Duct Seal HG Cable Duct Sealing System (large heavy cables) - ≤2 Bar Pressure Resistance
Description
DuctSeal HG (Water & Gas) Duct Sealing System for Large Cables and Pipes
Introducing the New DuctSeal HG (Water & Gas) System
The DuctSeal HG system is a cutting-edge, re-enterable duct sealing solution designed for sealing large, heavy cables and pipes within ducted networks. This innovative system is engineered to prevent the ingress of harmful or flammable gases, liquids, smoke, and vermin, ensuring your installations remain safe and secure. Whether you're working on data centres, substations, or waste-to-energy plants, DuctSeal HG offers unparalleled protection and compliance.
Key Features of the DuctSeal HG System
- Patent Pending Trefoil/Triplex Cable Separation: Our unique tubular rubber backing system can be configured in various ways—continuous strips, rings, or cross shapes—to provide optimal support and separation for large cables or pipes. This patented design ensures compliance with DSEAR and simplifies installation.
- MEKO-Free, FyBrid, Non-Hazardous Intumescent Sealant: DuctSeal HG uses our advanced GreyStuff and RedStuff sealants, which are flexible, zero-halogen, and free from MEKO, making them safe for installers and the environment.
- Water & Gas Tight: The system provides an impenetrable barrier against water and gas, making it ideal for critical infrastructure applications.
- Resistant to Toxic Gases: Designed for the water industry, DuctSeal HG effectively resists gases like methane, chlorine, and hydrogen sulfide.
- Resists Hydrocarbons: Perfect for the petrol forecourt industry, the system is built to withstand exposure to hydrocarbons.
- Flame Retardant: Tested to UL94: 2013 ANSI / UL 94: 2018 standards, ensuring high levels of fire resistance.
- DSEAR, WIMES, DCG, APEA, BLUE BOOK & ATEX Compliant: Fully compliant with essential industry standards, making it a reliable choice for various sectors.
- Microbial Defence: Enhanced to resist fungi and bacteria, ensuring long-lasting protection in challenging environments.
- Non-Adiabatic: Minimal Cable De-Rating: At a thickness of 20mm, thermal resistance is just 5.1 K/W, preserving the cable’s full current-carrying capacity.
- MADE IN UK: The DuctSeal HG system's components are proudly designed and manufactured in the UK, ensuring top-quality materials and craftsmanship.
Applications of the DuctSeal HG System
The DuctSeal HG system is versatile and suitable for a wide range of applications, including:
- Data Centres: Ensures secure sealing of large cables in critical data infrastructure, protecting against environmental threats.
- Sub Stations: Provides reliable duct sealing in electrical substations, preventing ingress of harmful substances.
- Pumping Stations: Ideal for water industry applications, where resistance to toxic gases and water-tight seals are essential.
- Waste-to-Energy Plants: Protects against harsh environmental conditions in waste-to-energy facilities, ensuring long-term duct integrity.
- Wind Farms / Turbines: Perfect for renewable energy installations, offering robust protection in exposed environments.
- Electrical Utilities: Ensures safe and secure duct sealing in various electrical utility applications.
- Rail Industry: Fully compliant with Network Rail standards, making it an ideal choice for rail infrastructure projects. (Network Rail Catalogue Numbers Available—Click Here)
Why Choose DuctSeal HG for Duct Sealing?
DuctSeal HG is not just another duct sealing system; it's a superior, patented solution designed to meet the highest industry standards. With its one-of-a-kind trefoil/triplex cable separation and advanced intumescent sealants, DuctSeal HG provides:
- Unmatched Flexibility and Protection: The re-enterable design allows easy maintenance and adjustments, while the unique backing system ensures optimal cable support and separation.
- Compliance and Safety: Fully compliant with DSEAR, WIMES, and other essential standards, DuctSeal HG is designed to keep your installations safe and compliant with regulations.
- Environmentally Safe and Non-Hazardous: Using FyBrid technology, the GreyStuff and RedStuff sealants are non-hazardous and environmentally friendly, ensuring safety for all users.
How to Install the DuctSeal HG Sealing System
Installing the DuctSeal HG system is straightforward and efficient. Follow these steps for a secure and reliable seal:
- Abrade the first 20mm of the duct and cables: This helps to remove any grease, old sealant, and dust, ensuring a clean surface for sealing.
- Clean the duct and cables: All debris, grease, and dirt must be removed to allow the sealant to adhere properly.
- Insert the larger tubes/sleeves: Start with the larger set of tubes or sleeves, inserting them into the duct and between the cables. Ensure proper separation between the cables and the inner duct. For trefoil cables, join the larger tubes to create a cross shape, maintaining separation between the three single cables.
- Fill smaller gaps: Use singular large or small tubes/sleeves to fill any remaining gaps, creating a tight and strong support structure.
- Adjust tube depth if necessary: If the tubes or sleeves are pushed too far back, use long-nose pliers to pull them forward, ensuring they are positioned 20mm deep from the duct edge.
- Apply the GreyStuff or RedStuff sealant: Start applying the sealant around the cables, working from the bottom up to ensure thorough coverage.
- Finish with the provided Magic Sponge: Wet and squeeze the provided Magic Sponge, then dab the GreyStuff or RedStuff sealant to ensure it has securely grabbed the cables and duct, leaving a neat finish.
- Completion: Your installation is complete, providing a secure and durable seal.
| Product No. | Product | Duct Opening Max | Unit Sold |
|---|---|---|---|
| Using 1 x DuctSeal HG Kit – up to 100mm | |||
| DSHG100 | DuctSeal HG | 100mm | x1 Kit |
| Using 2 x DuctSeal HG Kits – up to 150mm | |||
| DSHG150 | DuctSeal HG | 150mm | x2 Kits |
| Using 3 x DuctSeal HG Kits – up to 200mm | |||
| DSHG200 | DuctSeal HG | 200mm | x3 Kits |
| Using 4 x DuctSeal HG Kits – up to 225mm | |||
| DSHG225 | DuctSeal HG | 225mm | x4 Kits |
| Using 5 x DuctSeal HG Kits – up to 250mm | |||
| DSHG250 | DuctSeal HG | 250mm | x5 Kits |
Installation
One Kit per Box
All components are included to seal 1 x duct as per the kit size mentioned (A caulking gun is not included but can be sold separately). ** One kit may fill more than one duct, depending on the cable % filled. Call 0161 806 1666 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 separate and support single or multiple cables.
Using our patent-pending tubular rubber tubes, various shapes can be made to help with cable separation, such as trefoil/triplex cables.
Running Water
For best results, the duct and cables should be dry with no running water. All dirt, oil, or grease must be cleaned before applying GreyStuff. If you have running water, please contact AC Cable Solutions for advice on 0161 806 1666. We recommend using a Kraso Mechanical seal —click here for further information.
Cure Time
GreyStuff and RedStuff will cure 3-4mm daily, depending on humidity and temperature. The higher the humidity percentage and temperature, the quicker GreyStuff will cure. For an effective seal, a minimum of 20mm of GreyStuff or RedStuff is required.
Cleaning
Uncured material spillages can be cleaned with a solvent-based wipe.
Health & Safety
GreyStuff and RedStuff are based on a hazard-free neutral curing system to protect users when carrying out tasks like sealing cable ducts. Non-hazardous Zero MEKO.
Compliance
DuctSeal HG complies with WIMES, APEA, ATEX & DSEAR, SEWAGE FOR ADOPTION, and the DCG guidance.
Re-entry & Removal
GreyStuff and RedStuff will cure a similar hardness to 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 single-component neutral curing sealants containing no solvents. Our formulation does not damage the properties of a cable sheath or stain surfaces.
Storage
GreyStuff and RedStuff should be kept in a cool, dry environment and away from sunlight. The product shelf life is 12 months. Once opened, any remaining product can be used for one month, provided the screwcap is securely fitted.
Certifications
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 the correct DuctSeal system is specified 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 BS EN 1366-3:2021+A1:2024. 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.
Air Quality Certification
GreyStuff has achieved Indoor Air Comfort GOLD for ultra-low VOC emissions. This confirms compliance with strict European indoor air quality requirements, including BREEAM Exemplary Level, EMICODE EC1 Plus, French A+ and EU Taxonomy criteria.
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
Air Quality & Zero MEKO
Indoor Air Comfort GOLD and Zero MEKO Heavy-Duty Duct Sealing System
DuctSeal HG uses GreyStuff, an independently tested sealant that has achieved Indoor Air Comfort GOLD for ultra-low VOC emissions. This confirms compliance with strict European indoor air quality requirements, including BREEAM Exemplary Level, EMICODE EC1 Plus, French A+ and EU Taxonomy criteria.
For heavy-duty duct sealing applications, this matters. DuctSeal HG is commonly used where larger cables, deeper ducts and more demanding site conditions are involved. Engineers may be working for longer periods in chambers, plant rooms, substations, utility spaces and ducted cable networks, where cleaner air and reduced chemical exposure are important.
What Indoor Air Comfort GOLD Means
Indoor Air Comfort GOLD is a recognised certification for low-emission construction products. It shows that GreyStuff has been independently assessed for very low VOC emissions and supports projects where indoor air quality, sustainability and environmental performance are key considerations.
For contractors and specifiers, this helps position DuctSeal HG as a responsible heavy-duty duct sealing solution that supports both performance-led and low-emission project requirements.
Why Zero MEKO Matters
GreyStuff is formulated with zero MEKO. MEKO, also known as 2-butanone oxime, is found in some traditional sealants and may be released into the air during curing.
Compared with MEKO-containing sealants, GreyStuff provides a cleaner alternative by avoiding MEKO-based curing chemistry. This helps reduce avoidable exposure for engineers who regularly work close to sealants, particularly in enclosed or poorly ventilated installation areas.
Benefits for Engineers and Installers
- Indoor Air Comfort GOLD: Independently tested for ultra-low VOC emissions and compliance with strict indoor air quality standards.
- Zero MEKO formulation: Helps reduce exposure to MEKO-related curing emissions compared with sealants that contain MEKO.
- Better for heavy-duty installations: Suitable for larger cable duct sealing applications where installers may spend longer applying sealant.
- Cleaner air during installation: Supports improved air quality in chambers, substations, plant rooms, service risers and utility spaces.
- Supports sustainable specifications: Suitable for projects where BREEAM, EMICODE EC1 Plus, French A+, EU Taxonomy and low VOC requirements are important.
- No compromise on performance: DuctSeal HG remains re-enterable, flexible, water and gas tight, while supporting a cleaner working environment.
A Cleaner Choice from AC Cable Solutions
DuctSeal HG is designed for heavy-duty cable duct sealing applications, including larger cables and more demanding ducted networks. With Indoor Air Comfort GOLD and zero MEKO GreyStuff, it combines reliable duct protection with a cleaner, lower-emission installation environment for engineers and contractors.
Features & Standards
| Features | Standards / Measurements |
|---|---|
| Water & Gas tight to 2.0 bar | Pressure Resistance: 2.0 Bar |
| Designed for large, heavy cables and pipes | Application: Large cable, pipe and heavy-duty duct sealing |
| Patent pending tubular rubber backing system | Backing System: Modular tubular rubber backing system |
| Can be configured in strips, rings or cross shapes | Configuration: Suitable for single, multiple, trefoil and triplex cable arrangements |
| Non-slumping | Density: 1.27 |
| High bonding strength | Colour: Anthracite Grey / Brick Red |
| Odourless when curing | Skin Over Time: 10 mins |
| Flexible and re-enterable | Curing: 3-4mm per day |
| Intumescent | Tack free time: 22 mins |
| Very strong porous sticky char is formed when exposed to fire, which has excellent thermal insulation properties. | Hardness: 35 to 38 Shore A |
| Microbial resistance – coverage against Fungi, E-Coli, Escherichia coli, Staphylococcus aureus, & A. brasiliensis | Elongation: 250% |
| UV & Ozone resistant | Flow: 3.33 million cPs at 380°C |
| Non-hazardous | Tensile strength: 0.72 N/mm² |
| Zero halogens used | Operating Temperature: +5 to 40°C |
| Emits 0% MEKO | Temperature Resistance: -35 to +120°C |
| Resistant to Hydrocarbons including petrol, diesel, ASTM oil and LPG gas | Intumescence Activation Temperature: 210°C |
| Resistant to Methane, Hydrogen Sulphide, & Chlorine gas – Independently tested. | Shelf Life: 12 months |
| Resistant to many other gases & liquids, for example, ADBLUE & Antifreeze. | Age Tested: 50 years |
| Prevents moisture ingress and helps protect cables from water treeing damage | Notes: Tested performance varies by environment and installation method |
| Compliance & Standards | |
| Complies with DSEAR duct sealing regulations | DSEAR: Compliant as specified |
| WIMES compliant, as described in the WIMES Specification in section 3.02 2019 clause 6.4.3.2D(b) | WIMES: 3.02 2019 clause 6.4.3.2D(b) |
| Complies with 2011 NEC Articles 225.27, 230.8, 300.5(G), 300.7(A) on Raceway Seals, and 501.15(B)(2) | NEC (2011): 225.27, 230.8, 300.5(G), 300.7(A), 501.15(B)(2) |
| Petrol station forecourt accepted, as per the technology described in the APEA Blue Book - 4th Edition, 4.6.8 | APEA Blue Book: 4th Edition, 4.6.8 |
| ATEX Compliant – Contains no moving parts or any form of material that can create a spark | ATEX: Compliant as specified |
| Meets Network Rail standards for suitable rail infrastructure applications | Rail: Network Rail suitable as specified |
| Flame retardant performance tested to recognised UL94 standards | Flame Retardance: UL94:2013 / ANSI UL94:2018 references |
| Ultra-low VOC emissions and improved indoor air quality performance | Indoor Air Quality: Indoor Air Comfort GOLD, BREEAM Exemplary Level, EMICODE EC1 Plus, French A+ and EU Taxonomy criteria |
| Zero MEKO formulation to help reduce installer exposure to MEKO-related curing emissions | MEKO Emissions: Zero MEKO / 0% 2-butanone oxime |
| Fire resistance performance tested using GreyStuff sealant | Fire Resistance Test: BS EN 1366-3:2021+A1:2024 |
Blogs
The following BLOGS provide additional technical information, tips and tricks, and do's and don'ts about our duct sealing system.
- To learn more about Trefoil cables > Click Here <
- To learn more about Network Rail PADS > Click Here <
- To learn more about Data Centres > Click Here <
- To learn more about WIMES compliance > Click Here <
- To learn more about APEA & Blue Book compliance > Click Here <
- To learn more about MEKO, and 2-Butanone oxime > Click Here <
- To help choose a duct sealing system > Click Here <
To view all our BLOGS revolved around duct sealing, > Click Here <
FAQs
What makes DuctSeal HG different from other duct sealing kits?
DuctSeal HG features a patented trefoil/triplex cable separation system combined with advanced FyBrid intumescent sealants. This unique combination offers superior flexibility, protection, and compliance with industry standards, making it the best duct-sealing solution on the market.
Is DuctSeal HG suitable for harsh environments?
Yes, DuctSeal HG is specifically designed to withstand harsh environmental conditions, making it ideal for applications in the water industry, petrol forecourts, and other demanding sectors.
Can DuctSeal HG be used for retrofitting existing installations?
Absolutely. The DuctSeal HG system's re-enterable design makes it perfect for new installations and retrofits, providing flexibility and long-term protection in any scenario.
Is DuctSeal HG WIMES Compliant?
It definitely is. DuctSeal HG is used by all UK water authorities, including Ireland. The WIMES compliance number is 3.02 2019 clause 6.4.3.2D(b)
Related Products
Explore our full range of duct sealing kits, designed to meet the demands of various industries and cable sizes.
Why Buy from AC Cable Solutions?
AC Cable Solutions is dedicated to providing top-quality, British-manufactured duct sealing solutions. Our products are engineered to meet the highest performance and reliability standards, and our expert customer support team backs us.