Special Cable

Purpose-Engineered
Special Cables

Built by Elegar Kerpen for the environments where standard cables simply cannot survive.

Let's Connect View Specifications
Armoured special cable cross-section with elastomer insulated cores
Armoured Special Cable · Heavy-Duty Sheath / Elastomer Cores

Disclaimer: Cross-section shown is a representative illustration; actual product construction and dimensions may vary.

Up to 25 Years
Extended Service Life
8 Sectors
Industries Served
Class 1 / 2 / 5
Conductor Constructions
7 Standards
BS EN · IEC · BS · VDE · UL · DEF · ANS
Offshore oil and gas platform in the North Sea powered by special cables
About this product

Global Special Cables

When standard cables fall short, engineered solutions take over. As a leading special cable manufacturer and one of the most trusted wires and cables manufacturers in India, Elegar Kerpen designs cables tailored to your exact operational requirements, built to perform where conventional cables simply cannot survive. From extreme temperatures to continuous mechanical stress, we deliver precision where it matters most.

What a special cable does
Every special cable we manufacture is engineered with advanced materials, customised construction, and rigorous testing to meet the unique demands of your application. Whether you need composite, fire-resistant, armoured, or robotic cables, our solutions ensure maximum reliability, regulatory compliance, and long-term performance across the most challenging industrial environments.
Use cases

Applications of Special Cables

Engineered to perform across a wide range of demanding industries where conventional cables fail prematurely.

01
Industrial Manufacturing
In factories and production facilities, special cables withstand continuous motion, oil exposure, extreme temperatures, and aggressive chemical environments that would rapidly degrade standard cables.
02
Robotics & Automation
Modern automated systems demand cables engineered to endure millions of bending and torsional cycles while maintaining consistent electrical integrity and signal quality throughout their lifespan.
03
Power Generation
High-temperature special cables are critical for power plants, solar farms, and wind turbines, where extreme operating conditions and high electrical loads make standard solutions unsuitable.
04
Marine & Offshore
Specially engineered to resist water ingress, salt corrosion, and deep-sea pressure, ensuring reliable power transmission and data communication across offshore platforms and underwater installations.
05
Mining & Oil/Gas
Operating in some of the world's most hazardous environments, armoured and chemical-resistant cables deliver dependable performance under extreme mechanical impact and explosive atmosphere conditions.
06
Automotive & Aerospace
Electric vehicles and aircraft rely on lightweight, high-performance special cables to manage demanding electrical loads while meeting strict safety, space, and weight requirements.
07
Telecommunications
Hybrid and submarine cables transmit critical data across vast distances, including deep underwater routes, where signal integrity, durability, and long-term reliability are non-negotiable.
08
Building & Infrastructure
Fire-resistant and flame-retardant cables maintain circuit integrity during emergencies, keeping alarms, sprinklers, and evacuation lighting fully operational when lives depend on it.
Technical data

Special Cable Construction

Indicative construction parameters. Every special cable is built to the specification your application demands, defined together with our engineering team.

Special Cable Construction Parameters
ConductorAnnealed tinned copper wires — Solid (Class 1), Stranded (Class 2) or Flexible (Class 5), complying with IS 8130-1984
Separator TapeSuitable material separator tape may be applied over the conductor
InsulationGeneral service elastomer Type IE1 / Heat-resisting elastomer Type IE2 / Silicone rubber Type IE5, as per IS 6380-1984
Core IdentificationColoured insulation, numbered PE tape, coloured proof tape or numbered printing
FillersNatural or synthetic fibres or elastomer, suited to the operating temperature and compatible with the insulating material
SheathGeneral service sheath Type SE1 / SE2; Heavy-duty sheath Type SE3 / SE4, as per IS 6380-1984
ConstructionApplication-specific — advanced insulation materials, precision shielding and optimised build to match exact operational demands
Service LifeUp to 25 years under specified operating and installation conditions
Standards ComplianceBS EN, IEC, BS, VDE, UL, DEF, ANS
Compliance

Special Cable Standards

BS EN
European Norms
IEC
International Electrotechnical
BS
British Standards
VDE
German Electrotechnical
UL
Underwriters Laboratories
DEF
Defence Standards
ANS
American National Standards
Product enhancements

Additional Properties

Depending on the application, the cable can be engineered with:

Composite, armoured, fire-resistant or robotic constructions
UV-resistant jackets for prolonged outdoor and rooftop exposure
Moisture barriers and water-blocking for marine and submarine routes
Chemical, oil, acid and alkali resistant insulation systems
Silicone rubber (Type IE5) for elevated-temperature service
Continuous-flex construction rated for millions of bend and torsion cycles
E-beam cross-linking for enhanced thermal and mechanical strength
RoHS & REACH compliance
Product advantages

Why Elegar Kerpen Special Cables?

Decades of engineering expertise combined with cutting-edge manufacturing, from first consultation to final delivery.

Application-Specific Engineering
Every cable is custom-built with advanced insulation materials, precision shielding and optimised construction to match your exact operational demands.
ISO-Certified Manufacturing
Manufacturing excellence backed by certified quality systems and rigorous in-house testing at every stage of production.
Multi-Standard Compliance
Manufactured to BS EN, IEC, BS, VDE, UL, DEF and ANS, ensuring full regulatory compliance and certified performance.
Advanced E-Beam Technology
In-house electron beam cross-linking delivers superior thermal, mechanical and chemical resistance over conventional compounds.
Up to 25-Year Service Life
Extended operational life that reduces maintenance costs and minimises unplanned downtime across the asset lifecycle.
Proven Global Presence
Supplying engineered cable solutions to demanding projects across more than 40 countries and multiple industry sectors.
End-to-End Project Support
A dedicated technical team supports you from initial consultation through to delivery, ensuring the right solution every time.
Lower Cost of Ownership
Reliability where it matters most translates directly into fewer replacements, less downtime and superior total cost of ownership.
Support FAQ

Frequently Asked Questions

Find answers to frequently asked questions related to Elegar Kerpen special cables.

What makes special cables different from standard cables?
Special cables are custom engineered to meet specific application requirements that standard cables simply cannot fulfil. They are designed with advanced materials, specialised insulation, unique construction methods, and targeted protective features, ensuring reliable performance in extreme temperatures, harsh chemicals, continuous mechanical stress, or hazardous environments where conventional cables would fail prematurely.
Are special cables suitable for outdoor and harsh industrial environments?
Yes. Special cables are specifically designed to perform reliably in the most demanding outdoor and industrial conditions. Depending on the application, they can be engineered with UV-resistant jackets, moisture barriers, armoured protection, and chemical-resistant insulation, making them fully capable of withstanding extreme weather, mechanical impact, and corrosive industrial atmospheres.
Can special cables be used in continuous-flex or high-movement applications?
Absolutely. Flexible and robotic special cables are specifically developed to endure millions of bending, torsional, and tensile cycles without compromising electrical integrity or signal quality. They are widely used in robotics, automated machinery, drag chains, and any application involving continuous or repetitive mechanical movement.
Do special cables require specific joints, connectors, or terminations?
Yes. Most special cables require application-specific joints and terminations designed to match their unique construction and operating conditions. Using incorrect accessories can compromise the cable's performance and safety, so it is essential to follow manufacturer-recommended installation guidelines and use certified connectors, shielding terminations, and strain relief devices.
How long do special cables last?
When manufactured to international standards and properly installed, special cables can last up to 25 years. The actual lifespan depends on operating temperature, electrical loading, environmental exposure, installation quality, and routine maintenance practices.
Can you supply custom special cable configurations?
Yes. Elegar Kerpen specialises in manufacturing fully customised special cable configurations tailored to your exact application requirements. From conductor material and insulation type to shielding methods, jacket composition, and overall cable construction, our engineering team works closely with you to develop the right solution.
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