Passive Fire Protection in the Mumbai International Airport Expansion Project

Background
Mumbai International Airport (Chhatrapati Shivaji Maharaj International Airport) is one of India’s busiest airports and a critical infrastructure hub. With a massive expansion project underway to increase terminal capacity and improve passenger experience, fire safety was a paramount concern. The airport authorities and contractors collaborated to incorporate state-of-the-art passive fire protection (PFP) solutions throughout the new terminal buildings.

Challenge

The terminal expansion included multiple high-rise structures, extensive underground parking, and complex mechanical and electrical services. The main challenges were:

• Ensuring structural steel fire resistance to withstand potential fires for 2 to 3 hours.
• Preventing fire and smoke spread through service shafts, cable trays, and duct penetrations.
• Meeting strict Indian and international fire codes (NBC India, NFPA, IBC).
• Minimizing downtime during construction and maintaining aesthetic finishes.

Passive Fire Protection Solutions Implemented

1. Intumescent Coatings on Structural Steel:
The structural steel framework was coated with high-performance intumescent paint, providing up to 3 hours of fire resistance. The coatings were chosen for their slim profile, aesthetic finish, and ability to be applied on-site without affecting construction schedules.

2. Firestopping Systems:
To seal gaps around pipes, cables, and ducts passing through fire-rated walls and floors, intumescent firestop sealants and wraps were installed. These prevented fire and smoke migration, maintaining compartmentation integrity.

3. Fire-Resistant Boards:
Calcium silicate fireproof boards were used for shaft enclosures and ceiling barriers, offering robust protection with easy installation and light weight.

4. Spray-Applied Fire Resistive Materials (SFRM):
Cementitious spray fireproofing was applied to steel beams and columns in less accessible areas, ensuring consistent coverage and compliance with fire ratings.

Results and Benefits

• Regulatory Compliance: The PFP solutions helped the project achieve full compliance with the National Building Code (NBC) of India, as well as international standards such as NFPA 101 Life Safety Code.
• Safety Enhancement: Compartmentation measures and fireproofing ensured that any potential fire would be contained, significantly increasing occupant safety and protecting vital infrastructure.
• Aesthetic and Functional: Intumescent coatings provided a clean, visually appealing finish that integrated seamlessly with the terminal’s modern architectural design.
• Efficient Construction: The use of prefabricated firestop components and spray-applied fireproofing accelerated construction timelines without compromising fire safety.

Lessons Learned

• Early integration of passive fire protection planning in the design phase is critical for smooth execution.
• Combining multiple PFP methods (coatings, boards, sealants) tailored to different structural needs maximizes safety and cost-efficiency.
• Training and quality control during application ensure durability and performance.

Conclusion

The Mumbai International Airport expansion demonstrates how advanced passive fire protection techniques can be effectively implemented in complex infrastructure projects in India. With growing urbanization and high-rise construction, such projects set a benchmark for integrating passive fire safety seamlessly into modern building design and construction.