In hazardous and industrial environments, choosing the correct IP rating for cable glands is not optional — it is critical for safety, compliance, and operational reliability.
Engineers and procurement teams frequently compare IP66 vs IP67 vs IP68 cable glands but often overlook how ingress protection impacts performance in dust-heavy plants, offshore platforms, chemical facilities, and outdoor electrical panels.
Selecting the wrong IP level can lead to:
Moisture ingress
Dust contamination
Corrosion of conductors
Short circuits
Costly downtime
This guide explains IP66, IP67, and IP68 in detail — along with how they relate to cable gland size chart, cable gland sizing, and real-world installation conditions.
At Exgrip, we manufacture industrial-grade, ATEX-compliant cable glands designed for high IP performance across hazardous and non-hazardous areas.
Let’s break it down technically.
What Is IP Rating in Cable Glands?
IP stands for Ingress Protection, defined under IEC 60529.
The IP code indicates protection against:
-
Solid objects (dust, particles)
-
Liquids (water ingress)
IP Rating Format
IP = Ingress Protection
Example: IP66
-
First digit = Solid protection (0–6)
-
Second digit = Water protection (0–9K)
Solid Protection Scale (First Digit)
| Digit | Protection Level |
|---|---|
| 5 | Dust protected |
| 6 | Dust tight |
Water Protection Scale (Second Digit)
| Digit | Protection Level |
|---|---|
| 6 | Powerful water jets |
| 7 | Temporary immersion |
| 8 | Continuous immersion |
IP66 vs IP67 vs IP68 – Technical Comparison Guide
IP66 Cable Gland
-
Dust tight
-
Protected against powerful water jets
-
Ideal for outdoor panels & washdown areas
-
Not suitable for submersion
IP67 Cable Gland
-
Dust tight
-
Withstands immersion up to 1 meter for 30 minutes
-
Suitable for temporary flooding conditions
IP68 Cable Gland
-
Dust tight
-
Continuous immersion beyond 1 meter (manufacturer specified depth)
-
Used in underground, marine, and water treatment installations
Technical Comparison Chart
| Parameter | IP66 | IP67 | IP68 |
|---|---|---|---|
| Dust Protection | Complete | Complete | Complete |
| Water Resistance | Water jets | 1m immersion | Continuous immersion |
| Outdoor Use | Yes | Yes | Yes |
| Underground Use | No | Limited | Yes |
| Hazardous Area Suitability | Yes | Yes | Yes |
| Typical Industry | Manufacturing | Infrastructure | Marine / Offshore |
How IP Rating Affects Cable Gland Size Selection
IP rating is influenced by:
Seal quality
Compression ring
O-ring design
Cable outer diameter
This directly links to correct cable gland size chart selection.
Improper sizing reduces IP integrity.
Cable Gland Size Chart (Industrial Reference)
Below is a general industrial cable gland size chart in mm used for standard metric threads.
| Cable OD (mm) | Gland Size (Metric) | Thread Type | Application |
|---|---|---|---|
| 6–12 | M16 | Metric | Control panels |
| 10–14 | M20 | Metric | Instrumentation |
| 13–18 | M25 | Metric | Power cables |
| 18–25 | M32 | Metric | Industrial motors |
| 25–32 | M40 | Metric | Large feeders |
| 32–38 | M50 | Metric | Heavy-duty cables |
This aligns with common searches like:
cable size and gland size
cable gland sizing chart
gland size chart for cable
Armoured Cable Gland Size Chart (Double Compression)
For armoured cables, sizing must consider:
Inner bedding diameter
Armour diameter
Outer sheath diameter
| Cable Size | Typical Gland Size | Type |
|---|---|---|
| 4 Core 16 sq mm | M25 | Double compression |
| 4 Core 35 sq mm | M32 | Double compression |
| 4 Core 70 sq mm | M40 | Double compression |
| 3.5 Core 300 sq mm | M75 | Heavy duty |
This addresses high-intent searches like:
3.5 core 300 sq mm cable gland size
4 core cable gland size chart
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Thread Type & Material Selection
Thread Types
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Metric (M)
-
PG
-
NPT
-
BSP
Materials Comparison
| Parameter | Brass | Stainless Steel |
|---|---|---|
| Corrosion Resistance | Moderate | Excellent |
| Marine Use | Limited | Ideal |
| Cost | Economical | Premium |
| Hazardous Area | Yes | Yes |
Single vs Double Compression – IP Impact
| Feature | Single Compression | Double Compression |
|---|---|---|
| Seal Points | One | Two |
| Armour Clamping | No | Yes |
| IP Reliability | Moderate | High |
| Hazardous Area | Limited | Recommended |
Connector Compatibility
IP-rated cable glands must match:
-
Armoured cables
-
Unarmoured cables
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Hazardous Zones 1 & 2
-
IP66/IP67/IP68 enclosures
-
Temperature range (-40°C to +120°C typical)
Improper compatibility compromises ingress rating.
Installation & Maintenance Guide
Step-by-Step Installation
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Select correct gland using cable gland selection chart
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Verify cable outer diameter
-
Insert cable through gland body
-
Tighten armour clamp (for double compression)
-
Torque as per manufacturer spec
-
Inspect sealing ring alignment
Torque Guidance
-
Over-tightening damages seal
-
Under-tightening reduces IP rating
Always follow datasheet torque values.
Inspection Frequency
-
Quarterly in harsh environments
-
Annual in standard installations
Certifications & Compliance
Using certified cable glands is essential for industrial safety and global compliance. Certifications give confidence that the product can withstand demanding environments.
Key Certifications to Look For:
ATEX & IECEx: Required for explosive or hazardous areas
IP66 / IP67 / IP68 Ratings: Guarantee dust-tight and waterproof performance
RoHS & REACH Compliance: Ensure environmentally safe and lead-free materials
CSA / UL Approvals: Necessary for North American installations
At Exgrip, all cable gland types, including brass cable gland, waterproof cable gland, and specialty adapters like 90° and YADP, are manufactured with these certifications, making them reliable for industries worldwide.
Installation & Maintenance Guide
Step-by-Step Installation
-
Select correct gland using cable gland selection chart
-
Verify cable outer diameter
-
Insert cable through gland body
-
Tighten armour clamp (for double compression)
-
Torque as per manufacturer spec
-
Inspect sealing ring alignment
Torque Guidance
-
Over-tightening damages seal
-
Under-tightening reduces IP rating
Always follow datasheet torque values.
Inspection Frequency
-
Quarterly in harsh environments
-
Annual in standard installations
Conclusion & Call-to-Action
Selecting the right cable gland, whether it’s a waterproof cable gland, brass cable gland, or using the correct cable gland accessories, is vital for industrial safety and system reliability.
At Exgrip, we provide a full range of cable glands, connectors, and accessories, certified with ATEX, IECEx, IP, RoHS, and REACH, suitable for any industrial or hazardous application.
📩 Talk to our technical team today at Exgrip.com
📞 Or call us directly for quick assistance!
Contact Us:
📞 Phone: +91 9537118899
🌐 Website: www.exgrip.com
📩 Request a Quote: Contact Page
FAQs
What is the difference between IP66 and IP68 cable glands?
IP66 protects against powerful water jets, while IP68 supports continuous immersion beyond 1 meter. IP68 is suitable for underground or marine applications. Selection depends on environmental exposure and installation depth.
How do I select the correct cable gland size?
Measure cable outer diameter and refer to a cable gland sizing chart. Ensure the cable falls within the gland’s sealing range. Incorrect sizing reduces IP performance.
Is IP67 enough for outdoor panels?
Yes, for most outdoor panels IP67 is sufficient. However, flood-prone areas may require IP68 glands.
Does IP rating affect hazardous area certification?
IP rating supports environmental sealing, but hazardous area safety also requires ATEX or IECEx certification.
Can I use single compression glands for armoured cables?
For hazardous areas, double compression glands are recommended for secure armour clamping and improved sealing.
Where can I download an electrical cable gland size chart PDF?
Manufacturers like Exgrip provide technical datasheets and gland size charts upon request.
