James Daniels, business unit manager at BASEC, part of Kiwa, looks at how striking the correct balance between materials optimisation and cost reduction is helping to meet market demands for both innovation and compliance in cable manufacturing – and the role electrical contractors can play in furthering this process:
Strict regulations govern the manufacture of cables for commercial, industrial and public settings, ensuring they do not compromise fire safety, electrical integrity and environmental impact. In particular, the Construction Products Regulation (CPR), the UKCA marking scheme and the updated BS 7671 – the 18th Edition of the Wiring Regulations all set out detailed stipulations on performance.
Compliance procedure
Power, control and communication cables installed in buildings and civil engineering work must comply with CPR standard EN 50575. Meanwhile, testing and labelling of the fire performance of cables is mandatory. Cables can vary between Aca (non-combustible) and Fca (flammable), with the commonest required classification being Eca or higher. High risk public buildings may require Cca or B2ca.
A Declaration of Performance (DoP) must also be prepared and retained for at least 10 years and its reference and classification must be shown on all cable packaging. In the UK, products and/or, depending upon type, their packaging, must also carry the UKCA mark or the CE mark, which demonstrates compliance with the CPR. The UKCA mark requires products to be tested against the EU (EN) standards used for CE marking. Meanwhile, all cables should meet specific British Standards depending on their intended use.
Legislation also covers the manufacturing process itself. This includes the Restriction of Hazardous Substances (RoHS), restricting the use of materials such as lead and cadmium in cable production, and Registration, Evaluation, Authorisation & Restriction of Chemicals (REACH), which covers the safe use of chemicals in products.
Competitive element
Manufacturers must operate within highly stringent parameters to guarantee quality, safety and compliance. Yet they must also innovate to drive forward quality and performance and so remain competitive. Markets evolve rapidly and expectations change with them.
The growth of smart cities is precipitating demand for cables that are able to incorporate sensors and data transmission capabilities. Meanwhile, durable high voltage cables are in increasing demand for renewable energy applications such as offshore wind, solar and hydrogen power.
In all applications, however, compliance is proving for many to be a catalyst for innovation, rather than a constraint, and is helping to identify potential failures and hazards before they occur. This emanates from the adoption of strategies which embed quality and reliability from the outset of the production process.
Efficiency drive
The relentless innovation of advanced materials, as well as harnessing of technologies such as AI and sector specific enterprise resource planning (ERP) systems, is accelerating the pace of innovation and overall manufacturing efficiency across the sector. They are also helping to drive down waste and support the achievement of sustainability goals.
How, then, can electrical contractors support this continued drive for excellence and so assure their customers of the highest standards of safety and performance from the products they recommend and supply? Their role in influencing market behaviour is in fact a vital one. They can act as a critical line of defence against substandard products by enforcing strict standards when it comes to specification, while favouring supply partners with recognised quality certifications.
Tried and tested
The procurement process is key. Contractors should specify and purchase only cables bearing independent certification such as BASEC, which demonstrates the cable has been tested to recognised standards. Where the BASEC mark or logo is displayed on cable or packaging, it reliably shows that the product is continuously tested, and the manufacturer audited, to ensure maintained performance and the required levels of safety and quality.
It is worth noting that independent, accredited third-party product approvals, such as the Certificate of Assessed Design (CAD) from BASEC, play a vital role in validating the performance of new and innovative products that may not yet be fully addressed by existing standards. BASEC works closely with manufacturers, alongside traders and end users where appropriate, to thoroughly evaluate both the design intent and practical realisation of the product. This collaborative approach ensures that all relevant safety, quality and performance requirements are identified and rigorously applied.
Through a combination of detailed technical assessment, informed interpretation of existing standards and the application of established best practices, BASEC can develop a robust and proportionate testing regime tailored to the innovation in question. In doing so, it provides an independent and authoritative review that not only confirms suitability and compliance but also delivers a level of confidence and reassurance comparable to that associated with more established, widely standardised products.
Reducing the risk
The supply of full details when ordering, including British or international standards, cable codes, conductor cross-sections and specific manufacturer will help to minimise the risk of being offered lower quality or unaccredited alternatives. Sourcing directly from original equipment manufacturers (OEMs) or approved, reputable distributors also eliminates the chance of receiving substandard or counterfeit products.
The process also encourages manufacturers to move away from traditional PVC by specifying low smoke zero halogen (LSZH) compounds, which have been shown to reduce toxic fumes in enclosed spaces. There is also scope to actively request modern, high performance cables, such as those compliant with A4:2026 for smart buildings and EV hubs, providing a further incentive for suppliers to update their inventories.
Trusted partners
The focus of procurement should always be on the establishment of long-term partnerships with trusted manufacturers rather than relying on transactional purchasing. This approach will again encourage manufacturers to invest in quality rather than cutting corners.
Products should be rigorously checked on receipt to ensure the manufacturer identification is present. Deliveries should be inspected for any discrepancy against the product specified, with any non-compliant items immediately rejected. A robust quality management system such as ISO 9001 should be implemented to ensure a record of which cables have been delivered to each project, ensuring accountability from supplier to final installation.
A further way to optimise the supply chain comes via the use of supplier questionnaires to evaluate their environmental, social and governance (ESG) performance and encourage adoption of ISO 14001 and ISO 45001. Contractors can also request evidence of ethical sourcing and compliance with REACH and RoHS regulations.
When it comes to installation, by adopting high quality and compliant installation practices on-site, contractors set the standard for what is acceptable. Meanwhile, informing manufacturers and wholesalers about installation issues, such as difficulties with stripping, will ensure these are addressed promptly.
Supply and demand
By demanding transparency, insisting on independent testing and certification through third-parties such as BASEC and prioritising safety over purchase price, electrical contractors can drive compliance, quality and innovation throughout the supply chain. This reduces the risk of future cable failures and forges ever stronger partnerships with their own customers as a result.
