In industrial electrical systems, every connection matters and the cable gland is one of the most critical components for ensuring safety, sealing, and reliability. However, improper installation remains one of the biggest causes of installation failure, especially in armored or outdoor cable applications.
Even high-quality glands can underperform if installed incorrectly. From choosing the wrong gland size to overlooking environmental factors, simple mistakes can lead to costly downtime, electrical hazards, or even system failure.
At Exgrip, we’ve helped countless industries troubleshoot these exact issues. Here’s a detailed look at the most common mistakes and how you can prevent them.
Selecting the Wrong Gland Size
Choosing the right gland size is the foundation of a successful installation. If the gland is too small, it won’t seal properly; if it’s too large, it will cause strain on the cable sheath.
For armored cables, incorrect sizing often leads to poor earthing and mechanical instability. Always use a verified gland size chart and measure both the outer and inner cable diameters before installation.
Using the Wrong Gland Type
| Gland Type | Common Use | Issue When Used Incorrectly |
|---|---|---|
| Single Compression Gland | Ideal for unarmoured cables in indoor or controlled environments. | Using it on armoured cables can cause poor earthing and sealing failure, leading to moisture ingress or short circuits. |
| Double Compression Gland | Designed for armoured cables in outdoor or hazardous areas. | If used on unarmoured cables, the inner seal may not grip properly, reducing strain relief and increasing risk of cable slippage. |
| Flameproof (Ex d) Gland | Used in explosive or hazardous zones for maximum safety compliance. | Incorrect selection in non-hazardous areas adds unnecessary cost and complexity without additional benefit. |
| Weatherproof / IP68 Gland | Perfect for outdoor, marine, or wet environments requiring dust and water protection. | Using lower IP-rated glands in outdoor conditions can cause corrosion, leakage, and eventual installation failure. |
Exgrip Tip: Always match the gland type to your cable construction, environment, and certification needs. The right selection ensures proper sealing, electrical continuity, and long-term performance — preventing downtime and costly rework.
Over-Tightening or Under-Tightening
One of the most frequent installation mistakes is improper tightening.
Over-tightening can deform the cable sheath and damage the armor layer, while under-tightening can compromise sealing and strain r
Over-tightening or under-tightening is one of the most common mistakes during cable gland installation and it can seriously impact the reliability and safety of your electrical system. Applying the wrong torque can lead to seal failure, compromised strain relief, or even cable damage, especially in armoured cables.
When a gland is over-tightened, the excessive pressure can deform the cable sheath, damage the insulation, or crack non-metallic components. This not only affects performance but can also cause grounding issues and increase the risk of installation failure.
On the other hand, under-tightening leaves gaps between the cable and gland body, allowing dust, water, and vibration to enter. Over time, this can weaken the connection, cause corrosion, or result in complete electrical breakdown.
When tightened to the correct specification, cable glands provide:
Secure mechanical grip and proper strain relief
Effective sealing to maintain IP and ATEX protection
Long-term reliability even in hazardous or outdoor environments
Consistent performance across different gland sizes and materials
Neglecting cable preparation leads to installation failure even before the gland is fully fitted.
Always ensure that the cable sheath is clean, smooth, and free from debris. For armored cables, correctly trimming and securing the armor layer is essential for reliable grounding and long-term mechanical performance.
Poor Preparation of Cable Ends
Neglecting cable preparation leads to installation failure even before the gland is fully fitted.
Always ensure that the cable sheath is clean, smooth, and free from debris. For armored cables, correctly trimming and securing the armor layer is essential for reliable grounding and long-term mechanical performance.
Ignoring Environmental Factors
Follow this quick guide to select the right cable gland based on environmental conditions:
| Environmental Condition | Use | Do Not Use |
|---|---|---|
| Extreme Temperature (Hot or Cold) | Brass or stainless steel glands designed for wide temperature ranges. | Standard plastic glands not rated for temperature variation. |
| High Moisture or Outdoor Areas | IP68-rated waterproof or marine-type glands. | Indoor-rated or low IP glands. |
| Dusty or Hazardous Zones | Flameproof or double compression glands with dust protection. | Standard single compression glands. |
| Chemical or Corrosive Environments | Stainless steel or nickel-plated brass glands resistant to corrosion. | Plain brass or aluminum glands that corrode easily. |
| High Vibration or Machinery Movement | Glands with anti-vibration and strain relief features. | Basic glands without locking or support rings. |
Exgrip Tip: Always match the gland’s IP rating, material, and thread type with your environment.
This ensures maximum safety, durability, and compliance with IEC and ATEX standards.
Conclusion & Call-to-Action
Cable gland installation may seem straightforward, but small mistakes can lead to major failures.
By avoiding these common errors from incorrect gland size to improper tightening you can ensure a secure and compliant electrical system.
Looking for reliable and certified cable glands for your industrial project?
📩 Talk to our technical team today at Exgrip.com
📞 Or call us directly for quick assistance!
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🌐 Website: www.exgrip.com
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FAQs
What are the main causes of cable gland installation failure?
Installation failure often occurs due to the wrong gland size, poor cable preparation, over-tightening, or using non-certified products that don’t meet safety standards.
How do I select the correct gland size?
Check the cable’s outer and inner diameters against a manufacturer’s gland size chart. For armored cables, use double compression glands for proper sealing and grounding.
Can I use the same cable gland for armored and unarmored cables?
No. Armored and unarmored cables require different gland designs to ensure mechanical retention and sealing. Always select a gland that matches your cable type.
Why is proper tightening important during installation?
Correct torque ensures the gland seals properly without damaging the sheath. Over-tightening may deform the cable, while under-tightening reduces strain relief.
Which materials are best for harsh environments?
Stainless steel or nickel-plated brass glands are ideal for marine, chemical, and outdoor environments due to their corrosion resistance and strength.
What certifications should a cable gland have?
Look for ATEX, IECEx, and IP66/IP68 certifications. These confirm that the gland meets international safety and performance standards.
Does Exgrip provide certified cable glands?
Yes, all Exgrip cable glands are certified, tested, and globally approved for industrial, marine, and hazardous area applications.
