Off-Site Fireproofing Meets Common Job Site Challenges: Survey

Off-site fireproofing of steel building materials provides opportunities for builders of advanced manufacturing projects to alleviate some pressing challenges faced on such projects.

According to new research from Sherwin-Williams, key challenges include widespread project delays, budget pressures, and job site safety concerns. Each of these concerns, according to the company, may be alleviated with applications of shop-applied coatings processes. When specified, shop-applied coatings allow protected steel to arrive at job sites weather resistant and ready for construction, according to the company.

Nearly nine in 10 (87%) survey respondents, all working on projects larger than $30 million, have experienced project delays, with most attributing materials (71%) and weather (65%) as the primary drivers of those delays. Unpredictable weather, which can halt work completely, and supply chain disruptions, making critical materials delayed or unavailable, frequently prevent construction from progressing as planned.

Sherwin-Williams offers epoxy intumescent fire protective coatings and a network of applicators specialized in off-site, shop-applied coatings processes.

“Our shop-applied fireproofing can overcome common delays—whether from weather, materials or labor—helping contractors save time, reduce costs, and accelerate project completions,” said Joseph Windover, an executive with Sherwin-Williams Construction Solutions.

Job site safety is also a top concern for many in the industry. Nearly half (45%) of respondents identified “maintaining a safe job site” as a primary challenge. More than two in five (43%) reported incidents where someone working at a significant height was injured or fatally harmed on a project, highlighting the risks associated with advanced manufacturing construction.

“Shop-applied fireproofing significantly enhances job site safety by eliminating the need for workers to perform at heights and reducing the presence of risk-prone equipment, lines and hoses,” said Windover. “By moving fireproofing to a controlled off-site environment, we not only ensure quality compliance but also create a safer, more efficient worksite.”

The survey uncovered additional concerns for megaproject construction. A majority (53%) of respondents cited staying within budget as their biggest challenge. When selecting passive fire protection coatings, cure time (27%) was the top priority, followed by durability/longevity and price (both 18%). This signals that construction decision-makers prioritize coating performance over cost savings alone.

The survey also showed that most respondents (60%) agreed or strongly agreed that weather, temperature, and humidity have created delays specifically in the fireproofing process for their megaprojects. Additionally, 66% reported a 3.4-month average delay when using field-applied coatings. These are key problems that are directly addressed using shop-applied coatings.