What factors can affect the lifespan of wires and cables?

The core factors affecting the service life of wires and cables are external environmental erosion and internal performance degradation, which can be specifically categorized into four main types: environment, installation, usage, and materials. These factors accelerate damage to the cable's insulation layer, jacket, or conductor, thereby reducing its expected operational lifespan.

I. External Environmental Factors (Primary Source of Influence)

Various adverse conditions in the environment can directly erode the cable's external structure and internal insulation layer, making them the primary cause of reduced lifespan.

Temperature anomaly:

Prolonged exposure to high temperatures (such as near a heat source or in environments exceeding 60°C) can accelerate the aging of insulation layers, causing them to become brittle, crack, and even lead to direct burnout.

Extreme cold temperatures (such as below -20°C) can cause plastic or rubber jackets to become brittle, making them prone to cracking under external forces and losing their protective function.

Humidity and Moisture:

A humid environment or moisture seeping into the cable interior can degrade insulation performance, potentially leading to short circuits. Additionally, if conductors come into contact with moisture, it can accelerate oxidative corrosion and significantly increase electrical resistance.

Chemical corrosion:

Contact with oil stains, acidic or alkaline solutions (such as in chemical workshops or laboratories), or corrosive gases (like sea-breeze salt spray) can erode cable jackets and insulation layers, leading to structural damage.

Mechanical damage:

Prolonged compression, stretching, or bending—such as with equipment cables that are frequently moved—or being gnawed by rodents and insects can damage the jacket and insulation layers, exposing the conductors and posing safety hazards.

II. Installation and Construction Factors (Hidden Influence Points)

Improper installation can create long-term risks for the cable, and even if the materials are up to standard, it may still significantly shorten the cable's lifespan.

Improper installation: Bending the cable beyond its minimum radius (e.g., by forcibly folding it) can damage the internal insulation layer; when threading through conduits, friction against the pipe walls may scratch the jacket, making it susceptible to water ingress or corrosion.

Poor joint handling: Loose crimping and inadequate sealing at the joint can lead to increased contact resistance, causing prolonged heating that accelerates aging of the nearby insulation layer. Meanwhile, moisture easily penetrates through the joint, potentially triggering oxidation or even short circuits.

Environmental adaptation error: Using standard cables in special environments (such as burying non-armored cables underground or using non-flame-retardant cables in high-temperature areas) exposes them to conditions beyond their tolerance, accelerating damage.

III. Usage and Maintenance Factors (Human-Induced Factors)

Improper use and inadequate maintenance will further accelerate the degradation of cable performance.

Long-term overloading: When the actual current continuously exceeds the cable's rated current-carrying capacity, it leads to a significant increase in conductor heat generation, accelerating insulation aging—and in severe cases, could even trigger a fire.

Maintenance missing: Long-term failure to inspect cable conditions prevents the timely detection of issues such as sheath cracking, connector overheating, and insulation aging. These minor隐患s can gradually escalate into major failures, ultimately cutting short the cable's lifespan.

IV. Material Quality Factors (Foundation-Determining Factors)

The quality of the cable's own materials is the foundation of its lifespan—poor-quality materials inherently determine its short lifespan from the very beginning.

Poor insulation / sheathing materials: Using inferior materials such as recycled plastics and low-purity rubber results in poor resistance to aging, temperature fluctuations, and corrosion. These substandard materials may start cracking after just 3 to 5 years, whereas high-quality materials can maintain reliable performance for 15 to 20 years.

The conductor material fails to meet standards: Using copper with high impurity content or low-purity aluminum results in high conductor resistance, leading to severe heating during prolonged operation and indirectly accelerating the aging of the insulation layer. Some substandard cables even suffer from insufficient conductor cross-sectional area, further increasing the risk of overload.