Cable gland failures are one of the most overlooked causes of electrical downtime in industrial installations. In many cases, unexpected equipment failure, moisture ingress, cable damage, or safety non-compliance can be traced back to one simple issue: incorrect cable gland selection.
A cable gland may appear to be a small component, but it plays a critical role in cable termination, sealing, strain relief, and overall electrical safety. Choosing the wrong type of cable gland or ignoring environmental and application requirements can result in costly shutdowns, maintenance issues, and even hazardous situations.
In this blog, we will explain the common causes of cable gland failure and show how selecting the right electrical cable gland types can significantly reduce downtime and improve system reliability.
What Is a Cable Gland and Why It Matters?
Before understanding failure causes, it’s important to clarify what is a cable gland?
A cable gland is a mechanical device used to securely attach and seal an electrical cable where it enters equipment, panels, or enclosures. Its main functions include:
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Providing mechanical support and strain relief
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Preventing dust, water, and gas ingress
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Maintaining earthing continuity (for armoured cables)
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Ensuring safety in hazardous and industrial environments
When a cable gland fails, these protections are compromised, often leading to electrical faults or equipment damage.
Common Cable Gland Failure Causes
1. Incorrect Type of Cable Gland Selection
One of the most frequent causes of cable gland failure is choosing the wrong type of cable gland for the application.
For example:
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Using a single compression gland on an armoured cable
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Using a non-flameproof gland in a hazardous area
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Selecting indoor-rated glands for outdoor installations
Each application requires specific electrical cable gland types based on cable construction, environment, and safety requirements.
2. Mismatch Between Cable Size and Gland Size
Improper sizing leads to poor sealing and weak mechanical grip. A gland that is too large may allow cable movement, while a gland that is too small can damage the cable sheath.
This can cause:
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Water or dust ingress
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Insulation damage
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Increased maintenance and downtime
Always match the gland clamping range with the actual cable outer diameter (OD).
3. Environmental Exposure Beyond Gland Capability
Cable glands are often exposed to harsh conditions such as:
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Extreme temperatures
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Chemicals or corrosive atmospheres
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UV radiation
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Heavy vibration
Using standard brass or nylon glands in such environments can result in premature failure. For these cases, stainless steel cable glands or specially coated glands are recommended.
4. Improper Installation Practices
Even the correct gland can fail if installed incorrectly. Common installation errors include:
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Over-tightening or under-tightening
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Incorrect stripping of cable layers
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Poor armour clamping in armoured cable glands
Improper installation affects sealing performance and reduces the lifespan of the cable termination.
5. Ignoring Hazardous Area Requirements
In explosive environments, standard glands are unsafe. Using non-certified glands in hazardous zones can lead to:
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Non-compliance with safety standards
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Increased risk of ignition
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Regulatory penalties
This is where ATEX cable glands become critical.
Electrical Cable Gland Types and Their Role in Preventing Failure
Selecting the correct electrical cable gland type is one of the most effective ways to prevent premature failures, electrical faults, and costly downtime. Each type of cable gland is engineered for a specific cable construction, environment, and safety requirement. Using the wrong gland can lead to moisture ingress, loss of earthing, mechanical stress, or even explosion risks in hazardous areas.
Below is a detailed breakdown of the most commonly used electrical cable gland types, their applications, and how they help prevent failures.
1. Single Compression Cable Glands
Single compression cable glands are primarily used for unarmoured cables where basic sealing and strain relief are required.
How they prevent failure:
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Provide a tight seal around the outer sheath of the cable
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Reduce stress caused by cable pull or vibration
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Prevent dust and light moisture ingress in indoor installations
Limitations:
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Not suitable for armoured cables
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Not recommended for hazardous or high-vibration environments
2. Double Compression Cable Glands
Double compression cable glands are designed for armoured cables and heavy-duty applications.
How they prevent failure:
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Seal both the inner insulation and the outer cable sheath
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Provide secure armour clamping for effective earthing
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Prevent moisture ingress in outdoor and industrial environments
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Withstand vibration, mechanical load, and thermal expansion
Best use cases:
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Power plants
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Heavy machinery
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Outdoor panels and substations
3. Brass Cable Glands
Brass cable glands are widely used due to their strength, durability, and corrosion resistance.
How they prevent failure:
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Resist mechanical wear and tear
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Maintain consistent clamping pressure over time
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Perform well in industrial and moderately corrosive environments
Common applications:
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Manufacturing plants
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Control panels
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General industrial wiring
4. Stainless Steel Cable Glands
Stainless steel cable glands are designed for extreme and corrosive environments.
How they prevent failure:
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High resistance to chemicals, salt spray, and humidity
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Prevent rust-related degradation
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Ensure long-term reliability in harsh conditions
Typical applications:
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Marine and offshore installations
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Chemical processing plants
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Food and pharmaceutical industries
5. ATEX Cable Glands
ATEX cable glands are certified for hazardous and explosive atmospheres.
How they prevent failure:
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Prevent flame propagation through cable entry points
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Maintain enclosure integrity under explosion conditions
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Ensure compliance with ATEX and safety standards
Critical applications:
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Oil & gas facilities
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Refineries
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Chemical plants
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Hazardous zone electrical equipment
Comparison Table: Electrical Cable Gland Types
| Cable Gland Type | Cable Type | Primary Function | Failure Prevention Benefit | Typical Applications |
|---|---|---|---|---|
| Single Compression Cable Glands | Unarmoured | Basic sealing and strain relief | Prevents cable pull-out and minor dust or moisture ingress | Indoor panels, control rooms |
| Double Compression Cable Glands | Armoured | Dual sealing and armour clamping | Prevents moisture ingress and ensures effective earthing | Outdoor installations, industrial equipment |
| Brass Cable Glands | Armoured / Unarmoured | Mechanical strength and durability | Reduces wear and maintains sealing integrity | Manufacturing plants, industrial panels |
| Stainless Steel Cable Glands | Armoured / Unarmoured | Corrosion resistance | Prevents rust-related failures in harsh environments | Marine, offshore, chemical industries |
| ATEX Cable Glands | Armoured / Unarmoured | Explosion and flame protection | Prevents flame propagation and explosion risks | Oil & gas, refineries, hazardous areas |
How Proper Cable Gland Selection Prevents Downtime
Selecting the right cable gland helps to:
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Maintain consistent electrical performance
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Prevent moisture and dust ingress
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Reduce cable wear and tear
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Improve safety compliance
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Minimize maintenance and repair costs
By matching the gland type with cable construction and environmental conditions, industries can significantly reduce unplanned downtime.
Conclusion & Call-to-Action
Cable gland failures are often the result of incorrect selection rather than product defects. Understanding what is a cable gland, knowing the right type of cable glands, and selecting suitable electrical cable gland types for each application can prevent costly downtime and safety risks.
For critical installations, especially in hazardous environments, certified solutions like ATEX cable glands are essential. Proper selection and installation not only improve system performance but also ensure compliance and long-term durability.
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FAQs
What is a cable gland used for?
A cable gland is used to secure, seal, and protect cables entering electrical equipment, providing strain relief, environmental protection, and safety.
What are the most common cable gland failure causes?
Incorrect gland type selection, wrong sizing, harsh environmental exposure, improper installation, and ignoring hazardous area requirements.
Which type of cable gland should be used for armoured cables?
Double compression cable glands are recommended for armoured cables as they provide better sealing and mechanical strength.
Why are ATEX cable glands important?
ATEX cable glands are certified for hazardous areas and prevent flame propagation, ensuring safety and regulatory compliance.
How can proper cable gland selection reduce downtime?
Correct selection prevents moisture ingress, cable damage, and electrical faults, reducing maintenance issues and unplanned shutdowns.
