CABLE COATING

 

 

 

 

 

 

As mentioned in the home page we are into the manufacturing and distribution of Fire Retardant Coating – Organic & Inorganic Fire Proof Stuffing, Sealbags, Fire Proof Board, Epoxy, Polyurethane, Puro Acryl, Non-Toxic, Chlorinated Rubber, Stoving & other type of specialized paints, e.g. Fire and Chemical Resistant coatings for Metal, Wood & Civil applications.


The quality of our product matches those of the multinational companies, while the rates are comparatively lower. Many famous companies like E.I.L, Punj LLoyd, Lloyd Insulations (India) Ltd., Mark Auto Industries Ltd., CIMMCO Birla Ltd., Naveen Projects Ltd., Josts Engg. Ltd. (Bombay), Bachmann Industries Ltd., Frick India Ltd., Gallium Industries Ltd., and many more reputed customers are purchasing paints regularly from us since 1989. Our products have passed all of their quality tests.


A team of highly experienced, qualified and talented paint technologists forms the back bone of our progress. Our annual manufacturing capacity is 950-1200 tones of paints. Various industrial concerns have been dealing with us for the last 20 years due to our good quality, timely supply and well established good will. Being a growing concern we want to spread our wings further. We would be grateful to you if you could form a part of our new horizon.
   


These are the standard which we are follows for Fire Retardant Coating – Organic & Inorganic Fire Proof Stuffing.


Cable coating –IS10810 part 50, IS1255-88.


Flexibility test-IEEE-383


Fire resistance test confirm to-IEC331-20 minutes.


Fire propagation test confirm to -IEC322-3, SBNKSS434-1475, IS1081 part-61.


Scratching test confirm-IPSS-1-07-061-94-standard


Cable capacity rating confirm to –IPSS-1-07-061-94, 3% Maximum.


Smock density confirm to ASTM-2843<35%.


Limiting oxygen index confirm to ASTMD863, 77


Radiation test confirm to, radiation test IEEE383.


Die Electric strength confirm to IPSS-1-07-061-94(3KV-mil).


Flexibility confirm to IS10810 part 50.


Exelitated easing test confirm to IPSS-1-07-061-94.


General Information Coating is a water based, ablative fire protective coating, especially developed for the fire protection of grouped or bundled electrical cables and for penetration seals.
The main function of Coating is to prevent flame propagation along vertical and horizontal cable ways.

Coating will also delay short circuit, whereby circuit integrity depends on the distance of the cables from fire and the incurred temperature. Coating is easily applied by conventional methods such as spray and brush, as well as by hand (see application data).


How does coating work?
Coating protects electrical cables through ablation as opposed to insulation.
Energy is consumed or generated to change any material from one condition or state to another. Processes consuming energy are called “endothermic”. Some materials need large amounts of energy to decompose or “break down”. A good ablative composition requires a maximum of energy to decompose.

Coating when exposed to fire starts to ablate by chemical and physical reactions, for instance evaporation, chemical cracking, melting - all this is consuming energy (heat) while keeping the cable relatively cool (for a certain length of time, as the process is self- sacrificial).
The gases and vapors generated during the ablative process push oxygen away from the surface, dilute flammable gases preventing them from burning and interrupt the “chain reaction” of fire chemically. After decomposition of all organic components, a solid structure of inorganic components remains offering further protection by insulation.

Fire protection
Coating prevents flame propagation on cables, thus keeping a cable fire localized to its source, even if some minor damage to the most exposed cables may be sustained. According to studies by the British CEGB, a fire on vertical cable ways can spread 20 m per minute. Flame spread on KBS coated vertical cables in the 40 minute IEC 332-3 test has been restricted to less than 10 cm. Coating has a LOI value of 100 (Limiting Oxygen Index).

What is a LOI value of 100?
The Limiting Oxygen Index value test, in accordance with ASTM D 2863, determines the percentage of oxygen in a nitrogen/ oxygen mixture at which a material sustains and burns on its own. In this test, which determines the burning characteristics of all plastic materials, the sample is secured in a glass cylinder – containing a definite gas flow of O2/N2 mixture – ignited with a gas flame. Then the gas flame is removed and the sample is observed for continue burning. Soft PVC, as used for cable jackets, continues to burn at a low 25-30% oxygen content. Teflon, however, sustains burning only at ahigh 90-95% oxygen content.
Coating has a LOI of 100, which means, it does not burn in a 100% oxygen environment.

Mechanical Resistance Coating is tough enough to sustain physical abuse such as walking on coated cable trays.

Ampacity
Coating does not affect the current carrying capacity of electrical cables.
Coating is highly flexible Endurance = lifetime of cable

Application to Cable Surface Preparation

A thorough cleaning of cables is not required. However, oil or grease should be removed with dry rags (no solvent). Using a broom or vacuum cleaner to remove heavy layers of dust is sufficient.

Spray
Application by spray is done in the conventional way by spraying crosswise. The white of the coating should well cover the colour of the cable jacket. The wet thickness of the coating must be at least 2.5 mm on all exposed sides. For getting at hard to get at places, use an extension nozzle. Where cables are close to wall, stuff mineral wool between cables and wall and coat over. Generally, the required thickness maybe applied in one coat. How ever, where new vertical cables are to be coated, it is recommended to first apply a thin “fog coat” and let it dry, then apply the final coat.

Brush
Brushing Coating on all cables requires several coats to build up the required thickness. Again, a thin coat applied first and allowed to dry will aid in building up the required thickness.

Hand
Large diameter single cables or bundles may be coated by hand. Again, a thin coat should be allowed to dry before the rest is applied, using both hands like anextruder. To achiever a smooth, even finish, use a wet brush.

Recommended coating thickness on cables:
Wet approx. 2.5 mm – resulting in approx. 1.6 mm dry coating.

Coverage at recommended thickness:
Approx. 3.0kg/m² for level surface. For grouped cables or cables in trays allow 30% more material considering

Thinning
Coating has a water base, but thinning of Coating should not be necessary.

Spray equipment
Coating may be applied with a great variety of spray equipment designed for application of high viscosity materials. Good results have been obtained with the following:

Airless spray equipment
Ultra 1500 Mark V Pressure at gun: 0-200 bar Spray gun orfice:0.9-1.0
(preferably reversible tip)

Conventional spray equipment
(with pressure pot) Material pressure: 4-5 bar Pressure at gub: 4 bar
Spray gun orifice: minimum 3 mm diameter
Material hose: minimum 3/4” diameter
Air supply: compressor capable of delivering 200 I/ min, (tank vol. At least 40 I) 6 bar.

Please note
Air supply, air pressure, diameter of material hose as well as minimum orifice opening must be adhered to as recommended. All filters with the equipment must be removed prior to operating with Coating.


Technical Data
Composition:
Coating consists of water-based thermoplastic resins, inorganic incombustible fibres, fillers, pigments and various flame retardant chemicals. Coating is free of asbestos and solvents.

Colour: Off-white
Viscosity: Approx. 30, 000 mPas
Density: Approx. 1.26g/ cm³ pH-value: Approx 7.8
Solids: Approx. 70% Limiting
Oxygen Index (LOI): ž95
Toxicity: Non-toxic
Storage Temperature: 5-30°C Must be protected from frost!
Shelf-life: In closed original containers at room temperature at least one year.
Packaging: Plastic drums of 50 kg
Drying time: Depending on temperature and humidity
To the touch: within 5-6 hours (20 °C/65% RH)
Cured: approx. 3 days (20°C/65% RH)

Flexibility:
PVC cables of 12 mm diameter coated with Coating may be bent to a 3cm radius without cracking.
Thermal conductivity:
Wavelength(λ)=0.69WWm⁻ᴵ.K⁻ᴵ   at 25°C

Specific resistance:
PP = 1.06 . 109 (Ohm . cm) at 23°C
/50% RH
PP = 4.10 . 105 (Ohm . cm) at 23°C
/83% RH
 

Selection of Tests Carried out as per International Standards

   

 

Type of test                        Standard                             Result                  Test Report No.

Flame propagation on                DIN 4102                                       non                             AM1.6-78394 coated cables                               p. 1B1                                            propagating

Flame propagation on                IEC 332-3                                       passed                       AM33E/93 coated cables

Flame spread                                BS476, p.7                                     class 1                        AM80961

Fire spread                                    BS476, p.6                                     class 0                        AM81506

Flammability test                         FM3971                                         Passed                       AM1X8A7.AM/OC3A.AD

Current carrying capacity           -                                                      no derating               AMGR90.06.44/0.1

Current carrying capacity           FM3971                                         no derating               AM0X3D5.AS

Dielectric strength                       FM3971                                         -                                  AMNo. 1X8A7.AM/OC3A.AD

Salt water exposure                    FM3971                                         -                                  AM0X3D5.AS

FM Approval                                 FM3971                                         -                                  AMNo. 1X8A7.AM/OC3A.AD

Ageing and weathering              -                                                      no damage                8764/8543

LOI determination                       ASTM D2863                                100                             8764/8543

Dermatology test                         -                                                      no effect                    Rep. 21.7.2008

 

Note : The above data, particularly the recommendations for the application and use of our products are based on our knowledge and experience. Due to different materials and conditions of application, which are beyond our control, we recommend in any case to carry out sufficient tests in order to ensure that our products are suitable for the intended processes and applications. Therefore, any liability for such recommendations or any oral advice is expressly excluded unless we have acted
willfully or by gross negligence.

        
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