The Cast-In Fire Solution Built for Smarter Slabs
A smarter way to plan and protect service penetrations in new builds
The BOSS FyreBox Cast-In is a purpose-designed fire stopping system that installs directly into the formwork before the concrete pour. It creates a clean, compliant and future-ready penetration for bundled services in concrete floor slabs.
Instead of drilling multiple holes after the slab is cured, builders can install a single Cast-In unit and allow all mixed services to pass through one opening. This saves time, avoids messy concrete coring and removes a major source of compliance risk during construction.
Why Cast-In Makes Sense for Modern Construction
Traditional fire stopping often happens too late. Services clash, penetrations are inconsistent and post-installed core drilling slows everyone down. The Cast-In system solves these issues by planning passive fire protection early in the build.
Key benefits include:
- Pre-planning avoids compliance risks
- Saves time across all trades
- Avoids costly core hole drilling
- Creates space efficiencies in risers and shafts
- Allows mixed service bundles in a single penetration
Because it is built into the slab, the finished penetration is clean, consistent and ready for mechanical, electrical and hydraulic trades to use.
How the System Works
The Cast-In unit has an internal intumescent lining that expands during a fire to seal voids around metal pipes and fills the voids by melting plastic or combustible services. It forms a dense protective char that maintains separation between floors.
The internal BrushSeal makes installation fast and supports:
- Building movement in seismic areas
- Future additions or changes to services
- Easy inspections for maintenance and compliance in accordance with AS1851
Fire ratings of up to 4 hours can be achieved when installed correctly. (FRL -/240/240 accompanied by the P40-MAK Wrap).
What Can Pass Through the Cast-In
The Cast-In system supports unlimited combinations of mixed services, such as:
- Power cables – mains, sub mains & TPS
- Aluminimum core cables
- Data, comms and fibre optic cables
- COAX, CAT6, Intercom fig 8, EWIS and fire alarm cables
- uPVC pipes and conduits
- Steel and cPVC sprinkler pipes
- Insulated copper pipes and paircoil
- Steel, stainless steel and copper pipes
- HDPE, PP, PP-R, PE-RT and Kelox pipes
This flexibility makes it ideal for high-density service zones, risers and plant rooms.
FAQ
Q: Can the Cast-In be installed in existing slabs?
A: No, the Cast-In model is specifically engineered for new construction and must be installed before the concrete is poured. However our traditional FyreBox™ range does offer retrofit solutions to existing slabs for top of slab mount, standard in floor penetrations, and even offers a range of retrofit options for oversized penetrations with BOSS Batts™.
Q: Does it support mixed service bundles?
A: Yes. Unlimited combinations of approved pipes and cables can pass through one opening.
Q: What fire rating can it achieve?
A: Up to 4 hours depending on configuration.
Q: Can services be added later?
A: Yes. The BrushSeal allows new services to be installed without compromising compliance. The P40-MAK Wrap may need to be removed and re-fitted after adding services.
Q: Is an extension available for thicker slabs?
A: Yes. Extension sleeves in 200 mm increments adapt the Cast-In to almost any slab depth.
Q: Does it reduce installation time?
A: Yes. It eliminates core drilling and improves trade coordination and saves labour over traditional retrofit methods.
Ready to Plan Your Next Project
If you want to reduce risk, speed up construction and simplify service penetrations, the BOSS FyreBox Cast-In is the ideal solution.
Want to Know More?
BOSS Fire can provide full technical guidance, installation details and project support. Get in touch if you would like help selecting the right fire stopping system for your build.
