Project Snapshot
- Client: Transgrid
- Region: Central Sydney – Picnic Point & Beaconsfield, New South Wales, Australia
- Sector: Power Transmission and Distribution
- Application Type: Passive Fire Protection – Cable Trench Firebreaks
- Systems Used: CharCoat CC (Cable Coating), CharCoat FM (Fire Mortar)
- Fire Rating: 90 minutes, tested under FM3971 and IEC 60332-3
- Installation Partner: Transpacific Solutions
- Completion Date: December 2002
The Challenge: Mitigating Fire Risk in High-Density Cable Trenches
One of the most neglected fire hazards in substations is cable trenches. Bundled cables can transform these trenches into pathways for quick fire spread when they are subjected to heat stress, deteriorating insulation, or unintentional ignition. This directly jeopardizes public infrastructure, worker safety, and operational continuity at substations that handle vital power loads.
One of the biggest high-voltage transmission companies in Australia, Transgrid, was modernizing its Central Sydney substations. Installing a strong, long-lasting passive fire protection system that could effectively create firebreaks within existing cable trenches without interfering with ongoing operations was their clear requirement.
The Solution: CharCoat CC Cable Coating System
Using CharCoat CC, a water-based intumescent cable fire protection coating, CharCoat suggested a non-invasive, legal, and economical method for building fire-resistive cable trench barriers.
CharCoat CC, which is intended to provide fire resistance for up to 90 minutes, expands when exposed to heat to create a protective char that insulates and stops flames from spreading along cables. It can be applied directly onto new or existing cables with little preparation and satisfies strict international fire testing standards.
Unlike traditional firestopping boards or wraps—which are labor-intensive and difficult to retrofit—CharCoat CC offers:
- Fast installation via spray or brush
- No requirement for cable derating
- No service interruptions
- Long-term UV resistance (QUV approved)
Installation at Transgrid: Seamless Execution Without Downtime
The application was carried out by Transpacific Solutions, a trusted local contractor experienced in fire protection and coatings. The project involved trench systems at Picnic Point and Beaconsfield substations, both integral to Sydney’s transmission infrastructure.
Key highlights of the application:
- Surface preparation was minimal due to CharCoat CC’s water-based formulation.
- Airless spray equipment ensured uniform DFT (Dry Film Thickness) of 1.6 mm.
- Multiple coats were applied to achieve WFT (Wet Film Thickness) of up to 3.0 mm.
- Complex joints and confined spaces were treated with brush-on application.
Most importantly, all fireproofing was completed without requiring a shutdown—an essential requirement for critical transmission assets like these.
Fire Performance Certifications and Compliance
CharCoat CC is certified and independently tested to meet the following international standards:
- IEC 60332-3 – Flame spread limitation for bunched cables
- IEC 60331-21 – Circuit integrity during fire exposure
- QUV – Weathering and UV resistance for exterior applications
These certifications are particularly important in substations where fire scenarios can involve both hydrocarbon and non-hydrocarbon sources. CharCoat’s approvals ensured Transgrid met not just internal safety KPIs, but also the regulatory compliance required for public utilities.
About Transgrid
Transgrid runs more than 120 substations and more than 13,000 kilometers of high-voltage transmission lines throughout the Australian Capital Territory and New South Wales. The infrastructure of Transgrid, a key participant in Australia’s National Electricity Market (NEM), facilitates the transfer of energy to millions of homes and businesses.
Transgrid is updating its infrastructure with an emphasis on resilience, flexibility, and safety in response to the growing demand for continuous power and changing climate-related challenges. An essential component of this long-term goal is passive fire protection.
Passive Fire Protection vs. Conventional Barriers
Traditional passive fireproofing techniques—such as installing cement boards, fire wraps, or metal ducts—pose several operational and technical challenges:
- High installation time and cost
- Structural rigidity, which complicates cable upgrades
- Thermal derating of cables
- Difficult visual inspections and rework
By contrast, CharCoat CC offers a superior approach:
- Simple application (spray or brush)
- No impact on cable performance
- Scalable for large cable bundles or complex layouts
- Certified for long-term durability and weather resistance
For critical infrastructure like substations, this shift from reactive to proactive fire protection delivers significant advantages in cost, performance, and risk mitigation.
Project Outcomes
- Continuous firebreaks created across cable trenches
- Zero service interruption during application
- Full compliance with IEC standards
- Increased asset protection and system integrity
- Maintenance-friendly and future-ready coating system
The Transgrid project is a proven model for how passive fire protection can be modernized using coatings instead of construction-heavy firestop assemblies.
A Partner in Fire Safety Across Power, Tunnels, Steel, and Oil & Gas
CharCoat systems are currently installed in substations, tunnels, steel manufacturing plants, and refineries across more than 30 countries. The Transgrid case adds to a growing body of successful deployments where fire safety meets operational efficiency.
Whether you’re building new infrastructure or upgrading legacy assets, CharCoat offers:
- Globally certified fire protection coatings
- Custom firestop solutions for penetrations
- On-site training and technical support
- A long-term, non-toxic, and compliant approach to fireproofing
Want to explore a solution for your facility?
CharCoat Passive Fire Protection Inc.
Suite 301 – 220 Brew Street, Port Moody BC V3H 0H6, Canada
📞 +1 604 941 1001
📧 mail@charcoat.com
