A Polyurethane Primer — Cord Cover Technical Information

By: CableOrganizer®


Polyurethane is a synthetic polymer known for being extraordinarily durable and resistant to wear. This material is frequently used in many products including cable protectors. It covers cables in high-traffic areas, while withstanding abrasion and impacts. This material is flexible, which enables it to conform to uneven surfaces, and various cable sizes. Its high tensile strength ensures cables and hoses are protected under heavier loads. Polyurethane protectors weigh less than rubber or metal, which makes them easier to transport. Cable covers made of polyurethane have excellent elongation tendences, meaning they are pliable without permanently becoming warped, and can stretch before breaking. These cord covers are also often resistant to moisture, UV light, flames, and chemicals.


Different types of polyurethane are made when prepolymers and curatives are blended in varying proportions with one of two different manufacturing processes.

The first of those is Reaction Injection Molding (RIM). It is the combining of two — and sometimes more — liquids under high pressure in a mold cavity. They create a thermosetting polymer that hardens after the two components are mixed. There is precise control over the materials, which typically results in a consistent, high-performance polyurethane. RIM is a technique frequently used in places where precision and durability count, like automotive components.

Open Cast Molding is the other common manufacturing process where material is poured into an open mold. It cures within the mold and hardens at room temperature one of two ways. The first is a One-Shot technique where polyurethane is mixed then poured inside a mold. The second is Hot Melt manufacturing that relies on the application of heat to accelerate hardening of the material. While RIM is quickly injected into a mold, Open Cast Molding counts on the slower curing process for its result. This technique allows bubbles within the polyurethane to rise to the surface then vanish. It is the preferred method for some manufacturers because air globules during a quick curing process may result in imperfections within the finished product.



Yellow Jacket® Cable Protectors have a reputation for durability in heavy duty, and extreme heavy duty settings. They can safeguard cables while providing a safe crossing for pedestrians and vehicles. The yellow and black color combination in these products denote safety. These cable covers offer high visibility to alert pedestrians and drivers that additional caution is needed.

yellow jacket

The standard Bumble Bee® is designed with Durathane™, a proprietary polyurethane known for its strength. The “Egg Crate” composition behind the Bumble Bee® offers a lightweight product that weighs 21 pounds per segment. Bumble Bee® Low Profile Cord Covers are intended for industrial applications but have a medium and light duty construction. The low-profile design is easier to lift, eliminating both stress and fatigue during setup. This product offers greater accessibility over cables and hoses for individuals with disabilities. The Bumble Bee® General Manufacturing Cord Cover has four oversized channels that offer top loading capabilities and skid resistance, making it suitable for industrial settings.

ada compliant

The Yellow Jacket® is designed for heavier duty jobs, with up to 5 channels that protect cables and hoses in parking lots, construction sites, industrial locations, and similar places. End caps, turns, and 4-way crosses are sold separately to create various configurations. The Yellow Jacket® Wheelchair Ramp is Americans with Disabilities Act (ADA) compliant. It accommodates cables and hoses in up to 5 channels, while making crossings accessible for wheelchairs, strollers, carts, and dollies. Yellow Jacket® Advanced Modular System (AMS) is customizable and can be changed to suit multiple lengths and widths. The Yellow Jacket® Modular Extreme Crossover Cable Cover comes to the rescue in extraordinary environments. This urethane cover can take on a 400-ton vehicle, yet has a modular design that makes it easy to install, store, and transport the protector.


The lids on all these cable protectors were created to conform to uneven surfaces. They are constructed with flexible fiberglass hinge pins to offer longer wear and resistance to impacts. Rounded dividers inside the cable cover help protect cables against pinching.


    • Position the cable cover so traffic drives over the hinge side first whenever possible.
    • Start by placing cables in the channel closest to the leading edge.
    • Use grip tape to keep lids down.
    • To reduce risk of tearing, use a drill to make anchor holes rather than spiking the product.
    • Do not overstuff the cable cover — the lid can pinch the cable insulation.
    • Replace worn parts immediately as torn lids can present a tripping hazard.
    • Use end caps and other accessories to provide a clean, safe installation.
    • Adhere to ADA guidelines for the use of wheelchair ramps.
    • Avoid using solvents or acids to clean cable protectors. Use ordinary soap and water — or steam clean the product.

Need more assistance with installing polyurethane cable covers? Read our article How to Safely Install and Use Polyurethane Cable Covers, where you will find additional handy tips. Explore the full selection of cable protectors here at CableOrganizer®.

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