Where Are Cable Compounds Used?

Frustrated by cable failures in critical systems? Choosing the right compound solves insulation breakdown and signal loss before they cripple your operations.

Cable compounds find use across power grids, telecom networks, automotive wiring, solar farms, oil and gas installations, and transportation systems—ensuring safety, performance, and longevity in each sector.

In the next sections, I’ll map compound types to key industries then explain how to choose the right compound based on performance needs.

Where Are Cable Compounds Used? Key Industry Applications?

Worried that your cable materials won’t hold up under industry demands? Each sector has unique electrical and environmental challenges that specific compounds must meet to keep systems running safely and efficiently.

Cable compounds are tailored to protect conductors and signals in power distribution, telecommunications, automotive electronics, solar power arrays, oil and gas rigs, and rail and roadway transport. Each application demands distinct insulation, screen, and jacket materials optimized for voltage level, environmental exposure, mechanical stress, and regulatory compliance.

Power Industry

Power transmission and distribution cables use cross-linked polyethylene (XLPE) and ethylene propylene rubber (EPR) insulation for high dielectric strength and thermal endurance. Semi-conductive screens of carbon-loaded XLPE manage electric fields in medium-voltage lines. Outer jackets of polyethylene (PE) or low smoke zero halogen (LSZH) compounds protect against moisture, UV, and mechanical damage in overhead and underground cables.

Compound Function	Power Sector Material	Key Benefit
Insulation	XLPE, EPR	High voltage resistance, heat endurance
Screen	Carbon-loaded XLPE	Electric field grading
Jacket	PE, LSZH	Weather, moisture, fire safety

Telecommunications

Data and voice cables require low-dielectric-loss insulation such as cellular PE or fluorinated ethylene propylene (FEP). Semi-conductive and foil screens control interference. Outer jackets of PVC or LSZH ensure flame retardancy and smoke suppression in indoor and outdoor installations.

Compound Function	Telecom Material	Key Benefit
Insulation	Cellular PE, FEP	Low signal loss
Screen	Foil, braided copper	EMI/RFI shielding
Jacket	PVC, LSZH	Fire safety, smoke control

Automotive

Automotive wiring harnesses use PVC and thermoplastic polyurethane (TPU) insulation for flexibility and oil resistance. Semi-conductive layers in ignition and sensor cables ensure stable signals. TPU or cross-linked polyolefin (XLPO) jackets protect against heat, chemicals, and abrasion under the hood.

Compound Function	Automotive Material	Key Benefit
Insulation	PVC, TPU	Flexibility, chemical resistance
Screen	Semi-conductive polymer	Signal integrity in EMC environment
Jacket	XLPO, TPU	Heat, oil, abrasion resistance

Solar Power

Solar panel arrays demand UV-resistant XLPE or specialized TPE insulation. Inner semi-conductive screens and tinned copper conductors reduce corrosion. Jackets of solar-grade XLPE or LSZH withstand UV, temperature swings, and moisture over decades.

Compound Function	Solar Material	Key Benefit
Insulation	UV-stabilized XLPE, TPE	Sunlight and weather resistance
Screen	Semi-conductive XLPE	Uniform field distribution
Jacket	Solar-grade XLPE, LSZH	Long-term outdoor durability

Oil & Gas

Drilling and subsea cables use EPR and high-temp silicone insulation for extreme heat and chemical exposure. Armored semi-conductive screens control HV fields. Jackets of polyurethane or HNBR resist oil, abrasion, and marine environments.

Compound Function	Oil & Gas Material	Key Benefit
Insulation	EPR, silicone	High temp, chemical resistance
Screen	Metalized polymer	Field control in HV systems
Jacket	Polyurethane, HNBR	Oil, abrasion, water resistance

Transportation

Rail and roadway power and signal cables use XLPE or EPR insulation. Carbon-loaded screens prevent signalling errors. LSZH jackets ensure fire safety in tunnels and stations. Vibration and abrasion-resistant compounds maintain integrity in harsh transport environments.

Compound Function	Transport Material	Key Benefit
Insulation	XLPE, EPR	High reliability under load
Screen	Carbon-loaded XLPE	EMI control
Jacket	LSZH	Low smoke, no halogen in confined spaces

How to Choose the Right Cable Compound for Your Application?

Unsure which compound matches your project’s demands? Balancing dielectric strength, flexibility, temperature tolerance, and compliance ensures your cable performs safely and lasts its expected service life.

Selecting the right compound involves evaluating electrical, mechanical, and environmental criteria against application requirements. Key performance factors include dielectric strength for voltage rating, flexibility for routing and vibration, temperature range for ambient and short-circuit conditions, flame retardancy and smoke emission for safety, UV and chemical resistance for outdoor exposure, and regulatory compliance (UL, IEC, RoHS) for market acceptance.

Dielectric Strength

Choose insulation compounds tested per IEC 60811 and ASTM D149 for the required voltage class. High-voltage systems need XLPE or EPR rated above 30 kV/mm, while low-voltage uses PVC or PE at 20 kV/mm.

Flexibility and Mechanical Properties

Measure tensile and elongation per IEC 60811. Flexible TPE and EPR suit dynamic and bending applications, while rigid XLPE excels in stationary power runs. Screen compounds require uniform conductivity without cracking.

Temperature Range

Select compounds with continuous rating and short-term peaks per IEC 60216. EPR and silicone handle –50 °C to +150 °C. PVC and standard PE cover –40 °C to +70 °C. Outdoor and solar cables need UV-ageing per ISO 4892.

Flame and Safety Standards

For fire-sensitive areas choose LSZH per IEC 60332-1, IEC 61034, IEC 60754. Industrial cables might require UL 1581 VW-1 or UL 1581 FT1. Ensure compound passes required flame, smoke, and toxicity tests.

Chemical and Environmental Resistance

Use chemical test per ASTM D543 for oil, solvent, acid, and moisture exposure. HNBR and polyurethane resist oil and wax. outdoor cables need ozone and UV per IEC 62230.

Criterion	Test Standard	Typical Compounds
Dielectric Strength	IEC 60811, ASTM D149	XLPE, EPR, PVC
Flexibility	IEC 60811	TPE, EPR
Temperature Rating	IEC 60216	Silicone, EPR, XLPE
Flame Retardancy	IEC 60332-1, UL94	LSZH, PVC
UV Resistance	ISO 4892	UV-stabilized XLPE, TPE
Chemical Resistance	ASTM D543	HNBR, Polyurethane, EPR

Conclusion

Understanding where and how cable compounds apply across industries ensures you match compound to service conditions—protecting safety, performance, and longevity in every application.