Dual Extrusion HALAR/HMWPE Cable

One of the major causes of deep anode failures is the failure of cable insulation. This is especially evident in areas where brackish water is present in the ground. In this environment, anodes generate reactive gases such as chlorine and nascent oxygen. These gases cause rapid deterioration of conventional HMWPE insulation. Cathodic protection cable insulated with HALAR fluoropolymer is especially suited for deep anode lead wires. HALAR fluoropolymer is inert to reactive compounds and has an outstanding ability to prevent the passage of gases. Laboratory and field evaluations indicate that HALAR fluoropolymer insulated lead wire can extend the life of deep anode installations. The cable is composed of stranded copper wire covered by two layers of insulation. The outer insulation layer is made from high molecular weight polyethylene (HMWPE). It exhibits superior dielectric and tensile strength, and provides mechanical protection to the cable. The material is also resistant to water intrusion and is not affected by most organic or inorganic substances. The inner or primary insulation is composed of HALAR, a fluoropolymer. This insulating material demonstrates exceptional chemical resistance. In the presence of chlorine, hydrochloric acid, sulfuric acid, or other strong oxidizing agents the material remains stable. Further, it will not deteriorate when exposed to petroleum hydrocarbons which are encountered in numerous cathodic protection applications. The dual extrusion HALAR cable is made specifically for cathodic protection applications. It can withstand considerable abuse during installation.

HALAR/HMWPE Dual Extrusion Cable

Sizes and Specifications:

Item Number

No. of Strands

Circular Mils

AWG Diameter

Inner Layer Thickness

Outer Layer Thickness

Nominal Diameter

Weight per 1000 ft

DC Resistance at 20° C




0.142 in

0.020 in

0.065 in

0.32 in

81 lb

0.652 Ω/Mft




0.179 in

0.020 in

0.065 in

0.32 in

116 lb

0.411 Ω/Mft




0.225 in

0.020 in

0.065 in

0.32 in

170 lb

0.258 Ω/Mft




0.283 in

0.020 in

0.065 in

0.32 in

254 lb

0.162 Ω/Mft

Conductor: The copper conductor shall be Class B stranded, compressed, annealed, uncoated copper in accordance with ASTM B 3 and B 8.

Identification: The cable shall be surface ink printed with: "Conductor Size AWG, CU, Manufacturer, HALAR/HMWPE CATHODIC PROTECTION CABLE."

Test: The completed cable shall be tested in accordance with the requirements of ICEA S-61-402, Part 6.

Typical Applications:

HALAR/HMWPE cable is designed for anode lead wires in a wide range of environments. Due to its dual insulation construction, it can be installed directly in native soils or submerged in fresh, brackish, or salt waters. The cable is ideal for deep anode bed installations where chlorine and hydrogen gases are generated. The HALAR insulation will not become brittle at temperatures down to (-80°F) and will maintain dimensionally stability and dielectric strength at temperature up to 250°F. It is highly resistant to notch propagation.


This specification describes a special single conductor size 8 AWG-2 AWG, HALAR insulated. High Molecular Weight Polyethylene jacketed cable designed for use as a direct burial feeder in deep anode ground-bed cathodic protection systems. The cable is ideally suited for use in harsh chemical environments involving brackish water, sour gas, chlorine, acids, alkalis, and petroleum based solvents. The cable is suitable for use at voltage up to 600 volts ac or dc.

Applicable Standards:

  • ASTM Specifications B 3, latest edition, for Soft o Annealed Copper Wire
  • ASTM Specifications B 8, latest edition, for Concentric-Lay Stranded Copper Wire
  • ASTM Specifications D 1248, latest edition, for Polyethylene Plastics Molding and Extrusion Materials.
  • ICEA Standard S-61-402/NEMA Standard WC5 for Thermoplastics insulated Wire and Cable.


  • The conductor shall be insulated with an extruded layer of natural HALAR ECTFE fluoropolymer as a primary insulation.
  • The average thickness shall be 20 mils. The minimum thickness at any point shall be not less than 90% of the specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping.


  • A black High Molecular Weight Polyethylene jacket having both insulating and jacketing properties shall be extruded over the primary insulation. The jacket, before extrusion, shall comply with the physical and electrical requirements of ASTM Specifications D 1248 for Type 1, Class C, Category 5, Grade E-5 and J-1 material.
  • The average jacket thickness shall be 65 mils. The minimum thickness shall be not less than 80% of the specified average thickness.


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