CharCoat Xtend™ is a cable repair and life-extension system for aging electrical cables exposed to UV, salt water, salt mist, ozone, chemicals, mechanical damage, and harsh industrial environments. Restore damaged sheaths. Protect against future degradation. Extend service life by up to 25 years.
Cable replacement in an operating facility costs 10–30 times more than remediation — before accounting for scaffold, downtime, and lost production. CharCoat Xtend™ gives asset owners a better option: restore deteriorated cable sheaths in place, extend service life by up to 25 years, and — at 1.6mm DFT — achieve a full 90-minute fire rating at the same time.
Industries
Oil & Gas
Power
Infrastructure & Utilities
Industrial Plants
Mining
CharCoat Xtend™ is a cable repair and life-extension system for aging electrical cables exposed to UV, salt water, salt mist, ozone, chemicals, mechanical damage, and harsh industrial environments. Restore damaged sheaths. Protect against future degradation. Extend service life by up to 25 years.
Cable replacement in an operating facility costs 10–30 times more than remediation — before accounting for scaffold, downtime, and lost production. CharCoat Xtend™ gives asset owners a better option: restore deteriorated cable sheaths in place, extend service life by up to 25 years, and — at 1.6mm DFT — achieve a full 90-minute fire rating at the same time.
CharCoat Xtend™ restores and protects aging cables through a graded repair-and-coat system. A Remaining Life Assessment (RLA) first grades cable condition from CC-1 to CC-6, identifying the correct repair path — from a single protective coat to full sheath repair. Damaged sheath areas are then rebuilt using CharCoat RT self-amalgamating tape and CharCoat ST semi-conductive tape, restoring mechanical integrity and HV electrical stress control without primer or adhesive. CharCoat CC is then applied over the repaired zone in two coats, bonding directly to the sheath and curing into a permanently flexible, UV-stable layer — applied at 1.0mm DFT for life extension or 1.6mm DFT for combined life extension and 90-minute fire protection. Routine inspection follows at 6 months, then at intervals set by the cable’s RLA priority band.
CharCoat CC water-based intumescent latex applied by brush, roller, or airless spray. Bonds directly to XLPE, EPR, PVC, and PE cable sheaths without primer. UV-stable and permanently flexible after cure, rated to IEC 60331-11/21 for circuit integrity under fire. Available in 5-gallon / 22.5kg pails.
Linerless, waterproof self-amalgamating rubber splicing tape for cracked, split, or heavily perished cable sheaths. Rated for LV, MV, and HV cables. Applied ahead of the coating system on CC-4 and CC-5 grade cables to restore sheath integrity before coating.
Semi-conductive shielding tape for cable joints and splice repairs. Restores electrical stress control and EMI shielding on MV and HV circuits. Compatible with XLPE, EPR, and PVC insulated cables. ASTM D4388 compliant.
Standard/Test
Result
IEC 60331-11/21
Circuit integrity (750°C cellulosic & 1100°C hydrocarbon)
IEC 60502
Power cables: joints & terminations
IEEE-383
Flame propagation
UL723
Surface burn & flame spread
BS476
Fire tests on building materials and structures
IEC 60332-3
Flame propagation
ASTM E84 / E162
Surface burn & flame spread
ASTM D4388
Rubber electrical tapes
ASTM D3273-16
Mould Resistant
ASTM D149
Dielectric Strength
KERI
Non-Derating (cable capacity maintained)
ABS
American Bureau of Shipping (Marine Approval)
LEED Credit 4.1 compliant
19g/L
Extends cable life up to 25 years — Rehabilitates aging cables without full replacement
Reduces downtime & cost — In-situ repair at a fraction of replacement cost
Scalable protection — 1.0mm DFT for UV/weathering, 1.6mm DFT for fire + life extension
Resists UV, salt, ozone & chemicals — Built for offshore, marine, and industrial environments
Fire resistance up to 90 minutes — Activates at 175°C, rated to 750°C & 1,100°C
No cable derating — Maintains full ampacity and operational performance
Zero maintenance — Permanent protection; minor char damage can be recoated
Onshore & Offshore Oil and Gas
Petrochemical Plants
Utilities & Power Transmission
Marine & Port Infrastructure
Renewables
Any Exterior Cable Asset
Parameter
Value/Details
Life extension
up to 25 years
Warranty
25-year product performance warranty
DFT range
1.0mm (life extension / UV & weather) to 1.6mm (full fire rating)
Fire rating
90 minutes at 750°C cellulosic and 1,100°C hydrocarbon — IEC 60331-11/21
UV resistance
100% UV stable — ASTM D2565 / G155 certified
Cable compatibility
XLPE, EPR, PVC, PE — LV, MV, and HV rated
Application
Airless spray (primary), brush or roller (touch-up and inaccessible areas)
No derating of cable capacity
KERI certified
Maintenance
Zero maintenance required after application
Packaging
5 gal / 22.5 kg pails
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Securing Critical Electrical Infrastructure at a Philippine Mining Plant with 90-Minute Fire-Rated Cable Coating
Transgrid Central Sydney — Upgrading Fire Resilience in Australia’s Power Backbone with CharCoat CC
CharCoat Xtend™ is a cable repair and life-extension system that is water-based, non-toxic, halogen-free, and low VOC — for a safer work environment and easier regulatory compliance.
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