For industrial Ethernet and communication systems, as well as data-driven manufacturing and industrial automation, halogen-free cables for industrial networks are essential for performance and safety. LSZH (Low Smoke Zero Halogen) jackets are an expensive choice that drastically change the fire response characteristics from PVC, with less smoke and no corrosive halogen gases created by fire. Knowing when these cables are worth their price can help save crucial downtime and ensure greater system reliability for plants that need to be up and running, equipment protected, and compliant with regulations.
With more than 15 years of experience in designing and producing high performance industrial cables, Hulk Electric can assist engineers in selecting the appropriate solution for challenging applications. This guide explains the differences and decision criteria between LSZH and standard jackets used in Ethernet and fieldbus applications.
PVC vs LSZH Jackets on Ethernet and Communication Cables – What Changes?
PVC jackets are commonly used on standard industrial Ethernet and communication cables, appreciated for their low cost, durability and ability to withstand dynamic applications. But, during a fire, PVC produces dense smoke, hydrochloric acid and other toxic halogen gases. The byproducts can make it hard to see and break down delicate electronic equipment.
LSZH jackets are made without any halogenated additives which result in significantly reduced smoke formation and no corrosive emissions of halogens. This is usually more expensive, but there are today LSZH compounds that offer similar mechanical properties, abrasion resistance and flexibility, making them more and more attractive for high cycle applications in our LSZH product families such as robotic or drag chains.
Key differences at a glance:
- PVC: Less expensive, very durable, but will emit smoke and corrosive gas in the event of fire.
- LSZH: More costly investment but better fire safety profile because of low smoke and no halogens, thus helping to comply with sensitive installations.
How LSZH Jackets Improve Safety and Equipment Protection
Smoke Density and Visibility
In the event of burning, LSZH cables emit a very small amount of smoke. This helps to preserve visibility for longer in enclosed control rooms, server racks or high occupancy industrial spaces with lots of network cabling – which is essential for safe evacuation or emergency response.
Toxic and Corrosive Gas Reduction
LSZH materials do not generate halogen gases, unlike PVC, thus reducing damage to metal surfaces, circuit boards, PLCs, switches and other critical infrastructure. This minimizes secondary fire effects, helps to speed recovery and cuts replacement costs in areas where there are many cables.
When LSZH Jackets Are Worth the Extra Cost
Confined Spaces with Dense Cabling and People Present
LSZH excels in data centers, network closets, MCC rooms, and control hubs where there is a high density of cables and human operators. Reduces smoke and no corrosive by-products which is great for personnel and costly electronics.
Public Buildings and High-Risk Zones in Industrial Sites
Areas such as airports, hospitals, tunnels, schools or plant areas where it is important for staff to be able to escape or move around often use LSZH that are compatible with building codes and project specifications that focus on low smoke/halsgen-free performance.
Safety-Critical and High-Value Installations
AI compute rooms, process control systems, or businesses that prioritize sustainability and business continuity will benefit from the use of LSZH, which helps lower liability, recovery times after a disaster, and environmentally friendly materials.
When PVC Jackets Are Still Acceptable
For well-ventilled plant floors, low-density applications or short exterior runs, PVC is still a viable option. In environments with low fire demands and limited budgets, there is no need to over-specify; high quality PVC, such as from the manufacturer Hulk, will provide good mechanical properties. A combination of both approaches (LSZH only in high-risk areas), can often optimize the total investment in the project.
Cost Considerations and How to Justify LSZH
The premium for LSZH cables varies according to specifications and volumes, but is usually 15-30% above conventional cables due to the advanced compounding and manufacturing processes. But consider total cost of ownership: in critical applications, the initial savings in equipment corrosion, downtime and benefits for compliance are often far outweighed by the cost difference.
Don’t just look at the per-meter price, but the decision should be based on risk reduction, sustainability reporting, and long-term reliability.
Practical Selection Guide – LSZH vs PVC for Industrial Ethernet Runs
Choose LSZH jackets when:
- Mounting in data centers, dense wiring closets or control rooms.
- Cabling is installed in public areas, occupied areas or low-ventilated areas.
- Maintaining protection for sensitive electronics that may be damaged by smoke or corrosion and result in longer outages.
Use PVC jackets when:
- Runs in open, higher porosity industrial areas.
- There is no specific LSZH requirement in codes/owner specs.
Always verify:
- Local fire safety codes and tender requirements.
- Performance: Relevant standards are IEC 60332 – LSZH Performance, IEC 60754, and IEC 61034 – LSZH Performance.
Our CAT5e to CAT7A industrial Ethernet cables from Hulk Electric are specifically designed for industrial Ethernet requirements and have a high degree of flexibility. Our team can provide you with standard PVC or premium LSZH solutions, with custom shielding and torsion resistance, and we offer certified, high-quality cables that are tested and have very quick turnaround.
Discuss your project requirements with us and we will help you choose the right type of jacket for your project, based on the 3 criteria: performance, safety, and value.
