A Strategic Move Toward Safer Operations

PEMEX Cangrejera, one of Mexico’s key chemical manufacturing hubs, faced a critical challenge: high-risk electrical cabling infrastructure with no fire-rated protection. Operating in a volatile environment that involves hydrocarbon processing and complex electrical systems, PEMEX identified the need for an advanced passive fire protection solution that would meet international fire safety standards without disrupting daily operations.

To address this, PEMEX partnered with Tecnobahez-Lee and selected CharCoat CC, a high-performance, water-based intumescent cable coating. The goal was to secure three major substations across their polyethylene plant in both North and South zones while maintaining operational continuity and meeting hydrocarbon fire safety requirements.

The Challenge: High Heat, High Stakes

Chemical plants like PEMEX Cangrejera operate under constant fire risk due to high temperatures, flammable materials, and dense cable networks. The specific challenges included:

• Unprotected Electrical Infrastructure: Existing cables lacked certified passive fire protection.
• Hydrocarbon Fire Risk: Substations required a system that could withstand 1100°C for at least 90 minutes.
• Downtime Risk: Any disruption to electrical systems could trigger massive production losses.
• Regulatory and Insurance Pressure: Compliance with IEC and FM standards was mandatory.

In such high-risk environments, the cost of inaction is immense. A fire could lead to significant equipment damage, extended downtime, safety liabilities, and long-term operational disruptions.

The Solution: CharCoat CC Intumescent Cable Coating

PEMEX adopted CharCoat CC as the cable fire protection solution across critical substations. Applied at a 1.6mm Dry Film Thickness (DFT), CharCoat CC delivers 90-minute fire resistance under hydrocarbon fire conditions, without compromising cable performance.

Why CharCoat CC Was Selected:

• Hydrocarbon Fire Rating: Certified protection up to 1100°C for 90 minutes (IEC & FM Tested)
• Exterior-Grade Durability: Approved for outdoor exposure (QUV Approved)
• Maintains Ampacity: Electrical performance preserved during and after fire exposure
• Low Flame Spread: Prevents fire propagation along grouped or bundled cable trays
• Low VOC & Green Compliance: SCAQMD Rule 1113 compliant, suitable for ESG goals

CharCoat CC was installed across three substations—Polyethylene Plant North Side #1, South Side #1, and South Side #3—by certified applicators using controlled spray techniques to ensure uniform coverage and consistent DFT.

Implementation: Seamless Execution with Zero Downtime

Tecnobahez-Lee ensured a seamless application process. The deployment was conducted during scheduled maintenance periods to avoid disruption, using the following steps: 

1. Surface Prep: Existing cables were cleaned and inspected.
2. Controlled Application: CharCoat CC applied at 1.6mm DFT via airless spraying.
3. Curing & Testing: The coating was cured under controlled humidity with rigorous post-installation inspections.
4. Compliance Verification: Certified performance testing was conducted under IEC and FM protocols. 

The result: PEMEX achieved high-performance passive fire protection while keeping operations fully functional.

Results: Operational Resilience Through Fire Protection

The implementation of CharCoat CC at PEMEX Cangrejera brought transformative benefits:

• Fire Containment: Flame spread on electrical infrastructure eliminated
• System Integrity: Cables maintained functionality during fire exposure
• Audit Ready: Compliant with global safety standards (IEC60331, FM3971)
• Minimized Downtime: No interruption to plant operations
• Risk Reduction: Enhanced insurance profile and reduced hazard exposure

By proactively addressing one of the facility’s most critical vulnerabilities, PEMEX reinforced its commitment to employee safety, infrastructure protection, and uninterrupted production.

Sustainable by Design

CharCoat CC not only meets safety requirements but also supports PEMEX’s sustainability goals:

• Low VOC Emissions: <29g/l, aligning with green material certifications
• Water-Based Formulation: No hazardous solvents or chemicals
• Green Building Contribution: LEED-compatible, part of ESG initiatives

This case exemplifies how modern fire protection solutions can balance safety, compliance, and environmental responsibility without trade-offs.

At CharCoat Passive Fire Protection, our mission is simple: prevent disasters before they begin. With CharCoat CC, PEMEX Cangrejera gained not only a 90-minute fire barrier but also the confidence to operate in high-risk conditions with greater peace of mind.

From petrochemicals to infrastructure, CharCoat CC is engineered to protect what matters most.