame Build

Eagles Landing Begins in Las Vegas, Bound for Montana (Newton, MA — July 17, 2025) —This year, the only global event dedicated exclusively to the application of metal in design and construction is proud to launch a heartwarming project: a full-scale steel frame for a future veteran retreat in Hall, Montana, an inspiring new initiative for METALCON 2025. This special build will be showcased during the show, October 21–23, at the Las Vegas Convention Center, marking the first phase of

Read More »

METALCON Newsletter July 2025

WHERE THE INDUSTRY MEETS: CAN’T MISS NETWORKING AT METALCONAt METALCON 2025, networking completes the trifecta — alongside education and exhibits — to deliver a powerful, full-spectrum experience. Whether you’re looking to spark new partnerships or connect with peers, this year’s networking lineup has something for everyone.   Included with your registration, the Welcome Party returns Tuesday at 4:00 PM on the show floor, along with Oktoberfest Happy Hours all three days and last year’s favorite, Speed Networking. Women in the

Read More »

Why Attend METALCON as a Builder?

From groundbreaking techniques to future-focused education, METALCON is more than a trade show—it’s a launchpad for innovation in metal construction. While contractors, architects, and engineers have long benefited from the show, builders have unique opportunities to thrive at METALCON 2025. Whether you specialize in residential, commercial, agricultural, or mixed-use developments, METALCON offers a rare chance to gain knowledge, make connections, and discover solutions tailored to today’s building challenges. What Can Builders Expect at METALCON? 1. A Hands-On, Solutions-Driven Show Floor Builders who attend METALCON

Read More »

METALCON 2025 Top Product Awards

Applications due August 8, 2025 METALCON, the premier global event for the metal construction and design industry, announces its Fifth Annual Top Product Awards, honoring the most innovative products, technologies and solutions shaping the future of the industry. METALCON exhibitors are invited to submit nominations across 15 product categories, showcasing their most innovative offerings. Eligible products must have been introduced to the market on or after Jan. 1, 2024, and its manufacturer must be a participating exhibitor at METALCON 2025.

Read More »

Why Attend METALCON as a Contractor

Unique hands-on training at METALCON 2025 is just one of many reasons why attending is a smart investment for contractors. Discover how METALCON can help drive the future success of your business in today’s blog post.

Read More »