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Introduction to armored forms

Armored Cable Selection Guide

  1. Steel Tape Armor (STA)

    • Construction: Two-layer galvanized steel tapes helically wound with opposite directions

    • Key Properties:

      • Superior crush resistance (withstands up to 2500N/100mm)

      • Bending radius ≥12× cable diameter

      • Typical thickness: 0.2-0.8mm (IEC)

    • Applications:

      • Direct burial installations

      • Tunnels with potential rockfall

      • Industrial floors with vehicle traffic

  2. Steel Wire Armor (SWA)

    • Construction: Galvanized steel wires (Φ0.8-3.15mm) in single layer

    • Key Properties:

      • Tensile strength ≥350N/mm2

      • Bending radius ≥10× cable diameter

      • Zinc coating ≥40g/m2 (BS standard)

    • Applications:

      • Vertical risers (supports self-weight)

      • Aerial spans ≤50m

      • Mining drag applications

  3. Steel Wire Braid (SWB)

    • Construction: Interwoven galvanized steel wires (Φ0.2-0.4mm)

    • Key Properties:

      • Shielding effectiveness ≥60dB (100MHz)

      • Bending radius ≥8× cable diameter

      • Typical coverage: ≥80% surface area

    • Applications:

      • Mobile equipment connections

      • EMI-sensitive environments

      • Oilfield drilling cables

Special Case: Single-Core Cable Armor

  • Material Requirement: Aluminum armor mandatory

  • Technical Reasons:

    1. Prevents eddy current losses (steel causes ≈5% power loss at 50Hz)

    2. Limits temperature rise (ΔT ≤30K under full load)

    3. Maintains impedance balance (R±jX variation <3%)

Standards Comparison

Parameter IEC 60502-2 BS 6724
Steel Wire Optional Galvanizing Mandatory Zn Coat
Minimum Diameter 0.8mm 0.9mm
Tensile Test 150N/mm2 350N/mm2
Corrosion Test 72h salt spray 144h salt spray

Selection Methodology

  1. Mechanical Stress Analysis:

    • Crushing forces → Choose STA

    • Tension loads → Choose SWA

    • Flexing requirements → Choose SWB

  2. Environmental Factors:

    • Corrosive atmospheres: Galvanized SWA (BS standard preferred)

    • Electromagnetic interference: SWB with ≥85% coverage

    • Temperature extremes: Aluminum armor for >90°C operation

Industry Trends

  • Composite armor (steel tape + aramid yarn) gaining popularity for:

    • 30% weight reduction

    • 40% improved flexibility

    • Equivalent mechanical protection

This technical breakdown provides engineers with the essential criteria for selecting appropriate cable armor based on project-specific mechanical, electrical, and environmental requirements.