Below is a complete, ready-to-use training program for fireproofing (passive fire protection) system installers. It covers learning objectives, course modules (theory + hands-on), safety & compliance, assessments, tools/equipment, suggested timeline, sample competency checklist, and follow-up recommendations you can adapt for company or jurisdictional requirements.

Summary learning objectives

• Understand fundamentals of fire behavior and fire ratings.
• Know types of passive fire protection (intumescent coatings, cementitious, mineral fiber, firestopping, fireproofing boards, spray-applied fire resistive materials — SFRM/Thermally Conductive, etc.).
• Read and apply manufacturer specifications, drawings, and listed systems (tested assemblies).
• Correctly prepare substrates, mix/apply materials, achieve required thickness/density/coverage, and finish work per spec/standards.
• Perform quality control (thickness/density tests, adhesion, continuity) and document results.
• Recognize hazards and follow PPE, respiratory protection, ventilation, and jobsite safety procedures.
• Understand inspection, maintenance, and repair requirements for installed fireproofing systems.

Recommended prerequisites

• Basic construction/site experience (preferred).
• OSHA 10-hour or equivalent general construction safety training (recommended before on-site practicals).

Core training modules (classroom + practical)

1. Introduction & Terminology (1–2 hours)

• What is passive fire protection vs active systems.
• Common terms: fire-resistance rating, hour rating, firestop, membrane, through-penetration, GSA/UL/ASTM listings, IFI, etc.
• Overview of materials used: intumescent paints, epoxy intumescents, cementitious SFRM, cellular concrete, mineral wool, firestop sealants, collars, boards, and coatings.

2. Fire Science Basics (2–3 hours)

• Heat transfer (conduction, convection, radiation) and how fireproofing slows structural failure.
• Fire endurance tests and standards (principles behind ASTM E119, UL 263, and firestop standards like UL 1479 / ASTM E814 — note: verify current standard numbers for your jurisdiction).
• How structural steel behaves in fire and the role of insulation thickness/density.

3. Codes, Standards & Listings (2–3 hours)

• Applicable codes: International Building Code (IBC), NFPA 101 (Life Safety), local building codes (note: check local jurisdiction).
• Common test standards (ASTM, UL) and manufacturer system listings.
• Project submittals, shop drawings, and the importance of following listed systems and tested assemblies.

4. Product Types, Selection & Specification (2–3 hours)

• Pros/cons of spray-applied cementitious vs intumescent coatings vs board systems.
• Environmental conditions, durability, aesthetic considerations, VOCs, curing time, and compatibility with substrates.
• Reading technical data sheets (TDS) and material safety data sheets (SDS/MSDS).

5. Surface Preparation & Substrate Prep (3–4 hours; includes lab)

• Cleaning, rust remediation, primers, pre-treatment, and anchorage systems for boards and mats.
• Tolerances, substrate moisture limits, ambient temp/humidity effects.
• Practical: assessing/recording substrate condition, applying primer.

6. Mixing, Application & Thickness Control (4–6 hours; hands-on)

• Mixing procedures, pot life, batch control, and equipment calibration.
• Spray equipment setup and maintenance (nozzle selection, compressor requirements, hoses).
• Application techniques: spray patterns, multiple coats, feathering, working around penetrations.
• Measuring thickness (calipers, wet-film thickness gauges, destructive and non-destructive tests), density checks for SFRM.
• Practical: apply on test panels to required thickness, measure and document.

7. Firestopping & Penetrations (3–4 hours; hands-on)

• Types of penetrations: cables, conduits, pipes, rectangular openings.
• Firestop products: sealants, collars, wraps, mortar, and through-penetration systems.
• Installation to listed detail, annular space, bonding, and backing materials.
• Practical: install through-penetration systems and test mock-ups.

8. Finishing, Coatings, & Repairs (2–3 hours; hands-on)

• Surface finishing, smoothing, painting/intumescent topcoats, compatibility issues.
• Repair methods for damaged or thin areas; patching procedures and documentation.

9. Inspection, Testing & Quality Assurance (2–3 hours)

• On-site QC: measuring and recording thickness, density, adhesion tests, holiday testing where applicable.
• Preparing inspection reports, as-built documentation, and closeout packages.
• Interaction with third-party inspectors and local AHJs.

10. Health, Safety & Environmental Controls (2–3 hours)

• PPE for spray-applied materials (respirators, coveralls, gloves, eye protection), fit-testing for respirators.
• Ventilation, dust control, containment for overspray, lead/PCBs/other hazardous substrate considerations.
• Spill response, SDS use, and hazardous waste disposal.
• OSHA Respirable Crystalline Silica considerations (if cutting or grinding mineral wool/concrete) — include controls and medical surveillance if applicable.

11. Project Management & Best Practices (1–2 hours)

• Jobsite coordination, sequencing with other trades, storage/handling, inventory control, training records.
• Estimating material quantities, wastage factors, mixing ratios, and productivity expectations.

12. Final Assessment & Certification (varies; see below)

• Written exam (multiple choice and short answer).
• Practical exam: prepare substrate, mix/application, measure thickness/density, install a penetration system, perform required QC, complete documentation.
• Pass/fail criteria and remedial training plan for fail items.

Suggested course length and format

• 3-day intensive (preferred for experienced tradespeople): blends classroom and extended practical sessions.
• 5-day comprehensive (recommended for trainees without prior experience): more practice time and staged assessments.
• Or modular format: deliver modules over several half-day sessions to fit company schedules.

Tools, equipment & materials list (for hands-on)

• Spray rig and compressor suitable to product (per manufacturer).
• Spray nozzles, hoses, mixing drums, mixers, measuring buckets.
• Wet-film thickness gauges, dry-film thickness gauges, calipers.
• Density test kit (for SFRM), core sampler (if doing spot destructive tests), scale for density.
• Personal protective equipment: respirators (PAPR or elastomeric with cartridges), disposable/ washable coveralls, gloves, safety glasses, hard hats, hearing protection.
• Ladders, scaffolding, temporary barriers, drop cloths, masking tape.
• Firestopping products, sealants, collars, boards, primers, and sample substrates for practice.

Assessment & competency verification

• Written exam: 40–60 questions covering theory, standards, safety, product selection (passing score e.g., 75%).
• Practical exam: graded checklist for each task (mixing, application, thickness measurement, firestop installation, cleanup). Require ≥85% on critical safety and installation items.
• Issue certificates of competency showing scope (e.g., “Spray-Applied Cementitious Fireproofing Installer — Company X — Date — Validity: 3 years subject to refresher training”).

Sample competency checklist (practical)

• Identifies and reads the correct manufacturer TDS and system listing.
• Proper PPE and respiratory protection worn.
• Substrate properly prepared (clean, primed, dry).
• Correct mixing procedure and ratios followed.
• Equipment setup and nozzle selection correct for material.
• Applied material achieves specified thickness uniformly (measured at required number of points).
• Density (for SFRM) within tolerance on samples.
• Through-penetration detail installed to listed assembly.
• Surface finish acceptable and repair methods followed.
• Jobsite cleanup and waste handling performed properly.
• Completed QC documentation and inspection records.

Documentation & recordkeeping

• Daily application logs (weather, ambient temp, substrate temp/humidity, batch/lot numbers, nozzle sizes, thickness readings).
• Photos of prep, mid-application, and finished work.
• QC test results and non-conformance reports (with corrective actions).
• Training and certification records for installers.

Refresher training & continuing education

• Annual toolbox safety refreshers.
• Re-certification recommended every 2–3 years or when standards/manufacturer specs change.
• Immediate retraining when new products or system listings are introduced.

Site setup, sequencing & common pitfalls

• Coordinate with other trades (sprinklers, HVAC, electrical) before application.
• Protect adjacent finishes from overspray.
• Avoid application in unsuitable environmental conditions (too cold/humid).
• Watch for disbonding from improperly prepared or oily substrates.
• Ensure correct anchorage spacing for boards and mats to prevent sagging.

Legal, regulatory & standard cautions

• Always follow manufacturer’s installation instructions and only install systems that are part of a tested/listed assembly.
• Local building authority (AHJ) and project specifications may require third-party inspection or special approvals — confirm prior to work.
• Keep current with OSHA, NFPA, IBC and ASTM requirements that affect safety and installation; these standards can be updated — verify the applicable edition for your project.

Optional add-ons (value-add)

• Respirator fit-testing and training.
• Mock inspection with a third-party certified inspector.
• Training on specialty products (intumescent coatings for structural steel aesthetics, mineral wool board systems).
• Supervisor/QA training: how to read lab test reports, review submittals, and accept/reject material.

How to implement

• Use this syllabus to create course materials: slide decks, safety handouts (SDS/TDS templates), hands-on rubrics, and test forms.
• Arrange for a qualified instructor: experienced installer with manufacturer certifications or a third-party trainer from industry organizations (e.g., International Firestop Council, industry training providers).
• Set up a mock jobsite with relevant substrates and penetration types for practical testing.

If you want, I can:

• Produce a printable course schedule, slide outline, and sample written exam and practical scoring sheet tailored to a 3- or 5-day course.
• Draft a sample certificate of completion and a daily QC log template.

Which of those would you like me to produce next?