Wire Rope Cable Coatings

Choosing The Right Cable Coating

Choosing the right coating for your wire rope is just as important as selecting the correct diameter or construction. Coatings enhance durability, safety, and performance by protecting the cable from abrasion, weather, and chemical exposure. The three most common options—vinyl (PVC), nylon, and bare (uncoated)—each serve different purposes depending on your environment and application. Below, we break down the pros and cons of each to help you select the best option for your project.

Vinyl (PVC) Coated Wire Rope

Vinyl coated wire rope—also referred to as PVC coated wire rope—pairs the strength of a galvanized or aircraft cable with a durable, flexible vinyl (PVC) jacket. This coating protects against abrasion, moisture, UV exposure, and chemicals, while also preventing wire fray and making the cable easier to handle. The result is a safe, long-lasting solution for both indoor and outdoor applications.

PVC is more flexible, waterproof, UV resistant, and cost-effective than nylon, making it the preferred choice for general-purpose and outdoor applications.

Key Features:

• Material: Galvanized or stainless steel
• Coating Type: Extruded vinyl (PVC), available in clear or colored options
• Coating Thickness: Typically ranges from 0.010″ to 0.030″ depending on application
• Available Diameters: 1/16”, 3/32”, 1/8”, 3/16”, and 1/4” (measured with coating)
• Temperature Range: -20°F to +150°F (-29°C to +65°C)

Benefits:

• Flexible and easy to route around corners or equipment
• Shields against UV rays, moisture, and mild chemicals
• Provides a softer exterior for improved safety and grip
• Available in multiple colors for visibility or coding
• Cost-effective and ideal for both indoor and outdoor use

Available Sizes & Compatibility

PVC coating can be applied to most wire rope diameters up to 3/8″. It’s also compatible with standard end fittings and terminals such as cable eye ends, swage fittings, and thimbles, though coatings are typically stripped in the crimp area for optimal strength.

Nylon Coated Wire Rope

Nylon coated wire rope combines the high tensile strength of galvanized or stainless steel cable with the added protection and flexibility of a durable nylon jacket. The nylon coating helps reduce friction and abrasion, protects against corrosion, and extends the rope’s service life.

While it’s less flexible than PVC, nylon is harder, offering greater strength and abrasion resistance, especially in high-friction or high-cycle applications.

Unlike PVC, nylon is not ideal for prolonged outdoor exposure, as it tends to degrade under UV rays. However, it excels in demanding environments where cables face mechanical wear or frequent movement.

Key Features:

• Material: Galvanized or stainless steel core
• Coating Type: Extruded nylon (typically black or clear)
• Coating Thickness: Ranges from 0.010″ to 0.030″ depending on application
• Available Diameters: Common sizes include 1/16”, 3/32”, 1/8”, 3/16”, and 1/4” (measured with coating)
• Temperature Range: -40°F to +200°F (-40°C to +93°C)

Benefits:

• Higher strength and better abrasion resistance compared to PVC
• Withstands repeated mechanical contact (e.g., pulleys, cable guides)
• Strong chemical resistance (but not ideal for prolonged sun exposure)
• Hard, tough jacket suited for high-cycle or industrial applications

Comparing Wire Rope Coatings

When selecting a wire rope or cable assembly, the coating type plays a big role in performance, durability, and safety. Below is a quick guide to help you decide which option is best for your application:

In summary, Vinyl/PVC is more flexible, waterproof, UV resistant and cost-effective whereas Nylon is harder and offers better strength and abrasion resistance.

Wire Rope Coating Comparison Chart

Estimated Breaking Strength by Coated Diameter

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