Ask the Wire Experts:
STREET LIGHTING CABLE

Cable in roadways, bridges, and tunnels is used to connect lighting controls, traffic monitoring systems, and GPS signaling devices. Without reliable cable, we lose this functional transportation network. Here’s what to consider when selecting the right low voltage cabling solutions for DOT projects.
 

TOP TIPS FOR ROADWAY LIGHTING

WIRE AND CABLE

#1 Insulation Durability

PROBLEM: Roadway projects often involve complex layouts with long runs and multiple 90-degree bends in underground conduit. These installation conditions can cause damage to cable if the wrong insulation type is used.

SOLUTION: That’s why XLPE insulated cables (XHHW-2/USE-2) are recommended for DOT projects. This insulation is more resistant to abrasions with almost five times the crush resistance of THHN/THWN-2. XLPE cables are durable enough to outlast the pull and prevent cable fault, while still being flexible enough to bend with ease.
 

#2 Temperature Rating

PROBLEM: Extreme temperatures can negatively impact roadway cable exposed to the elements when installed outside of the recommended ratings. Cables like THHN/THWN-2 with substandard insulation compounds can melt under high heat or freeze and crack in extreme cold.

SOLUTION: It’s important to select cables with temperature ratings suitable for the local climate. XLPE insulation has a higher maximum and lower minimum temperature rating than thermoplastic insulations (PVC). XLPE is a thermoset compound. During the curing process, the polymers chemically crosslink so the insulation retains its shape and will not remelt under high heat or freeze in extreme cold (-40°C).
 

#3 Corrosion Resistance

PROBLEM: Roadways are treated with de-icing salts, corrosive chemicals, and excess moisture that can lead to premature cable failure. The cable’s insulation and conductors can corrode overtime.

SOLUTION: To prevent accelerated corrosion, use tinned copper conductors. Adding a layer of tin coating on the copper conductors will protect against oxidation that weakens the bonds of the metal and makes it brittle.
 

#4 Smart Technology Phase ID Color Codes

PROBLEM: Roadways are evolving to incorporate smart signaling and surveillance technologies. These devices often require cables with non-standard phase identification.

SOLUTION: Contractors will need to source black, red, white, green, and purple XLPE insulated cables to meet these specs.
 

XLPE CABLING SOLUTIONS

XLPE insulated cables enhance the overall reliability of transportation networks and reduce the risk of failures and disruptions—resulting in improved safety standards, operational resilience, and streamlined maintenance.
 

If you’re looking for a wire and cable partner for roadway projects, turn to Service Wire. We’re the experts in XLPE single and multi-conductor cabling solutions. We can supply standard street lighting cable in black, red, and white as well as non-standard green and purple color codes for video surveillance and GPS specifications.
 

Our high service levels and on-hand stock in our three nationwide facilities allow us to ship quickly and fast-track your roadway projects. Contact your rep to learn more about our transportation infrastructure products.

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