DuctSeal HG Cable Duct Sealing System
DuctSeal HG Cable Duct Sealing System
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The DuctSeal HG Cable & Pipe Sealing System is a re-enterable, heavy-duty duct sealing solution designed to handle large and heavy cables or pipes in underground and above-ground ducted networks.
Engineered for the toughest environments, DuctSeal HG delivers gas-tight, water-tight, and smoke-tight performance, preventing the ingress of harmful gases, flammable vapours, liquids, vermin, and debris.
What makes DuctSeal HG unique is its PATENT PENDING tubular rubber backing system – a modular design that can be:
• Extended in continuous strips for large ducts
• Formed into rings/collars for circular seals
• Cross-joined for trefoil/triplex cable separation
This ultimate backing system ensures reliable DSEAR compliance while also giving installers a simple, versatile way to support and separate large single-core, trefoil, or triplex cable arrangements.
The system is combined with our advanced FyBrid flexible intumescent sealing compounds – GreyStuff and RedStuff – which are zero-halogen, zero-MEKO, non-hazardous adhesives designed for maximum safety, durability, and long-term flexibility.
Proudly designed and manufactured in the UK, DuctSeal HG is trusted across the water industry, gas utilities, power distribution, data centres, petrochemical facilities, and renewable energy infrastructure, wherever heavy-duty duct sealing performance is required.
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| FEATURE | Density | Colour | Skin Over Time | Curing | Tack Free Time | Hardness | Elongation | Flow | Tensile Strength | Operating Temp. | Temp. Resistance | Intumescence Activation Temp. |
Pressure Resistance | Shelf Life |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| VALUE | 1.27 | Grey or Red | 10 mins | 3-4mm per day | 22 mins | 35 to 38 Shore A | 250% | 3.33 million cPs at 380°C |
0.72N/mm² | +5 to 40°C | -35 to +120°C | 210°C | 2.0 Bar | 12 months |
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Key Features
Patent-Pending Trefoil/Triplex Cable Separation
Our unique tubular rubber backing system can be configured as continuous strips, rings, or cross-shapes, delivering reliable support and separation for large single-core or trefoil cables. This one-of-a-kind design simplifies installation, ensures stability, and provides DSEAR-compliant trefoil cable sealing.
Advanced MEKO-Free, Non-Hazardous Sealant
DuctSeal HG incorporates GreyStuff and RedStuff – FyBrid flexible intumescent sealing compounds. These formulations are zero-halogen, MEKO-free, and non-hazardous, ensuring maximum installer safety and environmental compliance.
Water & Gas Tight
Provides a robust gas-tight and water-tight barrier against ingress, safeguarding ducts in critical infrastructure applications.
Resistant to Toxic Gases
Specifically designed for the water industry, DuctSeal HG is resistant to methane, chlorine, and hydrogen sulphide, protecting cables from chemical attack.
Hydrocarbon Resistance
Built for petrol forecourts and fuel distribution sites, DuctSeal HG withstands long-term exposure to hydrocarbons and other aggressive chemical agents.
Flame Retardant Performance
Independently tested to UL94:2013 / ANSI UL94:2018, ensuring flame retardancy for high-risk environments.
Industry Compliance
Fully compliant with DSEAR, WIMES, DCG, APEA Blue Book, and ATEX standards, making it suitable for water utilities, petrochemical plants, energy networks, and civil infrastructure.
Microbial Defence
Resistant to fungal and bacterial growth, providing durable protection in damp and contaminated environments.
Prevents Water Treeing
Creates a watertight seal that blocks moisture ingress and protects cable insulation from water treeing degradation.
Minimal Cable De-Rating
At a 20mm seal thickness, thermal resistance is just 5.1 K/W, allowing cables to maintain their maximum current-carrying capacity.
British Manufactured
All DuctSeal HG components are proudly designed and manufactured in the UK, ensuring consistent quality, performance, and reliable supply.
Installation
One Kit Per Duct
Each kit includes all components required to seal one duct, based on the kit size selected.
Note: A standard caulking gun is required (not included but available separately). Depending on the cable fill percentage, one kit may seal more than one duct. For advice, contact our technical team on +44 (0)161 874 1480.
Cable Separation & Support
Correct separation is essential for performance. The patent-pending tubular rubber backing system can be configured in continuous strips, rings, or cross-shapes to provide support and separation for large single-core, trefoil, or triplex cables. This ensures safe spacing, prevents movement, and guarantees DSEAR-compliant trefoil sealing.
Running Water Conditions
For best results, ducts and cables must be dry and free from running water. Clean surfaces of all dirt, oil, and grease before applying GreyStuff or RedStuff. If running water is present, please call +44 (0)161 874 1480 for technical advice. In most cases, we recommend using a Kraso Mechanical Seal.
Cure Time
GreyStuff and RedStuff cure at approximately 3–4mm per day, depending on humidity and temperature. Higher humidity and warmer conditions accelerate curing.
Minimum seal depth: 20mm for effective performance.
Cleaning
Uncured material can be removed using solvent-based wipes. Once cured, the compound must be removed mechanically.
Health & Safety
Both GreyStuff and RedStuff are based on a neutral curing, MEKO-free system, making them non-hazardous and installer-safe during application.
Compliance
DuctSeal HG is fully compliant with:
- WIMES (Water Industry Mechanical & Electrical Specifications)
- APEA Blue Book (petrol forecourts)
- ATEX & DSEAR (explosive atmospheres)
- DCG (Ducted Cable Guidance)
- Sewers for Adoption
- Network Rail PADS
Re-Entry & Removal
Once cured, the compound has a hardness similar to a rubber eraser. This allows ducts to be re-entered or resealed when required.
Always use sharp tools on de-energised cables. AC Cable Solutions accepts no responsibility for damage caused during re-entry.
Cable Suitability
GreyStuff and RedStuff are solvent-free, single-component systems that do not damage cable sheaths or stain duct surfaces.
Storage & Shelf Life
Store in a cool, dry location away from direct sunlight.
Shelf Life: 12 months unopened
After opening: reseal tightly and use within 1 month.
FAQs
Why choose DuctSeal HG for duct sealing?
DuctSeal HG isn’t just another duct seal—it’s a patent-pending system that delivers trefoil/triplex cable separation, gas- and watertight performance, and long-term protection. Its modular backing system supports heavy cables and simplifies installation, while our advanced FyBrid intumescent sealants provide non-hazardous, halogen-free sealing. The result is a versatile, re enterable solution that meets the highest safety and compliance standards.
What makes DuctSeal HG different from other duct sealing kits?
Unlike standard sealing systems, DuctSeal HG features a patent-pending tubular rubber backing system that can be configured for rings, continuous strips, or trefoil cable separation. Combined with GreyStuff and RedStuff sealing compounds, this design offers DSEAR compliance, hydrocarbon resistance, and flame-retardant performance, setting it apart from conventional solutions.
Is DuctSeal HG suitable for harsh environments?
Yes. DuctSeal HG is engineered for demanding sectors, including:
- Water industry (resists methane, chlorine, and hydrogen sulphide)
- Petrol forecourts and fuel sites (hydrocarbon resistant, APEA Blue Book compliant)
- Energy and utilities (WIMES and ATEX compliant)
- Industrial and civil infrastructure (resistant to moisture, chemicals, bacteria, and fungi)
Can DuctSeal HG be used for retrofits?
Absolutely. As a re-enterable sealing system, DuctSeal HG is ideal for both new builds and retrofitting existing ducts, allowing easy access for future cable upgrades or maintenance.
Is DuctSeal HG WIMES compliant?
Yes. DuctSeal HG complies with WIMES 3.02 (2019), clause 6.4.3.2(b) and is approved for use by water authorities across the UK and Ireland.
How does DuctSeal HG perform under pressure?
When installed to specification, DuctSeal HG delivers gas- and watertight performance up to 2.0 bar, suitable for most utility and industrial duct applications.
Does DuctSeal HG resist hydrocarbons and chemicals?
Yes. DuctSeal HG is specifically designed to withstand hydrocarbons, oils, and aggressive chemicals, making it suitable for petrol forecourts, refineries, wastewater plants, and chemical facilities.
Is DuctSeal HG flame retardant?
Yes. DuctSeal HG has been independently tested to UL94:2013 / ANSI UL94:2018 standards, providing proven flame-retardant performance for high-risk installations.
Does DuctSeal HG protect cables against water treeing?
Yes. By creating a watertight barrier, DuctSeal HG prevents moisture ingress, protecting insulation and preventing water treeing damage to power cables.
Will DuctSeal HG reduce cable performance?
No. At a 20mm seal thickness, the system has a thermal resistance of just 5.1 K/W, ensuring minimal cable de rating and preserving maximum current capacity.
Can DuctSeal HG be re-entered or removed?
Yes. Once cured, GreyStuff and RedStuff achieve a rubber-like consistency, allowing ducts to be re-entered and resealed when required. For safety, use sharp tools only on de-energised cables.
Why buy from AC Cable Solutions?
AC Cable Solutions is the UK’s trusted supplier of duct sealing systems, providing British-made, industry compliant solutions backed by expert technical support and next-day delivery. Our focus on quality, safety, and compliance ensures reliable results across all projects.