Beh Jing HanMing Chian YewYEW MING KUN0000-0001-6467-0239Bernard Saw L H2024-11-072024-11-072019-07-31https://doi.org/10.3390/coatings9080483https://dspace-cris.utar.edu.my/handle/123456789/6452This paper presents the heat release characteristics, char formation and fire protection performance of thin-film intumescent coatings that integrate eggshell (ES) as an innovative and renewable flame-retardant bio-filler. A cone calorimeter was used to determine the thermal behavior of the samples in the condensed phase in line with the ISO 5660-1 standard. The fire resistance of the coatings was evaluated using a Bunsen burner test to examine the equilibrium temperature and formation of the char layer. The fire propagation test was also conducted according to BS 476: Part 6. On exposure, the samples X, Y, and Z were qualified to be Class 0 materials due to the indexes of fire propagation being below 12. Samples Y and Z reinforced with 3.50 wt.% and 2.50 wt.% of ES bio-filler, respectively, showed a significant improvement in reducing the heat release rate, providing a more uniform and thicker char layer. As a result, the addition of bio-filler content has proven to be efficient in stopping the fire propagation as well as reducing the total heat released and equilibrium temperature of the intumescent coatings.journal-article