EFIXX

How is armoured cable made?

Armoured cable or steel wire armoured (SWA) is one of the most common cables used in the UK electrical industry. Buried in the ground or fixed to factory walls it used in applications from outdoor lighting to power distribution, but how is it made?  We visited Doncaster Cables to explore the full process from raw materials to finished cable.
By Gordon Routledge
Thursday 15th August 2019
SHARE IT

Video: We take a tour of Doncaster Cables to reveal the secrets of cable manufacturing.

1. Wire drawing
8mm diameter copper wire
drawn copper wire
The wire drawing process takes a thick copper wire and gradually stretches (draws) it down to the required wire diameter.
2. Stranding
Philips Coreline
Individual copper wires are twisted together to form a conductor of the required cross-sectional area - e.g. 4mm sq, 6 mm sq
3. Conductor insulation
extruded wire insulation
Insulation in the required core colour gets extruded over the copper conductor. In armoured cable, this is usually XPLE so the conductors can operate at high temperatures compared to PVC conductors.
4. Bundling
conductor bundle assembly
All of the conductors required in the cable get lightly twisted together to form a bundle.
5. Bedding
The conductor bundle is then extruded and covered with a plastic bedding material to form a perfectly round shape.
6. Armour
Philips Coreline
In a complicated mechanical process, individual strands of galvanised steel wire are twisted around the conductor bundle to form the armoured jacket.
6. Outer sheath
Philips Coreline
The tough outer sheath is extruded over the armour to complete the cable assembly.
7. Marking
Philips Coreline
The cable is laser marked with the specification and manufacturers data
8. Testing
high voltage cable testing
The completed cable is tested with high voltage to identify any defects.

Want to know more about cable?

ASK A QUESTION
SHARE IT


MOST POPULAR

7 things we learned about cables

This switch works by magic!

GET THE NEWSLETTER

Subscribe to eFIXX to get know how, product reviews and great business tips.

KNOW HOW

How are LED panels made?

Synchronous Media Limited

Unit 2B - Line side studios

The Sidings Business Park

Skipton

North Yorkshire - UK

BD23 1TB

Tel 0845 527 4998


Registered in England Company No 11898590

VAT No 320467918

ICO Registration ZA513207

©2025  eFIXX is a Synchronous Media brand