What's Protecting Your Cable? A Complete Breakdown of Cable Sheath Materials

■ Cable Sheath Materials - Complete Guide (Types, Characteristics & Applications) 

Whether you are designing and manufacturing a new cable or simply choosing an existing one for data, power, fiber optics, or industrial automation, the outer sheath (jacket) is much more than just a speaking cover to the eye; it is, in fact, an important job holder in mechanical protection, environmental resistance, chemical shielding, and fire safety. The sheath material plays an important role in the cable performance so that it can meet different functions in a certain environment. 

We will look into the 18 common and specialized sheath materials in this section, exploring their features, such as advantages, disadvantages, and situations for use.

■ What is a cable sheath? 

A cable sheath is the outer layer that encloses the conductors or the fibers. This protective sheath is important for defending the internal components from: 

• Abrasion due to mechanical reasons 

• Moisture and leaking of water 

• UV and ozone exposure 

• Oils, chemicals, and diesel 

• Fires and hazardous fumes 

The appropriate sheath selection not only ensures operational reliability, safety attributes, and cost-profit ratio with optimum performance but also protects.

■ Cable Sheath Material Comparison Table

■ Common Cable Sheath Materials: The Essential to Know Complete Overview 

PVC (Polyvinyl Chloride) 

Ideal for: Inner arrangements. 

✅ Fire-resistant, cheap, and flexible. 

✅ Resistant to oil, chemicals, and water. 

The following are the disadvantages of PVC: 

❌ Producing dangerous halogens (up to 28% HCl) while burnt. 

❌ Loss of its properties with ultra-violet (UV) light or extreme cold. 

Applications: Indoor wiring, for data transmission, or LAN, control systems.

PE (Polyethylene) 

Ideal for: Outdoor & underground lying pipelines. 

✅ Remarkable weather and moisture-proof. 

✅ Strong dielectric electric current. 

The following are the disadvantages of PVC: 

❌ Not a fire retardant material. 

❌ Kinkiness at low temperatures (HDPE). 

Types: 

• LDPE: Flexible. 

• HDPE: Tough and rigid. 

Applications: Telecom, coaxial cable, ducting, laying in the direct soil.

LSF (Low Smoke & Fume) 

Modified PVC compound. 

✅ Producing low smoke and neutral acid gas than PVC. 

❌ However, PVC emits still 22% of its content as the hydrochloric acid, so this is not properly halogen-free. 

⚠️ A vague term which admits many definitions. 

Low-priced internal use with modest fire protection needed. 

LSZH / LSHF (Low Smoke Zero Halogen): LS0H or OHLS. 

✅ <0.5% of halogen gas discharges. 

✅ Barely smoke-producing and poisonous fumes. 

✅ Good flame retardant. 

The following are the disadvantages of LSZH / LSHF: 

❌ Higher costs. 

❌ No matches with PVC flexibility. 

Applications: Hospitals, airports, subways, tunnels, and public buildings.

PUR (Polyurethane) 

Ideal for: Automated and flexible installations. 

✅ Environmentally resistant to abrasion, oil, and chemicals. 

✅ Very flexible even in medium temperatures. 

✅ Working in Low extremes: -40C to +125C.

The following are the disadvantages of PUR: 

❌ Not justified for high heat temperatures. 

Applications: Robotics, conveyance chains, mobile equipment.

PTFE (Polytetrafluoroethylene) 

Also called: Teflon. 

✅ Non-inflammable with chemical stability. 

✅ Permits operation from -75C to +200C. 

✅ Fuel, Oil, and aggressive solvents protected. 

The following are the disadvantages of PTFE: 

❌ Costs a fortune and requires a complex process. 

Applications: The aerospace sector, military, and top-notch electronics.

FEP (Fluorinated Ethylene Propylene): Teflon® variant. 

✅ Similar to Teflon duct, but processes more in ease. 

✅ Superb chemical weather-proofness, thermal stability. 

✅ Heat resistance up to ~200C. 

Applications: Chemical plants, cleanspaces, medical, and data transmission. 

Rubber (Natural or Synthetic)

✅ Being flexible even at sub-zero temperatures. 

✅ Water, oil, chemical, and UV resistant. 

✅ Stays durable even under great dynamic efforts. 

The following are the disadvantages of Rubber: 

❌ Natural rubber is expensive; There are many alternatives that are made from synthetics. 

Applications: Welding…and mining applications; Flexible power cables.

Neoprene 

✅ Great oil and ozone resistance. 

✅ Keeps flexible in cold weather. 

✅ Moderate to low flameproofness. 

Applications: Marine, portable power, and industrial equipment. 

Silicone

✅ -50° C to +180° C. 

✅ Flameproof without poisonous gas or smoke. 

❌ Mechanically weak – susceptible to cuts or scratches. 

Applications: Medical wiring, lighting, wires insulated against fire.

TPU (Thermoplastic Polyurethane)

✅ Clear, scratch-resistant. Does not contain Halogen. 

✅ Noticeable low-temperature flexibility and outstanding toughness. 

❌ UV resistance may demand modifiers. 

❌ Although, it costs more compared to PVC. 

Applications: Charging cables, robotics, medical.

EVA (Ethylene Vinyl Acetate)

✅ Smooth, ultra-light weight UV-Proof. 

✅ Is a dielectric insulator. 

❌ Performance may degrade is slight under fire and abrasion. 

Applications: Solar cables, toys, wearables, low-voltage wiring.

CPE (Chlorinated Polyethylene)

✅ Exhibiting strong fire, ozone, oil, and weather resistance. 

✅ Disallowing flame from propogating. 

❌ The drawback of CPE is its single flexibility. 

Therefore, CPE has applications like welding cables, mining, and harsh industrial cables.

EPR (Ethylene Propylene Rubber) 

✅ Exceptional heat/electrical power 

✅ UV effect and ozone proof 

❌ PUR is less than that in abrasion 

Applications: High Voltage Power, Marine, Rubber Sheath Cables.

TPO (Thermoplastic Polyolefin)

✅ Tough, UV fight back, recycle capability. 

✅ Halogen-free and flameretardent. 

❌ Resistance to corrosive chemicals is common. 

Applications: Automotive cables, solar power, flexible outdoor wires.

Nylon (Polyamide)

✅ Sturdy, abrasion resistant, and effective. 

✅ Low friction coefficient which is perfect for cables that are pulled. 

❌ Absorbs moisture but its UV resistance is poor. 

Applications: Instrumentation, THHN wires, armor coatings.

Hypalon® (CSPE - Chlorosulfonated Polyethylene)

✅ High weather and oil resistance. 

✅ Stronger against UV and ozone. 

✅ Flame retardant. 

❌ Another drawback is it being costly and low flexibility. 

This material is used for military, mining, marine, and outdoor industrial cables.

PBTP (Polybutylene Terephthalate)

✅ Great in heat aging & fuel resistance. 

✅ High precision results. 

❌  However, if treated within low temperatures (up to brittle, poor UV resistance). 

Applications: Automotive harnesses, sensor cabling

■ How to Select the Right Cable Jacket Material

Refer to the following questions: 

• Is it a cable for indoor or outdoor use? 

• Are flame resistance or smoke toxicity issues a concern? 

• Does cable wear or rod blocking involve abrasion, bending, oil, or chemicals? 

• What does the budget and lifespan look like? 

• Are there industry-specific standards (i.e. RoHS, REACH, IEC) that are involved?

■ Conclusion

The sheath material is responsible for the cable's safeguarding, safety, and regulation. All the materials, including PVC, PTFE, LSZH, and PUR, are designed to perform best in certain environments and applications. Knowing their aspects, one can choose the most efficient and suitable method in cabling.

michael@zion-communication.com

Chat on Whatsapp

+86 13757188184