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Testing Jackets for Power,
Instrumentation, and Control Cables
Developed by the
Insulated Conductors Committee
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IEEE Std 532™-2021
(Revision of IEEE Std 532-2007)
Developed by the
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Abstract: Properties of commonly used jackets, as well as selection and testing of jackets, are
covered in this guide. It is written for those responsible for optimizing cable designs. The purpose
is to present a reasonably complete picture of the role of jackets so that the subject can be
approached in an orderly and organized manner. An effort has been made to avoid the highly
technical language and theory commonly used by electrical engineers and chemists to discuss the
more detailed application of jackets.
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Participants
At the time this IEEE guide was completed, the Selecting/Testing Jackets for Underground Cables Working
Group had the following membership:
The following members of the individual Standards Association balloting group voted on this guide. Balloters
may have voted for approval, disapproval, or abstention.
When the IEEE SA Standards Board approved this guide on 9 February 2021, it had the following membership:
*Member Emeritus
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Introduction
This introduction is not part of IEEE Std 532-2021, IEEE Guide for Selecting and Testing Jackets for Power,
Instrumentation, and Control Cables.
This guide is concerned with jackets as they are defined in The Authoritative Dictionary of IEEE Standards,
Seventh Edition (“A thermoplastic or thermosetting plastic covering, sometimes fabric reinforced, applied
over the insulation, core, metallic sheath, or armor of a cable”). Users should note that this guide makes
reference to standards developed by the Insulated Cable Engineers Association (ICEA), the Association of
Edison Illuminating Companies (AEIC), and other organizations.
This guide is written to provide cable users guidance in the selection of jackets for the purpose of optimizing
cable design. A secondary purpose is to present a reasonably complete picture of the types and functions of
jackets so that the user can approach the subject in an orderly and logical manner.
An effort has been made to avoid the highly technical language and theory commonly used by electrical
engineers and chemists to discuss the more detailed application of jackets. As a result, the various topics
covered in this guide are not necessarily exhaustive in every respect.
This guide provides recommendations for the properties, characteristics, design, and testing of various types
of cable jackets. It is the intent of this guide to help ensure that jacket materials are suitably specified for their
intended applications. Also, jackets should provide a level of electrical, thermal, mechanical, and chemical
durability to help ensure that cable performance is reliable under normal use and should reduce the danger to
the user or surroundings. The users of this guide are cautioned that all data contained herein are presented for
information purposes only. Where deemed necessary, additional, as well as more detailed, information should
be obtained by consultation with the cable manufacturer and other experts in the field.
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Contents
1. Overview��������������������������������������������������������������������������������������������������������������������������������������������������� 11
1.1 Scope�������������������������������������������������������������������������������������������������������������������������������������������������� 11
1.2 Purpose����������������������������������������������������������������������������������������������������������������������������������������������� 11
1.3 Word usage����������������������������������������������������������������������������������������������������������������������������������������� 11
1.4 General historical perspective������������������������������������������������������������������������������������������������������������ 12
2. Normative references�������������������������������������������������������������������������������������������������������������������������������� 12
4. Jacket characteristics��������������������������������������������������������������������������������������������������������������������������������� 13
4.1 Overview�������������������������������������������������������������������������������������������������������������������������������������������� 13
4.2 Physical properties����������������������������������������������������������������������������������������������������������������������������� 14
4.3 Chemical and moisture resistance������������������������������������������������������������������������������������������������������ 14
4.4 Thermal stability��������������������������������������������������������������������������������������������������������������������������������� 14
4.5 Electrical characteristics of non-conducting jackets��������������������������������������������������������������������������� 14
4.6 Electrical conductivity of semi-conducting jackets���������������������������������������������������������������������������� 15
4.7 Flame retardance�������������������������������������������������������������������������������������������������������������������������������� 15
5. Corrosion protection��������������������������������������������������������������������������������������������������������������������������������� 16
5.1 General����������������������������������������������������������������������������������������������������������������������������������������������� 16
5.2 Corrosion protection of semi-conducting jackets on underground distribution concentric
neutral cables��������������������������������������������������������������������������������������������������������������������������������������������� 16
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9.5 Polyethylene (PE)������������������������������������������������������������������������������������������������������������������������������� 32
9.6 Chlorinated polyethylene (CPE)��������������������������������������������������������������������������������������������������������� 34
9.7 Chlorosulfonated polyethylene (CSPE)��������������������������������������������������������������������������������������������� 35
9.8 Nitrile butadiene rubber/polyvinyl chloride (NBR/PVC)������������������������������������������������������������������� 35
9.9 Ethylene propylene rubber (EPR)������������������������������������������������������������������������������������������������������� 35
9.10 Polypropylene���������������������������������������������������������������������������������������������������������������������������������� 36
9.11 Polyamide 6 (PA6)���������������������������������������������������������������������������������������������������������������������������� 36
9.12 Fluoropolymer���������������������������������������������������������������������������������������������������������������������������������� 37
9.13 Thermoplastic elastomers (TPE) and thermoplastic rubbers (TPR)������������������������������������������������� 37
9.14 Low-smoke/halogen free flame-retardant jacketing������������������������������������������������������������������������� 38
9.15 Identifiable jackets���������������������������������������������������������������������������������������������������������������������������� 38
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IEEE Guide for Selecting and
Testing Jackets for Power,
Instrumentation, and Control Cables
1. Overview
This guide provides recommendations for the properties, characteristics, design, and testing of various types
of extruded cable jackets. It is the intent of this guide to help ensure that jacket materials are suitably specified
for their intended applications. Jackets should also provide a level of electrical, thermal, mechanical, and
chemical durability to help ensure that cable performance is reliable under normal use, and to reduce danger to
the user or surroundings.
1.1 Scope
This guide covers the selection and testing of jackets for power, instrumentation, and control cables. It
is written for those responsible for optimizing cable design and performance. The purpose is to present a
reasonably complete picture of the role of jackets so that the subject can be approached in an orderly and
organized manner. An effort has been made to avoid the highly technical language and theory commonly used
by electrical engineers and chemists to discuss the more detailed application of jackets.
1.2 Purpose
The purpose of this guide is to provide cable users guidance in the selection of jackets to optimize cable
design. A secondary purpose is to present a reasonably complete picture of the types and functions of jackets
so that the user can approach the subject in an orderly and logical manner.
The word should indicates that among several possibilities one is recommended as particularly suitable,
without mentioning or excluding others; or that a certain course of action is preferred but not necessarily
required (should equals is recommended that).
1
The use of the word must is deprecated and cannot be used when stating mandatory requirements; must is used only to describe
unavoidable situations.
2
The use of will is deprecated and cannot be used when stating mandatory requirements; will is only used in statements of fact.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
The word may is used to indicate a course of action permissible within the limits of the standard (may equals
is permitted to).
The word can is used for statements of possibility and capability, whether material, physical, or causal (can
equals is able to).
Factors that influenced improvement of jackets for cable sheaths/shields include the following:
2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
explained). For dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments or corrigenda) applies.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
4. Jacket characteristics
4.1 Overview
Jackets provide protection for cables during installation and service—with several properties that are
highlighted in this clause. Evaluation criteria for these properties are dependent on the intended use of the
product. Variations in applications require that jackets be evaluated to many, but not necessarily all, of the
criteria discussed in 4.2 through 4.7.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
— Physical stability over a range of temperatures from the minimum installation temperature to the
maximum rated conductor temperatures (normal operating, emergency overload, and short-circuit).
The actual jacket temperature with the conductor at these temperatures depends on the cable design
and the installed environmental conditions.
— Resistance to shrinkback at a cable splice or termination.
— Resistance to heat aging during the jacket’s expected thermal environment based on the maximum
rated conductor temperatures.
— Resistance to deformation during the jacket’s expected thermal environment based on the maximum
rated conductor temperatures.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
circulating current losses. Non-conducting jackets provide a level of isolation between the metallic shield or
sheath and the system ground during system transients, including switching or lightning surges, as well as
short-circuit operation.
For unshielded insulated conductors, non-conducting jackets provide resistance to electrical discharge
likely to be experienced on power cables and reduce excessive surface leakage at conductor terminations of
unshielded power and control cables.
Different applications (such as cable tray, riser, and plenum) require different levels of flame retardancy. Riser
and plenum applications often have additional requirements such as low heat generation, low smoke, and low
toxicity.
Flame-retardant materials are not the same as fire-resistant or fire-rated materials that are used in cables
designed to withstand a high-temperature fire while continuing to operate.
Depending on the application, the properties of importance may include one or more of the following:
— Application temperature
— Toughness
— Combustion byproducts
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
5. Corrosion protection
5.1 General
An overall cable jacket provides a barrier between the metallic shield or sheath and the local environment,
which interrupts the dc corrosion cell. See IEEE Std 1617™ [B85] for more information on corrosion
mechanisms.
Some cable-jacket or cable-shield configuration designs discussed in 5.2 interact with a corrosive environment
in its own way. Examples of these interactions are as follows:
a) The metallic sheath or concentric neutral wires may be left bare for direct contact with ducts or earth,
or both.
b) The metallic sheath, metallic shield, or concentric neutral may be covered with a semiconducting
protective jacket for electrical contact with the ground.
c) The metallic components may be insulated from contact with ducts or earth, or both, by the use of a
non-conducting protective jacket.
Corrosion of the metallic sheath or metallic shield can be greatly reduced by the use of a non-conducting or
semi-conducting jacket. The jacket shall be continuous, without punctures, to reduce accelerated corrosion
that may occur at a discontinuity. The continuity of the jacket may be compromised in several ways, including
the following:
— Mechanical damage resulting from improper installation or poor duct system design (excessive bends
or pulling lengths). Similar hazards exist for direct buried cable, particularly when plowing methods
are used.
— Electrical puncture after installation resulting from excessive voltage on the metallic shield, sheath,
or ground currents caused by lightning. Methods of reducing voltages high enough to puncture non-
conducting jackets are discussed in 7.1.3.
— Damage caused by rodents or insects.
— Degradation caused by aging, chemical, or bacterial action.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
The overlaying (sleeved) jacket design uses a separator layer (polymeric film or metallic tape). The jacket is
extruded over this layer. This approach provides a cable that has minimal neutral indentation into the insulation
shield, easier jacket removal, and improved cable flexibility.
Overlaying jackets can allow water to enter and flow within the void spaces between the jacket and the cable
core (via open cable ends and jacket breaches as a result of electrical, mechanical, or chemical damage). For
applications where water ingress is an issue, this deficiency can be overcome by the incorporation of water-
blocking materials to impede longitudinal water movement. Most commonly, water-swellable tapes, yarns,
powders, or a combination thereof, are applied to achieve water-blocking.
Removal of the overlaying jacket can be facilitated even more by incorporation of ripcords under the separator
layer, thereby reducing the need for cutting tools.
For concentric neutral cables, an extruded-to-fill (encapsulated) jacket is a design option that can be used to
reduce water ingress (see Marciano and Cinquemani [B63]). In this design, the jacket is extruded in such a
manner as to fill the spaces over and between the neutral wires or straps. This approach provides a cable that
has minimal water ingress, allows higher sidewall bearing pressure during installation, and allows pulling
concentric neutral wire to facilitate jacket removal.
Extruded-to-fill jacket design can result in more indentation of the insulation shield by the neutral wires, more
difficulty in stripping the jacket, and a reduction in cable flexibility.
The specifications for underground distribution cable have requirements on the depth of the indentations of
the neutral wires into the semi-conducting insulation shield of the cable. The indents could potentially make it
more difficult to strip the insulation shield during termination or splicing operations
The stripping of the extruded-to-fill jacket and the flexibility of the cable is complicated by the filling of the
spaces between and around the concentric neutral. Removal of the extruded-to-fill jacket can be facilitated
even more by incorporation of ripcords, thereby reducing the need for cutting tools. For applications where
water ingress is an issue, this can be overcome by the incorporation of water-blocking materials to impede
longitudinal water movement. Extruded-to-fill jackets can be longitudinally water-blocked by incorporating
water-swellable powder under the jacket layer. Cable flexibility can also be improved when incorporating a
longitudinal water-swellable tape over the concentric neutral layer.
The most common jacket design used for multiple conductor cable is an overlaying (sleeved) jacket. The
jacket is extruded directly over a longitudinally applied or helically wrapped tape, which overlays the cable
core. Generally, the cable core binder is a polyester film tape, a coated fabric tape, a binder string, or the
cable jacket can be extruded directly over a metallic or metalized polyester shielding tape (especially for
instrumentation cables).
The overlaying design provides stable jacket thicknesses, good flexibility, and ease of removal as ripcords can
be incorporated into the design beneath the jacket.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
A less common design used on low-voltage power, control, and instrumentation cables is a pressure-extruded
jacket. The jacket is pressure extruded into the interstices of the taped multiple cable core and results in a
round outer surface. This type of jacket will make for a more rugged design, but also creates difficulty with
regard to variations in jacket thickness. The jacket will be thicker in those areas where it fills the interstices of
the core. Jacket removal becomes more difficult because of the thickness of the layer in these interstices. This
extra thickness or web causes increased mechanical resistance. A ripcord placed under this type of extruded
jacket may not have the strength to tear through the web of a thicker and tougher jacket.
For both overlaying and pressure extruded jackets, suitable fillers may be incorporated into the cable design to
provide an effectively round core to extrude over.
An extruded protective jacket may be applied over the insulation of single conductor cable. The purpose of this
jacket may be to provide additional mechanical protection, chemical protection or environmental protection,
fire retardance, or other properties, which, if incorporated into the insulation, could affect the electrical
properties and/or make the insulation less economical. The jacket may also provide additional properties to the
cable design.
The protective jacket may be extruded at the same time as the insulation or as a separate operation. The
advantage of extruding both layers at the same time is an increase in bonding strength between the layers,
especially when compatible materials are used for both insulation and jacket. This bonding can enhance the
removal of the extruded materials from the conductor, as both insulation and jacket may be removed in a single
operation.
A disadvantage of using a separate jacket instead of incorporating the desired properties into the insulation is
an increase in cable diameter and weight. For nuclear power applications, degradation can propagate across a
bonded jacket and result in failure of the primary insulation (see US NRC Information Notice 92-81 [B114]).
6.3.3 Common materials for low-voltage power, control, and instrumentation cables
The most commonly used jacket material for low-voltage power, control, and instrumentation cables is
polyvinyl chloride (PVC). The requirements for these jackets can be found in ICEA S-95-658 [B70] and
ICEA S-73-532 [B68]. Low-smoke zero halogen jackets are used in selected applications with the requirements
for these jackets generally being application specific.
A chlorinated polyethylene (CPE) jacket is most often used with shielded low-voltage power or instrument
cable having a polymer-coated electromagnetic shielding tape as described in UL 13 [B96]. The CPE jacket
will bond to the coating on the shield. The overall shielded cable is used when lightning or moisture protection
is a requirement.
The use of water blocking components, such as water-swellable tapes or powders, are generally not used
in low-voltage power, control, and instrumentation cables. However, a user may consider a water blocking
component if the cable will be used in a wet environment.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
Cable joints and accessories electrically connected to cables are to be covered with insulating tape or isolated
from electrolytes common to the metallic shield and ground. This protection keeps any current leaving the
metallic shield from being concentrated at the cable joint, fittings, oil-feed pipes, reservoirs, or adjacent cables,
and thereby it reduces concentrated corrosive damage. The effects of corrosion caused by dissimilar metals in
the sheath, shields, and accessories can also be reduced with a non-conducting jacket.
When separable connectors are used, IEEE Std 386™ [B77] and the manufacturer should be consulted.
Materials such as polyethylene (PE), ethylene propylene rubber (EPR), chlorosulfonated polyethylene
(CSPE), CPE, and thermoplastic elastomer (TPE) can be made semi-conducting by the addition of suitable
carbon blacks. Typical compounds have an electrical resistivity of less than 500 Ω-m at 90 °C. The temperature
coefficient of resistivity varies from compound to compound and may, in some cases, be higher. The jackets
may be either thermoplastic or thermoset and shall be compatible with any material in direct contact. The
National Electrical Safety Code® (NESC®) [B1] (NESC rule 354D2c) requires semi-conducting protective
jackets to have an electrical resistivity of no greater than 100 Ω-m when power cables are randomly laid
with communications cables. An advantage of semiconductive jackets over graphite coatings is that graphite
coatings could be rubbed off the cable during handling while semiconductive jackets are significantly more
durable.
Because of the nature of these semi-conductive materials, a substantial boundary resistance may occur
where contact is made with a metallic conductor. Special precautions should be taken in making electrical
measurements.
Semiconducting jackets are not designed to carry current or act as a grounding system. Permissible operating
stresses for sustained voltage on semi-conducting jackets are normally very low. When subjected to high
electrical stress from the metallic shield being temporarily energized during phase-to-ground cable faults,
semi-conductive jackets may fail by overheating.
Semiconducting jackets may swell when exposed to some fluids (transformer oils, wood pole treatments, etc.),
and become non-conducting with such contact. Care shall be exercised in controlling contact with oils, certain
pulling compounds, or other active ingredients, such as plasticizers, that may be a component of rubber-like
or PVC tapes. A cross-linked material is less susceptible and seems to be more compatible with the tapes or
mastics commonly used for sealing purposes at joints and terminations.
A semi-conducting jacket is often used in direct burial cable applications to provide a low-resistance covering
between the metallic shield and earth. It is necessary to recognize that voltages appear on the metallic shield
of cables carrying return currents or as a result of magnetic induction from the phase currents into the metallic
shields of cables in a three-phase operation. This should be kept in mind in situations that might concentrate
current flow through the jacket at specific locations, such as (but not limited to) contact with effectively-
grounded objects or the possibility of puncture at these contacts, including adjacent cables under surge events.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
Semi-conducting jackets have also been used as the outermost covering over metallic shields to provide
continuous grounding to limit the likelihood of jacket puncture in the presence of lightning. A compound of
low electrical resistivity is desirable for this application.
Semi-conducting jackets should not be used for single-point grounded or cross bonded applications because
the cable’s metallic shield would not be isolated from ground. The purpose of single-point grounding is to
avoid the flow of current in the metallic shield. A semiconducting jacket will allow current flow through
the jacket resulting in some flow of currents in the metallic shield and defeats the purpose of single-point
grounding or cross-bonding schemes.
An intact non-conducting jacket isolates the cable metallic shield from contact with earth and other
electrolytes reducing the likelihood of galvanic corrosion and transfer of stray ground currents. It is assumed
a non-conducting jacket having a dielectric withstand equal to or greater than the induced or transient shield
voltages will provide acceptable performance. Should the jacket integrity be compromised by overvoltage or
mechanical punctures or end seal leakage, the jacket will not provide protection.
A semi-conducting jacket does not isolate the cable metallic shield, but provides a lower-resistance path
between the metallic shield/sheath and the earth, which may reduce the number of ground connections (NESC
requires a maximum jacket radial resistivity of 100 Ω-m). Since the semi-conducting jacket reduces direct
contact between the earth electrolytes and the metallic shield/sheath of the cable, corrosion and loss of metal
should be minor.
NOTE—A jacket with a conducting outer surface for jacket testing as used for cables rated 46 kV and above is not a
semiconducting jacket.4
Methods for calculating sheath voltages and currents and descriptions for sheath bonding systems are
described in IEEE Std 575™ [B79]. Methods for handling shielding in low-voltage cables are described in
IEEE Std 525™ [B78] and IEEE Std 1143™ [B80].
4
Notes in text, tables, and figures of a standard are given for information only and do not contain requirements needed to implement this
standard.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
The use of single-conductor cable circuits with non-conducting jackets and long cable lengths between shield
or sheath sectionalizing or grounding points may result in induced standing shield/sheath potentials that could
be an exposure hazard. The user will need to verify the voltage exposure is within limits, or the exposure is
reduced by using suitable coverings or sealing and that adequate safety procedures are in force for workers
who may be exposed to this touch potential (see IEEE Std 575™ [B79]).
It has been shown (see Eaton and Issa [B62], Kuwahara and Doench [B86], and Wollaston and Kidd [B117])
that transient overvoltages of different origins are responsible for damaged cable sheath jackets, sheath
insulators, and sheath bonding leads.
a) Switching surges
b) Short-circuit currents (system faults)
c) Dielectric breakdown
d) Overhead line or termination flashover
e) Lightning
The influence of system disturbances is a complex event that, theoretically, may result in high magnitude
sheath voltages. Sheath-to-ground voltage caused by switching surges depends on power system configuration,
type of interrupting device, and bonding arrangement of the cable. Sheath-to-ground potentials of high values
have been reported (see Watson and Erven [B116] and Wollaston and Kidd [B117]) for 115 kV and 230 kV
three-phase, single-conductor underground power cables. The voltage across sheath insulators may approach
double the sheath-to-ground value. Surge arresters are often installed to limit the magnitude of the voltages.
Sheath-to-ground voltage caused by short-circuit currents depends on the magnitude of the short-circuit
current, length of cable, sheath bonding arrangement, and sheath material. Wollaston and Kidd [B117] have
provided a means for calculating this (60 Hz) voltage that can appear on the metallic sheath during fault
current events. Overvoltages caused by the flow of fault current in the sheath happen less frequently than do
switching surges and are lower in magnitude.
Jacket puncture resulting from transient overvoltages may result in exposure of the metallic component of the
sheath to corrosive influences.
Dielectric breakdown of cable insulation will initiate a voltage surge in the metallic sheath enhanced by the
discontinuity produced by the sheath insulator. Watson and Erven [B116] have shown that a sheath-to-ground
voltage of 28.5 kV could appear on the sheath of a 230 kV system cable.
Disturbances caused by lightning, cable termination flashover, and overhead line insulation flashover will,
in general, cause the most severe sheath-to-ground voltage. A portion of the incident surge on the cable
conductor will appear on the sheath as a result of the discontinuity produced by the sheath insulator (see UL
1569 [B110]). The magnitude of the incident wave is determined largely by the overvoltage control provided
for the circuit. In general, the incident surge on the conductor will be the protective level of the surge arrestor
or the coordinating gaps at the cable termination. For a typical 115 kV system, the portion of the incident surge
that may appear on the sheath could be approximately 30 kV.
Semi-conducting jackets provide effective grounding to cables during lightning strikes and faults, which limit
the likelihood of jacket punctures.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
Tests have shown that cables with non-conducting jackets are prone to lightning punctures of the jacket.
ICEA P-123-739 [B67] establishes methods to test the insulation properties of non-conducting jacket materials
specified in ICEA S-93-639 [B72], S-94-649 [B10], S-97-682 [B11], S-108-720 [B13], and S-113-684 [B14]
Standards. ICEA P-123-739 [B67] can be used to determine the minimum ac and impulse level breakdown of
the non-conducting jacket materials. The resulting information will be used to update the applicable sections
within these ICEA Standards.
a) Experience and analysis have shown that the sheath and sheath bonding accessories for three-phase,
single-conductor cable systems are subject to steady-state ac potentials and occasionally to transient
potentials of high value. As a consequence, non-conductive jackets for underground cables should
have the dielectric strength to withstand these conditions.
b) Investigators (see Wollaston and Kidd [B117]) dealing with power systems rated 230 kV have
indicated that extruded polymeric jackets with 2.8 mm to 3.05 mm (110 mil to 120 mil) thickness are a
practical means of protecting the metallic sheath.
c) Integrity of protective jackets with a metallic layer can be established by factory ac or dc tests. While
existing factory tests for jackets are effective tests for jacket integrity, they do not test a jackets ability
to withstand over voltages or its dielectric strength.
d) ICEA P-123–739 [B67] has developed a method of ac testing of jackets dielectric strength using
both full-wave-lighting impulse and ac step rise as sources of stress. The working group method
has not been published at the time of this guide’s publication. Cable buyers should consult the cable
manufacture if installation or company safety practices require a non-conducting or protective jacket
to withstand a defined level of impulse (BIL) or ac overvoltage.
e) For cables above 46 kV, where a semi-conducting coating is applied over the jacket, the integrity may
be verified by dc field tests of appropriate values (see IEC 60229 Edition 3.0 [B75]).
f) Investigators (see Wollaston and Kidd [B117]) point out that a system to limit the overvoltages should
be considered where it is not practical to provide dielectric strength to cover the predicted overvoltages
that may appear on the cable sheath and across sheath insulators or protective devices (see CIGRE
[B52], [B53]).
Another consideration relates to flammability. The introduction of halogen or hydrated mineral fillers [such
as magnesium dihydroxide (MDH) and aluminum trihydrate (ATH)] into the polymer structure is one method
of imparting a measure of flame retardancy to the material. Although halogenated compounds often provide
more robust fire retardancy, they can emit halogen acids in substantial amounts should a fire occur. These acids
can cause significant damage to nearby structures and personnel, depending on the level of exposure. The
performance requirements and risks should be considered when selecting the jacket materials.
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
The minimum installation temperature for jacketed power cables is an important consideration for many users.
Industry standards typically establish minimum temperature values and qualifying tests. Generally, these
temperatures are –10 °C for PVC, –40 °C for polyethylene, and –25 °C for polypropylene and nitrile butadiene
rubber (NBR)/PVC jackets. Polymeric jacket materials may be specially formulated for lower minimum
installation temperatures. When special low temperature compounds are required, the purchase specification
should designate the temperature to be used for the bending or impact test specified. The cable user should
refer to the cable supplier for minimum installation temperatures for any cable design.
Jacketing materials vary somewhat in their ability to withstand sunlight and weathering. To help ensure a
long and satisfactory life when exposed outdoors, it is recommended that the compound include a sufficient
quantity of well dispersed carbon black or other suitable ultraviolet light inhibitor (see 8.6.2).
Low-voltage shielding reduces electrical interference, whereas medium voltage shielding is applied for safety
purposes and fault current protection. Shielding can be in a variety of forms—a non-magnetic metallic shield
consisting of tape or tapes, wires, or sheath may be applied over a non-metallic semiconducting layer. The
metallic shield shall be electrically continuous throughout each cable length and shall be applied in such a
manner that electrical continuity or contiguity will not be distorted or disrupted during normal installation
bending.
NOTE—A metallic shield meeting the specified minimum requirement may not have sufficient fault current capability for
protective relaying purposes. ICEA Publication P-45-482 [B66] may be used to determine metallic shield fault-clearing
capability.
Historically, the first polymeric jacket material employed over paper-insulated lead sheathed cable for
installation into ducts was a composite neoprene jacket consisting of fibrous neoprene-filled cloth tapes and
neoprene compound tapes. These were vulcanized together to provide cohesion between components and
adhesion to the underlying lead sheath.
Low and linear low density (thermoplastic and cross-linked) polyethylene jackets can be used as protective
coverings over metallic shielded cables. Care should be exercised in the selection of pulling compounds to
reduce the risk of environmental stress cracking. Reference IEEE Std 1210™ [B82] for more information on
pulling compounds. Some points to consider when selecting a jacket for metallic shielded cables include:
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
Flooding compounds, water-swellable tapes, or powders are often used between the metallic shield and
jacket when cables are installed in wet locations to reduce water migration under the jacket. These flooding
compounds and materials should meet the longitudinal water penetration requirements of ICEA T-34-664
[B74].
The various industry cable flame-retardancy tests range from a single wire test to full cable design tests. The
single wire test (as outlined in UL 1581 [B111]) evaluates the flame retardancy of the insulated wire in horizontal
and vertical positions. The cable design tests evaluate the performance of finished cable configurations, which
could include insulated single conductors that are multiplexed, jacketed, and/or armored. Some examples of
these design tests include the following:
a) Industrial cable tray configurations (as outlined in IEEE Std 1202™ [B81])
b) Building riser configuration (as outlined in UL 1666 [B112])
c) Plenum cable designs (as outlined in NFPA 262 [B91])
d) Underground mining cables (as outlined in CFR 30 [B54])
The flame-retardant characteristics of neoprene, CPE, CSPE, PVC, and NBR/PVC depend to a significant
degree on the chlorine content in the base polymer. Fillers containing halogens (such as chlorine or bromine)
or appropriate hydrated mineral fillers can be added to improve the flame retardancy of the polymeric jackets.
Neoprene, CSPE, and NBR/PVC are thermoset jackets, whereas CPE jackets can be formulated either as
thermosetting or thermoplastic materials. All of these materials can be formulated for special low temperature
applications and the end-user should specify these requirements for the jacket.
Neoprene, CPE, CSPE, PVC and NBR/PVC jackets are typically tough and abuse resistant. CPE in its
thermoplastic form is typically less flexible and has a somewhat higher hardness than other halogenated resins
mentioned. Consequently, the surface of the CPE jacketed cable is usually smoother and typically exhibits
a lower coefficient of friction, which may be useful in ducted installations. Typically, CPE, CSPE, and
polyethylene are more moisture resistant than either neoprene or NBR/PVC jackets.
Flame-retardant jackets can be based on a variety of polymers, such as polyethylene copolymers [e.g.,
ethylene vinyl acetate polyethylene copolymer (EVA), ethylene ethyl acrylate polyethylene copolymer
(EEA), and ethylene butyl acrylate polyethylene copolymer (EBA)], ethylene propylene rubber (EPR),
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
ethylene propylene diene monomer (EPDM), TPOs, and some polypropylenes because these materials have
the ability to accept large amounts of halogen and non-halogen fillers. When reduced combustion emissions
are required, hydrated mineral fillers are normally used for non-halogen formulations. These flame-retardant
compounds can be formulated as thermosetting or thermoplastic materials. Thermoset designs may be
achieved by e-beam, peroxide, or moisture crosslinking. However, some limitations to moisture cured non-
halogenated formulations exist due to interactions of these fillers with the crosslinking reaction. Specific
desirable characteristics can be enhanced by careful formulation and mixing to provide suitable jackets for
cables.
Sunlight, and more particularly ultraviolet (UV) radiation, degrades the physical properties of the polymers
commonly used as jacketing materials. The degradation is observed initially as discoloration followed by
surface crazing, and finally, as embrittlement. For insufficiently protected polymers, the degradation can
become so severe that the jacket can no longer perform its design function.
One of the most effective and most commonly used means to protect polymers from the effects of exposure to
sunlight is to disperse well a minimum of 2% by weight of carbon black of a kind and particle size (< 35 nm
diameter) to impart weather resistance with or without any antioxidants or other additives in such proportions
as agreed upon between the seller and the purchaser (ASTM D 1248 [B16]). ASTM D 1765 [B17] standard
is only for rubber compounds. Well-dispersed carbon black in the jacket may be verified through absorption
coefficient testing (ASTM D 3349 [B18]).
For track-resistant jackets, such as those used for fiber optic cables and airport lighting, lower levels of carbon
black are typically used to reduce electrical arcing and subsequent surface erosion.
There are some jacket applications where carbon black cannot be used (e.g., for jacket stripes or where colors
other than black are required). In such cases, UV protection is afforded by the use of additives commonly
known as light stabilizers or UV stabilizers. The general classes of such additives that are commonly used in
cable jacketing compounds are as follows:
— UV screeners: They are typified by minerals such as calcium carbonate, magnesium oxide, and the
rutile form of titanium dioxide. UV screeners act by absorbing incident UV radiation and dissipating it
harmlessly, usually as heat. (Carbon black is also a UV screener.)
— UV absorbers: They are complex organic molecules, such as the commonly used benzotriazoles, that
dissipate incident UV radiation as heat.
— Antioxidants: Since photo-oxidation plays a major role in the degradation of polymers exposed to
sunlight, it is not surprising that certain antioxidants are effective. The most widely used are the
hindered amine light stabilizers. As in thermal oxidation, thioester antioxidants can act as synergists.
The testing protocols for sunlight resistance range from simple tests on film samples to complex testing on
cables. The former is typified by ASTM D 3349 [B18] that measures the UV absorption coefficient of a thin
film of carbon black pigmented polyethylene. Typical of the latter are the tests required by UL in order to print
“Sunlight Resistant” on cable jackets. Such tests measure the degradation of physical properties after exposure
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
to UV radiation generated by a xenon arc or carbon arc light source and with the addition of a periodic water
spray. For additional information on the topic of sunlight resistance, see UL 1581 [B111], ASTM D 3349
[B18], ASTM G 151 [B19], and ASTM G 155 [B20].
Jacket processing conditions are important in minimizing shrinkback. Factors most often involved are
drawdown and cooling. Minimization of internal stresses or memory within the polymer or compound can be
impacted by drawdown, or post extrusion annealing or cooling conditions.
Jacket movement is reduced when a restraint exists at the interface between the jacket and the metal shield,
as well as between the shield and the semi-conductive layer that is normally bonded to the outer surface of
the insulation. A loose extrusion permits unrestrained movement. Metallic tape shields do little to restrain the
jacket even if a reasonably tight extrusion exists. Wire shields are somewhat better since the jacket can adhere
more tightly to the cable core. Some compromise shall take place in bending flexibility versus restraint of the
jacket from longitudinal movement. Concentric wire shields, rather than longitudinally applied corrugated
tapes, will offer some restraint to jacket movement without sacrifice in flexibility.
Climates where large temperature swings from summer to winter occur tend to accelerate jacket shrinkback
due to the effects associated with the expansion and contraction cycles. Aerial cables exposed to sunlight are
subject to higher temperature swings than are underground cables. Load cycling of cables, underground and
above, can also impact jacket shrinkback.
To reduce shrinkback, users can implement mechanical restraints at terminations and splices. During
emergency overload conditions, these mechanical restraints will restrict radial cable expansion and may
cause damage. Shrink terminations or sleeves are less effective in restraining the jacket, but can be used in
combination with mechanical restraints to provide a good moisture barrier. A test method currently being
used to evaluate shrinkback potential in communication cables is contained in ANSI/ICEA S-56-434 [B7].
This test method is used for telecommunication cables; however, this test has not been shown to be applicable
to other types of cables. It involves the removal of a 12.5 mm (0.5 in) wide strip from the jacket, which is
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
measured in length before and after oven conditioning at 100 °C for 24 h. The percentage of shrinkage is
then calculated from these measurements. Of course, this test relates only to the jacket materials and to the
extrusion conditions and does not involve the overall cable design.
The cable jacket design, duct materials of construction and design can have an impact on installation
considerations, including the use of cable-pulling lubricants. This performance feature can be achieved
through cable design and/or the formulation for the outer jacket. Jackets with low coefficient of friction may
be of importance for wiring in plants where cables are installed in ducts and manholes (see IEEE Std 1210™
[B82]).
Overall, jackets may often be exposed to harsh environments. However, it should be pointed out that the whole
cable design needs to be considered when choosing a cable for use in harsh environments. The bonds between
the jacket, metallic shields, semi-conductive shield, and the insulation are also important considerations.
Improper bonding can result in catastrophic failure of both the jacket and underlying insulation (see Boggs and
Yu [B22] and Boggs [B23]). Jackets may be required to perform in the following harsh environments (among
others):
— Chemical contamination and exposure: Chemical exposure may occur in chemical manufacturing
plants due to exposure to chemicals from spills or within processes. Exposure to oils and gasses may
also occur within chemical or other industrial operations or in activities where chemical or oil exposure
may be possible.
— Exposure of buried cables to soil contamination: Contamination of cable jackets from the soil
chemistry, or road de-icing salts and/or lawn chemicals may occur to cables buried along roadways.
This contamination may lead to electrical tracking on the jacket, with subsequent degradation, and
potential failure of the cable.
— Wet environments: Cables have specific requirements for installation in wet environments, and these
requirements are covered by tests in various industry specifications. Cables meeting these requirements
are then marked for use in wet environments. It needs to be noted that the inner insulation also needs to
be chosen as appropriate for use in wet environments, not just the jacket as a protective layer.
Jackets tests are performed to help ensure the integrity of the cable jacket. The integrity of the jacket is
important to provide a mechanical and environmental barrier to water intrusion, corrosion, dig-ins, etc. It
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
is also important to test the integrity of the jacket when the jacket is used to isolate a voltage on the metallic
shield from ground, as in the case of single point grounded or cross bonded systems.
A spark test is applied in the factory for metallic shielded cables to verify the integrity of the cable’s insulating
jacket. During the factory spark-test, a voltage is applied between an electrode placed around the outside
surface of the cable jacket and that of the inner metallic shield (which is normally at ground potential). For
example, ICEA S-108-720 [B13], which is applicable to the manufacturer of transmission cables rated > 46 kV,
requires a factory spark-test voltage of 150 V/mil be applied across the cable jacket.
It should be noted that entirely semiconducting jackets are only visually inspected by the cable manufacturer.
For field testing of cable jackets there are several possible ways to check that the cable jacket has not been
inadvertently cut/perforated—for example, during the installation of the cable. For this test to be performed
effectively, a conductive material needs to be present on the outside of the cable jacket. This can be achieved in
three possible ways, as follows:
— By either coating the outside of the cable with a conductive graphite powder (which is typically done
by the cable manufacturer if requested).
— A semiconductive jacket can be extruded over the insulating jacket during manufacturing of the cable.
NOTE—A cable jacket test cannot be performed on a completely semiconducting jacket—an underlying
insulating jacket layer is required.
— Cable with an insulating jacket that is direct buried and the jacket is in contact with the soil/earth.
NOTE—This type of cable design should not be tested in a conduit (inaccurate data may result).
When performing cable jacket testing it is important to remove a suitable section of the conductive jacket layer
(whether semiconductive jacket or graphite powder) at the ends of the cable to allow clearance for high-voltage
testing. When graphite powder is used, care should also be taken to avoid rubbing off and contaminating areas
such as where splices or terminations are being installed. This can result in tracking and potential future failure
of the cable at this section.
For field testing, a dc test voltage of negative polarity is normally applied. The cable metallic shield needs to
be completely isolated from ground to complete this test. The dc voltage is applied between the metallic shield
and earth/ground. Any damage to the cable outer jacket will be indicated by a short circuit or excessively high
current when the voltage is applied.
NOTE—There will be a certain leakage current that flows even with a jacket that is in good condition, but this should
be small and stable (< 0.5 mA/mile). For example, on a 5-mile cable there may be a stable current of a few milliamps
(< 2.5 mA). It is important to use a test set that can deliver sufficient current output or it will incorrectly show a short circuit.
For newly installed cables, a test voltage > 70% of the factory test voltage should be applied. Test voltages
for aged cables should be at least 70% of the original factory test voltage. For cables with a semiconducting
jacket extruded over an insulating jacket, only the insulated jacket thickness should be used in the calculation
to determine the applied voltage (see IEC 60229 [B75]).
A test duration of 1 min should be used. The test report should include circuit name and phase, date, the duration
of the test, the applied voltage, dc or ac, the leakage/charging current, new or old installation, approximate
length of section tested, and pass or fail.
Should a cable fail the jacket test, there are various methods to locate the faulted section—these include bridge
and voltage gradient techniques as referenced in IEEE Std 1234™ [B83].
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The environment, including cable temperature rating, needs to be considered when selecting a jacket material
since the jacket will likely be exposed to a variety of temperature environments. Some jacket materials can
have a minimum cold bend test temperature of –50 °C. It is recommended that the cable not be installed when
ambient conditions are below –10 °C without the concurrence of the cable manufacturer. In high-temperature
applications, the cable temperature rating should be considered when selecting a jacket material. Some jackets
listed in this guide will perform better at higher temperatures than will others.
Neoprene, PVC, NBR/PVC, CSPE, and CPE compounds retard combustion as a result of their innate halogen
content on the polymeric backbone. However, the decomposition of these materials when burning may lead
to emission of chlorine and hydrochloric acid. These risks should be considered when using these jacket
materials. Flame-retardant additives, both halogenated and non-halogenated mineral fillers, can be combined
with other polymers to achieve similar resistance to flame when compared with the halogenated polymers.
Table 1 outlines the typical relative physical performance characteristics of commonly used jacket materials.
Table 2 outlines their relative chemical resistance when exposed to different chemicals. The performance of
the jacket materials in the actual field installation may be different than those listed in these tables, and it is
recommended the user refer to the actual cable standard’s requirements. This information is being provided so
the guide user can easily compare these properties among different jacket materials.
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Increasing CPE-TP G G G G G NR G E E E
melt Polypropylene G G G E E G E E E E
point TPE NR NR NR G G NR E E E E
Polyamide 6 E E E E E E E E NR NR
High Fluoropolymer E E E E E E E E E E
Thermoset materials
XLPE G G G E E G E E E E
CPE-XL G G G G G G G E E E
CSPE NR G G G G G G E E E
NBR/PVC E E E NR E E E E E E
Neoprene G-E G-E G-E G-E G-E G-E G-E E E E
EPR NR NR NR E E NR NR E E E
NOTE—The above chart is intended to provide a basic comparison of jacketing materials and their suitability in certain adverse
environments. The effect of chemicals on jacketing materials is dependent on the type of chemical, its concentration, and the temperature
at which it is tested. Specific chemical resistance should be checked with the cable or material manufacturer for a cable jacket.
E – Excellent, virtually not affected.
G – Good, slightly affected.
NR –Not Recommended, significantly attacked and unsuitable for the environment.
In 9.2 through 9.14, the characteristics of the different polymeric jacket materials that are currently in common
use are discussed and their typical properties in various performance categories that are deemed applicable for
jackets are outlined.
9.3 Neoprene
Neoprene (i.e., polychloroprene) is the generic name for elastomeric polymers derived from the polymerization
of chloroprene. Typical jacket compounds contain 40% to 60% by weight of the neoprene polymer. A treatment
is required to cross-link the polymer and thereby impart its thermoset characteristics.
Physical properties, such as tear strength, resistance to compressive flow, and abrasion resistance are typically
of a high order.
Prolonged exposure to elevated temperatures, however, can result in embrittlement and a loss of elongation.
The temperature related properties are sensitive to compound formulation, and the manufacturer should be
consulted for specific information.
Neoprene compositions have excellent resistance to chemicals and considerable resistance to flame
propagation. They can be formulated to provide sunlight/weathering, thermal aging, and ozone resistance.
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Since neoprene contains chlorine, the risks associated with these materials when burning should be considered
when using these jackets. This combination of properties has been responsible for its major uses. There is a
lack of overall industry standards for water permeability and water absorption, and the manufacturer should be
consulted for specific information.
In general, neoprene compositions have excellent resistance to aliphatic hydrocarbons, aliphatic hydroxyl
compounds, animal and vegetable oils and fats, fluorinated hydrocarbons, dilute mineral acids, alkaline
solutions, and all salts except those of a strong oxidizing nature. The manufacturer should be consulted for
specific information.
Thermal degradation during processing and in service is retarded by the addition of stabilizers, which, for
cable applications, were predominantly lead salts but have now been replaced by non-lead alternatives in
many applications. PVC jackets with non-lead stabilizers are commonly being used today. PVC, when
compounded with stabilizers, plasticizers, fillers, and other ingredients, is suitable for general purpose cable
jacket application in either black or colors. Physical properties such as tensile strength, elongation, and
abrasion resistance are good; tear resistance is good. These general purpose compounds are tough and abrasion
resistant, are low in water absorption, have excellent resistance to soil environments, and are highly resistant
to inorganic acids and alkaline solutions, but they can be attacked by some hydrocarbons, ketones, esters, and
chlorinated hydrocarbons. UV inhibitors, including a black color additive, can be added to provide excellent
weather resistance. Care should be taken when extruding PVC jackets directly over semi-conducting polymer
systems, as the plasticizers and other ingredients in the PVC can affect the conductive properties of the semi-
conducting layers.
The low temperature flexibility of these materials shall be treated with some caution. The temperature at which
fracture occurs is a function of the bending radius cable diameter ratio, the rate of bending, cable construction,
intensity of shock or impact, and other factors. It is usually recommended that cables with general purpose PVC
jackets be installed at temperatures above –10 °C. PVC, like other polymeric materials, can be compounded for
special purpose applications, including lower temperature use and better resistance to oil and hydrocarbons.
PVC can be distinguished from low and high-density polyethylene by its inherently better flame retardance.
This property can be enhanced even more by the addition of flame-retardant additives. It could therefore find
application over a cable core where flame retardance is of importance. In recent years, there has been a trend
away from halogen-containing jackets such as PVC, CPE, CSPE, and neoprene for cables to be employed in
generating plants, substations, and similar applications because they can generate halogen acid fumes when
burned. The health and equipment damage risks associated with halogen acid fumes during burning should be
considered when using these jacket materials.
Care should be exercised when selecting PVC as a jacket material to verify that it is suitable for the range
of temperatures that it will be exposed to. It should have good low temperature properties for installation in
colder locations and good deformation resistance at elevated temperatures for installation in warmer locations.
Since PVC materials are thermoplastic in nature, they tend to soften and deform at elevated temperatures.
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carbon black, coloring pigments, flame retardants, and/or UV protectors. Polyethylene can also be crosslinked,
transforming it into a thermoset material.
9.5.1 Thermoplastic PE
The amount and degree of branching in the polymer greatly affects the physical properties of polyethylene.
As branching decreases, the crystallinity, hardness, density, and softening point increase; in this respect,
polyethylene is specified by the range of densities within which they fall (see ASTM D 1248 [B16]). The
density ranges are commonly classified as very low-density polyethylene (VLDPE), LLDPE/ low density
polyethylene (LDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE) and
are outlined in Table 3. Table 3 also contains the typical softening range of the polyethylene type. The average
molecular weight, or length of the polymer chains, also influences the physical properties, particularly at
high temperatures. This quality is defined as an inverse molecular weight criterion called the melt index (see
ASTM D 1248 [B16]). The melt index is a measure of the fluidity of the polymer at an elevated temperature
(190 °C) and under specified conditions that control the shear stress; in general, a low melt index indicates a
high-molecular-weight material. Molecular weight distribution is important since it influences the processing
and property values of a polymer of a given melt index.
Polyethylene jackets exhibit excellent dielectric strength, low moisture absorption, good low-temperature
properties, a high degree of toughness, and abrasion resistance at normal installation temperatures, and
physical stability over the specified temperature range.
High-density polyethylene jackets are particularly well suited for direct earth burial cable because of their
exceptional toughness, abrasion resistance, and high degree of resistance to permeation by hydrogen sulfide
and other earth chemicals. The added stiffness imparted to the cable by this jacket compound should not be
objectionable in this type of installation. The selection of a high-quality polyethylene jacket compound and its
proper application to the cable core are extremely important to achieve a stable structure that will not become
brittle and crack in service.
VLDPE jackets are the most flexible of all PE jackets. They are also the most recent additions to the PE family.
In many cable standards, VLDPE may either fall under the LLDPE group or not be covered at all.
The mechanical properties of a polyethylene jacket will be impaired by contact with any liquid that swells the
polymer. In addition, contact with certain liquid polar materials such as soaps, detergents and/or wetting agents
can lead to brittle failure under conditions of biaxial mechanical stress. Hence, care shall be taken to verify
the compatibility of the pulling compounds and the jackets. Jacketing materials are chemically formulated so
that troubles from these causes will not be encountered under normal circumstances. Users should contact the
manufacturer to verify that the jacketing material is compatible with the selected pulling lubricant.
Care should be exercised in the selection of polyethylene jackets for high-temperature cable applications.
The local cable temperature environment should be considered since it is possible the local temperature may
approach the softening temperature of a thermoplastic jacket (see Table 3).
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Polyethylene can be mixed with other materials to become a deformation resistant thermoplastic (DRTP)—
higher temperature thermoplastics that do not deform as severely at elevated temperatures.
Polyethylene jackets are typically compounded with well-dispersed carbon black of small particle size to
protect against ultraviolet light and a stabilizer to protect against possible thermal degradation caused by
processing and operating conditions.
Although polyethylene has no inherent flame retardancy, it can be compounded with halogen or non-halogen
flame-retardant additives to meet a broad range of flame-retardant requirements. These materials have been
used in cable applications requiring reduced combustion emissions. Adding flame-retardant fillers to the
polyethylene will reduce its physical and electrical properties. Copolymers of ethylene and vinyl acetate,
ethyl/butyl acrylate, and/or acrylic acid have also found applications in jacket formulations where oil or other
chemical resistance, moisture resistance, and toughness are required.
Cable operation at higher temperatures or in more aggressive chemical environments may require cross-linking
of the polyethylene jacket. It may also sometimes be necessary to cross-link a highly filled polyethylene jacket
to retain the polymer’s physical properties. Crosslinking the jacket enhances flame performance and thermo-
mechanical properties, such as high temperature deformation, abuse resistance, and allows for higher fault
currents (in shielded cables only). The properties described in 9.5.1 for thermoplastic PE also applies to cross-
linked materials. The exception is that crosslinked materials cannot be re-melted.
Depending on the end-use application, the compounding chemist can choose a CPE product that is most
suitable for end-use performance.
The saturated backbone of CPE (no double bonds in the polymer chain) imparts outstanding ozone, oxidative,
and heat resistance to a compound’s performance. In addition, the chlorine content of the base CPE resin
plays a significant role in determining the performance characteristics of the CPE compound. The presence of
chlorine on the polyethylene backbone increases the polarity of the molecule and thereby affects its properties.
For example, higher chlorine content will increase oil and flame retardancy, Compounders can choose an
appropriate chlorine content to help provide the desired performance properties required for the finished
cable jacket. Since CPE contains chlorine, the risks associated with these materials when burning should be
considered when using these jackets.
CPE jackets may be either thermoset (crosslinked) or thermoplastic. CPE may be formulated with a variety
of ingredients (any number of antioxidants, plasticizers, fillers, curatives, etc.) to meet the performance
requirements for general purpose, heavy-duty, and extra heavy duty jackets on portable cables and for nuclear
power plant applications.
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Thermoplastic cable jackets containing CPE are typically referred to as deformation resistant. These
deformation resistant materials are suitable for jackets on instrumentation, control and power cables in power
generating stations, and fiber optic cables.
CPE, when properly compounded, provides excellent mechanical properties, abrasion resistance, toughness,
and flame retardancy. The resistance to chemicals, oil, ozone, corona discharge, moisture, and weathering of
properly compounded CPE is excellent for both black and colored jacket compounds. CPE can be compounded
to meet medium duty, heavy duty, or extra heavy-duty requirements in accordance with applicable ICEA
specifications.
The base polymers of CPE and CSPE are chemically similar and can often be used for the same jacket
applications. The ability to use one or the other often can depend on specific performance factors that may be
met more easily with one polymer versus the other.
There are many similarities between CPE and CSPE; however, one major difference is the presence of sulfur
in CSPE in the form of pendant SO2Cl functionalities. The SO2Cl group provides an alternative route to cross-
linking the CSPE polymer. Since CSPE contains chlorine, the risks associated with these materials when
burning should be considered when using these jackets.
CSPE jackets are typically cross linked. When compounded with antioxidants, plasticizers, fillers, and other
ingredients CSPE is suitable for general-purpose cable applications. In addition, CSPE may be compounded
for extra heavy-duty jackets on portable cables and for jackets on cables used in nuclear plants.
The weather and moisture resistance of properly compounded CSPE is excellent. The absence of double
bonds in the molecular structure of CSPE-based compounds provides excellent resistant to ozone attack
and oxidation. CSPE compounds are resistant to most acids, alkalis, and many other chemicals including
petroleum-based oils. The cable manufacturer should be contacted regarding specific resistance data.
The base polymers of CPE and CSPE are chemically similar and can often be used for the same jacket
applications. The ability to use one or the other often can depend on specific performance factors that may be
met more easily with one polymer versus the other.
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9.10 Polypropylene
Polypropylene is a thermoplastic, semi-crystalline hydrocarbon and can either be a homopolymer, a block
copolymer, or a random copolymer. Polypropylene is often used on cables with a 105 °C rating because of
its high melting point that translates into good deformation resistance in a temperature range of 105 °C to
140 °C. Polypropylene jackets, with melting points ranging from 130 °C to 170 °C, depending on the type
of polypropylene used, are well suited to withstand the higher 105 °C insulation temperature requirements.
This increase in temperature performance is required particularly in URD duct installations brought about
by increased energy (ampacity) demand. The relatively slippery surface of polypropylenes also provides for
easier pull into ducts.
The low-temperature performance of polypropylene depends on the polymer structure as well as processing
conditions. Polypropylene homopolymer has good low-temperature performance down to –25 °C, whereas
polypropylene random and block copolymers can demonstrate better low temperature performance down to
–50 °C.
Both homopolymer, random and block copolymer polypropylenes demonstrate excellent environmental
stress crack resistance as well as chemical and oil resistance. Polypropylene jackets also show good moisture
permeation resistance.
Polypropylene jackets are tough materials demonstrating high secant moduli. Secant moduli of polypropylene
copolymer and homopolymers typically range from 150 000 psi to 180 000 psi. This high modulus of
polypropylene translates into good toughness that has enabled wall thickness reductions for particular duct
installations.
Polypropylene jackets are typically produced by blending a weathering grade of carbon black masterbatch
with the polypropylene to achieve an absorption coefficient of 320 as measured per ASTM D 3349 [B18].
The polypropylene jackets currently used for 105 °C rated cables are based on a polypropylene random
copolymer (with a melting point above 130 °C). These materials are mixed with a carbon black masterbatch to
achieve an acceptable carbon black loading for good weathering performance.
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Polyamide 6 is commonly used in building wire and cable construction as a jacketing material over primary
insulation. The electrical properties of polyamide 6 are generally not adequate for use as a primary insulation
material. In wire jacketing applications, the polyamide 6 is typically a medium viscosity, heat-stabilized
homopolymer with an internal lubricant for improved resin extrusion.
The main function of polyamide 6 jacketing is to provide mechanical protection for the insulation. The
polyamide has excellent cut-through and abrasion resistance. The low coefficient of friction of polyamide 6
permits easier installation of jacketed conductors in new or existing conduit. Polyamide 6 also has excellent
chemical resistance. Polyamide 6 jacketing is often employed where electrical conductors are exposed to
gasoline, oil, and other hydrocarbon solvents.
Heat-stabilized polyamide 6 grades are suitable for continuous use up to 120 °C and short-term (less than 15
min) exposure of temperatures up to 185 °C. Prolonged exposure to sunlight and weathering may require the
addition of UV additives or pigment systems. The manufacturer should be consulted for specific information.
9.12 Fluoropolymer
Fluoropolymers used in the cable industry for jackets and insulations include: fluorinated ethylene propylene
(FEP), ethylene chlorotrifluoroethylene (ECTFE), and polyvinylidene fluoride (PVDF).
Typically, FEP is used for insulation, either solid or foamed, in fire alarm cables or high-frequency data cables
made according to the category system. It is also used less frequently for jacketing in the same applications
due to economic considerations. It has a melting point of 290 °C and is often used in applications requiring
continuous service temperatures of 200 °C.
ECTFE is used as a jacket for industrial control cables and nuclear plant cables. It has a melting point of
150 °C.
PVDF is used exclusively as a jacket and has a melting point of 171 °C. It can be cross-linked by irradiation and
for use as a jacket in demanding industrial cable applications for improved performance in high temperature
and/or harsh environments.
Fluoropolymers have high-temperature properties that lend themselves to applications where resistance to
external or environmental heat sources is required. The fluoropolymers have the ability to consistently meet
the requirements of the horizontal flame test (Steiner Tunnel Test outlined NFPA 262 [B91]) due to the high
limiting oxygen index of these fluorinated resins. They emit limited smoke during the flame tests, thereby
meeting the requirements for low smoke and low corrosivity required for safety cables. They do, however,
emit some toxic by-products in small quantities such as hydrogen fluoride. Overall, fluoropolymer jackets
have low coefficients of friction, high levels of hardness, tensile strength, and chemical resistance as compared
to other jackets. They require special extrusion techniques.
a) Flame retardance
b) Low-temperature performance (such as impact and crack resistance, flexibility, brittleness, etc.)
c) Oil resistance
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The TPE have properties similar to those of vulcanized (thermosetting) rubbers. They combine the flexibility
and impact resistance of thermoset rubbers with the strength and convenient processability of thermoplastics.
Because they are thermoplastic they can be recycled, TPEs are multiphase compositions in which the
polyolefinic phase and rubber phases are dispersed intimately. Depending on the properties desired the
crystalline phase or the amorphous phase may be adjusted to select the continuous phase. A continuous or
dominant amorphous phase will yield a more flexible material. In many cases, the phases are chemically
bonded by block or graft copolymerization. In others, a fine dispersion is sufficient.
Like many conventional rubber materials, TPE is highly resistant to oils, chemicals, ozone, and other
environmental factors but do not have the high temperature resistance of the thermosets. They have low
water absorption, low coefficient of friction, excellent electrical properties, and flexibility is adjustable by
compound design. TPE can be processed on widely used cable extrusion and jacketing equipment. TPE is used
in a variety of cable jacketing applications.
Compared with halogenated flame-retardant systems and resins, LSHF systems produce much less smoke
and toxic gases and, generally, no corrosive gases upon burning. These factors are important as most injuries
in cases of fire can be caused by disorientation from heavy smoke particulates blocking out light and irritants
(such as, but not limited to, HCl, HBr, HF, SO2, NO2, etc.). The smoke density with LSHF materials can be
much lower and take longer to reach its peak than halogen-containing systems. The lack of corrosive gases
decreases the secondary effect of a fire as the risks for damaging electrical equipment, machines, and so on are
reduced.
These materials are generally based on polyolefins, but other resins can be used based on the desired cable
performance requirements. LSHF compounds can be either thermoplastic or thermoset. Some materials are
developed with excellent flame retardancy and can meet some vertical flame test requirements. One type of
flame-retardant system that is frequently used is based on metal hydrates, such as aluminum and magnesium
hydroxides. These minerals act as flame retarders and smoke suppressants. Other flame-retardant systems can
include char formers based generally on melamine and/or phosphorus. Jackets with good flame retardancy
are designed to boost the overall flame rating of a completed cable construction. Thermoset jacket materials
are used when increased resistance to mechanical, thermal, and chemical abuse is required over those of
thermoplastic materials. These LSHF materials can be black compounds or natural to allow for coloration with
standard wire and cable color concentrates.
Selection of LSHF jacketing materials will be dependent on the end-use application and industry requirements.
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identification, such as red stripes or raised ridges, to supplement the NESC requirement. IEEE Std 1235™
[B84] was issued June 20, 2000 and reaffirmed in 2012 to establish a guide for identification markings of
jacketed underground power cables and ducts. Included in IEEE Std 1235 [B84] are various methods of
identifying underground power cables and ducts and the visual, chemical, and mechanical properties of
the identification materials and/or methods, as well as their impact on the properties of the overall jacket or
conduit and installation practices.
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Annex A
(informative)
Bibliography
Bibliographical references are resources that provide additional or helpful material but do not need to be
understood or used to implement this standard. Reference to these resources is made for informational use
only.
[B1] Accredited Standards Committee C-2, National Electrical Safety Code® (NESC®).5
[B2] Adamson, C., H. Taha, and L. M. Wedepohl, “Comparative steady state performance of crossbonded
cable systems,” IEEE Proceedings, vol. 115, no. 8, pp. 1147–1156, Aug. 1968.
[B3] AEIC CS1, Specifications for Impregnated Paper-Insulated Metallic Sheathed Cable, Solid Type.6
[B4] AEIC CS4, Specifications for Impregnated-Paper-Insulated Low and Medium Pressure Self-Contained
Liquid Filled Cable.
[B5] AEIC CS8, Specification for Extruded Dielectric, Shielded Power Cables Rated 5 Through 46 kV.
[B6] AEIC CS9, Specification for Extruded Insulation Power Cables and Their Accessories Rated Above 46
kV through 345 kVac.
[B7] ANSI/ICEA S-56-434, Standard for Polyolefin Insulated Communications Cables for Outdoor Use.7
[B8] ANSI/ICEA S-81-570, Standard for 600 Volt Rated Cables of Ruggedized Design for Direct Burial
Installations as Single Conductors or Assemblies of Single Conductors.
[B9] ANSI/ICEA S-86-634, Standard for Buried Telecommunications Wire Filled, Polyolefin Insulated,
Copper Conductor Technical Requirements.
[B10] ANSI/ICEA S-94-649, Standard for Concentric Neutral Cables Rated 5 Through 46 kV.
[B11] ANSI/ICEA S-97-682, Standard for Utility Shielded Power Cables 5 Through 46 kV.
[B12] ANSI/ICEA S-105-692, Standard for 600 Volt Single Layer Thermoset Insulated Utility Underground
Distribution Cables.
[B13] ANSI/ICEA S-108-720, Standard for Extruded Insulation Power Cables Rated Above 46 Through 500
KV AC.
[B14] ANSI/ICEA S-113-684, Performance Based Standard for Electric Utility Extruded Dielectric Shielded
Power Cables Rated 5 Through 46 KV.
[B15] ANSI/NEMA WC 53 ICEA T-27-581, Standard Test Methods for Extruded Dielectric Power, Control,
Instrumentation, and Portable Cables for Test.
5
The NESC is available from the Institute of Electrical and Electronics Engineers (https://standards.ieee.org/).
6
AEIC publications are available from the Association of Edison Illuminating Companies (https://www.aeic.org/).
7
ANSI publications are available from the American National Standards Institute (https://www.ansi.org/).
40
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[B16] ASTM D 1248, Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and
Cable.8
[B17] ASTM D 1765, Standard Classification System for Carbon Blacks Used in Rubber Products.
[B18] ASTM D 3349, Standard Test Method for Absorption Coefficient of Ethylene Polymer Material
Pigmented with Carbon Black.
[B19] ASTM G 151, Standard Practice for Exposing Nonmetallic Materials in Accelerated Test Devices That
Use Laboratory Light Sources.
[B20] ASTM G 155, Standard Practice for Operating Xenon-Arc Light Apparatus for Exposure of Nonmetallic
Materials.
[B21] Bebbington, G. H., “Effect of soil burial exposure on the properties of rubber, cross linked polyethylene,
and vulcanized wire coating,” Bell System Technical Journal, vol. 51, pp. 87–121, January 1972.
[B22] Boggs, S. and C. Xu, (October 30, 2006). “Effect of Ground Shield Properties on the Loss of Unjacketed
Distribution Cable.” Paper presented at the A2D meeting of the Power Energy Society (PES) Insulated
Conductors Committee (ICC), St. Petersburg, FL.
[B23] Boggs, S., (March 11, 2008). “Semicon-Concentric Neutral Interaction in Unjacketed Cable.” Paper
presented at the A2D meeting of the Power Energy Society (PES) Insulated Conductors Committee (ICC), St.
Petersburg, FL.
[B24] Campbell, H. D., “Lightning protection of buried cable by semi conducting jackets,” 14th Annual
Symposium on Technical Progress in Communications Wires and Cables, Atlantic City, N.J., Dec. 1965.
8
ASTM publications are available from the American Society for Testing and Materials (https://www.astm.org/).
9
CSA publications are available from the Canadian Standards Association (https://www.csa.ca/).
41
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[B44] CAN/CSA-C22.2 No. 233, Cords and Cord Sets for Communication Systems.
[B47] CAN/CSA-C22.2 No. 262, Optical Fiber Cable and Communication Cable Raceway Systems.
[B50] CAN/CSA-C68.5, Shielded and Concentric Neutral Power Cable for Distribution Utilities.
[B51] CAN/CSA-C68.10, Shielded Power Cable for Industrial and Commercial Applications.
[B52] CIGRE, “The design of specially bonded cable circuits, Part II,” Electra, no. 47, July 1976.10
[B53] CIGRE, “The design of specially bonded cable systems,” Electra, no. 28, May 1973.
[B54] Code of Federal Regulations (CFR), Title 30, Mineral Resources, Parts 0 199, Mine Safety and Health
Administration, revised July 1, 1980.
[B55] Connolly, R. A., “Soil burial of materials and structures,” Bell System Technical Journal, vol. 51,
pp. 1–21, January 1972.
[B56] CSA Std C170.3 1966 (Reaff 1989), Polyvinyl Chloride (PVC) Protective Covering on Paper-Insulated
Metallic Sheathed Power Cable.
[B57] CSA-C22.2 No. 0.3, Test Methods for Electrical Wires and Cables.
[B58] CSA-C22.2 No. 21, Cord Sets and Power Supply Cords.
[B59] CSA-C22.2 No. 35, Extra-Low-Voltage Control Circuit Cables, Low-Energy Control.
[B60] De Coste, J. B., “Effect of soil burial exposure on the properties of plastics for wire and cable,” Bell
System Technical Journal, vol. 51, pp. 63–86, January 1972.
10
CIGRE publications are available from the Council on Large Electric Systems (https://www.e-cigre.org/).
42
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
[B61] Eager, G. S., G. Bahder, and D. A. Silver, “Corona detection experience in commercial production of
power cables with extruded insulation,” IEEE Transactions on Power Apparatus and Systems, vol. 88, no. 4,
pp. 342–369, April 1969.
[B62] Eaton, A. G. and A. M. H. Issa, “Transient response of crossbonded cable systems,” Proceedings of the
IEE, vol. 117, no. 3, Mar. 1970.
[B63] Marciano, F. and P. L. Cinquemani, “Longitudinally Water Resistant Cables,” Jicable ‘91, Third
International Conference on Polymer Insulated Power Cables, Versailles, France, Paper No. A.6.1, June 24–
28, 1991.
[B64] Halperin, H., J. E. Clem, and K. W. Miller, “Transient voltages on bonded cable sheaths,” Transactions
of the AIEE, vol. 54, pp. 73–82, Jan. 1935.
[B65] Hamilton, R. L., “Water vapor permeability of polyethylene and other plastic materials,” Bell System
Technical Journal, vol. 46, pp. 391–415, February 1967.
[B66] ICEA P-45-482, Short Circuit Performance of Metallic Shields and Sheaths on Insulated Cables.11
[B67] ICEA P-123-739, Guide to Establish Electrical Test Methods for Non-Conducting Jacket Materials for
Power Cables Rated 5 To 500 kV.
[B68] ICEA S-73-532 (NEMA WC57), Standard for Control, Thermocouple Extension and Instrumentation
Cables.
[B69] ICEA S-75-381 (NEMA WC58), Standard for Portable & Mine Power Feeder Cables.
[B70] ICEA S-95-658 (NEMA WC70), Standard for Non-Shielded Power Cables Rated 2000 V or Less.
[B71] ICEA S-96-659 (NEMA WC71), Standard for Non-Shielded Power Cables Rated 2001–5000 V.
[B72] ICEA S-93-639 (NEMA WC74), 5–46 kV Shielded Power Cable for Use in the Transmission and
Distribution of Electric Energy.
[B73] ICEA T-33-655, Guide for Low-Smoke, Halogen-Free (LSHF) Polymeric Cable Jackets.
[B74] ICEA T-34-664, Test Method for Conducting Longitudinal Water Penetration Resistance Tests on
Longitudinal Water Blocked Cables.
[B75] IEC 60229 Edition 3.0, Electric cables, Tests on extruded oversheaths with a special protective function.
[B77] IEEE Std 386™, IEEE Standard for Separable Insulated Connector Systems for Power Distribution
Systems Rated 2.5 kV through 35 kV.
[B78] IEEE Std 525™, IEEE Guide for the Design and Installation of Cable Systems in Substations.
[B79] IEEE Std 575™, IEEE Guide for the Application of Sheath-Bonding Methods for Single-Conductor
Cables and the Calculation of Induced Voltages and Currents in Cable Sheaths (Withdrawn).9
11
ICEA publications are available from the Insulated Cable Engineers Association (https://www.icea.org/).
12
IEEE publications are available from The Institute of Electrical and Electronics Engineers (https://standards.ieee.org/).
13
IEEE Std 575 has been withdrawn; however, copies can be obtained from the Institute of Electrical and Electronics Engineers (http://
standards.ieee.org/).
43
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
[B80] IEEE Std 1143™, IEEE Guide on Shielding Practice for Low Voltage Cables.
[B81] IEEE Std 1202™, IEEE Standard for Flame-Propagation Testing of Wire and Cable.
[B82] IEEE Std 1210™, IEEE Standard Tests for Determining Compatibility of Cable-Pulling Lubricants
with Wire and Cable.
[B83] IEEE Std 1234™, IEEE Guide for Fault-Locating Techniques on Shielded Power Cable Systems.
[B84] IEEE Std 1235™, IEEE Guide for the Properties of Identifiable Jackets for Underground Power Cables
and Ducts.
[B85] IEEE Std 1617™, IEEE Guide for Detection Mitigation, and Control of Concentric Neutral Corrosion
in Medium-Voltage Underground Cables.
[B86] Kuwahara, K. and C. Doench, “Evaluation of power frequency sheath currents and voltages in single
conductor voltages in single conductor cables for various sheath bonding methods,” IEEE Summer General
Meeting, Toronto, Ontario, Canada, Paper no. 63 932, June 1963.
[B87] Kwei, T. K., “Effect of soil burial exposure on the properties of electrical grade reinforced plastic
laminates,” Bell System Technical Journal, vol. 51, pp. 47–49, January 1972.
[B88] Mildner, R. C., “A review of resistive compounds for primary URD cables,” 1969 IEEE Underground
Distribution Conference, 69C I PWR, pp. 311–320.
[B89] Mildner, R. C. and P. C. Woodland, “The electrical characteristics of some resistive plastics for the wire
and cable industry,” 13th Annual on Technical Progress in Communications Wires and Cable, Atlantic City,
N.J., 1964.
[B90] Miner, R. J., “Effect of soil burial exposure on the properties of molded plastics,” Bell System Technical
Journal, vol. 51, pp. 23–42, January 1972.
[B91] NFPA 262 Standard Method of Test for Flame Travel and Smoke of Wires and Cables for Use in Air-
Handling Spaces.13
[B92] Norman, R. H., Conductive Rubbers and Plastics. New York: Elsevier, 1970.
[B93] Pazinski, H. J., “Performance characteristics of semi conductive polyethylene,” Wire and Wire Products,
vol. 41, p. 402, Mar. 1966. Paper presented at the Wire Association Meeting, New York, Oct. 1965.
[B94] Polley, M. H. and B. B. S. T. Boonstra, “Carbon blacks for highly conductive rubber,” Rubber Chemistry
and Technology, vol. 30, p. 170, 1957.
14
NFPA publications are published by the National Fire Protection Association (https://www.nfpa.org/).
15
UL publications are available from Underwriters Laboratories (https://www.ul.com/).
44
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IEEE Std 532-2021
IEEE Guide for Selecting and Testing Jackets for Power, Instrumentation, and Control Cables
[B100] UL 493, Standard for Thermoplastic-Insulated Underground Feeder and Branch-Circuit Cables.
[B107] UL 1277, Standard for Electrical Power and Control Tray Cables with Optional Optical-Fiber
Members.
[B111] UL 1581, Reference Standard for Electrical Wires, Cables, and Flexible Cords.
[B112] UL 1666, Test for Flame Propagation Height of Electrical and Optical-Fiber Cables Installed Vertically
in Shafts.
[B114] U.S. Nuclear Regulatory Commission Information Notice 92–81, Potential Deficiency of Electrical
Cables with Bonded Hypalon Jackets.
[B115] Wargotz, B. and W. M. Alvino, “Conductive polyethylene resins from ethylene copolymers and
conductive carbon black,” Division of Rubber Chemistry ACS Meeting, San Francisco, CA, May 1966.
[B116] Watson, W. and L. C. C. Erven, “Surge potentials on underground cable sheath and joint insulation,”
IEEE Transactions, vol. 82, pt. 3, pp. 239–249, June 1963.
[B117] Wollaston, F. O. and K. H. Kidd, “Cable sheath jacket requirements to withstand abnormal voltage
stresses,” Transactions of the American Institute of Electrical Engineers, vol. 80, pt. 3, pp. 1116–1123, 1961.
45
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