As both a UK manufacturer and distributor, we’ve been providing high quality cables to a wide range of industries for decades, ensuring that our customers have equipment to hand that’s up to the job, long lasting and great value for money.
But even using the very best equipment, cables and wires do still need some TLC and, if they are sometimes overlooked and neglected, problems can arise.
In this Tips from the ‘top guide, we look at the risks of cable failures, the factors that can affect their durability and identify some simple but effective best practices that should extend their lifespan.
The Business Risks and Financial Impact of Cable Failures
Cabling is integral to business operations across many sectors and their failure can have far-reaching consequences - from financial losses to reputational damage.
Dependent on their importance, cable malfunctions can lead to significant downtime, disrupting production schedules and costing businesses valuable revenue. Being proactive with your care and following our tips can help avoid these unexpected halts.
Asset Lifecycle Optimisation
Poor cable performance can affect the efficiency of other tech and business assets that rely on them.
Optimising cable systems ensures that associated machinery and infrastructure function reliably, extending their overall lifecycle and creating savings across a wider part of the business.
Regulatory and Compliance Risks
Faulty cables can result in non-compliance with safety and environmental regulations. This can lead to hefty fines and reputational harm for your organisation.
Environmental Liabilities
Cables used in environmentally sensitive locations can add another layer of problems so taking steps to care for your cables is even more vital.
Badly cared for cables can leak harmful substances into the environment or contribute to general waste. Investing in high quality, sustainable cables, and having a plan to keep them tip-top, mitigates these risks, while supporting environmental responsibility.
How Long Do Cables usually last?
Obviously, this can differ dependent on the cable and how it’s used but gaining an understanding of a cable's expected lifespan can really help you manage their lifespan and efficiency effectively.
The unpredictable British weather
Cables that are regularly exposed to harsh environments, like extreme temperatures, chemicals, or UV radiation, degrade much faster.
If the cables are employed in a location that’s exposed to hot sun eg outdoors or overlooked by a window, the sun’s rays can degrade the cable's outer sheath, particularly if it’s not UV-resistant. These hot summers we now experience in the UK can soften or melt insulation.
In wintertime, or in applications in refrigerated areas, low temperatures can make the cable’s insulation brittle and prone to cracking. Even the British wet weather can have an impact.
Moisture and humidity play a part too and water ingress can lead to corrosion of the metal conductors as well as ongoing deterioration of the wiring’s insulation. In damp environments, mould can grow on the cables and this can contribute to the insulation degrading.
One other thing to bear in mind if the cables are used outside, try and protect them from rodents, as they can chew through cable jackets. And some insects can nest or cause damage within cable structures.
Physical Wear and Tear
Repeated flexing, bending, or twisting can weaken cables, especially in areas of heavy usage. If the cables rub against rough surfaces or sharp edges, it can wear away the outer insulation or jacket.
Excessive pulling or crushing forces can damage both the internal conductors and the outer layers of a cable.
Additionally, heavy usage of the cables and any mechanical stress placed on them can reduce their life. Vibrations from machinery or nearby equipment can cause loosening of connections or internal fatigue in cables over time.
Electrical and Connection Stress
Excessive current flow can overload and overheat the cable, damaging insulation and reducing the cable's lifespan and voltage surges can puncture or degrade insulation.
Even electrical interference or harmonics can heat the cables up, affecting the insulation. Continuous exposure to strong electromagnetic fields can degrade the cable shielding and lead to performance issues.
Poorly crimped or loose connections (always use quality crimping tools!) can lead to overheating or electrical faults and routing cables through areas with excessive vibration, heat, or movement can lead to wear.
Cable Quality
It goes without saying that you should always buy the best quality you can, and from a reputable supplier.
Poor-quality materials or manufacturing defects can make cables more susceptible to failure, even under normal operating conditions, and using cables that aren’t rated for the specific application or environment (e.g. using indoor cables outdoors) can lead to the cable’s life being cut short.
How to Care for Your Cables
As well as choosing top quality products, proper handling and maintenance of your wiring will significantly extend cable longevity.
We’ve compiled some of our favourite tips and techniques below:
Wrapping cables the right way
It's not just rockstars and road crew that need to keep cables in tip top condition. Anyone managing important cabling can prevent plenty of problems storing and maintaing them in the right way.
The roadie wrap technique
The roadie wrap alternates "over" and "under" loops when coiling cables, preventing tangles and kinks.
This method preserves cable integrity, ensures smooth uncoiling, and is widely used by professionals for efficient handling and longevity.
Check out the tutorial video here.
The bundle technique
The bundle method involves coiling cables in the same natural direction ("over-over" loops) without alternating. This straightforward technique is quick and prevents internal twisting but may lead to tangles and kinks over time if not handled carefully.
If you use the bundle approach, combine it with some tape or a clip to keep the bundle in one piece.
Proper Cable Storage
As we mentioned earlier, moisture or heat exposure can cause issues so always store cables in a cool, dry environment when not being used, wrapped nicely with one of the above techniques.
Use Cable Ties and Other Organisers
Tangled cables are prone to stress and fraying. Use cable ties or organisers to keep them neat.
Choosing and Using The Right Cable
Using cables specifically designed for their operating conditions ensures they can handle the load and environment without premature wear.
Avoid overloading cables with excessive tension or weight, which can stress the cable and weaken their structure, or using a cable that’s designed for a different purpose.
Utilise Best Practices During Installation
Proper installation is critical for cable durability. Avoid twisting, kinking, or subjecting cables to mechanical stress. Ensure cables are adequately protected from physical impacts and that health and safety considerations are adhered to.
Maintain detailed records of installation, repairs, and inspections as this can help ensure maintenance is regular and helps identify any recurring issues.
Regular Inspection and Testing
Routine inspections and tests are essential for identifying potential issues early.
- Visual Inspection: Look for visible signs of wear, such as fraying or cracks. Even minor damage can have a effect on performance.
- Electrical Testing: Test for continuity, resistance, and performance metrics like return loss to keep things running optimally.
- Inspection Frequency: Tailor your cable inspection schedules based on the environmental conditions they are used in. For instance, outdoor cables require more frequent checks than indoor ones.
Invest in Cable Protectors
Protectors shield cables from damage in high-traffic areas, prolonging their lifespan in a wide range of sectors and applications like electrical installations, transport and heavy industry.
Our sleeving products are tough and protect cables against dirt, moisture and temperature extremes, with some boasting flame-retardant qualities, high mechanical performance and added flexibility.
Fix Broken Cables Promptly
Addressing minor damage as it happens prevents it from escalating into a bigger problem. Using products like heat shrink and other forms of repair tubing can give cables a longer life.
Other ways to Extend the Lifespan of Cables
From a manufacturing point of view, we look to design cables with durability in mind—using materials resistant to wear, corrosion, and extreme conditions, and this ensures they withstand demanding applications.
Lifecycle Cost Analysis (LCCA)
Sometimes spending more on the cables in the first place can save money (sometimes a LOT of money when you factor in some of the issues we discuss above).
It’s always a good idea, in critical applications, to conduct an LCCA (Lifecycle Cost Analysis) as this helps assess the total cost of ownership, factoring in maintenance, repairs, and replacements, helping you make better purchasing decisions.
Invest in High-Quality Cables
High-quality cables are built for durability, featuring robust materials and advanced manufacturing standards. Buying the right gear from a trusted supplier reduces the likelihood of failure and minimises long-term costs.
Use the above guide to extend the lifespan of your cables, reducing costs and boosting reliability. From careful installation and regular maintenance to investing in quality products, proactive cable management pays dividends in operational efficiency and safety.
Have we missed something? Do you have any tips you’d like to share with us? Head to our social media and share your thoughts.
