Cable glands play a vital role in electrical and industrial applications by securing cables and protecting them from dust, moisture, and mechanical stress. Selecting the right cable gland material is essential to ensure durability, safety, and optimal performance in your specific application.

This guide explores the most commonly used cable gland materials—brass, stainless steel, aluminum, and nylon (plastic)—highlighting their advantages, disadvantages, and ideal use cases to help you make the best material choice for your installation.

The Importance of Cable Gland Material

Cable glands act as sealing and securing devices for cables entering electrical enclosures, machinery, or outdoor installations. The choice of material plays a crucial role in determining the performance, longevity, and safety of the overall system.

The selected material directly influences:

Durability: Determines resistance to environmental factors such as corrosion, temperature fluctuations, UV exposure, and mechanical impact.

Safety: Ensures protection against electrical faults, fire risks, and the ingress of dust, moisture, or chemicals, maintaining system integrity.

Suitability: Affects compatibility with specific cable types, insulation materials, and operating environments—from industrial plants to marine or explosive atmospheres.

Choosing the appropriate cable gland material is therefore not just a technical decision but a critical safety and reliability factor in any electrical installation.

Common Cable Gland Materials

Metal Cable Glands

Metal cable glands are preferred for applications demanding strength, durability, and environmental resistance. They perform exceptionally well in harsh industrial conditions where mechanical protection and grounding are essential.

Brass Cable Glands

Advantages:

High mechanical strength and long service life

Excellent corrosion resistance, especially when nickel-plated

Superior electrical conductivity for grounding purposes

Performs reliably in both indoor and outdoor installations

Disadvantages:

Heavier compared to plastic or aluminum types

Slightly higher cost than non-metal alternatives

Best for: General industrial applications, power generation plants, manufacturing facilities, and outdoor electrical systems.

Stainless Steel Cable Glands

Advantages:

Exceptional Strength and Durability: Maintain mechanical strength under heavy loads and extreme conditions.

Superior Corrosion Resistance: Chromium content forms a protective oxide layer, resisting rust in moist or salty environments.

High Temperature Tolerance: Suitable for applications involving heat exposure, such as furnaces or engine rooms.

Hygienic and Easy to Clean: Smooth surface prevents bacterial buildup—ideal for food, pharma, and medical equipment.

Aesthetic Appeal: Sleek finish enhances professional appearance; available in polished or brushed finishes.

Eco-Friendly and Sustainable: 100% recyclable with long service life, reducing waste.

Disadvantages:

More difficult to machine than brass

Higher energy consumption during production

Lower thermal conductivity than brass

Some grades are magnetic, which may interfere with sensitive equipment

Typical Uses:

Oil, gas, and petrochemical sectors

Marine and offshore environments

Food and beverage manufacturing

Pharmaceutical and healthcare fields

Renewable energy (solar, wind, hydro)

Railway and transportation systems

Aerospace and defense

Mining and heavy machinery

Aluminum Cable Glands

Advantages:

Lightweight yet mechanically robust

Offers decent corrosion resistance under normal conditions

A cost-effective alternative to brass and stainless steel

Disadvantages:

Less durable under heavy mechanical stress

Susceptible to corrosion in highly humid or salt-laden environments

Best for: Low to medium-risk industrial applications, electrical panels, and lightweight equipment installations.

Common Applications of Metal Cable Glands

Industrial Manufacturing and Machinery: Widely used in manufacturing environments to secure and protect cables exposed to vibration, dust, and oil. They ensure reliable electrical connections and mechanical stability in heavy-duty machinery and automation systems.

Power Plants and Electrical Distribution: Provide robust grounding and strain relief. Their ability to withstand high temperatures and electrical loads makes them essential for transformers, switchgear, and control panels.

Oil, Gas, and Petrochemical Industries: Particularly stainless steel and nickel-plated brass types are ideal for hazardous environments requiring chemical resistance and explosion protection.

Marine and Offshore Applications: Stainless steel glands are used extensively in ships, ports, and offshore drilling rigs to protect against moisture, salt, and mechanical impact.

Renewable Energy (Solar & Wind Farms): Ensure long-term durability against UV exposure, extreme temperatures, and weathering. Used in solar junction boxes, wind turbine control units, and inverter systems.

Railway and Transportation Systems: Required for vibration-resistant and fire-safe cable management in locomotives, signaling equipment, and infrastructure.

Food and Beverage Industry: Stainless steel glands are favored for their corrosion resistance and ease of cleaning, ensuring compliance with sanitation standards.

Non-Metal Cable Glands

Nylon Cable Glands

Nylon cable glands are ideal for applications where flexibility, ease of installation, and cost efficiency are key considerations. They are lightweight and provide reliable sealing in environments with moderate mechanical and thermal demands.

Advantages:

Lightweight and easy to install

Resistant to a wide range of chemicals and UV radiation

Cost-effective and corrosion-free

Disadvantages:

Less durable than metal glands

May deform or degrade under extreme heat or continuous mechanical stress

Best for: Indoor applications, telecommunications, control panels, consumer electronics, and small machinery.

Common Applications of Nylon Cable Glands

Electrical and Electronics Industry: Used in control panels, switchgear, and electrical enclosures to secure and insulate power or signal cables.

Telecommunications and Networking: Ideal for protecting fiber optic and data cables in communication cabinets, routers, and server installations.

Automation and Robotics: Ensure safe cable routing in robotic arms and motion control systems requiring vibration resistance.

Renewable Energy (Solar and Wind Applications): Provide reliable sealing and UV resistance for outdoor installations like junction boxes and inverter systems.

Automotive and Electric Vehicles (EVs): Used in EV charging stations, battery systems, and onboard electronic modules.

HVAC and Building Automation Systems: Facilitate secure cable connections in climate control equipment, sensors, and smart building networks.

Consumer Electronics and Appliances: Commonly found in home appliances, lighting fixtures, and electronic devices needing compact and cost-efficient protection.

Key Factors to Consider When Choosing a Cable Gland Material

Environmental Conditions

Harsh industrial settings → Stainless steel

Outdoor use → Brass or stainless steel

Indoor settings → Plastic glands

Temperature Resistance

Extreme temperatures → Stainless steel

Moderate temperatures → Brass or aluminum

Low-temperature environments → Polyamide

Chemical and Corrosion Resistance

Chemical/marine applications → Stainless steel

General industrial use → Nickel-plated brass

Mild chemical exposure → Polyamide

Cost Considerations

Budget-conscious → Plastic glands

Long-term investment → Stainless steel

Balanced option → Brass

Mechanical Strength Requirements

High strength needed → Stainless steel or brass

Low-stress applications → Polyamide

Electrical Conductivity Needs

High conductivity required → Brass

Non-conductive applications → Nylon or polyamide

Step-by-Step Guide to Cable Sealing and Termination

Prepare the Cable

Cut the cable to length and remove outer insulation carefully without damaging inner conductors. Keep wires clean and free of debris.

Place the Gland

Slide the cable gland onto the cable before termination. Position it correctly to allow proper alignment and future tightening.

Secure the Gland

Tighten the gland using a wrench until snug—ensure strain relief and dust/moisture sealing. Avoid overtightening to prevent damage.

Terminate the Cable

Connect inner conductors to terminals securely. Insulate all joints properly and verify no exposed wires remain.

Following these steps ensures a safe, durable, and reliable cable connection.

Top Mistakes to Avoid When Selecting Cable Glands

Using the Wrong Gland Size

Mismatched sizes lead to poor seals. Oversized allows contaminants in; undersized damages the cable. Always measure accurately.

Neglecting Environmental Conditions

Ignoring humidity, chemicals, or temperature can cause premature failure. Match the material to the environment.

Overtightening

Excessive force can crack insulation or break conductors. Tighten firmly but not excessively.

Avoiding these common errors ensures safer, longer-lasting installations.

Conclusion

Selecting the right cable gland material is key to ensuring durability and reliable operation of electrical equipment.

Brass offers strong mechanical and electrical performance at a balanced cost.

Stainless steel excels in corrosion resistance and suitability for extreme or hygienic environments.

Aluminum provides a lightweight, economical metal option for moderate conditions.

Nylon delivers cost-effective, non-conductive solutions for indoor and low-risk applications.

By considering environmental exposure, temperature, chemical resistance, mechanical needs, and budget, you can choose the optimal cable gland material for enhanced safety, efficiency, and long-term performance.