Marine Cable, Shipboard Cables Manufacturer

09 Sep.,2024

 

Marine Cable, Shipboard Cables Manufacturer

Complete Buying Guide of Marine Cable

  • What is Marine Cable?
  • Marine Cable Types
  • Marine Cable Features
  • Marine Cable Related Products
  • Marine Cable Packaging & Shipping

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What is Marine Cable?

When it comes to cables, we have a lot of options to choose from. However, when it comes to applications in marine or ship boards, you can&#;t use a general-purpose cable due to the harsh marine environment. This is where the marine cable comes in.

Marine cable is designed to resist the harsh marine environment and meets strict safety and efficiency standards. Keep in mind, access to help in case of emergency is not easily and quickly accessible on ship boards in the middle of the sea. This is why marine cable needs to be foolproof and must contribute to safety.

Marine cable can perform in extremely high as well as low temperatures. For this reason, the marine cable is flame resistant and doesn&#;t contribute to the propagation of fire. In addition, the marine cable also resists adverse conditions like oil, vibration, heat, cold, humidity, and saltwater corrosion. A quality marine cable is vital for the safety of the ships and other such property as well as protects the crew working on the ships.

Marine Cable Application

Marine cable has a wide range of applications in the marine environment. You can use it in ships, vessels, bulk carriers, tankers, cruise ships, drillships, bulk carriers, feeder vessels, gas tankers, reefers, etc. Marine cable also comes in different types to be used in a variety of situations. Some popular types include marine electrical cable, control cable, power cable, VFD cable, EMC cable, marine cable, marine rubber cable, marine data cable, marine coaxial cable, marine flexible cable, and marine wires.

Marine Cable Types

Here is the list of world-famous marine cable types that shipyards mainly use for shipbuilding projects.

TypesDescriptionMPRXCopper conductor XLPE insulation and SHF1 sheath marine rated cableMPRXCXXLPE insulation, tinned copper wire braid armored marine-grade cableLKM-HFXLPE insulated, PO SHF1 sheathing tinned copper cable marineLKSM-HFTinned copper conductor XLPE insulation tcwb screened SHF1 cableTXOICopper conductor XLPE insulated tcwb marine electrical cableM2XHUn-armored XLPE insulated LSOH sheath marine power & control cableM2XCHTC/XLPE/SHF1/TCWB/SHF1 armored marine cableTFOI0.6/1KV Armoured halogen-free & low smoke marine power cableHF-CXOSAHalogen-free marine electrical power & control cableTPYCGalvanized steel wire braided armored marine electric cableCJ86/SCTinned copper core XLPE insulation tcwb armored marine cableCHJ86/NCTwisted pair overall screened fire resistant marine cableCYJ86/SCTinned copper wire braid armored medium voltage marine power cableCJPF96/SCCU/XLPE/SHF1/GSWB/SHF1 flame retardant marine power cableCJPF/NCCU/MICA/XLPE/SHF1 fire-resistant marine-grade cableCEPF86/SCEPR insulation SHF1 sheath tinned copper wire braid armored cableCJPJ85/NCXLPE insulation SHF2 sheath armored fire-resistant cable marineMGCGEPR insulated copper wire braided rubber sheath shipboard power cableMGCHHalogen-free DIN standard tcwb armored shipboard cableFMGCHTwisted pair copper wire braided overall screen marine cableYZpLightweight, unarmoured, low voltage shipboard power cableYOZcLightweight, overall screen shipboard communication cable

Marine Cable Features

Compared with normal cable wires, marine cable achieves better results with increased features including flame retardant, lightweight, fire-resistant, low smoke, and halogen-free. Here are the key marine cable features that make it unique and different from other types of cable wires.

Flame Retardant

IEC -3-22 Category A is an IEC standard used for power cables and other types of cables to test the cable for its flame-retardant feature or characteristic. All marine grade cables must meet the standard or pass the test, as marine cables must be flame retardant to ensure safety on vessels and offshore installments in the case of fire. IEC -3-22 Category A test ensures that the marine grade cable is flame retardant and does not propagate fire. The marine-grade cable is tested under high temperature and exposed to fire to pass this test.

Low Smoke

Similar to the above standard, IEC -1 and 2 are IEC standards that ensure the marine-grade cable doesn&#;t create a lot of smoke in the case of fire. Low smoke emission is one of the key features of quality marine cables to ensure the safety of life on ships. The IEC is basically a smoke density test, in which the marine-grade cable is burned to check the density of smoke it produces.

Halogen Free

IEC -1 and 2 are IEC standards and tests that ensure the marine rated cable is halogen-free. So what does halogen-free feature mean? Halogen-free means the marine cable is free of any type of halogens, which are elements with similar properties but are highly reactive.

This makes the marine cable resist the extreme marine environment and adds to its durability. The Halogens include elements like chlorine, fluorine, bromine, iodine, and astatine. Out of these elements, you can find fluorine and chlorine commonly used in some other electric cables known as FEP (Fluorinated Ethylene Propylene) and PVC (Polyvinyl Chloride).

However, their use makes them reactive which is not suitable for the marine environment. Both fluorine and chlorine can produce toxic gases that can risk life on ships and other offshore structures. IEC -1-2 tests ensure that the materials used in the marine rated cable are without any halogen.

For this purpose, marine cables use EPR (Ethylene propylene rubber) or XLPE (Cross-linked polyethylene) tape and insulation instead of FEP or PVC. Marine cables also use the halogen-free compounds as a sheath which is called SHF 1 or SHF2.

Fire Resistant

IEC -21 is another IEC standard and test designed to ensure resistance against fired offered by the marine cable. This is achieved by the use of inflammable-material in the construction of a marine cable. The IEC -21 standard tests the marine cable against a high-temperature of 830 C.

This means marine cables not only resist fire and are very difficult to burn, but they also prevent the fire from spreading. They also keep their structure under high temperature, which means they don&#;t melt or drip easily. Good quality marine cables are also self-extinguishing. Here is the quick checklist for marine cable features:

  • Marine cables don&#;t produce toxic fume as they don&#;t use halogens
  • Marine cables don&#;t produce corrosive substances as they are designed to resist harsh surroundings
  • Marine cables emit low smoke in the case of fire
  • Marine cables don&#;t propagate fire
  • Marine cables resist fire and are extremely difficult to burn
  • Marine cables are environment-friendly and designed to keep the marine environment pollution-free

Fire Resistant VS Flame Retardant

Fire-resistant cable and flame retardant cable looks like similar features, but they are different, for which two different IEC standards and tests are used, as discussed above. The difference is in the material and construction of the cable. Fire-resistant cable has fire-proof mica tape around the tinned copper conductor while flame retardant cable does not have.

Marine Cable Related Products

Marine Cable Packaging & Shipping

Normally marine cable is packed by wooden drum as the following photo. It can meet export requirements. Packing length can cut as your request.

Honest cable has already delivered our marine cable wires to Singapore, Thailand, The Philippines, Indonesia, Spain, Brazil, Myanmar, UK, New Zealand, Malaysia, Australia, Turkey, India, Ukraine, Pakistan, Greece, Italy, Japan, South Korea, Dubai, UAE, Croatia, USA, Jordan, Sri Lanka, Vietnam, Mumbai, Hong Kong, Shanghai, Ho Chi Minh, Bangkok, Perth, etc.

If you are looking for a reliable marine cable manufacturer from China, you are in the right place. As a professional manufacturer of marine cable, shipboard cable, offshore cable, rubber cable, welding cable, electrical power cable, VFD/EMC cable, XLPE/PVC cable. Honest cable aims to provide a complete cable solution for you.

What Is The Function Of Marine Cable?

Figure 1- A Marine Cable

The design of a typical marine cable allows it to carry out a wide range of functions.

Essentially, the main functions of this cable include the following;

  • Power

Marine cable helps distribute power to different components used within the maritime setting.

The cable is sufficiently suited to transmit and distribute high voltage power to various marine components accordingly.

It is a vital function since it enhances the efficiency of a wide range of marine operations.

  • Communication

In a typical marine application, communication is a core element to ensure the efficiency of various functions within the setting.

Several communication devices are used in a marine setting, and most of them are facilitated by different marine cables.

High-quality marine cables make it easy for you to attain the best communication results with the marine environment.

  • Instrumentation

Marine cables are used in ensuring all the vital control parameters within the surrounding are attained effectively.

You can find these cables in different coding series suitable for specific instrumentation parameters.

  • Transmission

The ordinary marine setting has several instruments and devices that require a hi-tech transmission system for reliable and effective results.

Hence, dedicated marine cables are designed to ensure there is effective transmission among the numerous machines and equipment.

  • Control

Marine cables are also used to relay numerous automated commands to different systems to enhance overall efficiency.

Figure 2- The Role Of a Marine Cable Is To Aid In Communication Among Other Functions

What Are The Main Types Of Marine Cable Available?

Since marine cable is used in a broad range of marine applications, it implies you can find it in different types.

All types of marine cables are designed to suit a specific function to guarantee the utmost efficiency.

The common types of this cable include the following;

  • Sheathing tinned copper marine cable
  • Insulated electrical marine cable

Figure 3- Insulated Electric Marine Cable

  • Armored marine cable
  • Electrical power and control marine cable
  • Sheath armored fire-resistant marine cable

Figure 4-Sheath Armored Fire-Resistant Marine Cable

  • Screen shipboard communication cable
  • Unarmored, low voltage marine cable
  • Insulated electrical marine cable
  • Galvanized steel wire braided electrical marine cable
  • Halogen-free armored marine cable

Figure 5- Halogen-Free Armored Marine Cable

  • Fire-resistant marine cable
  • Flame-retardant marine power cable
  • marine cable
  • Armored voltage power marine cable
  • VFD marine cable

Figure 6- VFD Marine Cable

  • Marine instrumentation cable

What Are The Crucial Factors To Consider When Looking For Marine Cable?

It is always vital to consider some critical elements surrounding the design construction of marine cable when buying or looking for some.

The essence is to ensure you obtain the specific one which suits your requirements accordingly.

Some of these factors include the following;

  • Insulation

It uses an electric-resistant substance or a non-conductive material to cover the cable.

This element is critical in any marine cable since it inhibits current from coming into contact with conductors within the setting.

Most marine cables are insulated using thermoplastic materials because they are economical and guarantee reliability.

In other instances, rubber and fluoropolymer can also be used as insulation materials for marine cables.

  • Code of series

The details give you a basic idea of conducting marine cable coding in a specific sequence.

This element is critical in marine cable because it prevents potential loss of connectivity or consequential damage.

When choosing an offshore cable, it is necessary to know the code of the series to attain efficiency and desired results.

  • Sheath

The typical marine cable features an inner-sheath and outer-sheath.

It is essentially a component within the marine cable structure designed to protect it from external environmental elements.

Inner-sheath, for instance, comprises a non-magnetic lead alloy material.

Some marine cables have a seamless aluminum sheath, which is critical in marine applications where bending is a concern.

The outer-sheath, also known as over-sheath, is designed to provide mechanical strength to the cable.

Thus, it covers the marine cable from potential damage from dust, moisture, dirt, and corrosion among others.

  • Combustion properties

It is also a critical marine cable construction aspect you must consider when looking for the most suitable one.

Combustion in this cable takes place as an exothermic reaction.

Simply put, the reaction occasionally releases heat, gradually making temperature changes somewhat invisible.

Hence, it is necessary to know the actual combustion rate of your preferred marine cable.

  • Armor

This is the layering of galvanized steel wires applied as over-sheath to prevent the cable from mechanical damage.

Most marine cables consist of steel and copper wire armoring since they exhibit longitudinal length.

Thus, if there is a fault in the cable, fault current flows through the armor and gets earthed.

  • Screen

It is an enclosing web of earthed wire mesh protecting the marine cable from electromagnetic interference.

The screen is also essential in reducing EMI from a fault current.

Figure 7- Always Consider The Above Mentioned Crucial Elements When Selecting Your Marine Cable

Does Marine Cable Lie On The Ocean Floor?

Yes.

During the installation of marine cables, they go all the way down to the bottom of the ocean floor.

Those used nearer the shore are often buried under the sea to protect them from potential mechanical damage.

And this explains the reason you hardly see marine cables anytime you are around the beach.

Ideally, considerable preventive care ensures the marine cables follow the safest path.

This makes it easy to prevent interfering with anchoring areas, fishing zones, and fault zones among other dangers.

Moreover, most undersea marine cable companies educate involved parties on the location of such cables to minimize inadvertent damage.

What Is The Ideal Capacity Of Marine Cable?

Ordinarily, marine cable capacity often varies depending on a wide range of prevailing factors.

For instance, modern cables have a greater capacity than cables laid several years ago.

Nevertheless, you can measure the capacity of marine cable using the following principles;

  • Potential Capacity

It is the total amount of capacity the marine would handle if all the available equipment were installed at the cable ends.

Mostly, it is the metric often cited in the press.

  • Lit Capacity

This refers to the amount of capacity running over the marine cable.

It is a figure which merely presents a different capacity metric.

Ideally, most marine cables are rarely fully utilized; hence its total capacity is not fully utilized.

This often happens since most transmission equipments are relatively expensive; hence users prefer to gradually upgrade cables depending on customer demands.

Do Marine Cables Ever Break?

Yes.

The marine cables are exposed to several potential dangers, making cable faults relatively common.

Notably, most companies using marine cables often adhere to a safety number approach to usage, making it rare to hear about marine cable faults.

The safety number approach thus allows involved entities to spread capacity over different marine cables.

Hence, when one breaks, the operations continue running smoothly over other cables as they restore the broken cable.

Majorly, marine cables are often damaged by fishing vessels and ships dragging anchors.

Besides, environmental elements such as earthquakes are also significant contributors to damaging marine cables.

However, sharks bite and deliberate sabotage are also causes of marine cable damage, although rare.

What Is The Typical Design Life Of Marine Cable?

The engineering of marine cable guarantees a service lifespan of at least 25 years.

Often, these cables may operate for more than 25 years but in many instances retired earlier since they become economically obsolete.

Ideally, marine cables after 15 years cannot necessarily provide as much capacity as newer cables at a comparable cost.

Hence, the longer they stay in operation, the costlier they become in rendering desired services.

Nonetheless, the marine cable can be retired, but it remains inactive on the ocean floor.

But in other instances, they are pulled up, salvaged, and recycled for raw materials.

Therefore, the typical design life of the marine cable is quite long, but they are hardly used to their end-life due to economic factors.

Figure 8-The Marine Cables Can Serve Upto 25 Years Before They Become Economically Obsolete

Can Marine Cable Function At Same Temperature In Dry And Wet Conditions?

It depends on the actual type of marine cable you are using.

For instance, bare copper and tinned copper marine cables can operate in temperatures of up to 105°C in both wet and dry conditions.

However, a flat multi-conductor marine wire can operate at a temperature range of 105°C in dry conditions and 75°C in wet conditions.

In a nutshell, some marine cables can function effectively at the same temperatures irrespective of wet or dry conditions.

On the other hand, others can only operate satisfactorily at different temperatures based on their actual properties.

What Benefits Do Marine Cable Offer?

Ordinarily, the marine cable offers various advantages in different applications.

Of course, this makes it a preferred option as far as marine applications are concerned.

The common benefits include the following;

  1. Exceptional durability since it is constructed using relatively tough raw materials. This is advantageous because it reduces running costs substantially and guarantees efficiency and reliability.
  2. It is versatile, and you can use it in various marine applications. For instance, you can use it in communication equipment, transmission devices, power relay, etc.
  3. Guarantees excellent reliability in the harsh marine environment. The design construction of marine cable and raw materials used makes this component quite reliable and efficient.
  4. It provides immense conductivity levels since the base material used in making the cable consists of various copper alloys.
  5. Marine cables are sturdy hence can endure rocky sea beds, volcanoes, earthquakes, and occasional shark bites.
  6. The design of marine cables allows them to be lightweight, which is essential and convenient, especially during installation.
  7. The material used for constructing marine cables is non-pollutants hence keeping the marine environment safe throughout.
  8. Marine cable is relatively economical for communication than satellites, which are seemingly more expensive.

Figure 9- Marine Cables Are Versatile In Use or Applications

What Is The Importance Of Tinning Marine Cable?

Generally, the operating environment of marine cable is relatively harsh.

Hence, it is only a cable with suitable properties that can withstand such unfavorable conditions for a long.

Tin coating on marine cable thus protects it from possible corrosion and premature failure.

With competitive price and timely delivery, SUNUA sincerely hope to be your supplier and partner.

Since this cable is exposed to water, tinning is integral in extending its overall service lifespan in a harsh environmental setting.

Also, tinning prevents the marine cable from oxidizing.

Often, oxidization can inhibit you from attaining an ideal, tinned solder connection to the wire.

Besides, the tinning marine cable is vital since it creates tougher contact points when connecting the cables to the proper terminals.

What Are The Specifications Of Marine Cable?

Typical marine cable exhibits several specifications making it comparatively superior to the ordinary cable.

Some notable specifications of this type of cable include the following;

  • Flexibility; hence can endure different kinds of stress due to its ease of bending.
  • Low voltage
  • Low temperature tolerant of up to -40°C
  • Resistant to heat, flame, fire, moisture, gasoline, oil, acid, and alkalis among others.
  • Excellent protective mechanism against EMI (electromagnetic interference)
  • Exceptional longevity and resilient enough to tolerate chemical, mechanical, and environmental stress
  • Halogen-free and low-smoke

Why Should You Sheath Marine Cable?

Sheathing marine cable is fundamental because it prevents the conductor from punitive external damage and maintains current flow.

Besides, sheathing protects marine cables against thermal, mechanical, chemical, physical, or electrical damage.

Sheathing marine cable is also vital since it offers excellent resistance against numerous harmful elements like oil, acids, chemicals, flame, water, alkali, etc.

Importantly, it is necessary to sheath marine cables to prevent them from melting when exposed to relatively elevated temperatures.

Also, sheathed marine cables are substantively solid and durable.

In a nutshell, sheathing this component adds significant value to its overall efficiency, reliability, and performance.

How Does Marine Cable Compare With Regular Cable?

Figure 10- A Regular Cable Has No Tinned Layer

The primary difference between marine cable and regular cable lies in the tinning of copper.

Ordinarily, the marine cable features a tinned layer, which is often actuated through the electroplating process.

In essence, the tin coat on the marine cable makes it possible to be resistant to corrosion since it prevents it from oxidation.

Hence, the tinning aspect gives marine cable an edge over regular cable.

Ultimately, the tinning makes marine cable exceptionally durable and somewhat sturdier than ordinary cables.

It makes the marine cable resist corrosion from chemicals, acids, alkalis, moisture, chlorides, and salts among others.

Another significant difference is that marine cable has a 10-15% capacity more than an identical regular cable.

Often, the capacity of carrying current in cables usually rises with an increase in copper in the cable.

How Does Tinned Marine Cable Differ From Bare Copper Marine Cable?

Figure 11- A Tinned Marine Cable

Primarily, bare copper cables tend to be reasonably resistant to corrosive substances.

On the other hand, tinned marine wires are designed to prevent accelerated corrosion against wet and contaminated surroundings.

Regarding conductivity, bare copper cable exhibits similar levels as tinned copper cable.

However, as far as durability is concerned, a tinned copper cable exhibits 10 times more longevity than a bare copper cable.

Also, it is relatively easy to solder tinned copper cable than bare copper wire.

How Much Does Marine Cable Cost?

There is no fixed cost for marine cable.

Usually, several factors determine the actual cost of purchasing this wire, such as the following;

  • Manufacturer

Different marine cable manufacturers price these products differently based on various aspects.

Some have a defined price list for particular marine cables.

Also, the company&#;s reputation based on quality, reliability, and professionalism defines the pricing.

Of course, some manufacturers are a bit expensive, whereas others tend to be more affordable.

  • Type of marine cable

Marine cables come in different designs constructed for specific functions within the maritime setting.

However, these cables feature different properties hence causing price variance.

Thus, you need to be certain of the specific marine cable you purchase to determine its actual cost.

  • Volume

Often, when you buy marine cable in bulk, you are likely to save on unit cost since most manufacturers offer discounts.

Buying these cables in small quantities, on the other hand, becomes somewhat more expensive per unit price.

How Does Marine Cable Work?

It varies based on the specific marine cable you are using.

Ordinarily, different marine cables are designed for various functions such as transmission, instrumentation, power, control, networking, etc.

Hence, the manner in which the cable works is dependent on the particular functionality of the cable.

For instance, network and communication marine cable use modern fiber-optic technology.

In such marine cables, glass fibers are wrapped in plastic layers for ultimate protection.

What Is The Average Thickness Of Marine Cable?

Ideally, marine cables are used over long distances hence tend to be relatively thick.

The average thickness of this cable is more or less similar to the width of a garden hose.

But this is primarily dependent on the specific type of marine cable you are using and its particular function.

For instance, communication marine cables have fragile filaments, which carry light signals.

Hence, the fibers are sheathed in a few insulation and protection layers.

However, marine cables laid closer to the shore often use extra armoring layers for improved protection.

Figure 12-Marine Cables Are Relatively Thick

Where Do You Purchase Marine Cable?

Ordinarily, you will find several manufacturers producing different types of marine cables.

But you can only find the best deals worth each penny from reliable and reputable manufacturers and suppliers.

Finding the most suitable manufacturer of this component entails looking into their experience in this industry.

An experienced manufacturer indicates better products and an understanding of the market based on its evolution.

You also need to ensure your preferred manufacturer focus on research and development.

It is important since it guarantees the production of high-quality marine cables suited for different purposes.

Besides, it should have a team of knowledgeable, qualified, and experienced personnel and technicians to handle different levels in the production process.

Also, warranty is an important aspect you must look into when finding the ideal manufacturer for marine cables.

Nonetheless, Honest Cables is currently the best choice for all your marine cable solutions.

It guarantees all the aforementioned elements to ensure you get the most suitable and quality marine cables for your applications.

What Types Of Connectors Are Used With Marine Cable?

Different marine cables use various types of connectors depending on the actual function.

However, the most common connectors you&#;ll find around include the following;

  • Butt connectors
  • Ring terminals
  • Spade fork terminals
  • Blade disconnect terminals
  • Bullet snap plus connectors
  • Three-wire connectors

What Do Colors Used In Marine Cable Connectors Stand For?

Most of the colored marine cable connectors are electrical wires.

However, other cables used in different marine settings are colored and often designed for various functions.

Here is the meaning of some of these colored marine cable connectors;

  • Green &#; Bonding wires
  • Yellow/Black &#; Wire used in returns in negative mains
  • Red &#; Wires used in returns in positive mains
  • Pink &#; Wires used for connecting fuel gauge senders with the gauge
  • Yellow with Red &#; Wires used for connecting starting switch to solenoid
  • Purple &#; Wires used for connecting the ignition switch to the coil and electrical devices
  • Orange &#; Wires used for connecting distribution panels to accessory switches
  • Dark blue &#; Wires for connecting fuses
  • Brown &#; Wires used for connecting generator terminals regulators, generator armatures to regulators, and switches/fuses to pumps

Figure 13- Different Marine Cables

What Are The Standards Of Marine Cable?

Technically, marine cables are manufactured according to the defined standards designed for optimum efficiency and protection.

A cable can only be categorized as marine if it meets the stipulated standards, which include the following;

  • BS & BS Standards

These are vital standards that ensure the manufacturing process of marine cable meets the British Maritime standards BS & BS.

  • JIS C Standard

This is a Japanese standard applicable to the marine cable used for different purposes.

Some applications, which this standard applies to include , switchboard, electrical and control among others.

Ordinarily, the marine cable must pass through different tests and requirements to meet this standard.

  • IEC -3 Standard

It is an international maritime standard applicable to marine cables used for electrical, fixed, and offshore installations.

cables, electrical power, and control are some of the marine cables tested under this standard.

What Are The Common Certificates For Marine Cable?

Certificate of marine cable is one of the vital features that makes it a quality alternative.

Ideally, the more certificates a ship cable has, the higher its conformity to required marine standards.

Some common certifications of marine cables include the following;

  • American Bureau of Shipping (ABS)
  • Bureau Veritas (BV)
  • Lloyd&#;s Register Group Limited (LR)
  • ClassNK
  • Korean Register of Shipping (KRS)
  • Registro Italiano Navale (RINA)
  • Russian Maritime Register of Shipping (RS)
  • Biro Klasifikasi Indonesia (BKI)

I know you may also want to learn about:

For all your marine cables, contact us now.

Buying Better High Temperature Wire And Cables

Like many other products, high temperature cable has a huge variety, manufacturing specifications and diversity of application. Because of the vast differences in cable quality and application, it&#;s incorrect to say that one specific type of high temperature wire is better than another; or that Silicone high temperature wire 12 AWG is more suitable than Teflon 12 gauge high temperature wire. It is the application and the operating environment that determines which one is the better option.

In this High Temperature Wire Buyers Guide, we&#;ll address some of the common questions that most people have about high temperature heat resistant wire. We&#;ll also talk about the various types of wire insulations available, and some of their operating characteristics. We&#;ll also touch upon some of differences in high temperature wire manufacture processes, which will help you make more informed choices.

The objective of this High Temperature Wire Buyers Guide is to give you enough information so that you make the right high temp wire selection and procurement decisions. 

What Is High Temperature Wire?

High temperature wire often refers to electrical cables and wires that have a temperature rating of 125°C (257°F) or higher. However, in other context, high temperature electrical wire may also refer to wires and cables that have temperature ratings as low as 90°C (194°F). These cables and wires are available in various forms, including single-conductor or multiconductor variants.

Some of the common applications of high temperature heat resistant wire include:

  • Utility power stations
  • Electric arc furnaces
  • Casting furnaces
  • Die cast plants
  • Plastic molding plants
  • Weld robotic cells
  • Refineries
  • Blast furnaces
  • Fire protection equipment
  • Food industry professional ovens

On the face of it, a high temperature cable may seem to only be applicable for applications that generate excessive heat. However, that&#;s not the case. Many Teflon wire and silicone cable manufacturers offer products that can also operate in conditions that offer extremely cold environments.

Depending on the process of high temperature wire manufacture, these intense-heat shielding cables and wires may have various components. However, typically, they comprise of a conductor, which may be annealed, copper-plated, tinned copper, or nickel-coated copper, and high temperature insulation made from various polymers. Some high temperature wire may also have an additional external jacket made from either K-fiber material or fiberglass braid.

What Is Heat Resistant Cable?

Heat resistant cable is another name for high temperature wire, and share the same characteristics and operational application. When sourcing high-heat capable cables and wires, it&#;s important to remember that these products aren&#;t just ideal for high-temp applications. Many cables with high temperature wire cover or insulation function equally well in extremely low temperatures too.

Many high temp wire varieties have either Silicone or Teflon insulation, which makes them heat and cold resistant. Because of these characteristics, these products are ideal in environments that generate excessive heat &#; such as furnaces and ovens, as well as sub-freezing usage, such as in polar or deep-sea projects.

What Types Of Insulation Do High Temperature Cables Use?

Two of the most common materials used in manufacturing high temperature cable insulation are PTFE and ETFE polymers. High-quality high-temp cables are available using either of these insulations. Neither of the two types of polymers are &#;good&#; or &#;bad&#; &#; they both fit unique applications.

ETFE is an ethylene tetrafluoroethylene copolymer insulated heat resistant cable, and made from a carbon, fluorine, and hydrogen-based material. A better-known brand name of such cables is Tefzel®. The resins used in these coatings are the very resilient among the fluoropolymer range of polymers, and high temp wire may be manufactured by applying ETFE at film builds up to 1,000 micrometers &#; which is very tough.

PTFE, on the other hand, is a fluorocarbon and is made with carbon and fluorine atoms. A well-known brand for this type of polymer is Teflon®, a trade name of DuPont. While ETFE has a tensile strength that may be as high as 34% greater than that of PTFE, a high temperature cable made from the latter is a more flexible polymer with a comparatively higher (66%) elongation to break. 


You&#;ll also find plastic-based insulations, such as Polyvinyl Chloride (PVC) and Chlorinated Polyethylene (CPE); and rubber-based insulations, such as Neoprene (Polychloroprene) and Ethylene Propylene Rubber (EPR). As well, other high temperature cable insulations may use hybrids of these, and other, materials.

What Type Of Wire Is Used In Very High Temperature Locations?

Wire with high temperature insulation is required to support wiring and cabling applications in high temperature locations. Because of the intense heat properties required, either ETFE or PTFE cables are good for such locations. The reason for this is because of the thermal properties inherent in either types of insulated cables. While both types of insulation support high temperature wire, the melting temperature of ETFE is 267oC, while that of PTFE is 327oC. This means that the latter is a better high temperature electrical wire, compared to the former, in locations generating extreme heat.

The cable&#;s Limiting Oxygen Index (LOI) value also determines the choice of high temperature cable for a specific application. LOI is the minimum percentage concentration of oxygen at which the polymer used in the cable&#;s insulation starts to burn. For PTFE, that value is greater than 95%, while with ETFE cables, the LOI is between 30% to 36%. When choosing high temperature heat resistant wire for higher oxygen locations, therefore, a PTFE cable is a better choice.  

What Temp Does Wire Insulation Melt?

High temperature cable insulation melts depending on the materials used in manufacturing the insulation. The melting temperature of PTFE insulated cables is 327oC and ETFE 267oC, but both of these materials begin to soften at lower temperatures.

Plastic insulation, such as PVC has a maximum high temperature range of 105 degrees Celsius (221 F), while high temperature electrical wire with other plastic insulations, such as Polyethylene (PE) can withstand temperatures of up to 80 degrees Celsius (176 F).

Rubber high temperature insulation types, such as Styrene Butadiene Rubber (SBR), may withstand up to 90 degrees Celsius (194 F); while Fiberglass and Silicone insulated cables may operate in temperatures in excess of 482 degrees Celsius (899.6 F) and 180 degrees Celsius (356 F) respectively. Ethylene Propylene Rubber (EPR) high temperature wire cover may melt in temperatures approaching 160 degrees Celsius (320 F).

When it comes to high temperature cable insulations, melting point may not be the only cause for concern. Engineers, electricians and other infrastructure project managers, where heat resistant cable is used, may also be concerned about &#;outgassing&#; &#; a situation where heat causes component parts of an insulation to escape into the atmosphere. Using high temperature heat resistant wire, that leads to outgassing, may cause gasses like corrosive hydrofluoric acid to fume enclosed areas and wreak havoc on people and equipment.

Yes, there is high temperature cable available with both Teflon and silicone insulation. Which cable one chooses to use depends on the environmental conditions and the application. For example, a 16 high temperature wire with Teflon insulation might be ideal for applications that call for heat resistance, corrosion resistance, wear-and-tear resistance and friction resistance.

Because of its flexibility characteristics, high temperature wire with Silicone insulation is useful in hard-to-access applications. For example, a silicone insulated 14 gauge high temperature wire may be equally useful in rugged applications. That&#;s because Silicone high temp wire also offers additional resistance against weathering, ozone and ageing, and provides protection against radioactive rays as well as UV-radiation.

Ultimately, however, whether you choose Teflon cable insulation, or whether you choose to use silicone wire instead, your application and its operating environment will ultimately drive your choice of high temperature wire cover.FEP Wire and PFA wire belong to Teflon wire.


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