
About the product
HENSOTHERM® 421 KS is the single-component, water-based intumescent coating from Rudolf Hensel GmbH for passive fire protection of steel profiles and structures. When exposed to fire, it forms an insulating layer that slows down the heating of the profile and maintains the load-bearing capacity of the structure. It combines very low film thicknesses with exceptional cost-effectiveness.
Fire resistance R30 – R180
Tested according to DIN EN 13381-8 and classified according to DIN EN 13501-2. ETA 20/1228 · aBG Z-19.51-2313 · CE Mark. The dry film thickness is calculated according to the section factor of the profile and the required R value for the project.
25 years certified service life
Rudolf Hensel is the first manufacturer to obtain the European certificate for an extended service life of 25 years in dry interior conditions (category Z2), with and without a topcoat. Maintenance-free system.
Key Features
- ✓Water-based, single-component (1C): ready to use, no mixing or pot life issues.
- ✓Ultra-thin thicknesses: up to 1,000 g/m² (approx. 500 µm dry film) in a single airless application.
- ✓Virtually zero emissions: VOC < 1 g/m², emission class A+, AgBB tested. Suitable for LEED v4, DGNB Navigator, EPD, Minergie Eco, and Cologne List.
- ✓Ideal for renovation: direct on-site application in occupied buildings — public offices, schools, hospitals.
- ✓Optional finish: recoatable with HENSOTOP in RAL, DB colors, or custom color chart.
- ✓Water cleanup: no solvents for equipment washing.
Scope of Application
Steel elements in interiors, open structures, and exteriors protected from driving rain and condensation (use categories Y / Z1 / Z2 according to ETAG 018-2 / EAD):
- ✓Standard profiles R30/60/90/120: I/H profiles (bending beams, compressed elements, columns), circular and square hollow profiles, and box profiles.
- ✓Tensile elements in trusses R30/60/90/120: I/H profiles with utilization factor μfi ≤ 0.50, and compressed box profiles.
- ✓Tie rods R30/60: solid bars and round hollow tubes (according to aBG Z-19.51-2349).
Structural steels S235, S275, and S355 according to aBG; in other EU member states, construction steels according to EN 10025-1 (designation S, except S185). Consult for other grades.
The Complete System
- HENSOGRUND Primer — WB Green, 1966 E+, 1K AK or 2K EP, on steel blasted to grade Sa 2½ (EN ISO 12944-4) or manually derusted to PSt2/St2.
- HENSOTHERM® 421 KS up to the dry thickness calculated for the required R value.
- HENSOTOP Topcoat (WB Green, SB or 2K PU) — recommended, but not necessary in dry interiors without condensation. Never before 24 h and after passing the fingernail test.
Technical Data
| Manufacturer | Rudolf Hensel GmbH (Made in Germany) |
| Product Type | Water-based, single-component (1C) intumescent coating |
| Fire Resistance | R30 – R180 |
| Approvals | DIN EN 13381-8 · DIN EN 13501-2 · ETA 20/1228 · aBG Z-19.51-2313 · CE Mark (93/68/EEC) |
| Use Categories | Y / Z1 / Z2 (ETAG 018-2 / EAD) |
| Service Life | Minimum 25 years in dry interiors |
| Application | Airless (200–250 bar, 0.017"–0.025" nozzle, >4 l/min), wool roller, or long-bristle Chinex brush |
| Thickness per Coat | Up to 1,000 g/m² (≈500 µm dry). If more than one coat is required, the first max. 700 g/m² (≈350 µm) |
| Dilution | Water, maximum 3 % |
| Drying Time | Minimum 24 h per coat at +20 °C and 65 % RH (residual moisture <5 %) |
| Application Conditions | Material, substrate, and ambient ≥ +5 °C · RH ≤ 80 % · surface 5 °C above dew point · treated surface ≤ +35 °C |
| Workshop Application | Surface and ambient between +10 °C and +35 °C |
| Storage | Between +5 °C and +30 °C, protected from frost and direct sunlight |
| Shelf Life | 12 months in unopened container at +20 °C |
| Giscode | M-DF01 |
Professional application product
The system can only be applied by qualified personnel. The applicator must inform the owner in writing that protection is only guaranteed as long as the coating remains in good condition, and about the materials approved for its repair. Treated elements cannot be clad or boxed in (this would prevent expansion), must be accessible for inspection, and must bear the manufacturer's identification plates. Warranty claims require daily application reports.
Frequently Asked Questions
How much product do I need per m² of profile?
It depends on the required dry thickness, which is derived from the profile's section factor and the fire resistance minutes required in the project. Send us the profile list and the required R value, and we will help you with the calculation.
Can it be applied outdoors?
Only in exteriors protected from driving rain and condensation, and in covered open structures. It is not a system for full weather exposure. In these situations, the HENSOTOP topcoat is necessary to protect against moisture.
Is the topcoat enamel mandatory?
Not in dry interiors without condensation: the system has a certified service life of 25 years even without a topcoat. It is necessary when the surface is exposed to moisture, environmental agents, or cleaning, or when a specific color is required.
Can it be applied over galvanized steel?
Yes, provided that the galvanization has completely degassed and any residue that compromises adhesion is removed. It must be pre-primed with HENSOGRUND WB Green or HENSOGRUND 2K.
Is it suitable for factory-primed profiles?
Only if the third-party primer has been tested as a compatible substrate. If not, it must be removed, and the process for bare profiles followed. After prolonged outdoor exposure, any damage must be checked and the thickness measured before application.
Complete the system
- HENSOGRUND WB Green / 1K AK / 2K EP — system anti-corrosion primers
- HENSOTOP WB Green / SB / 2K PU — topcoat enamels in RAL and DB colors
- Airless equipment of 200–250 bar and 0.017"–0.025" nozzles
- Dry and wet film thickness gauges



















