Location: Nueva Vizcaya, Philippines
Client: FCF Minerals Corporation
Industry: Mining & Mineral Processing
System Used: 1.6mm CharCoat CC Intumescent Cable Coating
Application Partner: ShieldCrete® Philippines Inc.
Project Completion: August 2022
In the rugged terrain of Nueva Vizcaya, where the mining industry plays a pivotal role in economic development, FCF Minerals Corporation operates one of the most prominent processing plants in the Philippines-the Runruno Gold Project. Known for its technical advancement and commitment to environmental safety, FCF faced a critical challenge in safeguarding its lube pack sections and electrical infrastructure against fire risks.
With business continuity insurance and operational safety on the line, the company turned to ShieldCrete® Philippines Inc. and the globally certified CharCoat CC Cable Coating system-engineered for high-performance passive fire protection.
Project Objective
The core objective of this project was to ensure that FCF Minerals’ electrical cables-especially in critical process areas-were equipped with 90-minute fire-rated protection as per insurance compliance and facility safety standards.
Specifically, the mission involved:
- Fireproofing horizontal and vertical electrical cables in high-risk zones.
- Meeting the 1.6mm Dry Film Thickness (DFT) benchmark as required for full performance.
- Applying a certified intumescent coating that could withstand intense heat during both hydrocarbon and cellulosic fire events.
Why Passive Fire Protection Was Critical
In industrial environments like mineral processing plants, fire incidents can occur due to:
- Overheated machinery and cables.
- Accumulation of flammable residues near equipment.
- Electrical faults in high-voltage zones.
In such cases, unprotected cables can contribute to fire propagation, equipment failure, and significant downtime. FCF’s strategy to proactively install a passive fire protection system reflects a growing industry trend where safety is integrated into infrastructure not just emergency response.
Site Evaluation & Technical Presentation
Before the application began, the technical team from ShieldCrete® conducted a comprehensive site visit and hazard analysis. The purpose was to:
- Identify vulnerable cable runs and junctions.
- Demonstrate application methodology.
- Align on safety protocols for both plant personnel and contractors.
FCF’s maintenance engineering team participated in a detailed technical presentation showcasing the global track record of CharCoat CC, including:
- Fire test results under IEC60331-21 conditions.
- Application compatibility with cable types ranging from 10kVa to 20kVa.
- Minimal disruption during installation due to the spray-on or brush-on application technique.
Product Used: CharCoat CC Cable Coating
CharCoat CC is a water-based, intumescent, latex coating designed specifically for the fire protection of grouped or bundled cables, and is suitable for both interior and exterior applications.
Key Product Advantages:
- 90-Minute Fire Resistance (Certified by IEC)
- No Cable Derating Required
- Resistant to Weathering (QUV Approved)
- Easy to Inspect, Maintain, and Recoat
- Non-toxic, Non-halogenated Composition
The system expands under heat, forming a char barrier that insulates the cable from flames, delaying heat penetration and helping maintain circuit integrity during fire scenarios.
Installation Details
The coating was applied in three critical zones within the process plant:
- Vertical cable trays
- Horizontal cable ducts
- Lube pack control areas
Installation Process:
- Surface Prep – Removal of dust, oils, and previous contaminants.
- Primer Coat (if required) – Ensuring adhesion to complex cable types.
- Base Coat Application – Spray applied for large areas; brush applied for junctions.
- Thickness Testing – Final DFT verified at 1.6mm using calibrated micrometers.
- Cure Time – Curing allowed under ambient conditions; no heated chambers required.
Despite challenging site access and environmental conditions, ShieldCrete’s application team ensured zero disruption to plant operations, completing the job safely and efficiently.
Performance Verification
To meet international insurance and safety benchmarks, CharCoat CC was certified to:
- IEC 60331-21 (Fire-resistance of electric cables)
- ASTM E84 (Surface burning and smoke development)
- QUV Weathering Standards (Outdoor durability)
Post-installation inspections confirmed complete coverage, uniform film build-up, and absence of exposed cable areas, fulfilling both FCF’s internal standards and third-party audit criteria.
Impact on Operational Safety & Compliance
By implementing CharCoat CC, FCF Minerals achieved:
- Regulatory Compliance
Aligned with ISO/IEC fire standards for electrical infrastructure. - Enhanced Business Continuity
Improved insurance coverage and reduced risk premiums. - Operational Resilience
Minimized the probability of cascading failures from cable fires. - Sustainability & Environmental Alignment
CharCoat CC’s water-based, non-toxic formulation aligned with FCF’s commitment to safe and eco-friendly operations.
Regional Significance
This project holds significance not just for FCF, but for mining and industrial operations across Southeast Asia, where:
- High humidity affects the integrity of conventional fire wraps.
- Cable corridors are often tight, vertical, or obstructed, making sprays more practical.
- Local regulations are increasingly favoring non-toxic, halogen-free solutions.
The successful deployment of CharCoat CC Cable Coating at the Nueva Vizcaya processing plant reinforces the importance of proactive passive fire protection in industrial settings.
For facilities where high-value equipment and continuous operations are critical, intumescent cable coatings are not a luxury they’re a necessity.
Want a Consultation?
If you’re responsible for facility safety, plant reliability, or insurance compliance at a mining or industrial site, contact us today for a technical presentation or on-site evaluation.
