Kevlar multi conductor underwater cable — flexible polyurethane-jacketed multi-conductor cable for subsea, ROV, and offshore applications. Depth-rated waterblock construction, tinned copper conductors, Kevlar strength options. Custom OD and conductor count available.
This Kevlar multi conductor underwater cable is engineered for demanding subsea, ROV, and offshore marine environments where conventional cables fail. Built with a flexible polyurethane (PUR) jacket rated to 90°C, an elastomer-based thermoset waterblock filling all conductor interstices, and tinned stranded copper conductors, this cable maintains full electrical performance from the surface to operational depths of 2,000 m and beyond.
Whether you need a lightweight ROV tether, a rugged instrumentation cable, or a high-conductor-count umbilical for complex subsea systems, our multi-conductor underwater cable series provides the mechanical and electrical reliability demanded by professional offshore, scientific, and defence applications.
| Parameter | Specification |
|---|---|
| Voltage Rating | 300V / 600V / 1,000V (power cores); 300V (signal pairs) |
| Temperature Range | -25°C to +90°C operating; PUR jacket to 120°C short-term |
| Depth Rating | Standard: 2,000 m; Deep-rated: to 7,000 m with full waterblock |
| Conductor Material | Tinned stranded copper (ASTM-B-8 Class B) |
| Insulation | Cross-linked polyethylene (XLPE) or Polyethylene (PE) |
| Jacket Material | High-grade flexible Polyurethane (PUR) — oil, UV and ozone resistant |
| Shield (optional) | Al/mylar tape 100% coverage + tinned Cu drain, or braided tinned Cu 85% min |
| Break Strength | 500 lbs (light tether) to 25,000+ lbs (heavy umbilical) |
| OD Range | 6 mm to 90 mm (custom) |
| Weight in Seawater | Positive, neutral, or negative buoyancy — configurable per design |
| Conductor Count | 2 to 37 conductors (custom multi-element designs available) |
Generic submersible cables use air-filled cores that compress and deform under hydrostatic pressure, altering capacitance and impedance at depth. Our thermoset elastomeric waterblock is pre-loaded into the interstices, eliminating compressible air pockets entirely. Electrical parameters remain stable to rated depth.
PVC jackets become rigid and crack at low temperatures encountered in deep water (2–4°C). Our PUR jacket formula maintains full flexibility down to -25°C, critical for ROV systems operating near the seafloor where repeated mechanical bending occurs during launch, recovery, and station-keeping.
Bare copper corrodes rapidly when seawater contacts the core through jacket nicks or cut ends. Tinned copper conductors provide an electrochemically stable barrier, extending service life significantly and maintaining low contact resistance at terminations over years of continuous deployment.
Steel wire armour adds significant weight — often making cables positively buoyant only through heavy foam cladding. Kevlar aramid fibre achieves comparable tensile load ratings at a fraction of the weight, enabling neutrally buoyant designs with break strengths exceeding 25,000 lbs.
Through selection of jacket density, core fill material, and optional foam PUR or foam PE buoyancy layers, cables can be designed with positive, neutral, or negative buoyancy in seawater — matching the specific hydrodynamic requirements of the deployment system.
| Type | Cores | AWG Range | Shield | Strength | Typical OD |
|---|---|---|---|---|---|
| Light tether (power+signal) | 2–6 | 18–24 | Optional | Kevlar 500 lbs | 8–14 mm |
| Multi-conductor control | 7–16 | 18–22 | Overall braid | Kevlar 1,200 lbs | 14–25 mm |
| Heavy power umbilical | 3–12 | 12–16 | Al/mylar pairs | Kevlar/steel 5,000+ lbs | 20–40 mm |
| Instrumentation hybrid | 2–8 pairs + 2–4 singles | 20–24 | Per-pair Al/mylar | Kevlar 800 lbs | 10–22 mm |
| Custom deep umbilical | Up to 37 elements | Custom | Custom | Steel 180,000 lbs | 25–90 mm |
Maintain a minimum dynamic bend radius of 10× the cable OD during deployment and recovery operations. Static installation bend radius should not be less than 6× OD. Exceeding these limits causes conductor fatigue, shield displacement, and waterblock cracking over repeated cycles.
PUR jacketed cables accept hot-mould epoxy and polyurethane overmolding for waterproof field terminations. Ensure conductor pairs are individually sealed before overmolding to prevent water wicking through the core. For underwater mateable connectors, follow the connector manufacturer's torque specifications and verify O-ring seating before deployment.
Store on ventilated drums in a cool, dry environment away from direct sunlight and ozone sources. UV radiation causes surface crazing in PUR jackets over extended periods. Avoid drumming at temperatures below 0°C without pre-warming; cold PUR loses flexibility temporarily during spooling. Inspect for jacket damage, kinking, and delamination at connection points before each deployment.
Specify your conductor count, AWG, voltage, depth rating, break strength, and OD target — we will supply an exact-fit subsea cable matched to your ROV, instrument, or offshore system.
Custom designs | Fast quotation | Worldwide shipping
