⚡ Measurement of thickness of non-metallic sheaths of electric and optical fibre cables (separation sheaths and oversheaths) for the most common compounds (cross-linked, PVC, PE, PP) — slice under a measuring microscope or profile projector (at least 10×) or optical digital image analyser, ball-nose micrometer for sheaths over irregular surfaces, four measurements on peaks and troughs of a corrugated sheath, reading 0,01 mm, PN-EN 60811-202

Electronics and EMC PN-EN 60811-202

Overview

WHAT THE STANDARD COVERS. The PKN catalogue card of PN-EN 60811-202:2012 (Polish version) gives the scope: “This Part 202 of IEC 60811 gives the methods for measuring the thickness of non-metallic sheaths which apply to the most common types of sheathing compounds (cross-linked, PVC, PE, PP, etc.)” (our translation from the Polish text of the card). We read the text in the sample of IEC 60811-202:2012+AMD1:2017+AMD2:2023 CSV (edition 1.2, 2023-11, redline version: additions in green, deletions in red) — the sample covers the whole text of the standard, Clauses 1–5 and the figures; we read the changes from the images of pages 6–8. For comparison we also read the sample of IEC 60811-202:2012 (edition 1.0). The standard refers to IEC 60811-100:2012 (general requirements of the series), which we did not read here.

ACCORDING TO THE TEXT OF IEC 60811-202:2012+AMD1:2017+AMD2:2023 (foreword, introduction, Clauses 1–5, figures). Edition 1.2 combines the first edition (2012-03) with amendment 1 (2017-07) and amendment 2 (2023-11); the standard was prepared by IEC TC 20 “Electric cables”; according to the foreword there are no specific technical changes with respect to the previous edition — it refers to the foreword of IEC 60811-100:2012; Part 202 is used together with IEC 60811-100. Introduction: the IEC 60811 series gives test methods for non-metallic materials of all cables (insulation, sheaths, fillers, tapes), developed for energy cables and also widely used for optical fibre, communication, control, shipboard and offshore cables. Scope (1): methods for measuring the thickness of non-metallic sheaths for the most common compounds (cross-linked, PVC, PE, PP etc.). Reference (2): IEC 60811-100:2012; terms (3) from IEC 60811-100. General (4.1): use together with IEC 60811-100; the sentence about testing at room temperature has been deleted by the amendments; the measurement may be an individual test or a step in other tests (e.g. mechanical properties); the method applies to all sheaths for which thickness limits are specified — e.g. separation sheaths and oversheaths; selection of samples according to the cable standard. Equipment (4.2): measuring microscope or profile projector of at least 10× magnification or an optical digital image analyser with a reading of 0,01 mm; for a sheath with a specified thickness of less than 0,5 mm the reading is estimated to the third decimal place (the amendment replaced the word “insulation” with “a sheath” here); for sheaths over longitudinally irregular surfaces (e.g. over corrugated metallic sheaths) a micrometer with a ball nose radius of 1 mm and a reading of 0,01 mm may be used — only when the corrugation radius exceeds 1 mm; added by amendment: where the underlying surface is not irregular, a micrometer with a ball nose radius of 2,5–3 mm may be used, and for thicknesses above 5 mm and for oversheath materials ST1, ST2, ST3, ST7, ST8 and ST12 — any of the devices listed; in case of doubt the measuring microscope is the reference method; added by amendment: the device should not deform the oversheath. Samples (4.3): for longitudinally regular surfaces (4.3.1) — after removing materials inside and outside the sheath, a thin slice cut perpendicular to the cable axis, including indented marking, if any; for irregular surfaces (4.3.2) — a short piece of sheath including at least one complete pitch or helix of the underlying tape, left whole for the micrometer, and for a microscope or projector — six thin longitudinal slices (parallel to the cable axis); for a sheath over a corrugated metallic sheath (4.3.3) — a sample of complete cable taken 500 mm from the end of the drum, long enough to include two peaks and two troughs, with a reference line parallel to the axis; the position of minimum thickness is determined on an annular ring from the end of the sample and a strip parallel to the axis is cut at that point. Measurement (4.4): a) with a circular inner profile six radial measurements at approximately 60° (Figure 1); b) when the substantially circular inner surface is not regular or smooth — six measurements where the sheath is thinnest (Figure 2); c) with deep grooves from the cores — at the bottom of each groove (Figure 3), and with more than six grooves as in b); d) with irregularities on the outer surface (proofed tape, ribbed sheath) — according to Figure 4; e) sheathed flat cables — on lines approximately parallel to the minor axis of the cross-section and on the major axis at each core, with one measurement at the thinnest place (Figure 5); f) flat cables of up to six cores — on both rounded sides along the major axis and on both flat sides at the first and last core and at the thinnest place (with the opposite thickness), and with more than six cores also at the middle core (Figure 6); g) sheath over an irregular surface — the piece from 4.3.2 measured with a ball-nose micrometer or six longitudinal slices measured optically, in both cases for the minimum thickness; h) sheath over a corrugated sheath — four measurements on the strip from 4.3.3: on two peaks and two troughs. Indented marking is not included in the measurements for the mean; added by amendment: in such a case another slice is taken and measured in areas without marking. Readings in millimetres to two decimal places; in all cases the thickness at the position of the marking shall meet the minimum of the cable standard. Evaluation (4.5): according to the cable standard. Test report (5): according to IEC 60811-100.

STATUS (PKN catalogue cards as of 02.10.2026). The card of PN-EN 60811-202:2012 (Polish version, published 15-11-2021, 16 pages, price group H) has no “Withdrawn” heading: Electrotechnical Sector, KT 53 Cables and Wires, ICS 29.060.20 and 29.035.01, “Introduces: EN 60811-202:2012 [IDT], IEC 60811-202:2012 [IDT]”, “Replaces: PN-EN 60811-1-1:1999/A1:2002 – Polish version, PN-EN 60811-1-1:1999 – Polish version”; additional information: the standard partly replaces PN-EN 60811-1-1:1999 for measurements of the thickness of non-metallic sheaths, and together with PN-EN 60811-100:2012, -201:2012, -203:2012 and -501:2012 replaces it completely. Amendments: PN-EN 60811-202:2012/A1:2018-02 (Polish version, published 17-12-2021, 5 pages; changes 4.1, 4.2, 4.4 and 5; introduces EN 60811-202:2012/A1:2017 and IEC 60811-202:2012/AMD1:2017) and PN-EN 60811-202:2012/A2:2024-03 (English version, published 08-03-2024, 10 pages; changes 4.2; introduces EN 60811-202:2012/A2:2023 and IEC 60811-202:2012/AMD2:2023) — both without the “Withdrawn” heading.

HOW MANY LABORATORIES AND IN WHAT FORM (copy of the accreditation scope database, data up to 17.09.2026, read 02.10.2026). The number 60811-202 appears in 7 records at 7 laboratories: AB 044, AB 207, AB 261, AB 1776, AB 1814, AB 1917, AB 1974 — the same ones that have Part 201, usually in the same scope item. In the current scopes on the PCA website (read 02.10.2026, issues from 10.10.2025 to 18.08.2026) all seven laboratories give the 2012 edition with both amendments: in Polish notation (AB 261 — PN-EN 60811-202:2012, /A1:2018-02, /A2:2024-03; AB 207 — with the EN and IEC numbers in brackets; AB 044 — PN-EN, EN and IEC in the form “+A1+A2”) or IEC notation (AB 1776, AB 1974 — 2012, 2012-03/AMD1:2017-07, 2012-03/AMD2:2023-11; AB 1917; AB 1814 — “IEC 60811-202:2012+AMD1:2017+AMD2:2023” split over two lines in the PCA document, which is why a search for the number in the text of that document does not find it). In none of these scopes are the lines marked as suspended. The “Laboratories” tab shows 3 laboratories under “PN-EN 60811-202” (AB 044, AB 207, AB 261) and 5 under “IEC 60811-202” (AB 044, AB 1776, AB 1814, AB 1917, AB 1974) — checked with the tab query on the production server labcoda.pl on 02.10.2026.

WHAT THE LABORATORIES TEST (PCA entries). AB 044 — power cables and wires: sheath thickness (next to PN-EN 50396 points 4.2 and 4.3 and PN-HD 605 point 2.1.2). AB 207 — cables and wires of rated voltage up to 18/30 kV and outer diameter up to 100 mm: thickness of non-metallic sheaths (0–50) mm as part of linear dimensions. AB 261 — cables and wires with the same limits: checking the construction and dimensions of components. AB 1776 and AB 1974 — cables: insulation and sheath thickness (0,01–40) mm. AB 1814 — cables: insulation and sheath thickness (0,01–25) mm. AB 1917 — cables and cable accessories with Un = (3,6–500) kV: checks of construction and dimensions, including thickness of insulating and sheathing material.

WHERE A SEEMINGLY CORRECT RESULT IS EASY TO GET. Device: the micrometer with a 1 mm ball nose is suitable only for corrugations with a radius greater than 1 mm (4.2); the device should not deform the oversheath (4.2, added by amendment); in case of doubt the reference method is the measuring microscope. Cross-section with grooves from the cores: measurement at the bottom of each groove, but with more than six grooves — six measurements at the thinnest places (4.4 c, b). Flat cables: the number and positions of measurements depend on whether there are up to six cores or more (4.4 f). Corrugated sheath: sample 500 mm from the end of the drum, strip at the point of minimum thickness, four measurements — two peaks and two troughs (4.3.3, 4.4 h). Indented marking: not included in the mean — according to the amendment another slice has to be taken, and the thickness at the marking is checked separately (4.4). Reading: 4.2 requires estimating the third decimal place for sheaths thinner than 0,5 mm, while 4.4 speaks of readings to two decimal places — the text does not reconcile these two sentences.

WHAT WE DO NOT STATE. We did not read IEC 60811-100 — we do not state the general requirements of the series (conditioning, test temperature, number of samples). We do not state the required sheath thicknesses or how the result is calculated — according to 4.5 they follow from the cable standard. We do not explain the material designations ST1–ST12 — the text of Part 202 does not define them. We do not attribute individual text changes to amendment A1 or A2 beyond what the PKN cards state (A1: 4.1, 4.2, 4.4, 5; A2: 4.2).

Method principle

The thickness of a non-metallic sheath is measured on a thin slice cut perpendicular to the cable axis, under a measuring microscope, a profile projector (at least 10×) or an optical digital image analyser with a reading of 0,01 mm, at positions depending on the shape of the cross-section; for sheaths applied over longitudinally irregular surfaces a ball-nose micrometer or longitudinal slices are used, and for sheaths over corrugated metallic sheaths — a strip from the point of minimum thickness measured on peaks and troughs; the result is evaluated according to the cable standard.

Applications

• Oversheaths and separation sheaths of power cables and wires, including medium and high voltage (up to 500 kV); 7 laboratories in PCA scopes
• Cables with a sheath over a corrugated metallic sheath or over tape — measurement with a ball-nose micrometer or on longitudinal slices (4.3.2, 4.3.3)
• A step in other tests of sheathing materials (e.g. mechanical properties) that need the sheath thickness (4.1)

Key parameters

Standard

Standard number

PN-EN 60811-202:2012 (wersja polska; EN 60811-202:2012 i IEC 60811-202:2012 IDT) ze zmianami PN-EN 60811-202:2012/A1:2018-02 (wersja polska) i PN-EN 60811-202:2012/A2:2024-03 (wersja angielska)

Title (PL)

Kable i przewody elektryczne oraz światłowodowe — Metody badań materiałów niemetalowych — Część 202: Badania ogólne — Pomiar grubości powłok niemetalowych

Title (EN)

Electric and optical fibre cables — Test methods for non-metallic materials — Part 202: General tests — Measurement of thickness of non-metallic sheath

Step-by-step procedure

1. Samples

   Selection according to the cable standard; for regular surfaces a transverse slice, for irregular ones a piece with a complete pitch of tape, for a corrugated sheath a sample 500 mm from the end of the drum (4.1, 4.3). PN-EN 60811-202:2012 with A1 and A2 current (PKN cards as of 02.10.2026).

2. Device

   Microscope, projector or image analyser; on irregular surfaces a ball-nose micrometer; the device should not deform the sheath (4.2).

3. Measurement

   Positions according to the shape of the cross-section (Figures 1–6): circular, irregular, grooved profile, with tape or ribbing, flat cables; on a corrugated sheath peaks and troughs (4.4).

4. Readings

   In millimetres to two decimal places; indented marking excluded from the mean — take another slice; check the thickness at the marking against the minimum (4.4).

5. Evaluation and report

   Evaluation according to the cable standard (4.5); report according to IEC 60811-100 (5).

Required equipment and apparatus

Health and safety (OHS)

• In the text of Part 202 the standard gives no safety requirements

Frequently asked questions