🔌 Aluminium Armoured Cable: Comprehensive Guide

1. ⚙️ Construction and Design

Aluminium armoured cables feature a multi-layered structure designed for protection and performance:

• Conductor: Typically made from stranded plain annealed compacted circular copper or aluminium conductors. Aluminum conductors are often alloyed (e.g., AA-8000 series) to improve creep resistance, tensile strength, and flexibility 1710.

• Insulation: Common materials include Cross-Linked Polyethylene (XLPE) or ethylene propylene rubber (EPR), offering heat resistance (up to 90°C) and electrical insulation 13.

• Bedding: A Low Smoke Zero Halogen (LSZH) layer is often used to reduce smoke and toxic fumes during fires 13.

• Armour: Aluminium Wire Armour (AWA) or interlocked aluminium alloy tape provides mechanical protection against crushing, impact, and corrosion. For single-core cables, aluminium armour is preferred to prevent magnetic buildup in AC circuits 136.

• Sheath: The outer layer, often LSZH or PVC, adds further protection against moisture, chemicals, and abrasion 19.

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2. 💡 Key Standards and Certifications

• BS 6724: Specifies armoured power cables (600/1000V) with LSZH components, suitable for direct burial and hazardous environments 35.

• IEC Standards: Include flame propagation (IEC 60332), smoke emission (IEC 61034), and halogen-free requirements (IEC 60754) 13.

• BASEC Approval: Ens quality and safety compliance 1.

• C22.2 No. 131 (Canada): Applicable to Teck 90 cables with interlocked aluminium armour 2.

3. 🔧 Technical Characteristics

• Voltage Rating: Commonly 600/1000V, with higher ratings (e.g., up to 35kV) available for specific applications 39.

• Temperature Range: Typically -25°C to 90°C (operating), but installation is recommended between 0°C and 40°C to avoid material brittleness or damage 1.

• Bending Radius: Varies by cable size; e.g., 8× overall diameter for cables ≥25mm² 3. Aluminum armoured cables often have a smaller bending radius (e.g., 7× diameter) compared to copper cables, aiding installation 710.

• Weight: Lighter than steel armoured cables, reducing load and installation costs 10.

4. ✅ Advantages of Aluminium Armour

• Corrosion Resistance: Aluminum’s inherent oxide layer provides excellent resistance to environmental corrosion, especially in humid or chemical-rich settings 710.

• Non-Magnetic Properties: Ideal for AC circuits, as aluminium armour prevents magnetic interference and reduces losses 1.

• Lightweight: Significantly lighter than steel armour, easing transport, handling, and installation 10.

• Flexibility: Aluminium armour offers greater flexibility and easier bending, often with a smaller bending radius than steel armour 10.

• Cost-Effectiveness: Lower material and installation costs compared to copper or steel armoured alternatives. Aluminum cables can reduce installation expenses by 20–40% by eliminating the need for additional conduit or bridges 810.

5. ⚠️ Limitations and Considerations

• Mechanical Strength: While suitable for most environments, aluminium armour may be less robust than steel in extreme impact scenarios 6.

• Installation Precautions: Avoid installation at temperatures below 0°C to prevent sheath cracking 1. Proper glanding and grounding are essential for safety.

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• Connector Compatibility: Ensure connectors are designed for aluminium conductors to prevent galvanic corrosion or loosening over time 710.

6. 🏗️ Applications

• Industrial Power Networks: Used in factories, plants, and machinery due to mechanical protection and durability 13.

• Direct Burial: Suitable for underground installations thanks to corrosion resistance and armour protection 39.

• Hazardous Environments: LSZH sheathing makes it ideal for tunnels, mines, and areas where fire safety and low toxin emissions are critical 39.

• Buildings and Infrastructure: Commonly used in commercial complexes, sports stadiums, and high-rises for power distribution 910.

• Long-Span Installations: Aluminum armoured cables can support longer spans (up to 4000 meters) due to their lightweight and high tensile strength, making them suitable for bridges and large venues 810.

7. 📊 Comparison with Other Cable Types

8. 💁 Installation and Maintenance Tips

• Bending: Adhere to minimum bending radius guidelines to avoid damaging the armour or insulation 3.

• Gland Selection: Use glands designed for aluminium armour (e.g., size 25 gland for 95mm² cable) to ensure secure termination 1.www.adsscable.cn

• Corrosion Protection: In highly corrosive environments (e.g., alkaline soil), additional protective coatings or insulation may be needed 7.

• Testing: Perform regular insulation resistance and continuity tests to ensure long-term reliability.

9. 📜 Standards and Procurement

When purchasing aluminium armoured cables, ensure compliance with relevant standards (e.g., BS 6724, IEC) and check for certifications like BASEC. Suppliers like Superlec Direct 1 and Caledonian Cables 3 offer products with detailed specifications. For high-voltage needs (e.g., up to 35kV), specialized cables like YJHLV82 (ACWU90) are available 9.

💎 Conclusion

Aluminium armoured cable is a versatile, cost-effective solution for demanding electrical installations, offering a blend of mechanical protection, corrosion resistance, and flexibility. Its lightweight nature and non-magnetic properties make it particularly suitable for AC circuits, industrial settings, and long-span applications. However, proper installation and compatibility checks are crucial for optimal performance. When selected and installed correctly, it provides a reliable and durable power distribution medium 1310.