Overview

As the leading electricity producer and distributor in the Middle East, Saudi Electric Company (SEC) undertook multiple substation expansion projects across the Kingdom of Saudi Arabia. Given the strategic importance of these facilities to the national grid, maintaining circuit integrity during fire emergencies was non-negotiable. SEC turned to CharCoat to supply a tested and approved cable fire protection system that could meet IEC 60331 requirements under hydrocarbon fire conditions.

Project Scope and Locations

The application of CharCoat CC cable coating was executed across multiple SEC substations, including:

• 380/132/33KV HAIL-4 Bulk Supply Point (BSP)
• Al-Uwayqilah 380/33kV BSP
• Other high-value power transmission locations across KSA

The systems protected included:

• Existing and new single cables
• Trefoil cable configurations
• Cable trays, conduits, junction boxes
• Complex penetrations requiring firestop sealing (CharCoat FP, IS, FM)

The firestop materials provided were required to meet 3- to 4-hour protection benchmarks in accordance with SEC’s performance standards and regional codes.

Engineering Partners and Execution

Larsen & Toubro (L&T) was appointed as the EPC for the substation projects. A global engineering powerhouse, L&T’s Power Transmission & Distribution (PT&D) division delivered integrated services from design and manufacture through to installation and commissioning. Their endorsement of CharCoat products highlights the performance credibility CharCoat has built across global utilities.

Installation and application responsibilities were undertaken by Rigzone General Contracting LLC, a trusted contractor in the Kingdom of Saudi Arabia. With ISO 9001, ISO 14001, and ISO 45001 certifications, Rigzone’s reputation spans mechanical, civil, instrumentation, and industrial coating works across oil, gas, and utility projects. Additional applicators included SBC and HEISCO, further extending the reach and reliability of the implementation.

System Applied: CharCoat CC

CharCoat CC is a water-based, latex intumescent coating engineered specifically for grouped or bundled cables and penetrations. With global approvals including IEC and QUV, it is capable of preserving cable integrity for up to 90 minutes under hydrocarbon fire exposure as per IEC 60331-21.

Application Details:

• DFT (Dry Film Thickness): 1.6 mm
• WFT (Wet Film Thickness): 3.0 mm (multi-pass)
• Spray adhesion coat: Max 0.5 mm
• Final top coats: Up to 2.5 mm WFT

CharCoat CC was applied via airless spray for large cable trays and with brush-on techniques for single cables. Unlike wraps or fireproof boards, the coating allows for quick re-application and does not typically require cable derating.

Testing, Standards & Performance

CharCoat CC met or exceeded the following test standards:

• IEC 60331-11 / IEC 60331-21: 90-minute hydrocarbon and non-hydrocarbon fire rating
• ASTM E1725: 30-minute cable fire protection
• IEC 60332-3-22 / UL 723: Flame spread characteristics
• BS 6853, ISO 5660, BS 476: Smoke toxicity, smoke density, and corrosivity testing
• QUV Approved: Suitable for indoor and outdoor applications under UV exposure

CharCoat CC was validated through independent labs including Intertek and UL. Functionality of the coated electrical systems during fire was proven through controlled testing, certifying CharCoat CC as a highly reliable solution.

Technical Advantages Over Alternatives

Traditional methods such as cable wraps or ducting boards are:

• Labor-intensive to install
• Expensive
• Often require derating of cables
• Challenging to inspect or rework

CharCoat CC solves all of these pain points:

• Applied with airless sprayer or brush
• Non-invasive and easy to reapply
• No derating of cables
• QUV resistance for long-term performance in outdoor environments

Partner Commentary

“CharCoat was chosen not only for the strength of its technical documentation and test credentials, but also because of its practical advantages: no cable derating, ease of reapplication, and compliance with global standards.”
— Project Engineer, Larsen & Toubro

“From logistics to final spray application, our experience with CharCoat materials has been seamless. The coatings performed reliably under test conditions and passed all inspections on-site.”
— Site Manager, Rigzone General Contracting LLC

CharCoat CC proved its value across Saudi Electric Company’s substations as a dependable, scalable, and cost-effective fire protection solution for critical cable systems. From design to delivery, its performance was affirmed not just by documentation, but through on-ground results.

For utilities, EPCs, and industrial clients seeking high-integrity fire protection for power systems, CharCoat remains a partner of choice.

Interested in technical datasheets, performance reports, or a custom solution for your project?
✉️ Contact us at: mail@charcoat.com
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CharCoat Passive Fire Protection Inc.
Suite 301 – 220 Brew Street, Port Moody BC V3H 0H6, Canada
☎️ +1 604 941 1001 / +1 604 723 6744
✉️ mail@charcoat.com