Analysis of the Application of Protective Blocks and Structural Systems for Ultra-Fast Fire Response Accompanied by Overpressure

Ultra-fast fire, characterized by rapid heat release and associated overpressure, poses serious challenges to structural safety in industrial facilities. This study presents the design and evaluation of a protective block capable of resisting both the thermal and mechanical effects of ultra-fast fires. The study combined material- and component-level fire tests with structural simulations. The fire scenario was defined as reaching 1 MW within 60 s with a peak overpressure of 5 bar, comparable to dust fire conditions. Fire resistance was achieved with a layered system comprising a 1 mm perforated steel plate to prevent coating detachment, a 5 mm fire-resistant coating, a 2 mm front steel plate, 25 mm glass wool, and a 2 mm back steel plate. Structural analysis confirmed that a frame system with 200 mm × 200 mm H-beams (vertical) and 150 mm steel plates (horizontal) limited deflection to about 50 mm under 5 bar overpressure. These results demonstrate the feasibility of integrating material-level fire resistance with structural optimization, providing a practical basis for protective block design in ultra-fast fire scenarios.