What Happens When You Alter or Modify Communications Cables

Recently, we encountered a situation where communications cables were encased in closed cell spray polyurethane foam (SPF) insulation.

This compound is used for thermal insulation in walls and attics—the same places you find fire alarm cables, coaxial cables and Category cables. When these areas are sprayed with insulation, the material also covers the cables installed in those locations. Many end-users and contractors don’t realize the damage this can cause. In fact, when they peel away the insulation, they may not see any physical damage to the cable at all. Just because you don’t see visible damage doesn’t mean performance hasn’t been impacted—and just because you can spray cables with insulation doesn’t mean you should.

Over the years, we’ve discussed the problems associated with painting cables. These sentiments hold true for other contaminants and chemical compounds as well, including:

• Abrasives
• Cleaners
• Corrosive residues
• Paint remover
• Plaster
• Other contaminants, such as SPF insulation

Informational Note No. 3 in National Electrical Code (NEC) Article 800.24, Mechanical Execution of Work, discusses the alteration of wire and cable properties when contaminant exposure occurs. In short, it states that use of any of the contaminants listed above “may result in an undetermined alteration of wire and cable properties.”

Why Cable Alteration Can Void Your Warranty

From our point of view (along with the industry’s), there’s one significant reason why you should never cover a cable in a contaminant: They aren’t designed for it! Generally, wire and cable products are not designed to be painted over, covered with spray insulation or exposed to water or chemicals. If wire and cable will be exposed to these types of impacts, specific products are available to withstand those environmental challenges. They’re often called tactical or industrial-grade cables.

It’s impossible to test the long-term impact of chemicals (such as isocyanates and thousands of others found in contaminants) on a cable’s mechanical, electrical and flammability properties.

Because these contaminants create unpredictable interactions with the cable jacket that call into question the long-term performance of the cabling system, there’s no way to determine cable life or performance in those installation scenarios. Negative impacts may result over time and won’t be apparent right away; in these situations, a “passing” test today doesn’t guarantee performance in the future.

That’s why our General Terms & Conditions specifically state that warranties will not be honored if a product is altered in any way:

Repairs to, alteration of or work done on the products without Belden’s prior written authorization shall void the warranty on our products.

Applying paint or SPF insulation is considered a significant modification to or alteration of a cable’s original construction. Because the consequences of these actions aren’t fully known, negative effects on a cable’s electrical and mechanical performance are a real possibility. This is why we can’t honor a warranty for a product covered in a contaminant.

Painting or spraying insulation also makes it impossible to determine how the cable will perform during flame or smoke performance tests required for UL testing compliance. Contaminants can act as a combustion source or even alter or degrade the compounds of the cable jacket, changing its flame and smoke ratings.

Furthermore, painting or spraying SPF insulation covers the cable jacket legend, which must be legible by the authority having jurisdiction (AHJ) for fire safety purposes.

Long story short: If a cable is painted or has any contaminant applied to it, then its warranty cannot be honored.

Other Ways to Void Your Cable Warranty

Applying a contaminant to your cable isn’t the only action that may void a warranty. It’s also important to make sure your cables are designed for your specific environment.

For example:

• Don’t use indoor cabling (CMR or CMP) in outdoor applications or environments with prolonged exposure to UV light. These cables don’t use a sunlight-resistant jacket compound; as a result, their performance will suffer.
• Don’t install communications cables in wet environments that aren’t manufactured to resist moisture. These cables cannot be exposed to any liquids. When they are, the liquid may be “wicked” into the length of the cable and negatively impact performance. Efforts to dry out the cable will only push moisture further into the cable.

Finding Practical Workarounds

In many cases, you can protect your cables while still accomplishing what you need to.

Make sure you communicate your needs and concerns to the construction team. Share this blog with them to avoid these problems on your own site. It’s always easier to avoid an issue instead of dealing with a problem after it occurs. If you see a potential issue on your site, then put a halt to it immediately to limit damage and negative effects. This may cause contention early on, but it will save everyone time, aggravation and costs in the long run.

For example, if you want to paint or apply SPF insulation to an area where communications cables will be present, then schedule that work before cable installation. If that isn’t possible, then make sure the exposed cables are removed or completely and securely covered first.

If you’re thinking about painting cables to achieve a desired jacket color, then don’t let them proceed! Belden can help. Instead of painting, we can guide you to the several standard jacket colors we offer—or discuss custom color options, whether you need different colors to differentiate cables or want the cables to blend in with the environment.

Have Your Cables Already Been Altered?

We understand that mistakes happen. If you discover that your communications cables have been altered or modified, then Belden will work closely with you to assist with remediation, removal and replacement of affected cables to make sure you don’t experience a decrease in performance.

If you have questions about altering or modifying communications cables that aren’t addresses here, please send me a note. I’m happy to answer them.

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