Best Electrical Cable Protectors: Types & Specifications for Industry

Building on our previous discussion about the Functions and Benefits of Electrical Cable Protection, we now take a closer look at the various types available in the market.

Did you know?

Choosing the right cable protection is not just a matter of compliance. It’s a crucial decision that directly impacts the safety, efficiency, and lifespan of electrical systems across a wide range of industries. Proper cable protection can significantly affect industrial automation and automotive applications in commercial and residential settings.

With many solutions available, navigating the options can feel overwhelming. However, each type of cable protection is purposefully designed to meet specific industry demands, ensuring seamless integration and minimizing the risk of electrical failures.

In this article, we will explore key cable protection solutions tailored for diverse environments, including:

• Industrial robotics
• Pneumatic automation systems
• Drag chains and cable carrier systems
• Automotive and electronic applications
• Oil and gas industries
• Methane and hydrogen processing facilities
• Commercial and residential buildings

The Bawalaksana Central Industrial team will explain the specifications and advantages of each type to help you make informed decisions.

While some solutions are readily available, rest assured that others—such as multi-channel conduits with integrated copper wiring—can be custom-configured to enhance complex system performance.

Join us as we dive into the most effective cable protection solutions, empowering you to safeguard your infrastructure, maintain operational continuity, and drive long-term system reliability.

Cable Protector Spiral (General Purposes)

Spiral cable protectors are common in everyday scenarios, such as charger cables or computer equipment. Their primary purpose is to organize loose cables, keeping them tidy and well-protected.

These protectors are usually made from HDPE (High-Density Polyethylene), although metal options are available depending on the application’s specific needs. This type of spiral cable protector works best in situations where cables need to be grouped systematically within designated pathways while receiving solid protection against mechanical wear.

However, spiral cable protectors aren’t ideal for high-mobility applications, such as those involving industrial robots or drag chains, as they don’t offer enough resistance to abrasion, UV exposure, and moisture.

While spiral protectors provide flexibility for various cable sizes and purposes, choosing the right pitch (or width) is critical for the particular application. Additionally, the thickness of the material should match the intended use to ensure optimal and proportional protection for the cables.

One standout option for general-purpose spiral cable protectors is the HDPE Protection Spiral from Mebra Plastik Italia. This high-quality product not only provides excellent protection but also offers ease of use, making it a top recommendation.

Rigid Cable Protection Pipes (ATEX Environment)

Rigid and antistatic cable protectors are crucial in specialized industries like oil and gas processing and handling methane and hydrogen. These sectors fall under the category of ATEX environments, which require adherence to strict safety standards.

In these sensitive settings, static electricity and airborne dust can pose significant hazards, potentially igniting sparks that lead to fires. Thus, the materials used for conduits and cable protection must meet rigorous criteria to ensure they are appropriate for ATEX conditions.

Typically, these protective conduits are crafted from materials such as polyurethane (PU), PVC, metal, or harsh composite substances known for their impact resistance. Manufacturers’ research and development teams treat these materials to prevent the buildup of static electricity, which could otherwise result in dangerous sparks.

Fortunately, rigid cable protection for ATEX environments does not have to be metal; high-quality polymer alternatives that provide exceptional durability and friction resistance are on the market. For instance, the Polyurethane (PU) 98 Antistatic hose from Mebra Plastik Italia, with a hardness rating of 52/55 Shore D, is engineered for high mechanical resilience.

Therefore, the Polyurethane 98 Antistatic is the best rigid cable protection. It is robust, abrasion-resistant, and sufficiently rigid to shield cables from mechanical damage.

The Rigid Polyurethane 98 Antistatic Cable Protector offers several key advantages:

• Certified for ATEX environments: Suitable for Group 2, Categories 2/3 G&D, installation zones 1 and 2.
• Triple-layer polyurethane construction: Flexible and surface resistivity ≤ 10⁶ Ohm, in compliance with ISO 8031:2009(E).
• Electrical and mechanical resistance: Ensuring safe usage in oil & gas, methane, and hydrogen processing industries.
• Heat-resistant and ATEX-certified protection: Engineered from a specialized polyurethane formulation that withstands mechanical friction and static electricity.

Durable and Rigid Flexible Cable Protection

Flexible yet sturdy cable protection is crucial across numerous industries, such as industrial automation, office settings, and even home applications. For example, in industrial automation systems, where conditions can be harsh but controlled, or in fields relying on machine tools, vacuum systems, and cable chains (also known as drag chains) for robots and 3D machines, having reliable cable protection is a must.

This type of protective sleeve is perfect for situations where cables require moderate flexibility while ensuring high rigidity and durability. It provides essential protection against minor damage without sacrificing structural integrity.

One of our top picks is Polyurethane ELASTOLLAN® C 98, which boasts several key benefits:

• Consistent Quality: Enjoy excellent thermal stability and mechanical resistance, ensuring reliable performance in various conditions.
• Durability: Highly durable and wear-resistant, this product guarantees long-lasting performance even under tough usage.
• Flexibility and Rigidity: A hardness rating of 52 Shore D strikes the perfect balance between flexibility and rigidity, making it highly resistant to breakage.
• Superior Quality: Recognized as a premium-grade product, it outperforms standard alternatives like Polyurethane MB-Longlife, offering unmatched quality and reliability.

High-Mobility Cable Protection (Water, Abrasion, and Twist Resistant)

Suppose you’re looking for an air hose or cable protection solution that boasts exceptional dimensional stability in high and low temperatures and is resistant to twisting and abrasion. The PU 1190 WR hose is an ideal choice.

This cable protection is designed for outdoor use to ensure long-lasting durability even in the harshest conditions.

The Polyurethane (PU) 1190 WR is a specialized hose that offers superior defense against water exposure, high humidity, and microbial threats, making it suitable for a variety of indoor and outdoor applications, including:

• Modern manufacturing: Perfect for automation systems and high-mobility robots.  
• Oil drilling operations: Well-suited for energy chains or drag chains, delivering both twist and abrasion resistance for mining and rig activities.  
• Food processing industry: Safeguards cables from heat and moisture exposure.  
• Coastal applications: Engineered to endure high humidity levels in marine environments.  

We highly recommend the Polyurethane (PU) 1190 WR from Mebra Plastik Italia, which comes with several advantages:

• Reduced Mechanical Friction: This tubing aids in minimizing mechanical friction, leading to less wear over time.
• Superior Abrasion Resistance: It offers three times better abrasion resistance than standard Polyurethane 1190 Extraflex tubing, making it highly durable.
• Ideal for Energy Chain Applications: This material is highly effective in energy chain settings, ensuring smooth operation.
• Exceptional Strength: This tubing has an outstanding twist and tensile strength, allowing it to withstand repeated stretching and movement and ensuring long-lasting performance.

Multi-Tube Cable Protection Equipped with External Protection

The following cable protector is a multi-tube with external protection. It is designed with heat resistance in mind and can endure temperatures up to 80°C. This innovative cable shield features a multi-channel design complemented by an external tube that provides enhanced cable protection.

The multi-channel configuration is versatile, making it suitable for various applications, including pneumatic systems, chemical transfers, and general industrial automation.

We can accommodate your request through a custom order if you need a multi-tube preloaded with copper cables. Given the specialized nature of this product, you have the flexibility to configure advanced settings tailored to your specific requirements.

For instance, you can customize the number of cable channels, select different color options, decide whether the channels should have uniform or varying diameters, and choose your preferred type of external tube.

To ensure the product meets your needs, submit a request to us. This way, you’ll receive the exact configuration of channels, colors, and specifications that match your industrial applications.

When ordered as a custom request, this multi-tube cable channel can come with embedded copper cables, saving you the trouble of manually fitting cables into each channel.

As previously mentioned, this multi-channel tubing’s unique specifications make it perfect for various sectors, from pneumatic and chemical transfers to air brake systems (meeting DIN 73378/74324 standards).

One of the standout options in multi-channel tubing is the PA 12 PHL MB-Longlife® Multi-Tube, which boasts an array of advantages:

• Diverse Applications: Perfectly suited for various uses, including pneumatic systems, industrial automation, automotive components, clutch systems, and chemical or oil transfer.
• Customizable Options: Tailor your solution with customizable options, allowing for the integration of copper cables within multi-channel tubing based on your specific requirements.
• Versatile Configurations: Choose from a wide array of configurations, offering 2 to 19-channel variations with a broad selection of color options to meet your preferences.
• DIN Compliant: Our products are DIN 73378 / 74324 compliant, ensuring they meet reliability standards for air brake systems in the automotive industry.
• Engineered for Extreme Conditions: Designed to withstand harsh environments, providing heat-resistant cable protection for industrial applications operating from -40°C to 80°C.

Spiral Multi-Tube Cable Protection

One of the most sought-after types of cable protection in the industrial and manufacturing sectors is multi-tube cable protection, available in spiral and straight configurations.

Specialized cable protection solutions with specific specifications are essential in complex industrial settings that rely on high-mobility automation systems.

Various cable protection products offer different benefits. While some standard versions lack advanced features like heat resistance, abrasion resistance, or anti-static properties, others come equipped with enhancements such as moisture resistance, UV protection, antimicrobial properties, and even rodent resistance.

Given these differences, it’s crucial to consult with industry experts when choosing the most suitable cable protection solution.

One of our leading suggestions for protecting multi-tube cables is the Spiral Coiled Multi-Tube, which provides several key benefits:

• Space-Saving Design: The spiral shape allows for efficient installation in manufacturing environments, taking up less space while maintaining functionality.
• Excellent Elastic Memory: This feature enables the multi-tube to return to its original shape after being stretched multiple times, ensuring durability and reliability.
• Seamless Welding Technique: The exclusive welding method joins multiple spiral tube channels together without leaving any residue, allowing for easy separation when needed.
• Versatile Applications: It is ideal for various fields, such as pneumatic, vacuum, industrial automation, and machine tool applications, making it a flexible choice for diverse projects.
• Custom Orders: Customization options are available for copper cable integration within the Spiral-Coiled Multi-Tube, catering to your project’s specific requirements. The Spiral-Coiled Multi-Tube stands out as a top-tier solution for adequate cable protection!

Linear Multi-Tube Cable Protection

The next multi-tube cable protector is designed with a linear configuration (straight) and is devoid of an external tube. This product operates similarly to its predecessor in multi-tube cable protection, making it an ideal choice for pneumatic systems, industrial automation, and machine tools.

While the Thermo Welded Multi-Tube may not provide specific benefits for extreme industrial applications (as previously mentioned), it is constructed from high-quality polyurethane, making it well-suited for drag chains or cable carriers in manufacturing settings.

With a wide range of configuration options available, you can easily customize the diameter of each channel and select from various colors, ranging from 2 to 12 channels.

Here are some of the key advantages of the Thermo Welded Multi-Tube Cable Protection:

• Exclusive Welding Technique: Each channel is permanently fused using a specialized welding method, allowing easy and clean separation without residue.
• Compact Multi-Tube Configuration: Designed without an external tube, this configuration is permanently bonded, enhancing efficiency and simplifying cable or tube management.
• Premium Material: Constructed from high-quality polyurethane, the system provides excellent flexibility and durability, making it ideal for applications in pneumatic systems, industrial automation, drag chains, and machine tools.
• Customization Options: This product is fully customizable in color, size, and number of channels. Upon request, it can even include embedded copper cables within each channel.

UV-Resistant and Waterproof Cable Protection

One vital solution for protecting electrical cables is Polyurethane tubing, which is known for its UV resistance and waterproof properties.

However, it’s essential to be aware that not all Polyurethane (PU) or Polyamide (PA) tubing can effectively withstand UV exposure, moisture, and abrasion.

Manufacturers of pneumatic tubing or cable protection made from Polyurethane (PU) or Polyamide (PA) must invest significant effort into research and utilize specialized formulations to meet specific performance criteria.

The Polyurethane (PU) 1198 Clear from Mebra Plastik Italia is a standout option in this category. This high-performance tubing provides excellent resistance to UV rays, moisture, and abrasion and offers several distinctive advantages that set it apart from standard Polyurethane tubing. Here’s a brief overview of its key benefits:

• Hardness and Durability: Boasts a 52 Shore D hardness rating, ensuring high mechanical wear and abrasion resistance while maintaining excellent flexibility.
• UV Resistance: Offers exceptional protection against UV rays across all colors, preventing degradation from prolonged sunlight exposure.
• Water Resistance: Designed to be water-resistant, ensuring safe operation in humid environments and preventing dimensional changes and cracking.
• Abrasion Resistance: It provides superior abrasion resistance while retaining high flexibility, making it ideal for various applications.
• Clear Color: This product is clear (transparent) and perfect for fluid monitoring and visual inspection applications.
• Versatile Applications: Suitable for multiple uses, including industrial automation, pneumatic systems, vacuum systems, machine tools, drag chains (for cable protection), and robotics.

Spiral Cable Protection with High-Flexibility

The final recommendation for high-quality cable protection is the PU Spiral High Flexibility 1190 Extraflex tubing. This product is notable for its powerful elastic memory, which makes it highly resistant to twisting and repeated stretching.

Although spiral cable protection with high flexibility is not commonly found in industrial environments or residential electrical setups, it is essential in applications where organized cable management and enhanced safety are priorities.

Here are some key advantages of the PU Spiral 1190 Extraflex cable protector:

• Excellent Hydrolysis Resistance: The tubing offers outstanding resistance to moisture and microbial attacks, effectively preventing any damage to cable protection.
• Abrasion Resistance: Its durable surface ensures the protective layer remains intact, significantly reducing the risk of peeling that could lead to electric shocks or short circuits.
• Strong Elastic Memory: The tubing exhibits strong elastic memory, enabling it to return to its original shape even after repeated stretching, which enhances its longevity.
• High Durability: Designed to withstand excessive elongation and repeated twisting, this tubing maintains its structural integrity over time, ensuring reliable performance.

We provide a diverse range of high-quality spiral hoses engineered to withstand extreme industrial conditions. One of our top-performing and highly recommended options is the PA 12 EHF Air MB-Longlife®.

Enhancing Safety and Reliability in Your Electrical Systems

A well-protected electrical system is crucial for its functionality, safety, efficiency, and longevity. Proper cable protection can significantly impact smooth operations and help prevent unforeseen failures in industrial automation, office environments, or residential settings.

The solutions we’ve discussed are tailored specifically for demanding industrial settings—from automation and drag chains to complex robotic systems. Each product is engineered to meet unique challenges across various sectors, ensuring your cables remain secure, flexible, and durable.

Behind these cutting-edge innovations is Mebra Plastik Italia, a reputable manufacturer with over 50 years of experience creating industrial tubing, pneumatic hoses, and advanced cable protection products. Their dedication to quality and innovation has established them as a global leader in the industry.

At PT. Bawalaksana Central Industrial, we take pride in being the official distributor for Mebra Plastik Italia. Our mission is to deliver top-notch cable protection solutions tailored to your requirements. Whether you need standard tubing or customized configurations, our team can assist you at every turn.

Let’s Find the Ideal Cable Protection for You!

Still uncertain about which solution suits your needs? Our Sales Engineers are eager to help!

Click the button below for a FREE consultation, and allow our experts to recommend the best cable protection for your business. Reach out today to explore tailored solutions and exclusive offers!

Romanta Pinrih Linuwih

Pneumatic Automation Systems Expert

This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality insights.