Below is a practical, safety-focused summary of maintenance requirements for common fireproofing materials (spray-applied cementitious/Agglomerated SFRM, intumescent coatings, fireproofing boards/wraps, fire-retardant-treated wood, and firestopping). I’ve included typical inspection frequencies, what to look for, basic repair/acceptance principles, recordkeeping and training items, and regulatory/test references to consult for project-specific decisions.

Key principle up front

• Fireproofing is part of a tested/listed fire-resistance assembly and must be maintained “continuously” in accordance with codes, the listing, and the manufacturer’s instructions. Do not assume appearance alone proves compliance — thickness, adhesion, continuity, and location relative to the protected element matter. (ifpmag.com)

1. Inspection frequency (typical program)

• Visual/operational walk-throughs: monthly to quarterly (look for obvious damage, penetrations, mechanical abrasion, exposed substrate, water staining).
• Detailed visual inspections: annually (measure thickness in representative locations, inspect adhesion, check for compromised continuity around penetrations and joints).
• After events: also inspect after renovations, mechanical work, impacts, fire/hose-stream tests, seismic events or any significant building work that could disrupt protection.
• Third-party or AHJ inspections: as required by project specifications, code, or insurance; often encouraged on a 1–5 year cycle for critical structures.
  These intervals are typical program guidance; the Authority Having Jurisdiction (AHJ), owner risk profile, and manufacturer recommendations determine exact frequency. (ifpmag.com)

2. What to inspect / common defects to find

• Thickness shortfalls: reduced or missing thickness at edges, beams, column corners, or where SFRM has been feathered. Thickness affects listed fire-resistance performance.
• Density / delamination / poor adhesion: cracking, sagging, or flaking SFRM or intumescent that indicates poor bond.
• Mechanical damage: gouges, impact holes, abrasions from rigging, ductwork, piping, or maintenance activities.
• Exposed substrate: fireproofing removed or abraded to the steel/structure.
• Penetrations and breaches: unsealed penetrations (pipes, conduits), damaged firestops, or improperly reinstalled sleeves after work.
• Water damage and corrosion: staining, softening of SFRM, or corrosion of protected steel under breached coating. Water can change density and adhesion.
• Paint or incompatible coatings: non-listed topcoats or repairs that change performance (some coatings interfere with listed intumescent systems).
• Firestopping integrity: gaps in joints, missing firestop materials, or incorrectly installed through-penetration systems.
  Document all findings with photos, locations, and measurements. (wconline.com)

3. Measurement & testing methods

• Thickness measurement: use calibrated dry-film thickness gauges (where applicable), or cores/bores for SFRM where gauges are not reliable (follow tested/listed design for measurement points).
• Adhesion testing: pull-off tests (per manufacturer/standards) if delamination is suspected.
• Density checks for SFRM: sample cores can be measured to verify dry density meets listing.
• Thermocouple/temperature testing is for lab fire testing (ASTM E119 / UL 263) — in-field, thickness, continuity and adhesion are the practical acceptance checks.
  Standards such as ASTM E119 and UL 263 are the fire-test bases for listed assemblies; inspection methods should ensure the installed system continues to meet the tested/listed assembly’s installation details. (store.ASTM.org)

4. Repair and acceptance principles

• Repair to the tested/listed detail: repairs must restore the fireproofing to the same material, thickness, density and configuration as the approved tested/listed design and the manufacturer’s instructions. Temporary patches are not acceptable for critical structural protection. (wconline.com)
• Use manufacturer-approved materials and installers: use the same product or manufacturer-approved equivalent and qualified applicators. For intumescents, surface preparation and specified primer/topcoat are essential.
• Re-measure and document: after repair, re-measure thickness/density/adhesion at representative locations and document results.
• Firestopping repairs: any through-penetration or joint repairs must follow the tested/listed firestop system and be installed by qualified personnel (often requiring rejigging of penetrations and re-certification by a firestop inspector).
• Avoid incompatible coatings or field “touch-ups” that are not in the listing; these can invalidate the tested assembly. (wconline.com)

5. Materials-specific notes

• Sprayed Fire-Resistive Materials (SFRM, cementitious): watch for water damage, sagging, and mechanical damage. Core sampling is common to verify thickness and dry density. Repairs usually require local removal to clean substrate, reapplication at specified thickness/density, and finishing to match adjacent areas. (wconline.com)
• Intumescent coatings (architectural/structural): inspect coating continuity, thickness (DFT), and topcoat integrity; intumescents are sensitive to surface prep, contamination and incompatible topcoats. Small damaged areas can sometimes be spot-repaired if done to manufacturer specs; larger damage often requires full recoat.
• Boards/wraps/panels: inspect fasteners, joints and seals; replace damaged boards and maintain overlap/seaming per listing.
• Fire-retardant-treated (FRT) wood: inspect for weathering, loss of treatment (e.g., heavy abrasion), biological decay, or coatings that cover required labels; maintain coatings as specified.
• Firestopping sealants/caulks: these are frequent failure points after trades work. Inspect joints and penetrations after any service work and at least annually; cutouts and re-penetrations must be re-firestopped to the tested system. (facilitiesnet.com)

6. Documentation and recordkeeping (critical)

• Maintain an up-to-date fireproofing register that lists: assembly locations, tested/listed design references, product name and batch if available, original installation records (thickness, density), inspection dates/findings, repair work and post-repair verification results, and contractor qualifications.
• Photographic records before/after repairs and measurement logs (thickness, pull-off test results, core reports) are essential for AHJ, insurance, and life-safety audits.
• Note all deviations from the listed designs and the corrective actions taken. Continuous maintenance is a code requirement in many model codes. (ifpmag.com)

7. Personnel, qualifications & training

• Inspections and repairs should be performed by personnel familiar with fire-resistance assemblies, the product manufacturer’s instructions and the listings. Many jurisdictions and projects require contractors with fireproofing or firestop installation qualifications and training (e.g., FCIA membership, manufacturer-certified applicators).
• Train maintenance and trade contractors to avoid damaging protected elements (e.g., rigging, piping installers) and to identify and report breaches immediately. (wconline.com)

8. Environmental, corrosion and compatibility issues

• Moisture and leaks: prevent standing water and leaks that can reduce SFRM density and adhesion and accelerate corrosion of protected steel.
• HVAC/ductwork and piping: when modifying systems that penetrate fire-resistance assemblies, coordinate to ensure firestopping and fireproofing are restored to the tested detail.
• Chemicals and solvents: avoid solvent cleaning or coatings that the manufacturer identifies as incompatible with the fireproofing system. (wconline.com)

9. When to involve testing labs or structural engineers

• If you find large areas of missing protection on structural members, extensive delamination, or corrosion under the protection, consult the project structural engineer and the manufacturer. In some cases, load-bearing capacity and fire-resistance may be compromised and require engineering evaluation.
• If disputes arise about whether a repair restores the tested/listed condition, third‑party inspection or laboratory testing (e.g., core testing, pull-off testing) can document acceptability. ASTM E119 / UL 263 are the baseline fire test standards used to define what the “listed” performance means. (store.ASTM.org)

10. Codes & standards to consult (project-specific)

• Model codes and lifecycle requirements: International Fire Code (IFC) and NFPA guidance require that fire‑resistance-rated construction be maintained; local adoption and AHJ interpretation will affect specifics. (ifpmag.com)
• Test standards: ASTM E119 and UL 263 are the primary fire-resistance test standards for assemblies.
• Manufacturer installation and maintenance instructions and the product/listing detail (UL/other evaluation listings) are essential and take precedence for how to repair and verify an installed system. (store.ASTM.org)

Quick actionable checklist to start a maintenance program

• Create an inventory of all fire-resistance assemblies and the tested/listed designs that apply.
• Set inspection frequencies (monthly/quarterly walk-throughs; annual detailed inspections) and responsibilities.
• Train maintenance staff and trades on how to protect fireproofing during work.
• Require that any penetrations or repairs be reinstalled per tested/listed firestop and fireproofing details.
• Keep photographic and measurement records; require contractor qualifications for repairs.
• Escalate to structural engineer/manufacturer when large areas are missing or steel corrosion is found.

If you’d like, I can:

• Provide a one-page inspection checklist tailored for SFRM versus intumescent systems, or
• Draft an example inspection log/record template you can use on-site.

Sources consulted (examples)

• Industry guidance and trade articles on inspection/maintenance of fire-resistance protection. (wconline.com)
• Model code commentary about continuous maintenance (NFPA/IFC context). (ifpmag.com)
• Test standards describing fire-resistance testing used to create listed assemblies (ASTM E119 / UL 263). (store.ASTM.org)

If you want the one‑page checklist or a templated log, tell me which material(s) (SFRM, intumescent, boards, firestopping) you want covered first and I’ll prepare it.