Single Core & Multicore Flexible Cable Manufacturer

✓ ISO 9001:2015 Certified

Single Core & Multicore Flexible Cable

BMI Cables manufactures single core and multicore flexible cables for industrial, commercial, and residential applications — providing reliable electrical connectivity for power distribution, portable machinery, automation systems, and control panels. Available in FR, FRLS, and LSZH grades to IS 694 / IEC 60227 / IEC 60228.

Product Overview

Single Core & Multicore Flexible Cables — What They Are and When to Use Each

Single core and multicore flexible cables are electrical cables designed specifically for applications where the cable is subjected to bending, flexing, twisting, or repeated movement during installation or in service. The defining characteristic is the conductor — finely stranded Class 5 or Class 6 copper conductors per IEC 60228, which distribute mechanical stress across hundreds of fine copper strands instead of concentrating it on a few thick wires. This makes flexible cables far more resistant to conductor fatigue failure under repeated bending than rigid or semi-rigid cables.

Single core flexible cables consist of a single finely stranded copper conductor with PVC, FRLS, or LSZH insulation — used for internal panel wiring, switchgear connections, equipment interconnections, and trailing flexible leads where only a single current path is needed. Multicore flexible cables contain two or more individually insulated conductors within a common PVC or LSZH outer sheath — used for portable equipment connections, motor feeder cables, control panel supply cables, and automation system wiring where multiple circuits must run within a single cable.

BMI manufactures single-core and multicore flexible cables at our ISO 9001:2015 certified facility in Bhiwadi, Rajasthan — in FR, FRLS, and LSZH insulation grades, to IS 694, IEC 60227, and IEC 60228 as applicable. Available from 0.5 sq.mm to 630 sq.mm in single core, and from 0.5 sq.mm upward in 2-core through multicore configurations.

Class 5 & Class 6 Stranded Copper

Finely stranded ETP copper conductors per IEC 60228 Class 5 for standard flexible applications, Class 6 for extra-flexible requirements where maximum bend radius and movement frequency are the highest.

FR / FRLS / LSZH Insulation Grades

Standard Flame Retardant (FR), Flame Retardant Low Smoke (FRLS), and Low Smoke Zero Halogen (LSZH) insulation and sheath options matching any fire safety specification from general commercial to enclosed infrastructure installations.

Wide Cross-Section & Core Range

Single core from 0.5 sq.mm to 630 sq.mm. Multicore from 0.5 sq.mm in 2-core, 3-core, 4-core, 5-core, and higher core counts covering panel wiring through heavy industrial equipment power supply.

IS / IEC / BS Compliance Available

Manufactured to IS 694, IEC 60227, and IEC 60228 as applicable to the cable type. BS 6004 compliance available for export and projects with British standard requirements. Test certificates per drum on request.

Single Core vs Multicore

Single Core vs Multicore Flexible Cable Choosing the Right Configuration

Both single core and multicore flexible cables use the same finely stranded Class 5 or Class 6 copper conductors and the same insulation grades. The choice between them depends on the number of circuits needed and how the cable will be installed.

Single Core Flexible Cable

One conductor per cable multiple cables run together

Ideal for internal panel and switchgear wiring each core routed independently through the panel for maximum installation flexibility
Available in multiple insulation colours for circuit identification within switchboards and distribution boards
Easier to terminate individually in panel busbars, terminals, and switchgear
Largest cross-section range — up to 630 sq.mm for very high current busbar connections
Multiple individual cables required for multi-phase circuits — cable management more complex for external installations
No common outer sheath — less mechanical protection for external or portable equipment use

Best for: Panel wiring, switchgear connections, busbar connections, and internal equipment wiring where each conductor is routed independently

Multicore Flexible Cable

Multiple conductors in a common sheathed cable

All circuit conductors in a single cable simplifies cable routing, management, and identification for portable equipment connections
Common outer sheath provides mechanical protection for the full cable suitable for portable equipment trailing leads and industrial floor environments
2-core, 3-core, 4-core, 5-core — covers single phase, three phase, three phase with neutral, and control circuit configurations
Easier to route through conduit, cable trays, and glands as a single cable compared to multiple single cores
Complete cable must be replaced if any single conductor fails cannot replace individual conductors in service
Larger overall diameter than equivalent single core cables — requires larger conduit and cable glands

Best for: Portable equipment connections, motor feeder leads, control panel supply, automation wiring, and any multi-circuit flexible installation

Cable Grades

Single Core & Multicore Flexible Cable Available Types & Grades

BMI manufactures flexible cables across FR, FRLS, and LSZH fire grades and single through multicore configurations — all using Class 5 or Class 6 finely stranded ETP copper conductors to IS 694 / IEC 60227 / IEC 60228.

Single Core FR / FRLS Flexible Cable

Fine-stranded single core flexible cable with FR or FRLS PVC insulation for panel wiring, switchgear connections, and equipment internal wiring. Available across the full cross-section range in standard IS colour coding for phase, neutral, and earth identification.

Conductor	Class 5 stranded ETP copper
Insulation	FR-PVC / FRLS-PVC
Cross-Section	0.5 sq.mm to 630 sq.mm
Voltage	1100V (IS 694)
Colours	Red / Yellow / Blue / Black / Green

Multicore FR / FRLS Flexible Cable (2 to 5 Core)

Standard multicore flexible cable in 2-core, 3-core, 3.5-core, 4-core, and 5-core configurations with FR or FRLS PVC outer sheath — for portable equipment power connections, motor feeder leads, industrial machinery supply, and general commercial wiring applications requiring a common sheathed multi-circuit cable.

Conductor	Class 5 stranded ETP copper
Insulation	FR-PVC / FRLS-PVC per core
Sheath	FR-PVC / FRLS-PVC outer
Cores	2C, 3C, 4C, 5C
Cross-Section	0.5 sq.mm to 300 sq.mm per core

LSZH Single Core & Multicore Flexible Cable

Low Smoke Zero Halogen flexible cables for metro stations, railways, tunnels, data centres, airports, and offshore installations where halogen gas emission during fire is a safety concern. Zero HCl / HF gas emission per IEC 60754, low smoke opacity per IEC 61034, flame retardant per IEC 60332.

Conductor	Class 5 / Class 6 stranded ETP copper
Insulation	LSZH compound — zero halogen
Sheath	LSZH compound (multicore)
Standards	IEC 60754 / IEC 61034 / IEC 60332
Applications	Metro, rail, tunnels, data centres

Extra-Flexible Class 6 Conductor Cable

Extra-fine stranded Class 6 conductor flexible cables for applications requiring maximum flexibility and highest bending cycle endurance CNC machine tool connections, robotics, portable welding equipment leads, drag chain installations, and any application involving continuous repeated bending at tight radii.

Conductor	Class 6 extra-fine stranded ETP copper
Stranding	Finer than Class 5 — maximum flexibility
Insulation	FR-PVC / FRLS-PVC / LSZH
Applications	CNC, robotics, drag chain, trailing leads
Key Property	Highest bending cycle endurance

Heavy-Duty Industrial Flexible Cable (Large Cross-Section)

Heavy-duty multicore flexible cables in large conductor cross-sections for power supply to heavy industrial machinery, large motors, compressors, welding equipment, and mobile plant installations where high current capacity and mechanical robustness are both required.

Conductor	Class 5 stranded ETP copper
Cross-Section	25 sq.mm to 300 sq.mm per core
Sheath	Heavy-duty PVC — robust mechanical protection
Applications	Heavy motors, compressors, mobile plant
Cores	3C, 3.5C, 4C

Custom Specification Flexible Cables

Non-standard cross-sections, bespoke core counts, special insulation colours, custom drum lengths, and export-standard cables (IEC/BS) for OEM equipment manufacturers and large project buyers. BMI confirms feasibility and pricing within 24 hours of a complete specification enquiry.

Cross-Section	Custom — confirm at enquiry
Core Count	1C to high multicore — custom
Standard	IS / IEC / BS — project requirement
Drum Length	Custom — project quantity
Lead Time	Confirmed within 24 hours of specification

Design & Construction

Flexible Cable Construction - Layer by Layer & Abbreviations

Understanding how a flexible cable is constructed and what the abbreviations in a cable designation mean helps ensure the right cable is specified for each application.

Flexible Cable Construction

1. Conductor — Class 5 / Class 6 Stranded ETP Copper

Finely stranded copper conductors per IEC 60228 Class 5 for standard flexible cables, Class 6 for extra-flexible. Multiple fine strands distribute bending stress to prevent conductor fatigue under repeated flexing

2. Core Insulation — PVC / FRLS / LSZH

Individual insulation applied over each conductor, colour-coded for circuit identification per IS / IEC colour convention. Provides turn-to-turn insulation between adjacent conductors in the cable

3. Fillers & Binder Tape (Multicore)

Non-hygroscopic fillers maintain circular cross-section of the assembled cable. Binder tape holds cores together before sheathing critical for cable roundness and gland sealing

4. Outer Sheath — PVC / FRLS / LSZH

Overall protective sheath over all cores provides mechanical protection, colour identification (usually grey or black), and the fire performance rating of the cable (FR / FRLS / LSZH)

Cable Designation Abbreviations

Cu

Copper conductor electrolytic tough pitch (ETP) copper, minimum 99.9% purity, fine stranded per IEC 60228

PVC

Polyvinyl Chloride standard insulation and sheath material for general wiring applications up to 70°C conductor temperature

FR

Flame Retardant PVC compound that resists flame propagation per IS 1554 / IEC 60332. Cable self-extinguishes after ignition source removed

FRLS

Flame Retardant Low Smoke flame retardant plus reduced smoke density during fire. Measured per ASTM E662 / IEC 61034 smoke opacity tests

LSZH / ZHFR

Low Smoke Zero Halogen / Zero Halogen Flame Retardant no halogen compounds in insulation or sheath. Zero HCl / HF gas emission per IEC 60754

Cl.5 / Cl.6

Conductor class per IEC 60228. Class 5 = flexible (stranded fine wires). Class 6 = extra-flexible (even finer stranding). Both designed for repeated bending

1C / 2C / 3C / 4C

Number of cores in the cable 1 core (single), 2 core, 3 core, 4 core. 3.5C = 3 full-size cores plus one half-size neutral core

Key Features

What Makes BMI Single Core & Multicore Flexible Cables the Reliable Choice

Performance parameters that matter to panel builders, electrical contractors, and industrial equipment OEMs built into BMI’s manufacturing and verified per batch before despatch.

Class 5 / Class 6 Fine Stranding True Flexibility

IEC 60228 Class 5 and Class 6 finely stranded conductors distribute bending stress across hundreds of individual copper strands preventing the conductor fatigue failure that rigid or semi-rigid cables experience when subjected to repeated flexing in service.

High-Conductivity ETP Copper

Minimum 99.9% purity electrolytic tough pitch copper conductor ensuring minimum conductor resistance and maximum current-carrying capacity for the rated cross-section, with conductor resistance per unit length verified against IS 8130 / IEC 60228 limits per batch.

Full Fire Grade Range - FR / FRLS / LSZH

Standard FR for general applications, FRLS for commercial buildings requiring low smoke performance, and LSZH for enclosed infrastructure where halogen gas emission is a safety concern all available from BMI as a single certified supplier.

Dimensional Compliance to IS / IEC

Conductor cross-section, insulation wall thickness, and overall cable dimensions verified against IS 694, IEC 60227, and IEC 60228 requirements for every cross-section and configuration produced. Dimension records in test certificates per drum on request.

Standard Colour Coding - IS / IEC Convention

Core insulation colour-coded to IS and IEC colour convention for phase, neutral, and earth identification — Red/Yellow/Blue (phase), Black (neutral), Green-Yellow (earth) — with custom colour arrangements available for OEM panel builders.

Robust Outer Sheath for Industrial Use

Heavy-duty PVC or LSZH outer sheath on multicore cables provides mechanical protection during installation, conduit pulling, and in service in industrial environments with abrasion, oil, and chemical exposure — maintaining cable integrity throughout service life.

Corporate / Sales & Marketing Office
SF-1, 1st Floor, Bhikaji Cama Bhawan, Bhikaji Cama Place,
Delhi 110066, India

Works
F-83+84, Riico Industrial Area, Kushkhera, Bhiwadi, Alwar, Rajasthan 301019, India

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