Saving Frozen Fish from Going up in flames: Rescuing a Three-Phase Cable disaster with Proper Armoured Installation!

This client specializes in importing frozen fish products from overseas, storing them in a vast, temperature-controlled warehouse, and distributing them nationwide to independent retailers through their own logistics network.

The facility’s cold storage rooms are enormous—large enough to accommodate multiple vehicles inside. To maintain a constant temperature of -25°C, the warehouse relies on several heavy-duty, three-phase industrial refrigeration compressors housed in a secure outdoor compound. However, much of their equipment is aging, and they are gradually upgrading their systems.

A critical concern is the condition of their existing power cables, which have significantly deteriorated over time. The cables are in an advanced state of decay, falling apart, and now pose a serious fire hazard. Despite their poor condition, they continue to supply power to the high-demand three-phase compressor units that keep the freezers operational.

As experienced electricians with years of installation expertise, we strongly advise against using SY-type braided cable with clear outer sheathing for external fixed-wire installations. This type of cable is simply not designed for outdoor conditions. When exposed to UV light from the sun, the outer sheath becomes brittle, leading to rapid deterioration, cracking, and eventual failure. Despite this, many refrigeration installers continue to use SY cable because it is cheaper and easier to work with. Unfortunately, some lack the necessary skills to correctly terminate armoured cable, leading to subpar installations that may work initially but pose significant safety risks in the long run.

In many cases, cost-cutting decisions play a major role. Some businesses, operating on tight budgets, opt to bypass professional electricians and instead allow refrigeration engineers to handle the electrical work. The result? Unsafe and unreliable installations that compromise both efficiency and safety. In this particular case, we discovered severely deteriorated SY cables that were still powering high-demand refrigeration compressors—an extremely dangerous fire hazard.

Fortunately, we identified the issue before disaster struck. Our team provided the client with a safe, long-term solution by replacing all faulty wiring with properly rated armoured cable designed for external conditions and the required current load. The difference is night and day—what was once a hazardous installation is now a professionally executed, code-compliant system built to last.

Take a look at the attached images to see just how badly the SY cables had deteriorated. This case serves as a vital reminder of why using the right materials and hiring qualified professionals is essential for electrical safety.ere...

New Heavy duty Armoured cable installation

New Installation work

As you can see from the images, the new installation was carried out to the highest professional standards. To ensure a safe and reliable power supply, we installed two separate runs of heavy-duty, three-phase 5-core 16mm² armoured cable. Each conductor within the cable has a 16mm² cross-sectional area, providing the necessary capacity to handle the high current demands of the refrigeration compressors.

The new cabling was routed neatly from the building’s internal refrigeration power distribution board to the external compressor compound. We securely cleated the cables to the brickwork, ensuring a tidy and robust installation. All drilled entry points were properly fire-sealed to maintain safety and compliance. At the compressor compound, we installed two three-phase 63A rotary isolators, allowing for safe power disconnection when required.

For durability and long-term reliability, we used outdoor-rated SWA (Steel Wire Armoured) glands to terminate the new cables. From the isolators, the cables were routed through the tray system and connected to the incoming side of each new compressor. Finally, the old, deteriorated wiring was safely removed and made redundant, eliminating the fire hazard and ensuring a future-proof installation.

This project highlights why professional installation is crucial for high-power, industrial refrigeration systems. Poorly executed electrical work doesn’t just lead to breakdowns—it can cause severe business disruption, including the risk of losing massive quantities of imported frozen stock due to power failures. The financial losses from such failures can be devastating. That’s why it’s essential to plan and install these systems correctly from the start.

At our company, we take pride in delivering high-quality, professional electrical installations at fair and affordable prices for our local clients. Investing in a properly executed installation today prevents costly problems in the future.