Armoured Cables – The Complete Guide

Introduction to Armoured Cables

Armoured cables are a crucial part of electrical installations, offering enhanced protection and durability in challenging environments. Whether you’re working in industrial, commercial, or residential settings, understanding armoured cables is essential for ensuring safety and compliance. In this comprehensive guide, we’ll explore everything you need to know about armoured cables, including their types, uses, benefits, installation tips, and more.

What Are Armoured Cables?

Armoured cables are electrical cables designed with an additional layer of protection to ensure that they can withstand mechanical stresses, chemical exposure, and environmental conditions. This protective layer, typically made of steel wire or aluminium, prevents the cable from damage caused by physical impact, crushing, and external threats.

Types of Armoured Cables

Armoured cables come in several variants, each designed to perform in specific environments, resist different mechanical stresses, and meet industry-level safety requirements. Below is a clear breakdown of the most common types, what makes them different, and where they’re typically used.

1. SWA Cable (Steel Wire Armoured)

Best for: Power distribution indoors and outdoors, underground installations, commercial sites, industrial plants.Why it’s used:

• Strong mechanical protection from steel wire

• Suitable for direct burial

• Handles moderate tensile stress

• Widely available and cost-effectiveTypical voltages: 600/1000V

2. AWA Cable (Aluminium Wire Armoured)

Best for: Single-core power cables in high-voltage installations.Why it’s used:

• Aluminium armour prevents magnetic fields forming around single-core conductors

• Lighter than steel armour

• Reduces eddy current lossTypical applications:

• Substations

• LV and MV power networks

• Large-scale industrial power feeds

3. STA Cable (Steel Tape Armoured)

Best for: Indoor or duct installations requiring radial (crush) protection rather than tensile support.Why it’s used:

• Flat steel tape provides excellent crush resistance

• More flexible than SWA

• Often used inside buildings or in cable traysCommon in:

• Control cable systems

• Light industrial installations

• Areas with low pulling tension

4. Flexible Armoured Cable

Best for: Locations where cable movement or bending is expected.Why it’s used:

• Flexible steel braid or wire construction

• Ideal for portable equipment, machinery, generators

• Maintains mechanical protection while remaining manoeuvrableTypical applications:

• Workshops

• Temporary power

• Mobile plant and tools

5. LSZH Armoured Cable (Low Smoke Zero Halogen)

Best for: Enclosed public spaces and areas requiring enhanced fire safety.Why it’s used:

• Produces minimal smoke if burned

• Contains no halogens

• Reduces toxic gas outputCommonly installed in:

• Transport hubs

• Data centres

• Schools and hospitals

• High-occupancy buildings

6. MV Armoured Cable (Medium Voltage, e.g., 6.6kV-33kV)

Best for: Utilities, industrial power distribution, and infrastructure networks.Why it’s used:

• Designed for higher voltages

• Typically includes copper wire screening, armour, and multi-layer insulation

• Built for durability in harsh or buried environmentsApplications:

• Renewable energy sites

• Manufacturing facilities

• Larger commercial complexes

• Grid-level installations

7. Outdoor Armoured Cable

(Often a category that overlaps with SWA)Best for: Direct burial, outdoor routing, exposure to weather or UV.Why it’s used:

• Weather- and moisture-resistant sheathing

• Armour protects against impact and rodents

• Reliable for garden, driveway, or external building feeds

8. 6mm, 10mm, 16mm Armoured Cable (Size Variants)

These sizes matter because users frequently search by mm measurements.Best for:

• 6mm: Smaller outdoor circuits, sheds, garages

• 10mm: EV chargers, outbuildings, multi-circuit subfeeds

• 16mm+: Large domestic feeds, small commercial installations

9. Armoured Control Cable

Best for: Signal and control circuits in industrial environments.Why it’s used:

• Armour adds protection from mechanical damage

• Multicore options support complex control requirementsApplications:

• Machinery

• Conveyor systems

• PLC-controlled environments

10. Fire-Resistant Armoured Cable (e.g., MICA, FP-rated)

Best for: Emergency systems that must continue operating during a fire.Why it’s used:

• Maintains circuit integrity at high temperatures

• Suitable for critical infrastructureApplications:

• Alarms

• Emergency lighting

• Smoke control systems

Key Benefits of Armoured Cables

• Enhanced Protection: The steel or aluminium armour provides excellent resistance to mechanical damage, making armoured cables suitable for use in harsh environments.
  • Durability: Armoured cables are designed to last longer than non-armoured cables, reducing the need for frequent replacements.

• • Safety: These cables are ideal for installations where safety is paramount, such as in industrial and outdoor applications.

• • Versatility: Available in various configurations, armoured cables can be used in a wide range of applications, from residential wiring to large-scale industrial power systems.

Common Uses of Armoured Cables

• • Industrial Installations: Armoured cables are often used in factories, plants, and construction sites where cables are exposed to potential mechanical damage.

• • Underground Installations: Their durability makes them ideal for underground electrical wiring, providing protection from physical damage and environmental factors.

• • Marine Applications: Armoured cables are used in ships and offshore platforms where they need to withstand corrosive conditions.

• • Outdoor Power Lines: Aerial bundled cables are commonly used for overhead electrical lines in rural and urban areas.

How to Choose the Right Armoured Cable for Your Project

When selecting the right armoured cable, it’s essential to consider several factors:

• • Voltage Rating: Ensure the cable is rated for the voltage level of your electrical system.

• • Environmental Conditions: Choose a cable with the appropriate armour material (steel or aluminium) based on the potential exposure to physical damage or corrosive elements.

• • Size and Flexibility: The size and flexibility of the cable should be chosen based on the installation space and the amount of current the cable needs to carry.

Armoured Cable Installation Tips

Proper Handling: Always handle armoured cables carefully during installation to avoid damaging the armour or conductors.

Use of Correct Tools: Ensure you use the right tools for stripping the cable without damaging the armoured protection.

Compliance with Standards: Make sure your installation complies with local electrical standards and regulations.

Protection During Installation: If you’re installing cables underground, make sure they’re adequately protected with suitable ducting and markers.

Maintenance and Care of Armoured Cables

Armoured cables generally require minimal maintenance. However, regular inspection is necessary to ensure that the cable remains in good condition and continues to perform safely. Look for signs of physical damage, wear, or exposure to chemicals, and replace the cable if necessary.

Armoured Cable Size Options

Choosing the right armoured cable size is one of the most important steps in planning a safe and efficient electrical installation. The correct cable not only ensures your system operates reliably but also prevents overheating, voltage drop, and long-term wear. Armoured cables are available in a wide range of sizes, each designed for different current loads, distances, and installation conditions.

Smaller sizes, such as 1.5mm to 4mm, are typically used for lighting and low-demand circuits, while 6mm and 10mm armoured cables are better suited for supplying power to larger equipment, outdoor buildings, or machinery. The key is to match your cable’s current-carrying capacity to the requirements of your installation – and to always consider the route, distance, and type of load you’re working with.

At Batt Cables, we supply armoured cables in all standard sizes, manufactured to British Standards (BS5467) for maximum safety and performance. Whether you’re wiring a domestic outbuilding, an EV charging point, or an industrial machine, selecting the right cable size ensures your project runs efficiently and complies with IET Wiring Regulations (BS 7671).

Below, we take a closer look at two of the most commonly used armoured cable sizes: 6mm and 10mm. Each has unique strengths and applications, helping you make the right choice for your installation.

6mm Armoured Cable

When planning electrical installations in domestic settings, selecting the appropriate cable size is crucial for safety and efficiency. 6mm armoured cable strikes an ideal balance between current-carrying capacity and flexibility, making it a preferred choice for various applications.

Why Choose 6mm Armoured Cable?

The 6mm² cross-sectional area of this cable allows it to handle moderate loads, making it suitable for powering outbuildings, garden rooms, and workshops. Its steel wire armouring provides robust protection against mechanical damage, moisture, and other environmental factors, ensuring longevity and reliability.

Key Applications

Common uses for 6mm armoured cable include:

• Power Supply to Outbuildings: Ideal for supplying electricity to garages, sheds, and garden offices.

• Outdoor Lighting Circuits: Suitable for powering external lighting systems, enhancing security and aesthetics.

• Electric Vehicle (EV) Charging Points: Capable of handling the electrical demands of home EV chargers.

For a detailed overview of 6mm armoured cable specifications, including current-carrying capacities and installation methods, refer to our comprehensive guide on armoured cables.

10mm Armoured Cable

For projects requiring higher power delivery, 10mm armoured cable offers enhanced capacity and durability. Its increased cross-sectional area makes it suitable for more demanding applications, ensuring efficient and safe power distribution.

Why Opt for 10mm Armoured Cable?

The 10mm² conductor size allows this cable to handle higher currents over longer distances, reducing voltage drop and maintaining performance. The steel wire armouring provides excellent protection against physical damage, making it ideal for both indoor and outdoor installations.

Common Applications

Typical uses for 10mm armoured cable include:

• Industrial Machinery: Supplying power to heavy-duty equipment and machinery.

• Commercial Lighting Systems: Powering large-scale lighting installations in commercial properties.

• Electric Vehicle (EV) Charging Stations: Providing the necessary power for public or private EV charging points.

For a comprehensive understanding of 10mm armoured cable specifications, including current-carrying capacities and installation guidelines, consult our complete guide on armoured cables.

Why Choose Batt Cables for Your Armoured Cable Needs?

At Batt Cables, we pride ourselves on providing high-quality armoured cables that are built to last. With decades of experience in the industry, we offer a wide range of armoured cable options for every application. Whether you’re an electrical contractor or a business looking for reliable cables for your next project, we have the right solution for you.

• • Wide Range of Products: From SWA to AWA and ABC cables, we provide an extensive selection to suit your needs.

• • Expert Advice: Our team is always ready to help you select the right armoured cable for your specific requirements.

• • Quality Assurance: All of our armoured cables are manufactured to meet the highest industry standards, ensuring reliability and safety.

Using the BATT Cable Size Calculator to Choose the Correct Armoured Cable

Selecting the correct armoured cable size is crucial to ensure electrical efficiency, safety, and compliance with regulations. To make this process simple and accurate, BATT Cables offers a free, easy-to-use Cable Size Calculator that helps you identify the most suitable cable for your specific installation.

The BATT cable size calculator is designed to consider all key parameters that affect cable performance, including:

• Current-carrying capacity and load requirements

• Cable length and voltage drop

• Installation conditions such as temperature, grouping, and burial method

• Cable type, including XLPE SWA, PVC SWA, and armoured control cables

By entering your installation details, the SWA cable calculator automatically recommends the correct cable size to meet both performance and safety requirements. This ensures your project remains compliant with relevant standards while helping to avoid costly under- or over-sizing.

For a more detailed explanation of how to calculate cable size and interpret the results, you can refer to our SWA Cable Calculator Guide.

Whether you’re planning a commercial installation, industrial project, or domestic wiring, the BATT Cables Size Calculator provides an accurate and reliable way to determine the correct armoured cable size every time.

Explore now: BATT Cable Size Calculator

External Links for Further Reading

To deepen your understanding of armoured cables and ensure compliance with relevant standards, we recommend reviewing the following resources:

• • British Standards Institution (BSI) on Armoured Cables

• • IEC Standards for Electrical Cables

• • HSE Guidance on Electrical Safety in the Workplace

These resources provide detailed guidelines, standards, and best practices for working with electrical cables, ensuring safety and compliance in all applications.

Frequently Asked Questions (FAQ) About Armoured Cables

Q1: What is the difference between SWA and AWA cables?

• • A single core armoured cable will always have a layer of aluminium wire armour (AWA) instead of steel wire armour (SWA). This is because the steel in SWA has a much lower conductivity/ higher resistance than aluminium. If it were used in a single core cable the magnetic field generated would induce an electric current in the armour (eddy current) and, combined with the increased resistance, can cause overheating in AC systems. AWA is non-magnetic and has a much better conductivity/ lower resistance, so can conduct these induced currents to earth more with a greater efficiency than steel. SWA is used in multicore armoured cables because the electromagnetic fields from the cores effectively cancel each other out, meaning less current is induced into the armour.

Q2: How long do armoured cables last?

• • Armoured cables are designed for long-term use. Under proper conditions and maintenance, they can last up to 30 years or more, providing reliable service throughout their lifespan.

Q3: Can armoured cables be used outdoors?

• • Yes, armoured cables are ideal for outdoor use due to their enhanced protection. However, they should be installed with proper sealing and support to avoid environmental damage, especially in coastal or industrial areas.

Q4: Can armoured cables be buried underground?

• • Armoured cables are often used in underground installations because the armour provides protection from physical damage. It is crucial to install them in suitable ducting or use additional protective measures when burying them.

Q5: Do armoured cables need earthing?

• • Yes, earthing is essential for armoured cables. The steel or aluminium armour is typically used for earthing purposes, helping to prevent electric shock hazards and ensuring safety in electrical systems.

Q6: Are armoured cables flexible?

• • While armoured cables are designed for durability, they are available in various levels of flexibility. For applications requiring a more flexible option, consider choosing a cable with flexible armour or one specifically designed for that purpose.

Do you need armoured cables?

Armoured cables are an essential part of modern electrical installations, offering safety, durability, and long-term reliability. By understanding the different types of armoured cables and their applications, you can make informed decisions for your projects. Batt Cables is here to provide the best quality armoured cables, backed by expert advice and exceptional customer service.