Protective gel applied to skin and costumes for fire stunts – creates a heat-resistant barrier allowing performers to safely be near or engulfed in flames for limited periods.
What is Burn Gel?
Burn Gel (Feuerschutzgel) is a specialized gel applied to skin and costumes to protect performers during fire stunts. It forms a heat-resistant barrier that shields against flames and heat for a limited time.
How it Works
| Principle | Description |
|---|---|
| Insulation | Barrier between skin and heat |
| Evaporation | Cooling through water evaporation |
| Non-Flammable | Gel does not ignite |
| Oxygen Deprivation | Prevents combustion |
Product Types
| Type | Use |
|---|---|
| Protective Gel | General skin protection |
| High-Temperature Gel | Extreme heat |
| Costume Gel | For fabrics |
| Hair Gel | Head/facial hair |
Known Brands
| Brand | Description |
|---|---|
| Zeller International | Industry standard |
| Fire Gel | Widely used |
| Cool Gel | Actively cools |
Application Areas
| Stunt | Gel Application |
|---|---|
| Partial Burn | Arm, leg burn |
| Full Burn | Entire body |
| Face Burn | Head protection |
| Flash Fire | Short flame exposure |
| Proximity | Close to fire |
Application
| Step | Activity |
|---|---|
| Preparation | Clean, dry skin |
| Base Layer | Thin gel layer |
| Build-up | Multiple layers |
| Reinforcement | At critical areas |
| Undergarment | Fire-resistant layer |
| Costume | Treated with gel |
Layering System
| Layer | Function |
|---|---|
| Skin | Clean, prepare |
| Gel Base | Initial protection |
| Gel Build-up | Several cm thick |
| Nomex Underwear | Additional insulation |
| Costume | Treated, flammable |
Time Limits
| Burn Type | Max Duration |
|---|---|
| Flash Fire | 3–5 seconds |
| Partial Burn | 10–15 seconds |
| Full Burn | 15–30 seconds |
| Proximity | Minutes |
Safety Team
| Role | Task |
|---|---|
| Stunt Coordinator | Planning, execution |
| Fire Safety | Fire department liaison |
| Safety Divers | For water extinguishment |
| Medic | On standby |
| Gel Technician | Application |
Extinguishing Systems
| Method | Description |
|---|---|
| Fire Blanket | Immediate smothering |
| CO2 Extinguisher | Rapid extinguishing |
| Water Crew | On standby with hoses |
| Jump into Water | For water burns |
Preparation
| Phase | Activity |
|---|---|
| Test | Test gel on skin |
| Rehearsals | Movement sequences |
| Communication | Establish signals |
| Backup | Replacement performer |
| Exit | Plan escape route |
Costs (approx.)
| Item | Price |
|---|---|
| Burn Gel (Liter) | €50–100 |
| Full Burn Setup | €5,000–15,000 |
| Stunt Performer | €1,000–5,000 |
| Safety Team | €2,000–5,000 |
| Fire Department | Variable |
Risks and Limitations
| Risk | Measure |
|---|---|
| Burns | Strict time limits |
| Inhalation | Respiratory protection during rehearsals |
| Panic | Experienced performers |
| Equipment Failure | Redundancy |
Alternatives
| Alternative | Situation |
|---|---|
| CGI Fire | Post-production |
| Controlled Flames | No body contact |
| Dummy Double | Extreme burns |
| LED Flame | Simulation |
Today
Burn Gel is essential for safe fire stunts. The technique enables spectacular scenes that are difficult to achieve with CGI alone – but only with the highest safety standards, experienced teams, and strict protocols.
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