At a large timber frame manufacturing facility, a newly constructed cable chamber was showing early signs of vulnerability. Gaps between ducting and core drilled concrete created clear leak paths exposing the substation to the risk of water ingress and, ultimately, disruption to a busy production environment.
Project summary
| Organisation | Construction services provider |
| Asset | Substation cable chamber at timber frame manufacturing plant |
| Scope | Sealing of 15 cable ducts |
| Solution | NOFIRNO® Duct Seal System |
| Completion | June 2023 |
Manufacturers across the UK and EU were projected to lose up to £80 billion in 2025 due to unplanned downtime, with electrical failures and asset damage among the leading causes of production disruption. In many facilities, even a short outage can cost millions per hour in lost output, repair costs and supply chain impacts
In a process-driven manufacturing setting, protecting power supply is essential. Interruptions can halt production lines, damage equipment, and delay time-critical fulfilment schedules. Ensuring full sealing integrity was therefore a priority for both the construction partner responsible for delivery and the end client operating the site.
The challenge
A total of 15 cable entries required attention, many located tightly together in a single wall section.
Individual sealing would have led to inconsistent protection and future risks.
Key considerations included:
- Variations in opening size and spacing
- Interfaces between ducting and concrete
- Ensuring reliable sealing performance across the entire wall area
The preferred outcome was a single, consolidated sealing system that eliminated potential leak paths and provided long-term confidence in site resilience.
The solution
CSD Technical Services developed a tailored approach using the NOFIRNO® Duct Seal System.
Works included:
- Installing stainless-steel L-brackets to frame and stabilise the area
- Encapsulating all 15 ducts within one continuous sealing assembly
- Fitting 60mm NOFIRNO® insert sleeves to ensure cable separation and fill free space
- Applying 20mm NOFIRNO® Sealant within each duct
- Over-sealing the full 1m x 1m opening face to eliminate all ingress paths
This method provided a clean, uniform solution and ensured sealing performance did not depend on cable spacing or individual duct condition.
The outcome
The substation chamber is now fully water and gastight, providing robust protection for electrical infrastructure powering the manufacturing plant.
Results
- Long-term protection against water ingress and environmental damage
- Reduced risk of operational disruption to production processes
- A single, high-performance sealing system with future cable re-entry capability
