High Voltage Cable Heating Jackets
Proven solutions for straightening, bending and joining HV/EHV cables.
HeatXperts' high voltage cable heating jackets are designed to withstand the challenges of handling high- and extra-high-voltage (HV/EHV) power cables. Developed in close collaboration with European cable manufacturers and installation teams, our jackets provide consistent, controlled heat, enabling technicians to straighten, bend and prepare cables quickly and safely across production, testing, jointing and termination processes.
Why use heating jackets for high-voltage cables?
HV/EHV cables form the backbone of modern energy infrastructure, from national transmission networks and interconnectors to grid-scale renewables. While their robust construction ensures reliability, it also makes them extremely rigid, particularly in cold climates or for large conductor sizes. When engineers need to position a cable precisely, for example before jointing or when connecting to GIS, switchgear or transformers, the work can become slow, strenuous and error-prone without controlled heating.
Controlled, even heating matters because it:
- Softens the cable’s outer layers in a predictable way, improving pliability without damaging insulation;
- Reduces mechanical stress locked into the cable after production or handling;
It also shortens preparation time and increases repeatability from team to team and site to site.
Where heating jackets add the most value
Cable jointing
Shorter jackets (typically 1.0–1.5 metres) focus heat on the active work zone, enabling jointers to straighten and shape stiff cores with precision prior to applying joint kits. Consistent heat distribution reduces local stress, supports clean alignment and helps to deliver reliable, repeatable joints.
Cable terminations
For GIS, switchgear or transformer terminations, longer jackets (up to 2.0 metres) make it easier to guide the cable into the correct position. Even heating enables controlled bending, reduces the risk of insulation damage and improves the fit to equipment entries.
Manufacturing and testing
In factory environments, jackets facilitate pre-forming and stress relief between process steps and during QA. The result is faster throughput, more consistent inspection conditions and reduced strain from manual handling.
Cold-weather operations
At low ambient temperatures, cables become significantly stiffer. By restoring workability prior to jointing or termination steps, jackets help to ensure that projects remain on schedule throughout the colder months.
Note: cables cool rapidly in seawater during marine overboarding; it is best to apply heating to controlled preparation steps (e.g. joints, terminations, pre-forming) rather than using it as a substitute for installation engineering.
Why HeatXperts Heating Jackets – what sets them apart?
Our heating jackets are designed specifically for HV/EHV work. Unlike improvised heaters or general-purpose blankets, they provide uniform load density and repeatable temperature control across the entire contact area.
Core advantages:
- Uniform, controlled heat via a built-in PT100 sensor and detachable digital controller.
- A safe 90°C process limit is designed to reduce insulation stress and minimise jointing/termination failures.
- A modular design allows multiple diameters and working lengths to be covered, with units able to be combined when needed.
- They offer fast, practical setup with adjustable straps and plug-and-play power.
- Teams benefit from predictable handling characteristics, improved ergonomics and a consistent process that can be scaled across shifts and sites.
Technical specifications (standard configuration)
- Cable diameter range: 60–160 mm (custom sizes available)
- Available lengths: 1.0 m, 1.5 m, 2.0 m (for joints, terminations and preforming)
- Voltage options: 230V or 110V AC, 50/60Hz
- Power rating: 1500 W heating element
- Temperature control: PT100 sensor with detachable digital controller (adjustable set-point)
- Set-point / Max temp: 90 °C operating – thermal fuse at 130 °C for safety
- Outer material: Silicone-coated fibreglass – splashproof and durable
- Thermal insulation: 6 mm high-temperature glass fibre
- Fastening: Quick-fit adjustable straps – no tools required
- Ingress protection: IP54 (controller must be protected from direct exposure)
- Plug type: Schuko, UK, US, or as specified
Heating times depend on cable cross-section, ambient temperature, and insulation. The following table gives typical durations for heating up to 80 °C:
Typical heating times
- 400 mm² cable: approx. 4 hours to 80 °C (176 °F)
- 1200 mm² cable: approx. 5 hours to 80 °C (176 °F)
- 2500 mm² cable: approx. 6 hours to 80 °C (176 °F)
Key benefits for manufacturers and installers
- Faster installation prep: Quickly straighten and position HV cables with consistent results
- Controlled, even heating: Reduces risk of hotspots, damage, and operator error
- Repeatable quality: Achieve uniform results across teams and projects
- Better ergonomics: Requires less force when bending or aligning stiff cable cores
- Reliable performance: Stable temperature, robust materials and easy handling in field use
- Flexible usage: Ideal for jointing, terminations, preforming, and cold-weather work
Selection guide: choosing diameter and length
Selecting the right jacket is simple: match the jacket diameter range to your cable outer diameter (OD), then pick the length that fits your task.
- Cable OD: ensure the 60–160 mm coverage matches your cable's outer diameter.
- Task type: Jointing: 1.0–1.5 m keeps heat where you need it and improves the straightening and shaping of cores. Terminations: up to 2.0 m provides the working length needed to guide the cable into equipment.
- Ambient conditions: In colder environments, consider a longer heated section to compensate for heat loss.
- Power supply: Choose a 230 V or 110 V model to match the site's power requirements and ensure compliance.
If you’re unsure, our team can recommend a setup based on your cable specifications and work sequence.
Typical process steps
Preparation
Confirm the cable outer diameter (OD) and select the appropriate jacket. Inspect the work area, PPE and site power.
Placement
Wrap the jacket evenly around the cable and secure the straps to ensure consistent contact.
Control setup
Connect the detachable controller, select the target set-point (90 °C safe process) and monitor the display.
Conditioning
Allow the cable to reach the desired pliability and avoid sharp bends during the heating process.
Manipulation
Straighten or shape the cable smoothly and methodically into the required position.
Stabilisation
Allow a brief conditioning/cooling period as per your internal procedure before applying the joint or termination.
Finalise
Remove the jacket and perform the final QA checks before proceeding to the next step.
Why is the process limit 90 °C?
Some systems allow set points up to 100 °C or beyond. However, our field experience with cable manufacturers indicates that 90 °C provides a safer and more consistent process for handling HV/EHV. It provides sufficient softening to enable efficient work while helping to minimise insulation stress and downstream issues.
Benefits of 90 °C control:
- Reduced risk of overheating and insulation degradation.
- It helps lower failure rates during jointing and terminations.
- It improves repeatability, which is an important factor for QA and warranty contexts.
- It keeps technicians within a conservative, predictable operating window.
Safety & best practices
HeatXperts jackets are designed with safety in mind: They feature PT100 feedback, a clear digital interface and integrated thermal protection. As with any site work, follow local electrical safety practices, PPE requirements and lock-out/tag-out procedures.
Practical tips for achieving safe and consistent results:
- Use the correct voltage (230 V/110 V) according to site standards, and ensure you have the necessary protection (e.g. RCDs if required).
- Do not exceed the recommended set points and monitor the controller during the warm-up process.
- Keep the straps snug to ensure even contact and avoid loading the cable with sharp bends while heating.
- Allow for the necessary conditioning/cooling time before fixing or handling again.
- Protect controllers from direct rain and avoid allowing water to pool on live electrical components.
FAQs
What cable sizes do the standard jackets cover?
Standard models cover an outer diameter (OD) of 60–160 mm. For cables outside this range, we can manufacture custom sizes.
Which length should I choose for my task?
As a general guideline, 1.0–1.5 metres is ideal for jointing, and up to 2.0 metres is suitable for terminations and equipment entries. However, your ambient conditions and work sequence may also influence the choice.
Can we use jackets outdoors?
Yes, in typical site conditions. However, protect controllers from direct rain, follow local electrical safety requirements and ensure proper cable support during heating and manipulation.
Why limit the process set-point to 90 °C?
This provides a reliable operating window that reduces insulation stress and jointing/termination failures, ensuring consistent QA and long-term reliability.
Do you support 110 V sites?
Yes, standard models are available in 230 V and 110 V configurations.
Do you offer custom manufacturing?
Absolutely. We can customise lengths, diameters, shapes and controller/plug configurations to suit your project.
Custom manufacturing
Not every project is standard. HeatXperts provides custom heating jackets when you need special diameters, extended lengths, non-standard geometries or tailored controller/plug options. If you have a unique process or demanding environmental conditions, our engineering team will design a bespoke solution to fit your exact requirements, ensuring your workflow remains safe and efficient.
Why choose HeatXperts?
Industry experience
Years of collaboration with European cable manufacturers and onshore installation teams.
Proven results
We have deployed our solutions across production facilities and field operations to reduce downtime and rework.
Safety by design
Controlled temperature and thermal protection with robust materials and insulation.
Fast delivery
Standard jackets in stock for rapid European shipping.
Customised solutions
Tailored lengths, diameters, controllers and plug types to fit your exact application.
Support you can trust
Direct access to product specialists for assistance with selection, setup and best practices.
With HeatXperts, you get more than just a heater — you get a repeatable, reliable process and a partner that is focused on your operational success.
Improve your HV cable handling process!
Straightening and bending HV cables no longer has to be slow or risky. HeatXperts' high voltage cable heating jackets deliver uniform, controlled heating, making preparation faster, safer and more consistent, whether you're working in a factory or on site.
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