Project Overview

• Client: Transgrid – Central Northern Region
• Industry: Power Distribution
• Application Type: Passive Fire Protection – Cable Coating
• System Used: CharCoat CC + CharCoat FM Mortar
• Fire Rating: Trench Fire Breaks
• Standards & Tests: IEC 60332-3
• Applicator: CAMS
• Completion Date: April 2008

In 2008, CharCoat successfully delivered a comprehensive passive fire protection solution to 47 Transgrid substations located throughout the Central Northern region of New South Wales, Australia. This large-scale infrastructure project focused on reducing the risk of fire spread within cable trenches in substation switchyards — a critical safety concern in power distribution environments.

The Challenge

Power substations contain extensive networks of electrical cables, many installed in open trenches and vertical cable trays. These installations can act as a pathway for fires to rapidly travel across facilities, putting critical infrastructure and public power supply at serious risk.

Transgrid required a reliable, certified, and long-lasting passive fire protection solution that would:

• Prevent the spread of flames along grouped cables
• Operate effectively in exterior environments
• Meet strict international fire testing standards
• Provide long-duration fire resistance
• Reduce reliance on traditional firestopping methods

Additionally, as a statutory state-owned corporation, Transgrid needed absolute confidence in compliance, performance, and durability to protect the New South Wales high-voltage electricity network, which supplies electricity to homes, businesses, and other Australian states.

The Solution: CharCoat CC Cable Coating System

CharCoat supplied CharCoat CC, a water-based, latex intumescent fire protection coating specifically developed for electrical cables in both interior and exterior environments. This advanced coating was applied in accordance with IEC-60332-3 standards to create effective fire breaks along cable trenches, significantly reducing the risk of fire propagation.

Why CharCoat CC Was Selected

CharCoat CC offered multiple decisive advantages:

• 90-minute hydrocarbon fire rating
• Approved for exterior use (QUV tested)
• Tested to international standards (UL & IEC)
• Intumescent technology that expands under heat
• Reduces flame spread in grouped and vertical cable arrangements
• Protects cable integrity for up to 90 minutes under hydrocarbon fire conditions (IEC 60331-21, tested by Intertek)

Upon exposure to heat and flame, the coating expands and forms a thick insulating char layer. This layer absorbs heat, limits oxygen supply, and keeps the cable cool, preventing ignition and structural cable failure.

This solution moved Transgrid away from traditional firestopping methods, offering greater protection, flexibility, and long-term performance.

Application & Installation

The system was applied by professional applicators CAMS, who implemented CharCoat CC and CharCoat FM Mortar across 47 substations. The coating system was installed directly onto cable surfaces and within cable trenches throughout the switchyards.

In the project images, you can observe:

• A long cable trench protected by coated surfaces
• Active substation components surrounding treated zones
• A finished, neat, and uniform protective application

This ensured uninterrupted functionality while significantly upgrading fire-resistance performance.

The Result

Following successful completion in April 2008, the Central Northern Region of Transgrid achieved:

• Significantly reduced fire risk across substations
• Improved safety for infrastructure, personnel, and communities
• Extended asset protection under extreme fire conditions
• Compliance with international fire protection standards
• Increased reliability of NSW’s energy network

CharCoat’s involvement directly supports Transgrid’s mission to maintain a safe, secure, and reliable power supply to homes, businesses, and interstate partners.

Why CharCoat?

CharCoat provides cutting-edge passive fire protection technology with a broad range of fire ratings and solutions designed to save lives and protect assets. With nine firestop and coating products, CharCoat is trusted across major sectors including power, energy, transport, and industrial facilities.

The success of this project demonstrates CharCoat’s ability to perform at scale in high-risk environments while maintaining the highest compliance and performance standards.

Looking for a Similar Solution?

Whether you are managing power infrastructure, industrial facilities, transport networks, or critical assets, CharCoat’s passive fire protection solutions can help minimise risk and maximise safety.

Contact CharCoat today to discuss how we can protect your infrastructure from fire threats.