Duct Seal FR Cable Duct Sealing System (fire resistant) - ≤2 Bar Pressure Resistance

Description

Duct Seal FR is an innovative, low-smoke, zero-halogen duct sealing system designed for exceptional flexibility. It effectively seals all cable sizes, including large, heavy cables and pipes within ducted networks. This system is engineered to prevent the ingress of harmful or flammable gases, liquids, fire, smoke, and pests, and it has been rigorously tested according to BS EN 1366-3:2021.

Duct Seal FR features our patented, pending design comprising Intumescent circular-shaped tubes manufactured from our FireStuff marine-grade granulate. These tubes can be seamlessly connected, torn apart, and reconfigured into a cross-shaped structure to accommodate trefoil cables. This unique backing support system provides robust structural integrity and minimises cable movement during the application of our flexible intumescent adhesive and sealing compounds, GreyStuff or RedStuff. All components are designed and manufactured in the UK, ensuring high quality and reliability.

Duct Seal FR, along with GreyStuff or RedStuff, is a non-hazardous, superior single component, neutral curing sealant that has been specifically developed to cope with the harsh environments around duct openings to ensure ducted networks and penetrations are protected.

Features

• Fire resistant protection: Tested to BS EN 1366-3:2021, providing up to 4 hours of certified fire resistance in approved configurations.
• Intumescent technology: Uses intumescent technology in both the sealant and sleeves for fire-resistant duct sealing performance.
• Trefoil and triplex cable separation: Patent-pending tubular backing system helps separate and support complex cable arrangements.
• Low smoke, zero halogen: Designed for safer performance in critical environments where smoke and halogen emissions must be reduced.
• MEKO-free sealant: Uses FyBrid, non-hazardous intumescent sealant based on a neutral curing system.
• Fire, water and gas tight: Helps protect cable ducts from fire, smoke, water, gas, vermin and environmental ingress.
• Resistant to toxic gases: Suitable for demanding environments where methane, chlorine and hydrogen sulphide may be present.
• Hydrocarbon resistant: Suitable for petrol forecourts and installations exposed to fuels, oils and similar contaminants.
• Industry compliant: Designed to support DSEAR, WIMES, DCG, APEA Blue Book and ATEX requirements where specified.
• Microbial defence: Formulated to resist fungi and bacteria for long-lasting protection in harsh environments.
• Minimal cable de-rating: At 20mm thickness, thermal resistance is 5.1 K/W, helping preserve cable current-carrying capacity.
• Made in the UK: Designed and manufactured locally for quality, consistency and reliable performance.

Certs

Fire Resistance

• Up to 4 hours (240 mins) Fire Resistance (in both directions)
• BS EN 1366-3:2021 which supersedes BS EN 1366-3:2009
• Cables tested: Small, Medium, Large, Telecommunication & Bundles
• Cable types: NYY-O, N2XH-J, HO7V-K, J-Y(ST) Y
• Warrington Fire cable Ref: (B), (G), (D3), (F) & (E)
• Tested in horizontal penetrations up to 200mm (8 inches) in diameter
• Tested in 140mm thick low-density concrete walls (no duct or sleeve)
• Tested at Warrington Fire (Exova)

Electrostatic Properties

GreyStuff has been independently tested to assess its electrostatic behaviour in accordance with recognised industry standards for electrical insulation and static charge performance.

Testing was conducted to:

• BS EN 60079-32-2 / IEC 60079-32-1 (Surface Resistivity – electrostatic hazards guidance)
• BS EN 61340-2-3 (Volume Resistivity – resistance through material)

Test Results

• Surface Resistivity: > 2.0 × 10¹³ Ω/sq (at 25% RH)
• Volume Resistivity: > 1.7 × 10¹² Ω·m

Applications

• Data Centres
• Sub Stations
• Pumping Stations
• Waste to Energy Plants
• Wind Farms / Turbines
• Electrical Utilities
• Rail
• All Construction sectors
• Anywhere requiring fire resistance through cable penetrations

Installation

One Kit per Box
All components included to seal 1 x duct as per the kit size mentioned. Caulking gun not included, but can be sold separately.
** One kit may fill more than one duct, depending on cable % fill.**
Call +44 (0)161 874 1480 for advice.

Cable Separation
It’s imperative to ensure separation between each cable and from the inside of the duct. Our unique daisy-chained circular tubes easily separates and supports single or multiple cables. Using our patent pending tubular rubber tubes, various shapes can be made to help with cable separation, for example, trefoil/triplex cables.

Running Water
The duct & cables can be damp but with no running water. All dirt, oil or grease must be cleaned before applying GreyStuff or RedStuff.

Cure Time
GreyStuff and RedStuff will cure 3-4mm daily, depending on the humidity and temperature. The higher the humidity % and temperature, the quicker our sealants will cure. A minimum requirement of 25mm is required for an effective seal.

Cleaning
Uncured material spillages can be cleaned with a solvent-based wipe.

Fire Certification
Important Note: A fire rating is applicable only to an "as fire tested" system or an otherwise approved configuration. The entire system or configuration achieves the described fire rating only when a specific proprietary brand of product is installed in an identical manner to the approved tested configuration. Always ensure that your installation matches our fire test certification. It is the end user's responsibility to verify that DuctSeal FR is the correct system for the project requirements. Please contact our technical department to request a copy of our test report, and refer to our Duct Sealing Disclaimer.

GreyStuff or RedStuff Fire Resistance
GreyStuff sealant was tested according to BSEN1366-3:2023. RedStuff has not been tested, but can be used with your authorisation only (customer and/or end user). We can confirm that the difference between GreyStuff and RedStuff is less than <1%. The only change in the formulation from GreyStuff to RedStuff is the pigment component. This alteration does not affect the fire resistance, physical properties, or manual handling of the final product.

Health & Safety
GreyStuff & RedStuff are based on a neutral curing system that is hazardous-free to protect users when carrying out tasks like sealing cable ducts. Non-hazardous Zero MEKO.

Re-entry & Removal
GreyStuff & RedStuff will cure to a similar hardness of a rubber eraser, so re-entry and removal are achievable. The ease of this depends on the type of tools used. For example, a sharper tool will be easier than a blunt-ended tool. Only use sharp tools when cables are de-energised. AC Cable Solutions accepts no responsibility for damaged cables.

Cable Suitability
GreyStuff and RedStuff are a single-component neutral curing system containing no solvents. Our formulation does not damage the properties of a cable sheath, or stain surfaces.

Storage
Both GreyStuff & RedStuff should be kept in a cool, dry environment and away from sunlight. Product shelf life is 12 months. Once opened, any remaining product can still be used for 1 month afterwards, provided the screwcap is securely fitted.

Specs

Technical Features & Standards

Kit Sizes