Lighting cables are absolutely everywhere. In your home, in your office, in public buildings, in security systems, on film sets, in complex machinery and much more. Anywhere that lighting is required, a lighting cable is needed to safely deliver electrical power to the equipment.
However, with so many possible environments and applications, there’s a wide range of lighting cable types, cable sizes and constructions to choose from. From simple lighting circuits to highly specialised industrial lighting control systems, selecting the correct cable can be challenging.
With this in mind, we’ve created a complete guide to Lighting Cable design, construction and applications to help you understand the different options available.
What is a lighting cable?
A lighting cable is an electrical cable designed to deliver power or control signals to lighting equipment such as lamps, floodlights, LED lighting systems and stage lighting fixtures.
These electric cables form part of wider electrical systems and lighting control networks, enabling reliable power delivery and safe operation across a wide voltage range.
Depending on the application, lighting cables may be required to carry power, transmit control signals, or combine both functions within a single cable assembly.
For standard lighting installations, general-purpose cables may be suitable. However, many commercial and industrial applications require custom lighting cables designed specifically for the operating environment. This may involve specialised materials, reinforced construction or enhanced cable shielding to ensure safe and reliable performance.
Cable vs flex cable
It’s common for the terms cable and flex cable to be used interchangeably, but they serve slightly different purposes:
- A lighting cable usually refers to the fixed electrical cable used within an installation to distribute power or control signals.
- A flex cable, on the other hand, is designed to provide greater flexibility and is often used as a general supply lead for portable lighting equipment or adjustable lighting fixtures.
Flex cables are typically constructed with tinned copper strands, which improve flexibility and reduce the risk of fatigue when the cable is repeatedly bent or moved. These strands are protected by insulated plastic layers and a PVC outer sleeve, ensuring electrical safety and durability.
In more complex lighting systems standard flex cables may not provide the required performance. In these cases, a custom lighting cable solution may be required.
Lighting cable construction
Lighting cables can range from small single-core cables to large multicore lighting control cables designed to carry significant electrical loads or transmit complex signals.
Although designs vary depending on the application, most cables for lighting share several common cable components.
Conductors
The conductors inside the cable are typically made from copper wires, chosen for their excellent electrical conductivity. In flexible cables, these conductors are often made from tinned copper strands to improve durability and resistance to corrosion.
Insulation
Each conductor is covered with insulated plastic or PVC insulation to prevent electrical leakage and protect the integrity of the cable.
Fillers and internal structure
Some cables include polyester fillers between conductors to maintain the cable’s shape and improve structural stability.
Protective sheath
Finally, the cable is protected by a PVC cable jacket, which provides mechanical protection and resistance to environmental factors. For demanding environments, lighting cables may also include additional protective layers such as:
- Aluminium/polyester screen shielding
- Low Smoke Zero Halogen (LSZH) insulation
- Steel Wired Armoured cable (SWA armoured version)
LSZH cables are particularly important in public buildings and transport infrastructure because they reduce smoke and toxic gas emissions during a fire. These cables are tested according to recognised standards including:
- IEC 61034-1 & 2
- IEC 60754-1 & 2
Lighting cable sizes and cable selection
Selecting the correct cable size is an essential part of designing any lighting system. The appropriate cable size depends on several electrical and environmental factors, including:
- Current-carrying capacity
- Circuit resistance
- Circuit length
- Volt drop
- Loop impedance
- Installation environment
Electrical engineers often use a cable size chart to determine the appropriate conductor size for a particular application. These calculations ensure the cable operates within acceptable voltage limits while maintaining safe operating temperatures.
Lighting cable design must also consider derating factors, which can reduce the effective current capacity of a cable. These factors may include ambient temperature, cable grouping or installation methods.
To ensure safe operation, cable specifications should comply with relevant British standards and electrical regulations, including BS 7671, which defines safe limits such as Zs limit and VD limit requirements.
Applications of lighting cables
Lighting cables are used across a wide range of industries and environments. While some applications use standard cable types, many specialised systems require custom-designed lighting cables.
Commercial and industrial lighting
Lighting cables are widely used in commercial buildings, warehouses, manufacturing facilities and professional workspaces. In these environments, cables must provide reliable power delivery while withstanding mechanical stress and environmental exposure.
Telescopic lighting masts
Telescopic masts are commonly used for floodlighting, mobile lighting towers and security lighting systems. These systems extend and retract during operation, meaning the lighting cables used must be flexible enough to move with the equipment while maintaining their electrical performance.
Custom retractable or coiled cables are often used for this purpose, as they can extend and retract without damaging the internal conductors.
Moveable lighting fixtures
Adjustable lighting systems, such as stage lighting rigs or movable industrial lighting fixtures, also require cables that can withstand repeated movement. In these cases, flexible lighting control cables are used to prevent mechanical fatigue while maintaining consistent power delivery.
Security and CCTV systems
Lighting cables are commonly used in CCTV and security installations, where lighting is required to improve visibility for surveillance cameras.
These systems may combine power and control functions within a single cable assembly to simplify installation and reduce the number of separate cable routes required.
Airfield and infrastructure lighting
Some of the most demanding lighting cable applications exist within the aerospace industry. Airport and airfield lighting systems power critical lighting infrastructure such as runway edge lights, centreline lighting and approach lighting systems used during aircraft take-off and landing.
Because these systems are safety-critical, cables must meet strict electrical and environmental standards while delivering consistent performance over long operating lifetimes.
Types of lighting cables
To suit these many applications, several different lighting cable types are used across industrial and commercial environments.
Three core lighting cable
Three-core cables are commonly used in lighting systems that require multiple conductors for power distribution or control functions.
Flexible lighting cables
Flexible cables are designed to allow movement within lighting systems without damaging the internal conductors. These cables are commonly used in adjustable lighting fixtures, retractable lighting systems and mobile lighting equipment.
Lighting control cables
Lighting control cables are used in advanced lighting systems where control signals must be transmitted between controllers and lighting fixtures. These cables are commonly used in stage lighting, broadcast environments and large-scale architectural lighting systems.
Armoured lighting cables
Where additional mechanical protection is required, Steel Wired Armoured (SWA) lighting cables may be used. The armoured construction protects the cable from physical damage in demanding industrial environments.
Custom lighting cables
For many specialised applications, standard cable types are not suitable. In these cases, custom lighting cables can be designed to meet the exact requirements of the installation.
Custom cable solutions allow engineers to specify the ideal combination of conductor materials, insulation types, shielding and mechanical protection for their application.
Benefits of custom lighting cables
When standard cable designs cannot meet the requirements of an installation, custom lighting cables offer several important advantages.
- Greater flexibility – Custom cables can be engineered to provide the flexibility required for systems involving moving parts, retractable lighting or adjustable fixtures.
- Improved durability – Specialised materials and protective layers allow custom cables to withstand harsh installation environments including moisture, vibration and extreme temperatures.
- Enhanced reliability – Because they are designed for the exact application, custom cables typically offer more consistent performance and a longer operational lifespan.
- Tailored cable design – Custom cable manufacturing allows engineers to specify conductor type, shielding, insulation materials and cable construction, ensuring the final product meets the precise technical requirements of the project.
- Long-term performance – By designing cables specifically for their intended environment, businesses can reduce the risk of cable failure and minimise maintenance or replacement costs over time.
Designing the right cable for lighting applications
Choosing the right lighting cable depends on a range of factors including electrical requirements, installation environment and mechanical demands. For specialised projects, working with an experienced cable manufacturer can help ensure the final cable design meets both technical and operational requirements.
If you’re planning a lighting project and require a custom cable solution, our team can help. We work with businesses across multiple industries to design, manufacture and test bespoke lighting cables, lighting control cables and armoured cable assemblies tailored to demanding environments.
Get in touch today to discuss your requirements.