Wire & Cables The Hidden Fire Risk

The Hidden Fire Risk And How To Make Them Safe

From Silent Lifelines to Hidden Hazards : Why Safer Cables Are Essential for Fire Protection

Wires and cables are often called the nerves of our modern society. From powering homes, offices, and industries to enabling data transmission and connectivity, they are embedded in every building, machine, and product we use daily. Without them, electricity, communication, and automation would come to a standstill. However, while they silently empower our lives, wires and cables can also become hidden hazards if not chosen and maintained wisely.

Role Of Wires & Cables In Buildings – Fire Spread Characteristics

In a building, thousands of meters of cables are laid in walls, ceilings, shafts, and false floors. During a fire, these cables can act as fuel and channels for flame and smoke spread.

• Flame propagation : Ordinary PVC cables ignite quickly and allow flames to travel along cable routes.
• Toxic fumes & smoke : Burning cables release dense smoke and toxic gases such as hydrogen chloride, which reduce visibility and endanger lives during evacuation.
• Cable bundling effect : In shafts and conduits, closely packed cables accelerate fire spread from one floor to another.

This makes wire and cable selection a critical fire safety decision in building design. In India, studies show that nearly 70–80% of fire incidents in cities like Mumbai are linked to electrical short circuits, many due to poor-quality or substandard wiring. In Goa, almost 85% of fire accidents are caused by use of wrong or non-standard wires. Such statistics highlight the urgency of making correct cable choices.

Technology Advances – Fire-resistant & Flameretardant Cables

Over the years, cable technology has evolved to reduce risks :

• FR (Flame Retardant) Cables: Designed to self-extinguish and slow down the spread of fire.
• FRLS (Flame Retardant Low Smoke) Cables: Minimize smoke emission, aiding visibility in evacuation.
• LSZH (Low Smoke Zero Halogen) Cables: Do not emit halogen gases, reducing toxic exposure.

Technology Advances – Fire-resistant & Flameretardant Cables

• Fire-Resistant (Circuit Integrity) Cables : Withstand high temperatures and continue to supply power to emergency systems like fire alarms, sprinklers, and evacuation lifts during fire incidents.
• Mineral Insulated Copper Clad (MICC) Cables : With inorganic insulation such as magnesium oxide, these can withstand extreme fire conditions (often above 950°C) while remaining smokeless and non-toxic.

Manufacturers today are also applying advanced extrusion, cross-linking, and automated testing to ensure uniform insulation thickness, higher copper purity, and consistent fire performance. Smart cables with inbuilt sensors for overheating detection are an emerging technology.

Importance Of Choosing The Right Cable

The cheapest option is often the most dangerous. Developers, contractors, and facility managers must understand that the right cable is not just about electrical performance but also about life safety. Choosing certified fire resistant cables can :

• Prevent the spread of fire.
• Provide safe evacuation time.
• Protect costly equipment and property.
• Ensure compliance with legal and insurance requirements.

Globally, the fire-resistant cable market is valued at nearly USD 2 billion in 2023 and is projected to reach USD 2.88 billion by 2032. This growth shows how industries worldwide are prioritizing safety and compliance.

Intumescent Coating – An Extra Layer Of Protection

Even with the best fire-resistant cables, additional safety measures are valuable. Intumescent coatings can be applied to cable surfaces to further cut off fire propagation.

• How it works : Under heat, the coating swells to form a charred insulating layer that prevents fire from traveling along cable surfaces.
• Benefits : Cost-effective, easy to apply with brush/spray, widely available in the market.
• Application areas : Electrical rooms, server rooms, high-rise risers, industrial plants, and any place where fire safety is critical.
• In existing buildings, cables can be protected with ARC-260A, a specialized fire-retardant coating designed specifically for cables. It not only prevents the spread of fire along cable surfaces but also helps maintain the integrity of electrical systems during fire incidents.

This simple step can make the difference between a controlled incident and a devastating fire.

Upgrading Existing Cables With Fire-retardant Coatings

Not every building has the luxury of replacing its entire wiring network with new fire-resistant cables. For such cases, applying fire-retardant coatings on existing cables is a practical and cost-effective solution.

• Extends the useful life of cables while upgrading their fire performance.
• Minimizes downtime and avoids the high cost of re-cabling.
• Especially useful in older high-rise buildings, hospitals, data centers, and industrial facilities where continuity of service is critical.

By adopting this method, facility managers can significantly enhance fire safety without major structural changes or large capital expenditure.

Importance Of Testing & Certification

Using cables that look fire safe is not enough. Independent testing and certification by reputed laboratories is essential. Only certified products assure :

• Compliance with fire resistance, smoke emission, and toxicity limits.
• Reliability of performance during real fire incidents.
• Peace of mind for designers, builders, and occupants.

Internationally recognised labs (like ESL and UL) and Indian institutions (like CPRI) provide certifications that validate the fire safety of wires, cables, and coatings. Poor-quality products with false claims are one of the main causes of fire accidents and subsequent asset losses.

Recommended Codes & Standards

To ensure compliance, designers and builders must align with national and international standards :

Indian Standards & Codes :

• NBC 2016, Part IV – Fire & Life Safety
• IS 1554 / IS 694: PVC insulated cables
• IS 17048: Fire survival cables
• IS 1641, 1642, 1643: Fire safety of buildings (general requirements)

International Standards :

• IEC 60332 : Flame propagation tests on cables
• IEC 60754 : Tests for halogen acid gas emissions
• IEC 61034 : Measurement of smoke density
• BS 7629 / BS 7846 : Fire-resistant cables
• UL 94 / UL 1581 : Tests for flammability and fire resistance

Recommendations

Wires and cables are silent enablers of our daily life, yet when neglected, they can turn into dangerous fire carriers. With modern technology, certified fire resistant cables, and additional safety measures like intumescent coatings, we can prevent catastrophic fire spread in buildings. For developers, engineers, and facility managers, the message is clear: choosing the right wire and cable is not a cost—it is an investment in safety and resilience. Statistics from across India reveal that nearly 70–80% of building fires are caused by electrical short circuits linked to poor-quality cables. These incidents result in thousands of fatalities and destroy assets worth crores of rupees every year. By adopting quality-certified fire-resistant cables, following standards, and applying protective coatings, we can turn these preventable tragedies into safer outcomes.

A proven approach is to engage with reputed suppliers like Ameetuff, an Indian paint company whose fire-retardant coatings have been trusted by prestigious projects such as the New Parliament of India, major airports, and tunnels. Their solutions demonstrate that practical, tested, and locally available products can make our infrastructure truly fire resilient.

About The Author

KP Dominic has spent over three decades advocating safe practices and advancing safety in India’s built environment. He is the co-founder of premier industry bodies including the Fire & Security Association of India (FSAI), the Forum of Construction Utility Services (FOCUS), and the National Federation of Engineers for Electrical Safety (NFE). Actively engaged in national code development committees such as the National Building Code of India 2025 (Part IV – Fire & Life Safety), he has been instrumental in raising awareness on fire safety, electrical safety, and passive fire protection through hundreds of conferences, seminars, and publications.

Disclaimer : This article reflects the personal experience and professional knowledge of KP Dominic. The recommendations provided are based on his expertise and insights in the field of safety.