Protective Coatings Solutions

Published 2 December 2025

Hydrogen sits at the centre of global decarbonisation strategies. Governments and industries view it as a critical tool to cut emissions across hard-to-abate sectors. In 2025, global spending on hydrogen projects is expected to jump 70% reaching about $7.8 billion, according to the International Energy Agency. As more projects move from planning to construction, saftey becomes a bigger concern, especially the need for stronger fire protection. 

Hydrogen isn't like traditional fuels. It needs special storage, like high-pressure tanks or super-cold containers. It's used in many places, from industrial sites to fueling stations and even offshore. These systems have to work safely in all kinds of conditions, often near people or important infrastructure. Because of that, it's important to take a closer look at how hydrogen behaves in a fire. 
 

Hydrogen fires are not like hydrocarbon fires

Like most emerging technologies, expanding the hydrogen industry presents numerous issues, one of which is fire protection. Hydrogen fires, exhibiting characteristsics distinct from traditional hydrocarbons, present unique risks. They burn hotter and faster due to a higher volumetric outflow compared to cellulosic fires. 

Hydrogen fires can overwhelm unprotected infrasturcture. Tests have shown uncoated carbon steel reaching failure temperatures in less than a minute. These temperatures can compromise structural integrity before first responders arrive. Most current passive fire protection (PFP) standards stem from events in the oil and gas industry, such as the Piper Alpha disaster. Those standards never considered hydrogen's unique behavior. 

Why standards fall short

Many hydrogen infrastructure projects today rely on standards like the International Organization for Standardization (ISO) 22899-1 jet fire test standard. It remains widely used for offshore oil and gas environments. However, it fails to capture the characteristics of hydrogen fires, such as the narrow flame shape, higher flame speed and peak heat flux. 

Without a hydrogen-specific fire test standard, asset owners must choose between overdesign and uncertainty. Some may install thicker coatings or additional layers. Others may underestimate the hazard. Either path can increase cost or risk. 

This lack of a formal benchmark also affects regulatory approval, as authorities require assurance that installed systems meet a defined safety threshold. Without it, they must elevate test data on a case-by-case basis, resulting in delays and inconsistent decisions. 

Infrastructure expansion requires stronger protections

The growth of hydrogen touches many sectors. Electrolyser installations are appearing in chemical plants, transportation hubs and power generation sites. Refueling stations are serving public fleets, buses, and long-haul trucks. Data centres and hospitals are exploring hydrogen for backup energy storage. Pipeline networks are beginning to blend hydrogen into natural gas systems. 

The diversity in hydrogen storage and transport forms - cryogenic liquids, cryo-compressed hydrogen, hydrogen/natural gas blends (typically 25% hydrogen), and high-pressure cylinders of 350 to 700 bar (15,000 to 10,000 psi) - adds complexity to fire safety considerations. The industry tends to focus on mitigating risks associated with the widely used forms, such as high-pressure cylinders, to keep applications ranging from fuel-cell vehicles to power for data centres safe. 

PFP must work under all these conditions. It cannot depend on ideal environments or fixed assumptions. Engineers and asset owners need data that reflects real-world hydrogen fire scenarios, not extrapolations from legacy hydrocarbon testing. 

What testing reveals 

PPG, in collaboration with the UK's Health and Safety Executive, commissioned a hydrogen jet fire test at a specialised facility to benchmark the performance of PFP coatings. These tests focused on whether existing oil and gas fire standards could apply to hydrogen fires, particularly evaluating the heat flux and survivability of steel and coatings. 

Steel panels recieved coatings or remained bare for comparison. The test setups included high-pressure hydrogen releases that ignited into sustained jet flames. Temperatures, exposure times, and thermal images captured the outcome. 

The results revealed a stark contrast. Bare steel reached critical temperatures (400°C or 752°F) quickly, in some cases under 60 seconds. Coated panels, however, maintained core steel temperatures below 100°C (212°F) for extended periods, sometimes beyond 30 minutes. 

These early tests suggest that materials designed for hydrocarbon fires can meet the ISO 22899-1 jet fire test standard under hydrogen conditions, if properly formulated and applied. Video footage showed the coatings swelling and forming insulating barriers. Even under erosive conditions, the system held up. 

How fire protection materials perform 

The recent test data points to promising solutions. Flexible, intumescent epoxy systems that swell under heat form a thick char layer. This layer insulates steel, slows heat transfer and helps resist thermal erosion. 

Coatings also face other threats in hydrogen environments. These include cryogenic spills from liquid hydrogen, mechanical impact from modular assembly, and corrosion from salt and moisture. A coating that works in fire tests must also perform in field conditions. 

Developers must consider cyclic thermal loads, long-term adhesion, and exposure to chemical agents. These variables affect coating longevity and performance, especially in harsh climates. Material design must address more than fire. 

Some formulations now aim for dual protection: insulation during fire, plus protection against corrosion. This multi-functional approach can help improve fire safety and extends asset life, delivering stronger value for owners and operators. 

Progress towards a better benchmark 

While these tests are a great first step, collaborative efforts remain essential to evaluate and improve fire protection measures and develop industry-specific standards. Several industry groups now push for new hydrogen-specific fire protection standards. Organisations like FABIG (Fire and Blast Information Group) lead collaboative projects to gather data and develop recommendations. These groups include operators, saftey specialists, engineers and test laboratories. 

National safety bodies, including the UK's Health and Safety Executive, take part in these efforts. Their involvement adds credibility and regulatory relevance. The process includes not just material testing but also scenario modeling, failure analysis and long-term exposure studies. 

Until a formal international standard appears, some regulators allow performance-based design. This method lets asset owners submit verified third-party test results in place of prescriptive codes. It allows progress but requires transparency and rigorous documentation. 

Ultimately, the industry requires a hydrogen fire test standard that specifies flame exposure, heat flux, test durations and performance thresholds. These parameters will help ensure consistent evaluations across countries and various applications. 

What's ahead

Hydrogen is likely to continue to grow, thus the industry must match innovation with safety. Passive fire protection plays a key role. It buys time for evacuation, protects critical assets, and helps minimise escalation. It works best when designed into the system from the start, rather than being added later as a patch. 

Hydrogen offers clear benefits but also introduces new safety demands. Fires fueled by hydrogen behave in ways that legacy systems may not fully address. Testing shows that proven materials can meet the challenge. What's needed now proves that a common language, a common benchmark and commitment to transparency are a must. 

The fire protection community must take the lead. By building sound data, designing with real-world risks in mind, and supporting the path to formal standards, the industry can help hydrogen grow safely and responsibly. 

Standards will evolve through shared data, open trials and practical engineering. Test results must become part of a global conversation. 

Stakeholders from every corner of the indusrty, including owners, regulators, material experts and engineers, must participate. 

Richard Holliday is the PPG Global Director of Hydrocarbon Passive Fire Protection for Protective and Marine Coatings. He is an industry-recognised expert on fires, explosions and cryogenic spill testing standards.