Selecting the wrong industrial cable can lead to overheating, insulation failure, or even fire — while over-specifying wastes money on unnecessary copper and insulation. Here's what to check before you order.
1. Voltage Rating
Match the cable's rated voltage to the system voltage with margin — for example, use 1.1kV grade cable for LV distribution and appropriately rated XLPE cable for MV feeders. Under-rating insulation is a serious safety hazard; it isn't just a paperwork detail.
2. Current-Carrying Capacity (Ampacity)
The cable's cross-sectional area must be sized for the expected load current, de-rated for installation conditions — ambient temperature, grouping with other cables, and installation method (buried, in conduit, on tray, in free air) all reduce the safe current-carrying capacity versus the cable's baseline rating.
3. Conductor Material — Copper vs Aluminium
Copper offers higher conductivity for a given cross-section (meaning a smaller cable for the same ampacity) and better long-term connection reliability. Aluminium is lighter and cheaper for large feeder sizes but requires larger cross-sections and special lugs/connectors rated for aluminium to prevent oxidation-related joint failures.
4. Insulation & Sheath Type
XLPE (cross-linked polyethylene) is the industry standard for MV power cables due to its high thermal rating and moisture resistance. PVC is common and economical for LV wiring. For harsh environments — chemical exposure, high heat, or fire-rated applications — consider specialized sheathing like FRLS (Flame Retardant Low Smoke) or LSZH (Low Smoke Zero Halogen), especially in enclosed industrial or commercial buildings.
5. Installation Environment
- Buried direct in ground: Needs armoured cable (e.g. steel wire armoured) for mechanical protection.
- Cable tray / open air: Unarmoured cable is usually acceptable, but UV-resistant sheathing matters for outdoor exposure.
- Vibration-prone areas (near motors, compressors): Flexible, multi-stranded conductors resist fatigue cracking better than solid conductors.
- Chemical plants / corrosive atmospheres: Chemically resistant sheath compounds are essential.
6. Short-Circuit Withstand
For MV and large LV feeders, verify the cable's short-circuit current rating against the fault level of the system — a cable that's fine for normal load current can still fail thermally during a fault if it wasn't sized for the available fault current and clearing time of the upstream protection.
Not sure which cable spec fits your installation? Submit an RFQ with your load, voltage, and installation details and our team will help you specify the right cable.