Project Overview
Industrial mining facilities operate in some of the most demanding environments imaginable. High electrical loads, complex processing equipment, and continuous operations mean that fire resilience is not optional; it is fundamental to business continuity.
At the Runruno Gold Project in Nueva Vizcaya, Philippines, FCF Minerals Corporation undertook a proactive step to strengthen the fire safety of its mineral processing infrastructure by upgrading its electrical cable protection systems. The objective was clear: achieve a verified 90-minute fire rating for critical cable routes, aligned with insurance, operational, and safety requirements.
This case study outlines how a certified intumescent cable coating system was implemented to protect key electrical assets without disrupting production, while meeting international fire performance benchmarks.
Client Background: FCF Minerals Corporation
FCF Minerals Corporation is a mining company engaged in the exploration, development, and commercial operation of mineral claims through the Runruno Gold Project in the Philippines. As part of its operational governance, FCF maintains strict compliance with business continuity insurance requirements, which include safeguarding critical electrical systems against fire-related failures.
Within mineral processing plants, electrical cables serve as the backbone of operations powering control systems, conveyors, lubrication units, and safety mechanisms. Any fire-induced failure in these systems can result in prolonged shutdowns, safety risks, and substantial financial loss.
The Fire Risk Challenge in Mining Processing Plants
Mining and mineral processing facilities face several inherent fire hazards:
- High-voltage electrical cables operating continuously
- Dense cable routing in vertical and horizontal trays
- Presence of oils, lubricants, and combustible residues
- Elevated ambient temperatures near processing equipment
- Restricted access for firefighting in enclosed cable zones
At the Runruno facility, lube pack sections and electrical cable corridors were identified as high-risk areas requiring enhanced fire resistance. The goal was not just to delay fire spread, but to maintain cable integrity long enough to allow safe shutdown and emergency response.
Project Scope and Objectives
The project focused on delivering a 90-minute fire-rated cable protection system across multiple critical sections of the processing plant.
Key objectives included:
- Protecting both vertical and horizontal electrical cables
- Applying fire protection to cables ranging from 10kVA to 20kVA
- Ensuring full compliance with a 1.6mm nominal Dry Film Thickness (DFT)
- Completing application with minimal disruption to plant operations
To meet these objectives, FCF Minerals conducted technical evaluations and site inspections before selecting a solution and an experienced applicator partner.
Technical Evaluation and Solution Design
Prior to application, a technical presentation was conducted with FCF’s maintenance team. This session addressed:
- Fire performance expectations
- Application methodology
- Safety procedures for contractors and plant personnel
- Inspection and quality assurance protocols
A detailed site visit followed, allowing the project team to assess access constraints, cable routing configurations, and operational safety requirements. Based on this evaluation, ShieldCrete® Philippines Inc. was awarded the project for the supply, preparation, and application of the fire-rated cable coating system.
System Applied: 1.6mm Intumescent Cable Coating
The selected system was a 1.6mm intumescent cable coating, engineered specifically for passive fire protection of electrical cables in industrial environments.
Key system characteristics:
- Designed to deliver 90-minute fire resistance
- Applied directly to electrical cables and cable trays
- Expands under fire exposure to form an insulating char layer
- Maintains cable integrity during critical fire scenarios
The coating was applied to three identified critical sections of the process plant, covering both vertical and horizontal cable runs Project Profile.
Application Methodology and Quality Control
The application process followed a structured and controlled methodology:
- Surface PreparationAll cables and trays were cleaned to remove dust, oils, and contaminants that could affect adhesion.
- Controlled ApplicationThe intumescent coating was applied uniformly across cables and trays, ensuring consistent coverage even in complex routing areas.
- Thickness VerificationThe full specification of 1.6mm nominal DFT was verified across all application zones, ensuring compliance with fire performance requirements.
- Safety and Operational ContinuityAll works were executed with strict adherence to site safety protocols, allowing the plant to remain operational throughout the project.
Performance and Compliance Outcomes
The completed installation achieved the following outcomes:
- 90-minute fire-rated protection for critical electrical cables
- Compliance with insurance-driven fire safety requirements
- Enhanced resilience of electrical systems in high-risk zones
- Improved confidence in emergency response readiness
By reinforcing cable integrity, the facility significantly reduced the risk of cascading electrical failures during a fire event—an essential factor in mining operations where downtime can be extremely costly.
Why Intumescent Cable Coatings Are Effective in Mining Facilities
Compared to traditional fire wraps or board systems, intumescent cable coatings offer several advantages in mineral processing environments:
- Seamless protection for complex cable geometries
- Reduced installation time in congested areas
- No requirement for cable removal or rerouting
- Easier inspection and long-term maintenance
- Better adaptability to vibration and thermal cycling
These attributes make intumescent systems particularly well-suited for active mining and processing plants, where accessibility and uptime are critical.
Project Impact and Long-Term Value
For FCF Minerals Corporation, the project delivered more than compliance—it strengthened operational resilience.
Long-term benefits include:
- Reduced fire-related operational risk
- Stronger alignment with insurer expectations
- Improved asset protection for critical electrical systems
- A scalable fire protection approach for future plant expansions
The successful execution at Nueva Vizcaya also serves as a reference model for mining operations across Southeast Asia, where similar risk profiles and environmental conditions exist.
Fireproofing electrical infrastructure is no longer a reactive measure, it is a strategic investment in safety, continuity, and asset protection.
At the Runruno Gold Project, the implementation of a 90-minute fire-rated cable coating system demonstrates how mining operators can proactively address fire risks without compromising operational efficiency. Through proper evaluation, certified materials, and skilled application, passive fire protection becomes a reliable safeguard rather than an afterthought.
Explore how certified intumescent cable coating systems can enhance fire resilience in mining, power, and heavy industrial environments.
