UV-stable, water-blocked, and shielded for the systems that run unattended for decades.
Every obstruction lighting cable we build begins with your installation. Our engineers work directly with OEM designers, tower owners, and system integrators to build cable that performs in the actual environmental conditions of the structure: UV, thermal cycling, moisture, and where required, electromagnetic interference. Reliability from first installation through the full service life of the system is the standard, not the goal.
Every obstruction lighting cable is designed around your tower type, environmental conditions, run length, and service life. We start with your application, not a catalog.
We produce the cable and the finished assembly together. Terminated runs, connectorized assemblies, and weatherproof overmolded connections under one specification and one team.
Prototype in two weeks. Production in three to four weeks. Scalable volume from short runs to ongoing supply with consistent quality and predictable lead times.
You work directly with the engineers designing and building your cable. No distributors, no middlemen. Questions get answered by the people doing the work.
Obstruction lighting cable systems must perform reliably for years or decades, often installed on structures where access for repair or replacement is limited or costly. We engineer cable solutions that account for the environmental exposure, mechanical demands, and electrical requirements of the installation: from the specification stage through long-term production supply.
Engineered obstruction lighting cable is cable designed and built around the specific environmental, mechanical, and electrical requirements of a tower installation, rather than selected from a standard outdoor catalog. The engineering process accounts for UV exposure, thermal cycling range, moisture ingress risk, RF environment, conductor sizing for the full run length, and service life target. The result is a cable construction that performs reliably across a 20-year outdoor service life, not just in year one.
Reliable obstruction lighting performance begins with understanding the actual conditions the cable will face across its full service life. Instead of selecting a standard outdoor product and adapting it, we start by understanding your tower type, environmental exposure, system architecture, and service life target. Our engineers work with your team to align cable construction with the specific requirements of your installation.
Our engineers collaborate with your team to align cable construction with the requirements of the specific installation.
Environmental and mechanical design considerations include:
Obstruction lighting cable constructions vary significantly based on tower type, environmental exposure, and system design. We engineer the construction to the specific requirements of your installation rather than selecting the closest available catalog option.
Polyurethane and thermoplastic elastomer jacket compounds selected for UV stability and thermal cycling range at the specific installation site. Engineered to maintain flexibility and jacket integrity across the structure’s full outdoor service life.*, not just initial installation conditions.
Specialized tapes, gels, or flooding compounds integrated between jacket and conductors to stop moisture migration at the point of breach. Specified as standard construction for marine, offshore, and exposed outdoor tower installations where moisture ingress is a certainty across the service life.
Foil, braid, or foil-and-braid combination shielding engineered for the RF environment at the specific installation site. Broadcast towers co-located with AM and FM transmitters require shielding matched to actual field strength and frequency range, not a generic shielded outdoor specification.
Terminated runs, connectorized assemblies, and weatherproof overmolded connections produced alongside the cable under one roof. One specification, one team accountable for the outcome from design through delivery.
The table below reflects our typical design envelope for engineered obstruction lighting cable. Your application may require a different construction and that conversation starts with your engineering team and ours.
| Specification | Typical Range or Capability |
|---|---|
| Temperature Rating | -40°C to +105°C |
| Jacket Material | Polyurethane (PUR), TPE, PVC, and Polyethylene — selected for UV stability, thermal cycling range, and chemical resistance at the installation site |
| Shielding | Foil, braid, or foil-and-braid combination — braided shielding for high-flex tower applications; foil or combination construction matched to the RF environment at broadcast tower and co-located transmitter sites |
| Water Blocking | Dry blocking (absorbent swelling tape) or gel-filled (water-repelling compound) — both methods stop moisture migration at the point of ingress; specified based on exposure type and installation environment |
| Conductor Gauge | Engineered per system voltage, current draw, and run length |
| Conductors | Single, multi-pair, and multi-conductor configurations available |
| Insulation | PVC, PE, or cross-linked compounds selected for voltage rating and temperature range |
| Armor | Steel wire armor available for direct burial and exposed mechanical environments |
| Voltage Rating | 300V standard; 30V, 100V, 600V, and 1000V available |
| Assembly | Termination, connectorization, and weatherproof overmolding available |
| Manufacturing | Spencer, Massachusetts — Made in the USA since 1967 |
| All Specifications Are Application-Specific | Specifications reflect our typical design envelope. Your application may require a different construction. Contact our engineering team to confirm the right specification for your installation. |
Not all cable suppliers start with your installation. Most start with their catalog. Here is what the difference looks like in practice.
We review your tower type, environmental conditions, run length, and service life requirements before a single foot of cable is specified. The construction is built around your application, not adapted from the closest available option.
We produce the cable and the finished assembly under one roof with one team accountable from design through delivery. No coordination gap between the cable manufacturer and the assembly house.
Obstruction lighting cable fails years after installation, not year one. We engineer for the cumulative environmental load of the installation: UV exposure, thermal cycling, moisture ingress, and mechanical fatigue across the structure’s full service life.*
All obstruction lighting cable and assemblies are designed and manufactured at our facility in Spencer, Massachusetts. Faster response, direct communication, and a supply chain you can reach when something matters.
*Engineered service life varies by installation environment, jacket compound, conductor specification, and site conditions. Mercury Wire engineers cable to your specific application and service life requirements.
Share your tower type, environmental conditions, run length, and system requirements. Our engineering team will respond with a cable construction built for your application, not a catalog selection.
Want to go deeper before you specify? Read our full obstruction lighting cable overview.
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