Cable Protection

We have a large number of cable protection systems:

1. Thermal cups for flexible cables.

1.1. These are similar to the “beads” on the wiring of toaster and iron. They allow flexing while keeping the cable enclosed.

2. Insulation boards as radiant heat barriers.

2.1. Must cover line-of-sight from ignition sources.

3. Fire proof paint.

3.1. An oxygen barrier R48/kg

4. Intumescent paint.

4.1. A good looking, normal paint until it gets hot then its turns into an insulating R845/5ltr tin.

5. Firebreak.

5.1. Mineral matter contained in a non-woven textile. These should be wrapped around all cables for 1m length every 5metres, to the stop a fire from spreading.

6. Electric blue.

6.1. A sticky insulating putty which will adhere to cables.

7. Wall plugging materials.

7.1. Kerafire where it can be poured into shuttering. R18/kg Resin & Powder.

7.2. Insulag where it can be plastered, indoors. R32/kg.

7.3. Kerratuff 2: Same but exposed to rain. R26/kg.

7.4. Electric Blue for small gaps.

8. Passive insulation.

8.1. Mostly around furnaces for runout. Plastic bags of Hollofill are hung over the drainage area. Radiant heat melts the bags to release Hollofill, which flows over the molten metal and stops the radiant heat. R31/kg.

9. Cable covers.

9.1. For cables or cable trays, a mineral cover nailed or screwed to the wall, with ceramic fibre. Price varies from R40 to R150/m depending on size.

10. Fibre Plaster.

10.1. A heavy duty plaster mostly to stop molten metal. R116/kg.


In all of the above systems allowance must be made for the internally generated heat from power supply cables to be dissipated.

The cost of total cable protection is about 1% of the cost of replacement of cables. It is therefore always worthwhile .

Fire retardant paint is not recommended. Intumescent paint is much better, but not adequate as the only fire prevention measure.

Prices above are 2016

Electric Blue

Description: An extremely sticky insulating ceramic for fire protection of cable trays.

 Colour: Blue

Composition: Quartz free and asbestos free. Contains mostly closed cell ceramic bubbles, spun ceramic fibre, zirconia- ceramic drawn fibres, organic binders, plasticizers and moisture retainers, inorganic binders, plasticizers and ablative materials. Contains no toxic or hazardous materials and has no restrictions on disposal.

Density: 1.14g/m³

Thermal conductivity: After initial flames, drops to 0.3W/mK.

Melting point: 1250°C

Application: Clean cables and trays from dust and oil. Rub material onto surface to make it stick. Build up to 20mm thick, 30mm if ambient temperature is high, 50mm where fire hazard is particularly high, eg. solvent store, gas bottles, Oxygen lines. Paint with roof paint if exposed to rain.

Packaging: 6kg in 10 litre buckets, 12kg in 20 litre buckets.

Fibre Plaster

Description: Aluminosilicate ceramic fibre in plaster form, supplied wet ready to use. Very easily applied to any surface


High temperature insulation

Heat shields

Burner cores


Thermal shock protection

Furnace hoods

Preheater lids

Ladle lids

High gas flow areas of fibre lined furnaces

Repair of cracks and joints

Protection of equipment

Protection of electrical cables

Upgrading of linings for thermal efficiency or faster cycle times.

Repair of broken element holding lips.

Sealing of kiln and furnace doors

Lightweight doors.


Very low thermal conductivity: 0.2W/mK.

Electrically insulating.

Very low density: 1.3g/cm³ wet, 0.7g/cm³fired.

Low shrinkage: Normally 12% but all taken up in the thickness of the layer, therefore no cracks.

Extreme thermal shock resistance.

Very low thermal mass.

High reflectivity.

Low permeability compared to fibre blanket or modules.

High reflectivity.

Rapid commissioning.

Excellent adhesion to all surfaces.

Minimal anchoring required.

Chemical composition:

Aluminosilicate 55%
Fe2O3 < 0.1%
Alkalis 0.27%
Volatiles 45%



Fibre Plaster is supplied wet in well sealed plastic 10kg buckets. The wet density is normally 1.1g/cm³.

It can easily be thinned down with water or it ordered stiffer for tamping applications

Onto brick: Blow dust off and trowel on.

Insulating firebrick or very porous surfaces: Rub a thin layer on very firmly before building up the profile.

Cables: No preparation required.

Ceramic fibre: Over fresh fibre, softening by water dilution usually helps.

Onto steel: Expanded metal, Mentex 72 or similar. Cut and bend a few strands backwards and tack them onto the steel so that the expanded metal sheet is about 5mm off the steel surface. Squeeze some Fibre Plaster through the mesh and then plaster over it to the desired thickness. Free standing structures; Use expanded metal as a skeleton.

Door seals: Plaster a narrow strip onto one surface, cover with fibre paper and close the door to press the Fibre Plaster into the exact thickness required.

Fire proof paint

This is a genuine fire proof paint, not a fire resistant paint nor an intumescent paint. It is totally inorganic. The only chemical released in a fire is water. The paint forms an air tight skin, preventing oxygen from getting to the substrate.

Fire proof paint is much harder than normal paint; it is difficult to scratch with a knife.

Fire proof paint is not as flexible as normal paint. It can be coloured with oxide pigments.

Fire proof paint is highly alkaline and similar to soap in its corrosive, skin contact and eye contact hazards.

Fire proof paint will stick to most surfaces, including whitewash, but not to oil contaminated surfaces.

Fire proof paint is slightly soluble in water. Clean paintbrushes with water.

Be careful of dry paint on the bucket; it is hard and razor sharp.

Development no.   94720

Intumescent Paint

Intumescent paints are paints that foam up into a thermal insulation coating as soon as they come into contact with fire.

We make a white one which looks just like highest quality paint until it is heated. It costs R845/litre (2016 price). Uses 3.3kg per m²

Both are based on the exfoliation of raw vermiculite.

Thermal Cups

Protect flexible cables, hydraulic hoses and water cooling pipes around furnaces. They withstand intense radiant heat and molten metal splashing. The ceramic sleeves are threaded over the pipes or cables, and allow them to bend while still covering them. Steel springs cast into the ceramic thermal cups give them good resistance to abrasion and impact.
I.D. 22 40
O.D. 60 83
Length 48 60
Cups/ metre 21 17
Mass/ cup 185g 315g
Mass/ metre 3.9kg 5.4kg
Rad. of bend 350mm 600mm
Price/ cup R14 R22
Price/ metre R959 R1535


Moulds can be made for any I.D.
For I.D. 20 to 35mm, O.D. = 60mm
For I.D. 35 to 50mm, O.D. = 83mm