Industrial cables are the lifelines of manufacturing plants, power grids, oil refineries, and other heavy-duty operations. Their reliable performance is critical to avoiding costly downtime, safety hazards (such as electrical fires or equipment damage), and production losses. However, industrial cables often operate in harsh conditions—exposed to extreme temperatures, chemicals, mechanical stress, and poor maintenance—that make them prone to failure. Understanding the common causes of industrial cable failure is the first step in preventing unexpected breakdowns. Below is a detailed breakdown of the most prevalent issues, along with real-world context to help plant managers, engineers, and maintenance teams identify and mitigate risks.
The insulation layer of an industrial cable serves a critical purpose: it isolates the conductive core from external elements and prevents electrical leakage or short circuits. When this insulation degrades, the cable’s integrity is compromised, leading to failures like ground faults, arcing, or even fires. Insulation degradation is one of the most common causes of cable failure, driven by three key factors:
Industrial environments—such as steel mills, foundries, or power generation facilities—often expose cables to extreme temperatures. High heat (exceeding the cable’s rated temperature, typically 70°C to 150°C for industrial-grade cables) causes insulation materials (e.g., PVC, cross-linked polyethylene (XLPE), or rubber) to soften, crack, or melt over time. For example, in a cement plant, cables near kilns may be subjected to sustained temperatures of 180°C, far beyond the tolerance of standard XLPE insulation. This leads to the insulation losing its flexibility and developing microcracks, which allow moisture or dust to seep in and trigger electrical faults.
Conversely, extreme cold (common in refrigerated warehouses or outdoor winter operations) can make insulation brittle. In a food processing plant with frozen storage areas, PVC-insulated cables may become so rigid that they crack when moved or vibrated, exposing the conductive core to moisture and causing short circuits.
Cables installed outdoors (e.g., in solar farms, construction sites, or overhead power lines) are vulnerable to ultraviolet (UV) radiation from the sun. UV rays break down the chemical bonds in insulation materials, leading to discoloration, brittleness, and eventual cracking. A solar farm in a sunny region, for instance, may see its outdoor cables’ insulation degrade within 3–5 years (instead of the expected 10–15 years) if not protected by UV-resistant jacketing.
Additionally, prolonged exposure to humidity, rain, or snow accelerates insulation degradation. Moisture penetrates even small cracks in the insulation, reducing its electrical resistance and increasing the risk of ground faults. In coastal industrial facilities, saltwater mist further exacerbates this issue by corroding both the insulation and the cable’s metallic components.
Many industries—including chemical processing, oil and gas, and wastewater treatment—use cables in environments with aggressive chemicals (e.g., acids, alkalis, solvents, or petroleum byproducts). These substances react with insulation materials, breaking down their structure. For example, in a petrochemical refinery, a cable with rubber insulation exposed to gasoline vapors may swell, lose its insulating properties, and eventually split open. Similarly, in a wastewater treatment plant, acidic effluents can dissolve the PVC insulation of underground cables, leading to electrical leaks that damage pumps or control systems.
Even high-quality industrial cables can fail prematurely if installed incorrectly. Poor installation creates hidden stress points or vulnerabilities that worsen over time, often leading to failures months or years after setup. The most common installation-related issues include:
Every industrial cable has a minimum bending radius— the smallest radius it can be bent without damaging the insulation or conductor. Bending a cable tighter than this radius (e.g., to fit into a cramped control panel or around equipment) crushes the insulation, stretches the conductor, or breaks internal shielding. For example, a large-diameter power cable (used to supply electricity to a factory’s main motor) has a minimum bending radius of 10 times its diameter. If installed with a radius of 5 times its diameter, the insulation will crack, and the conductor may fray, leading to a short circuit.
Cable joints (where two cables are connected) and terminations (where a cable connects to equipment, such as a motor or switchgear) are weak points in any industrial cable system. When joints or terminations are not installed correctly—e.g., poor crimping, inadequate sealing, or using the wrong connectors—they create gaps for moisture, dust, or chemicals to enter. For instance, in an offshore oil platform, a cable joint that is not sealed with a waterproof gland will allow saltwater to penetrate, corroding the conductor and causing a power outage. Similarly, a termination with loose screws will create high resistance at the connection point, leading to overheating and insulation damage.
Industrial cables are often installed in tight spaces, alongside pipes, or under heavy machinery—environments where they are at risk of physical damage. For example, during the construction of a manufacturing plant, a backhoe may accidentally dig into an underground cable, crushing the insulation and cutting the conductor. Even minor damage, such as a scrape from a sharp pipe, can weaken the insulation and lead to failure over time. In some cases, cables are pulled too tightly during installation, stretching the conductor and breaking internal strands, which reduces the cable’s current-carrying capacity and causes overheating.
Industrial cables are designed to carry a specific maximum current (rated ampacity). When a cable is forced to carry more current than its rated capacity—known as overloading—it generates excessive heat, which degrades the insulation and damages the conductor. Overloading is a common issue in facilities where equipment is added or modified without upgrading the cable system.
Many factories expand their operations by adding new machinery (e.g., additional assembly lines, pumps, or heaters) without assessing whether the existing cable system can handle the increased load. For example, a beverage bottling plant may add a new packaging machine that draws 50 amps, but the existing cable supplying power to that area is only rated for 30 amps. Over time, the cable will overheat, causing the insulation to melt and leading to a short circuit or fire.
Electrical systems in industrial facilities are prone to voltage spikes (sudden, temporary increases in voltage) caused by lightning strikes, power grid fluctuations, or the switching of large equipment (e.g., motors or transformers). These spikes can exceed the cable’s voltage rating, breaking down the insulation and creating electrical arcing. For instance, a lightning strike near a factory’s power lines can send a 10,000-volt spike through the cables, even if the system has basic surge protection. This spike can puncture the insulation, leading to a ground fault that shuts down critical equipment.
Industrial equipment like variable frequency drives (VFDs), welders, and rectifiers generates harmonic currents—additional electrical frequencies that disrupt the normal alternating current (AC) waveform. These harmonics cause the cable to carry more current than intended, increasing heat generation and accelerating insulation degradation. In a metal fabrication shop, for example, welders produce high levels of 3rd and 5th harmonics. Over time, the cables powering these welders will overheat, leading to insulation cracking and conductor damage.
Industrial cables in moving or high-traffic areas are subjected to continuous mechanical stress, which wears down their outer jacket and insulation. This is particularly common in applications like conveyor belts, robotic arms, or mobile equipment (e.g., forklifts or cranes).
Cables used in robotic assembly lines, for example, are constantly bent, twisted, or dragged across metal surfaces as the robot moves. Over time, this friction abrades the outer jacket, exposing the insulation underneath. If the insulation is also worn down, the conductor may come into contact with the robot’s metal frame, causing a ground fault. Similarly, cables along conveyor belts are often crushed or rubbed by moving parts, leading to jacket damage and eventual failure.
Heavy machinery like pumps, motors, or compressors generates constant vibration, which affects nearby cables. Over time, vibration can loosen cable clamps, causing the cable to move and rub against other surfaces. It can also damage the conductor by causing internal strands to break (known as “strand fatigue”). In a power plant, for example, cables near a turbine may experience vibration levels of 5–10 Hz. This vibration can cause the cable’s conductor strands to fray, reducing the cable’s current-carrying capacity and leading to overheating.
In busy industrial environments, cables are at risk of being hit by forklifts, pallets, or falling objects. A forklift accidentally backing into a cable tray, for instance, can crush the cables inside, flattening the conductor and breaking the insulation. Even a small impact—like a tool dropped on a cable—can create a dent in the insulation, which may not cause an immediate failure but will weaken the cable over time, making it more susceptible to moisture or heat damage.
Many industrial cable failures are avoidable with regular maintenance, but facilities often neglect this step due to time or budget constraints. Without proactive inspections, small issues (e.g., minor insulation cracks, loose joints, or signs of overheating) go unnoticed and escalate into major failures.
Dust, dirt, and debris accumulate on cables over time, especially in manufacturing plants or mining operations. This buildup acts as an insulator, trapping heat and preventing the cable from dissipating excess temperature. For example, in a flour mill, dust can coat cables in the electrical room, causing them to overheat and degrade the insulation. Additionally, conductive dust (e.g., metal shavings in a machining shop) can settle on damaged insulation, creating a path for electrical leakage and short circuits.
During routine walks through a facility, maintenance teams may spot small issues like a cracked cable jacket or a loose termination but delay repairs. Over time, these minor problems worsen: moisture seeps into the cracked jacket, corroding the conductor; the loose termination creates high resistance and overheats. What could have been a 1-hour repair becomes a 12-hour downtime event when the cable finally fails.
Many facilities rely on outdated testing methods (e.g., visual inspections alone) instead of advanced techniques like thermal imaging, partial discharge testing, or insulation resistance testing. Thermal imaging, for example, can detect hot spots in cables (a sign of overloading or loose joints) before they cause failure. Without these tools, maintenance teams miss early warning signs, leading to unexpected breakdowns.
At FRS, we understand that industrial cable failure is not just an inconvenience—it’s a threat to your operations, safety, and bottom line. That’s why our factory designs and manufactures industrial cables specifically engineered to address the common failure causes outlined above, delivering long-lasting performance even in the harshest environments.
Our cables are built with high-performance insulation materials (such as UV-resistant XLPE and chemical-resistant fluoropolymers) that withstand extreme temperatures (-50°C to 200°C), UV radiation, and aggressive chemicals—eliminating insulation degradation as a failure risk. We strictly adhere to industry standards for minimum bending radius and provide detailed installation guides to prevent damage during setup, while our precision-engineered joints and terminations (sealed with waterproof, corrosion-resistant glands) ensure reliable connections in offshore, coastal, or chemical-rich environments.
To combat overloading and electrical stress, FRS cables are rated for high ampacities and include built-in surge protection to withstand voltage spikes and harmonic distortion. For applications with mechanical wear (e.g., robotics, conveyors), our cables feature abrasion-resistant jackets and flexible conductors that resist strand fatigue from vibration or movement.
Beyond manufacturing, FRS offers comprehensive support to help you maintain your cable systems: our team provides on-site inspections using thermal imaging and insulation resistance testing to identify early warning signs, and we offer customized maintenance plans to keep your cables in optimal condition.
When you choose FRS, you’re not just buying a cable—you’re investing in a solution that minimizes downtime, enhances safety, and reduces long-term costs. Let FRS’s factory-engineered cables be the reliable backbone of your industrial operations.
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