Cable runs in hazardous and potentially explosive locations need to be carefully planned, with every component chosen to meet strict performance and safety requirements. Lee Frizzell, CMP Products’ Technical Director, looks at their importance in these environments and how correct specification can be achieved every time.

The importance of cable glands simply can’t be underestimated – especially in hazardous and potentially explosive installation locations. Put simply, without the correct specification there’s the very real risk of gas migration and the increased danger that products aren’t able to prevent or contain an explosion.

Attention to detail

Of course, all aspects of cable runs in these kinds of installations demand exceptional attention to detail; with every component – from cables to junction boxes and everything in between – carefully specified to ensure they remain operational in times of system stress and prevent ignition of surrounding explosive atmospheres.

And while cable glands may seem a minor part of the specification challenge, it’s vital that they aren’t underestimated. They are, after all, the primary sealing point for cable entry and exit points and on top of that provide mechanical retention, environmental protection, earth continuity and, in explosive atmospheres, they help to prevent or contain an explosion.

Explosive atmosphere installations are classified into various types depending on the type of hazard; typically flammable gases, vapours or combustible dusts. In these situations, cable glands serve five essential functions:

• Explosion protection: Flameproof (Ex d) glands prevent flames produced by an explosion inside an enclosure from transmitting into the external atmosphere. While Increased Safety (Ex e) glands terminate and seal the cable into the enclosure, which itself contains certified components that cannot spark or reach temperatures high enough to ignite an explosive atmosphere.
• Gas migration prevention: Correctly specified or installed glands will prevent explosive gases travelling along cable runs into neighbouring equipment, causing explosion risks.
• Environmental sealing: Glands must block ingress of moisture, dust and corrosive elements. This is particularly important in offshore, marine or chemical processing plants.
• Mechanical stability: Pull-out resistance, or strain relief prevents cable damage and preserves safety over the equipment’s lifespan. 
• Earth continuity: Any armour or metallic screen in the cable is terminated and grounded inside the cable gland.

Safey first

If not correctly specified, then even a high quality cable installation and enclosure can become dangerously compromised. So, what steps need to be taken to ensure correct and safe specification?

There are several key steps that need to be taken; starting with understanding the environment in which the system will operate. This is classified by different zones – with Zones 0, 1 and 2 relating to explosive gas; and Zones 20, 21 and 22 concerning explosive dust.

These zones are then broken down to confirm the explosive atmosphere and subgroup and from there the type of enclosure protection concept needed can be identified. As mentioned, Ex d is flameproof, while Ex e is increased safety – no sparks or heat sources. There are also Ex i, Ex nR and Ex t options. The correct type of cable gland is then chosen to complement the enclosure. Problems arise if the wrong kind of gland is used – for example, fitting an Ex e gland on an Ex d enclosure is extremely dangerous.

The cable type then needs to be matched to the appropriate gland. For example, armoured cables require glands that can correctly terminate steel wire armour (SWA), steel tape armour (STA) or aluminium wire armour (AWA). The material of the cable gland itself, most commonly brass, nickel-plated brass, stainless steel or aluminium must also be selected appropriately.

Attention must also be paid to the cable’s inner bedding diameter, overall diameter, any armour or braid thickness and the applicable tolerances. Any uncertainty in selection risks compromising the cable or cable gland’s performance and overall system integrity.

The inner construction of the cable also needs careful consideration. For example, multicore cables increase the risk of gas migration and flame transmission through any gaps; to mitigate this risk and maintain Ex d integrity, a barrier type gland is required to seal directly around the cable inner cores. Barrier glands are mandatory for Ex d with unfilled multicore cables (per EN/IEC 60079‑14).

A correctly specified barrier gland will provide the peace of mind that gas will be prevented from travelling between the inner cores into neighbouring equipment or enclosures. This is essential in installations where explosive gases (e.g. hydrogen, acetylene, methane, ethylene) are present and pressure differentials exist.

Up to standard

As with every element of any cable installation, cable glands need to comply with industry wide standards. For projects following UKEX/ATEX or IECEx requirements, the key is the EN/IEC 60079 series and every explosive atmosphere cable gland we sell complies with the strict requirements of these internationally recognised standards.

On top of this, glands should carry certification markings that match the explosive atmosphere classification of the system; with temperature ratings that meet or exceed site requirements; gland materials match environmental and chemical exposure profiles; and Ingress Protection (IP) ratings align with enclosure and site specifications. Any deviation can make the entire installation non-compliant.

And the specification challenge doesn’t end there:

• Corrosion resistance requirements instruct the choice of product material and coating or plating
• Thread type mismatch is a frequent cause of installation error. Enclosure and gland entry threads need to match in type, length and taper. For Ex d, minimum thread engagement must also meet EN/IEC 60079-1

And, of course, and it should go without saying – the manufacturer’s installation instructions need to be followed precisely.

Structured approach

Cable glands may be small, but their importance in hazardous and explosive atmospheres is mighty. They protect personnel and infrastructure by maintaining the integrity of the system. Incorrect gland specification or installation increases the risk of a catastrophic explosion, gas migration, or moisture ingress.

By following a structured approach — beginning with proper explosive atmosphere classification and matching gland design to cable type, through to confirming certification, assessing environmental conditions and ensuring correct thread engagement — engineers and installers can achieve the right cable gland specification every time.

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Jake Green, Head of Technical Engagement with Scolmore Group, which incorporates the Unicrimp division of cable accessories, explores how correct cable support prevents strain and damage – and why wholesalers are central to ensuring contractors have the right products to meet BS7671 requirements.

For wholesalers, cable support is more than a simple add‑on sale. With BS7671 placing clear obligations on installers to protect cables from mechanical strain and damage, contractors rely heavily on their wholesaler to supply compliant, high‑quality fixings and accessories.

Why cable support matters

Regulation 522.8.1 of BS7671 requires wiring systems to be selected and installed so that cables and their terminations are not damaged during installation, use or maintenance. In practice, this means contractors need access to a wide range of support solutions – and they often turn to wholesalers for guidance on what’s appropriate for each job.

Regulations 522.8.5, 522.8.11 and 522.8.12 go further, stating that:

• Cables must not be subjected to mechanical strain
• Supports must not have sharp edges
• Fixings must not damage the cable

This places real emphasis on choosing the right product for the right application – something wholesalers are ideally positioned to support.

Types of support wholesalers should stock

Contractors expect wholesalers to carry a broad and reliable range of cable support options, including:

• Cable ties
• Cable cleats
• Cable clips
• Cable tie accessories
• Cable glands

Products such as Unicrimp metal cable cleats and Unicrimp brass meter tail glands are examples of items that help installers meet compliance requirements while ensuring long‑term system integrity.

The choice of fixing depends on:

• The installation surface (e.g., clips for timber, ties for basket tray)
• The cable type (e.g., cleats for SWA cables)

Wholesalers who understand these distinctions can better support their customers and strengthen their technical credibility.

Guidance contractors rely on

The IET On‑Site Guide (OSG) remains a key reference for installers. Appendix D provides recommended spacing for cable supports, with Table D1 detailing distances for accessible cable runs.

For example:

• A cable with a diameter up to 9 mm requires closer clip spacing
• Larger cables can be supported at greater intervals

Wholesalers who understand these guidelines can help contractors select the correct quantity and type of fixings – improving customer service and reducing returns.

Bending radii are also critical. Regulation 522.8.3 requires cables to be bent without placing strain on internal conductors. The OSG’s Table D5 gives examples, such as the minimum bending radius for 1.5mm² twin and earth.

Cable entry: a common point of failure

Wholesalers frequently supply the accessories that prevent damage at cable entry points.

Two issues must be addressed:

1. Sharp edges on metal boxes – requiring grommets or bushings
2. Strain on terminations – requiring proper support and compression glands

Stocking the right glands, grommets and strain‑relief products ensures installers can meet Regulations 522.8.5 and 522.8.12.

What this means for wholesalers

Electrical wholesalers are a vital link in ensuring safe, compliant installations. By offering a comprehensive range of cable supports – and understanding the regulatory drivers behind them – wholesalers can:

• Help contractors meet BS7671 requirements
• Reduce installation faults and call‑backs
• Strengthen customer trust
• Increase sales of complementary products

Unicrimp’s extensive range of clips, cleats, ties and glands gives wholesalers the opportunity to supply everything a contractor needs to install cables safely and compliantly.

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In this month’s Face to Face we speak with Paul Ruddick, Founder CEO of D-Line, and hear about the latest developments in cable management.

Q. What are the origins of D-Line as a UK based manufacturer of cable management solutions?

Back in 2004, I was running an electrical product consultancy based in Newcastle-on-Tyne supplying innovative product mixes for electrical installation projects.

That’s when I recognised the need for ‘design-led’ cable management solutions to provide attractive surface-mounted options for use ‘when time, safety and appearance matter’.

The first range was ‘D-shaped and linear’ mini trunkings, hence the name ‘D-Line’ for the new company.

Q. Are there any specific products that have proved to be particularly popular with installers and electrical wholesalers this year?

D-Line Wrap & Lock Conduit Saddles have become very popular with installers wanting speed, safety and style. They’re approximately 50% faster to install than traditional saddles, fire-rated for regs compliance, and give a uniquely streamlined appearance.

Q. How does D-Line ensure it develops innovative products that stand out in a crowded cable management market?

We only develop products that are ‘quick to install, look great!’ This combo brings best-value and distinct advantages over traditional choices. It has enabled D-Line to pioneer niche leader positions in a global market. 

Q. What are the cable accessories features and trends to look out for over the next few years?

Around the world we are supplying trunkings for fibre-at-home cable installations, and we expect such demands to increase in UK.

Now there’s full market awareness of 18^th Edition requirements for fire-rated cable supports, we see continued growth for our market-leading Safe-D ranges that secure all PVC trunkings, conduits and direct-to-surface cables.

And no doubt higher EV ownership will bring increased demand for D-Line’s Ultra Cable Cover. This provides a use-and-remove inexpensive solution that can facilitate EV-charging in terraced streets.

Q. How does being part of the Luceco Group benefit D-Line?

Working with Luceco sales teams has brought fantastic new possibilities in terms of sales reach and also benefits from partnering with Luceco product development teams. Now we are progressing new opportunities for future innovations.

Q. What are D-Line’s future plans in both the UK and international markets?

From our reputation for innovative cable management we’ll be checking scope to evolve some other traditional-type products. D-Line’s aim is always to provide exciting new options for installers and wholesalers who want to give best-value choices.

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Terry Adams, Technical Services Manager at Marshall-Tufflex, outlines how wholesalers can help installers to select the correct cable tray, including considerations such as materials, loading capacities, fire safety requirements and installation methods.

Cable trays are an ideal cable management solution for many applications. In busy commercial environments, cable tray can be used to support and route large quantities of electrical cable in a structured manner. They also provide easy access, allowing cables to be added, removed or re-routed. The perforated construction of cable tray also aids ventilation to help avoid overheating.

There is a wide range of cable tray options available, from smaller, light gauge products ideal for less demanding applications to heavyweight options engineered to support large numbers of cables of increased size and weight. Leading manufacturers will also have an extensive portfolio of components including bends, risers, tee pieces, crosses and lids to meet any installation requirement.

However, there are a number of factors that must be considered to ensure the correct products are selected, especially as this can impact the compliance of the installation with the IET Wiring Regulations.

The right material for the job

The first consideration is the type of cable tray that would be most suitable, and the biggest differentiator is the material. Metal cable tray, typically made from pre-galvanised steel is recommended for interior installations such as data centres, warehouses or commercial retail buildings. Usually available as light, medium or heavy duty gauges, metal cable tray is strong and simple to install. Look for systems that interconnect and bolt together without the need for separate couplers to speed up installation times.

PVC Cable Tray is lightweight and ideally suited for installation into environments where Metal Cable Tray cannot be used due to the corrosive nature of the environment. Suitable applications might be water treatment plants or high humidity environments where a non-corrosive installation is recommended.

For outdoor applications or where the cable management will be exposed to more harsh conditions, Glass Reinforced Polyester (GRP) may be the most suitable. GRP products are commonly used on rail, road, marine, industrial and petrochemical projects. This is because GRP products are highly resistant to corrosion, are UV resistant and effective at temperatures between -80 degrees and 130 degrees. GRP is also a low smoke zero halogen (LS0H) material, has excellent fire performance and withstands contact with many common chemicals. As well as being extremely robust, GRP is considerably lighter than aluminium or steel, making it easy to install and move around site.

Contractors working on transport projects, may also be looking for a supplier who are RISQS verified. RISQS is an independent qualification assessment of a supplier’s products and services.

Loading capacities

It is essential that the specified cable tray can support the weight of the cables installed, especially where heavier armoured cable is being used. It is often the case that cable management systems are overloaded with cables, increasing the risk of failure. To ensure the right product is chosen, installers should calculate the number and weight of the cables using information from the cable manufacturers. This figure can then be compared to the safe working load of the cable tray, again available from the manufacturer, to determine which product is required. Similarly, when providing advice on the support system, it is important to also account for the weight of the cable tray itself.

If the installation is likely to be expanded in the future with additional cables, it is worth recommending that installers select a product that provides a higher loading capacity than is currently required. This will ensure it is future-proofed and reduce the overall costs for end clients over the long term as the cable management will not need to be upgraded later at additional cost.

Fire safety

The correct choice of cable management system plays a crucial role in maintaining the safety of the building in the event of a fire and ensuring compliance with the requirements of the 18^th Edition of the Wiring Regulations. Where cable management systems fail due to the heat of a fire, the falling and fallen cables present a serious hazard to those evacuating as well as firefighters moving into and through the building. In fact, there have been a number of cases of firefighters losing their lives when they became caught in the cables and unable to escape.

In response to this hazard, Regulation 521.10.202 of the Wiring Regulations states that all cables should be adequately supported using non-combustible fixings to prevent premature collapse in the event of a fire. This means that cables need to be supported using a material with a melting point of 1000°C for up to 120 minutes.

It is important to note that it requires all cables to be fixed to prevent them falling, rather than just those in escape routes, as was stated in earlier editions of the regulations. Providing they are fixed to a fire-resistant element of the building’s fabric, steel cable trays are an ideal solution to meeting this requirement. The 18^th Edition states that: ‘cables installed in or on steel containment systems are deemed to meet the requirements of this regulation’. This is because, depending on the steel’s composition, it has a melting point of between 1200 and 1500°C.

Where products with a lower melting point are used, such as those manufactured from PVC-U or aluminium, the cables must be securely fixed to the structure of the building using fixings that will not disintegrate in fire. BEAMA has produced guidance on this topic which is referenced by the IET Wiring Regulations. In the ‘Prevention of Premature Collapse: A Guide to the Design, Installation and Inspection of Cable Management Systems’ document, BEAMA provides specific guidelines on maximum distances the cables can move in the event of a failure of the containment. Installers should refer to this guidance to ensure the installation is fully compliant.

Those working in wholesaler branches are ideally placed to help installers select products that will meet the requirement of the current project and ensure the installation is fully compliant with the regulations.

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As an essential part of a surface cable installation, D-Line’s Safe-D fire-rated clips – which can be fixed direct to surface or in PVC trunkings – have been designed following extensive research and development, with a host of technical features and installer benefits that not only deliver exceptional safety but also outstanding quality and value, making them an essential line for wholesalers seeking to provide the best for their customers.

To provide assurance and peace of mind, all D-Line Safe-D clips have been certified by Exova Warringtonfire and comply to 18th Edition regulations. This requires that non-combustable fixings are to be used for all new surface cable installations. D-Line Safe-D Clips can withstand temperatures 970°C for at least two hours, affording sufficient time to evacuate densely populated buildings and to prevent the potentially fatal risks for end users and firefighters of cable entanglement in a burning building, as well as being able to withstand levels of shock, vibration and water spray.

As well as U-Clips that can be fitted direct to a surface or in non-metallic trunking systems and Conduit Saddles that provide a modern look, the Safe-D range also includes F-Clips, the fire-rated, thumb-friendly, flexible cable support supplied in flat form with three fixing holes that can be folded in seconds to make a variety of shapes to most effectively secure cable installations. Labour saving, the wrap & lock adjustable clip comes in three sizes from 10-17mm to 22-26mm diameter.

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WISKA produces one of the widest ranges of cable glands, grommets and entries to provide a solution to the wiring of 18^th Edition compliant consumer units. In this article, the company takes a closer look at its range of entries and grommets and how they can be used as an alternative to standard cable glands.

TKS 32 – Membrane Tail Kit Solution

The TKS 32 is a direct result of WISKA listening to the demands of users and developing a product to suit those needs. One major issue that WISKA kept hearing was the size of the cable gland and its general “bulky” appearance when used in consumer units. The TKS offers a simple, quick fitting solution for tails, it has an M32 entry with 4 entries offering IP66 protection and cable retention to EN 62444. The TKS 32 is suitable for 16 or 25 tails and 10 or 16mm earth.

How does it work?

The TKS 32 is simply pushed into the entry point (no locknut is required) then pierce the required entry and insert tails or earth. The TKS 32 is quick and easy to install, and its low-profile design allows for a flush fitting helping to save on space.

Since its launch in 2017 the TKS 32 has gone on to win Professional Electrician & Installer Magazine’s Top Product Award as well the Electrical Industry Award for Domestic and Residential Product of the Year.

“At WISKA we are always looking to create solutions that offer an advantage over existing products on the market, the TKS 32 is a prime example of this” comments Callum Wilson, Distribution Business Development & Training. “The TKS 32 offers all the same features and benefits of a conventional cable gland tail kit solution however, its functionality, speed and low-profile design offer benefits that help everyone from wholesaler, electrician and consumer.”

QUIXX (EMT-F Kits) and QUIXX – Grommet Solutions

WISKA offer two excellent grommet options for the wiring of 18^th Edition consumer units. The first is QUIXX – EMT-F Kit – these are flame retardant, IP66 push-in grommets that come in a pack with various sizes (8 x M20, 3 x M25 and 3 x M32). Quick and easy to use, simply push the QUIXX grommet into your entry (as with the TKS 32 no locknut is required) pierce the membrane and insert your cable (ensuring you pull back slightly to get a good seal around the cable and membrane). QUIXX EMT-F can be used for single or multiple cables. The other alternative to QUIXX EMT-F is CLIXX. CLIXX offers IP66/67 protection and the added bonus of cable retention to EN 62444. Available in M16, M20 and M25 sizes CLIXX is designed for single cables only and can be used with twin and earth. CLIXX is simply pushed into your entry (no locknut required), pierce membrane and insert cables. CLIXX offers 75% assembly time saving compared to regular cable glands.

As you can see, WISKA can offer an excellent range of high-quality solutions for cable entries on 18^th Edition consumer units. To find out more about these products and display stand solutions for your WISKA Tail Kits contact WISKA UK Ltd direct on 01208 816062 or via e-mail info@wiska.co.uk, or visit https://www.wiska.co.uk/

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