Ma’aden Alumina, part of Ma’aden—Saudi Arabia’s national mining company—has steadily expanded its operations to become the largest multi-commodity mining firm in the Middle East. To support its growth and adhere to strict fire safety protocols, the company adopted CharCoat’s cable protection systems at its critical processing and infrastructure facilities.
Ma’aden required a fireproofing solution that could:
- Upgrade non-rated electrical cables to a fire-rated status
- Provide tested and certified protection in extreme temperature environments
- Safeguard operational uptime by reducing fire risk
CharCoat CC Cable Coating and CharCoat FP Firestop Panels were selected as the preferred solutions after rigorous evaluation and performance comparisons.
Project Challenges
As a large-scale alumina refinery, Ma’aden faced multiple fire safety risks:
- Combustible Cable Pathways: Thousands of meters of electrical cable in bundled, grouped trays posed a major flame spread hazard.
- Environmental Exposure: Outdoor substations and coastal humidity required a durable, UV- and weather-resistant solution.
- Mission-Critical Operations: The facility required uninterrupted operations; hence, solutions had to be quick to apply, compliant, and tested to stringent international standards.
Solution Deployed
- CharCoat CC Cable Coating
CharCoat CC was applied to all critical electrical cable routes to provide 90 minutes of fire protection under cellulosic conditions. Its water-based, low-toxicity formulation made it ideal for use in both indoor control rooms and exterior substations.
Key Benefits:
- Approved to IEC60331-11/21 standards
- Fire resistance at 850°C
- QUV Approved for outdoor durability
- Highly flexible and non-fiber formulation
- Fast application and drying times
- CharCoat FP Firestop Panels
CharCoat FP was deployed to protect cable penetrations in fire-rated walls and floors. With up to 4 hours of integrity under fire conditions, the FP system ensured compartmentalization of fire and smoke, meeting the E & EI temperature rating standards.
Key Benefits:
- Lightweight and easy to install
- Zero maintenance post-installation
- Compatible with various substrates
- Resistant to moisture, chemicals, and vibration
Why Ma’aden Chose CharCoat?
- Compliance-Driven Performance: Fully compliant with international testing certifications including FM3971, IEC60332-3, and IEC60331-21.
- Exterior Use Approved: CharCoat CC was specifically approved for long-term exterior use, a non-negotiable requirement for Saudi Arabia’s harsh desert climate.
- Flexible Global Support: CharCoat provided continuous supply and training support, and coordinated logistics for timely project execution.
- Long-Term Reliability: With successful application results since 2014, Ma’aden continues to use CharCoat systems as a preferred standard across sites including Ras Al Khair and Wa’ad Al Shamal.
Measurable Impact
- Improved Fire Resistance: Existing cable systems were upgraded to 90-minute fire-rated status, ensuring safer operational zones.
- Fire Spread Containment: Installed firestops and coatings effectively block flame propagation between compartments.
- Operational Uptime: Preventative passive protection significantly lowered the risk of downtime caused by fire incidents.
- Scalable Application: The modular design of FP Panels and ease of CC coating allows seamless rollout across Ma’aden’s network.
CharCoat’s advanced fire protection systems have enabled Ma’aden Alumina to meet global fire safety benchmarks while maintaining efficient, cost-effective operations. This case exemplifies how intelligent passive fire protection can play a pivotal role in safeguarding industrial infrastructure, employees, and national assets.
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