In demanding industrial and commercial settings, cable protection is essential to ensure performance, safety, and system longevity. When cables are subjected to crushing forces, abrasion, and movement, the risk of failure rises dramatically. That’s where smooth bore spiral covers come in—a versatile, robust solution that combines flexibility, durability, and ease of installation.
Smooth bore spiral covers, sometimes referred to as spiral reinforced tubing or helix tubing, offer superior protection for cable bundles in harsh environments. Whether you’re managing power cables on a production line, organizing wires in a vehicle, or protecting control systems outdoors, these products deliver consistent performance and reliability.
What Are Smooth Bore Spiral Covers?
Smooth bore spiral covers are flexible tubing systems made from thermoplastic materials—most commonly, PVC or polyethylene. The term “smooth bore” refers to the interior of the tubing, which is designed to be slick and uniform to reduce friction during cable insertion and removal.
The “spiral” refers to the reinforcement method: a helical structure embedded within the tubing wall that adds strength without compromising flexibility. This makes the tubing crush-resistant yet easy to route through tight spaces or around bends.
Key Characteristics:
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Smooth internal bore for fast cable insertion and minimal wear
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Spiral reinforcement for crush resistance and torsional strength
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UV and chemical resistance depending on the material
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Self-extinguishing properties in many formulations
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Flexible handling, even in tight enclosures or moving machinery
Why Use Spiral Covers with a Smooth Bore?
Many cable protection products provide strength but sacrifice ease of use. Smooth bore spiral covers offer a balance of durability and user-friendly handling. Here’s why they’re so effective:
1. Ease of Cable Insertion
Rough or ribbed inner surfaces can snag or damage sensitive cables during installation. The smooth bore design allows installers to easily thread cable bundles through the tubing without resistance or tool assistance.
2. Crush and Impact Resistance
The spiral reinforcement embedded in the tubing absorbs compressive forces from machinery, tools, or foot traffic. Even under pressure, the tubing maintains its shape, preventing pinching or deformation of internal cables.
3. Flexible Routing
These covers bend easily around corners, through tight spaces, or within control cabinets. Unlike rigid conduit, they adapt to space limitations without cracking or compromising protection.
4. Vibration and Torsion Resistance
Smooth bore spiral covers resist damage from vibration and twisting, common in moving equipment. This ensures that wiring systems stay secure and intact even in high-motion applications.
5. Cost and Labor Savings
Their lightweight design and tool-free application reduce installation time. Maintenance teams can easily open or reposition the tubing, saving hours of labor during inspections or retrofits.
Common Materials for Smooth Bore Spiral Covers
1. Polyvinyl Chloride (PVC)
PVC is the most common material used in standard smooth bore spiral covers. It’s flexible, lightweight, and resistant to water, oils, and most industrial fluids.
Ideal for:
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General manufacturing
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Indoor and outdoor control panels
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Vehicles and trailers
Advantages:
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UV-resistant
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Flame retardant
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Cost-effective
2. Polyethylene (PE)
Polyethylene tubing offers higher chemical resistance and a more flexible profile. It’s widely used in agricultural and light industrial settings.
Ideal for:
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Water-resistant environments
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Chemical handling
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Cable bundles in humid conditions
3. Polyamide (Nylon)
Nylon spiral covers provide excellent abrasion and heat resistance. These are ideal for heavy-duty or high-temperature applications.
Ideal for:
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Automotive wiring harnesses
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CNC equipment
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Heavy machinery
Where Smooth Bore Spiral Covers Excel
1. Control Panels and Cabinets
Industrial control panels often require neat, safe cable organization. Smooth bore spiral covers make it easy to bundle, route, and protect cables inside enclosures without creating clutter.
2. Robotic Arms and Moving Equipment
In dynamic systems like conveyor belts, robotic arms, or CNC machines, wiring must flex and twist with moving components. Spiral reinforcement ensures that the tubing can bend and stretch without stress failure.
3. Outdoor Installations
UV-resistant spiral covers stand up to weather, sunlight, and environmental changes. They’re commonly used for:
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Outdoor lighting
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Agricultural equipment
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Mobile machinery
4. Automotive and Fleet Vehicles
From trucks and trailers to forklifts and service vans, vehicle wiring faces vibration, grease, and moisture. Spiral covers prevent wire wear, reduce maintenance needs, and extend cable life.
5. Data Centers and IT Infrastructure
Smooth bore tubing organizes patch cables, bundles network wires, and prevents tangling behind racks. The smooth inner surface prevents damage to high-speed data lines.
Benefits at a Glance
| Feature | Benefit |
|---|---|
| Smooth Interior | Reduces cable wear and insertion time |
| Spiral Reinforcement | Prevents crushing and absorbs vibration |
| Flexible and Lightweight | Speeds up installation |
| Flame Retardant Options | Increases safety in high-risk environments |
| Reusable and Adjustable | Ideal for temporary installations or retrofits |
| UV and Weather Resistance | Supports long-term outdoor use |
| Range of Diameters | Accommodates everything from fine wires to thick cables |
Installation Tips
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Measure Bundle Diameter
Always select tubing with an internal diameter slightly larger than your bundle for easy insertion. -
Use Cable Lubricant if Needed
For dense bundles or long runs, use a safe lubricant to ease cable movement through the tubing. -
Secure Entry and Exit Points
Use strain relief boots or grommets to protect the tubing ends and maintain seal integrity. -
Trim Cleanly
Use sharp cutters to avoid ragged ends that could scratch cables or hinder insertion. -
Inspect During Maintenance
Over time, check tubing for UV wear, cracking, or pinching. Replace any compromised sections to maintain protection.
Environmental and Regulatory Compliance
Many smooth bore spiral covers are:
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ROHS Compliant: Free from restricted hazardous substances
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REACH Compliant: Approved for use in regulated industrial sectors
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UL Listed: Recognized for fire and performance safety in North America
Always verify product datasheets for compliance with your application’s safety standards.
Product Review: HellermannTyton 166-90503 HelaGuard SR PVC Tubing
The HellermannTyton 166-90503 HelaGuard SR Spiral Tubing is a top-tier example of smooth bore protective sheathing. With a 2.0" diameter and 100-foot length, this standard-weight tubing provides reliable coverage for large cable bundles.
Its spiral-reinforced construction balances strength with flexibility, making it easy to route cables around tight corners or within complex control systems. The smooth internal bore significantly eases cable insertion, while the UV-resistant PVC exterior handles outdoor exposure with confidence. It resists crushing, abrasion, and limited torsional movement without creating pinch points or micro-cracks.
The tubing is self-extinguishing according to EN IEC 61386 and meets UL recognition standards in both the US and Canada. With a working temperature range of -4°F to 158°F, it’s well-suited for automotive, automation, and general industrial use.
Easy to cut, install, and manage, the HellermannTyton 166-90503 delivers dependable, long-term cable protection in demanding environments.
Wrapping Up
Smooth bore spiral covers offer a smart solution for routing and protecting cables in a wide variety of environments. From factory floors to fleet vehicles and control systems, their flexibility, crush resistance, and smooth inner surface improve performance and ease of installation.
Products like HellermannTyton’s HelaGuard SR tubing combine these features with UV stability, chemical resistance, and safety certifications. When chosen carefully and installed correctly, smooth bore spiral covers can extend the life of your cables, simplify maintenance, and improve the safety of your systems.
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