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Methods for sealing wall penetration holes of cable trays and trunking

Wall penetration holes for cable trays and trunking can be effectively sealed using firestop packs, intumescent pillows, mineral wool, mastic, and sealing plates to ensure fire safety, moisture protection, and structural integrity.Firestopping and Passive Protection

Sealing wall penetrations is critical to maintain fire resistance and prevent the spread of flames, heat, smoke, and toxic gases through openings where cable trays or trunking pass. Openings must be tightly sealed without visible cracks or voids, and large openings may require a fire-resistant backing plate before sealing. Firestop materials should be chosen based on the wall type, penetration size, and fire rating requirements, such as fire-rated boards, firestop packs, intumescent pillows, or mineral wool .

Common Sealing Materials and Methods
  1. Intumescent Firestop Pillows or Bags
    • These expand when exposed to heat, sealing gaps around cables and trays.
    • Products like AF BAGS are certified for up to EI 240 fire resistance and can be inserted into thin walls without additional framing .
    • Pillows are easy to reposition, facilitating maintenance or modifications.
  2. Firestop Packs and Mineral Wool
    • Mineral wool or firestop packs are placed in the penetration gap, ensuring the gap area does not exceed 1 cm² and packing thickness meets design requirements (typically ≥24 cm for large penetrations), .
    • Gaps inside and around metal trunking must be sealed both internally and externally.
  3. Firestop Mastic or Sealant
    • Applied around cables or trunking to fill small gaps and provide a tight, durable seal.
    • Non-corrosive and non-conductive mastics also protect against moisture, dust, and chemical ingress .
  4. Sealing Plates and Cable Entry Systems
    • Round or rectangular plates can accommodate multiple cables and provide strain relief.
    • Cable entry boxes with self-sealing diaphragms or threaded areas allow for environmental protection and easier installation .
Installation Considerations
  • Ensure floor and wall finishes are completed and shaft doors installed before sealing .
  • Maintain reasonable layout and positioning to facilitate installation and future maintenance.
  • Conduct QA/QC inspections to verify proper sealing, no bridging of trays, and compliance with fire rating standards .
  • For large or irregular penetrations, combine multiple methods (e.g., backing plate + intumescent pillows + mastic) to achieve a complete seal.
Environmental and Safety Benefits

Properly sealed penetrations prevent:

  • Fire and smoke spread
  • Moisture ingress and corrosion
  • Entry of gases, VOCs, or rodents
  • Electrical hazards such as short circuits or equipment damage By selecting the appropriate combination of fire-rated materials, intumescent products, and sealing plates, and following proper installation procedures, wall penetration holes for cable trays and trunking can be effectively sealed to meet safety, fire, and operational requirements.
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