In AC systems, if you’re still using traditional steel wire armored (SWA) cables for single-core high-current applications, the heat generated by induced eddy currents will eventually burn out your wiring.
Many buyers, in an effort to save on material costs, overlook hysteresis loss. Our aluminum wire armored (AWA) control cables are essentially designed to solve two major problems:
- Completely eliminate magnetic loss: Aluminum is a non-magnetic material, physically eliminating the source of cable heat generation, resulting in higher efficiency and a cable lifespan at least 5-10 years longer.
- Reduced weight translates to reduced cost: For the same level of mechanical protection, aluminum wire is significantly lighter than steel wire. Ask any installer on a construction site—it’s easier to pull, easier to lay, and saves labor—this is true cost reduction and efficiency improvement.
We are a direct cable supplier from China. In the international market, concerns about Chinese cables typically revolve around two aspects: copper and aluminum purity and armor density.
If your project is currently at one of the following stages, let’s discuss:
- Stuck on selection: Unsure about the most suitable aluminum wire diameter and sheath material.
- Costs exceeded: Direct contact with the original manufacturer in China is needed to cut out middlemen’s markups.
- Tight deadline: Local distributors don’t have stock; urgent expedited processing from the domestic factory is required.
Add us on WeChat/WhatsApp or send an inquiry. A deal isn’t guaranteed; consider us a backup technology pool for the Chinese market. Send us your specifications, and we’ll calculate the most realistic CIF price for you.
What are AWA control cables?
AWA control cables are power or signal transmission cables with an aluminum wire armor layer wrapped around the cable core as a protective layer. Unlike common steel wire armor (SWA), AWA is specifically designed for single-core cables.
Features:
High compressive strength: The aluminum wire armor layer can withstand greater mechanical forces, preventing damage to the internal core.
Non-magnetic: Aluminum is a non-magnetic material, suitable for environments sensitive to magnetic fields (such as ships and precision instrument workshops).
Lightweight: Compared to steel tape armor (SWA), it is approximately 50% lighter, facilitating transportation and installation.
Corrosion resistant: With a PVC or PE outer sheath, it has excellent acid and alkali resistance and termite resistance.
Why must single-core cables use aluminum wire armor?
Because when alternating current (AC) flows through a single-core conductor, it generates an alternating magnetic field around the cable.
If magnetic materials (such as steel wire SWA) are used for armor, the magnetic field will generate eddy currents in the armor layer.
Eddy currents cause the cable to overheat rapidly, not only wasting electrical energy but also burning out the insulation layer.
Aluminum is a non-magnetic material that effectively prevents eddy current heating effects, ensuring the safety of the system under high current.
AWA Control Cable Structure:
1. Conductor: High-purity copper or aluminum conductor.
2. Insulation: XLPE (cross-linked polyethylene) or PVC material, providing excellent electrical insulation.
3. Filler layer: Enhances cable roundness and stability.
4. Armor layer: Aluminum wire spirally wound, forming a robust mechanical protective layer.
5. Outer sheath: PVC or LSZH (low smoke halogen-free) material, resisting environmental corrosion.
Common AWA cable models
| standard | Common models | Model Meaning | Applicable number of cores | voltage level | Common cross-sections | Remark |
|---|---|---|---|---|---|---|
| BS5467 | 6941AX | Cu/XLPE/AWA/PVC: Copper conductor/cross-linked polyethylene insulation/aluminum wire armor/PVC sheath | single core | 600/1000V | 50mm² – 1000mm² | British standard, most commonly single-core AWA, used in power networks and auxiliary control to avoid magnetic interference. |
| BS5467 | XLPE/AWA/PVC (single core) | XLPE insulation/aluminum wire armor/PVC sheath | single core | 0.6/1kV | 35mm² – 630mm² | General term: Single-core control/power line for fixed installation. |
| IEC 60502-1 | Cu/XLPE/AWA/PVC | Copper conductor / XLPE insulation / aluminum wire armor / PVC sheath | single core | 0.6/1kV | 50mm² – 400mm² | International standard, applicable to single-core cables for direct burial or conduit installation. |
| IEC 60502-1 | AL/XLPE/AWA/PVC | Aluminum conductor / XLPE insulation / Aluminum wire armor / PVC sheath | single core | 0.6/1kV | 70mm² – 500mm² | Aluminum conductor version, lightweight and lower cost |
AWA vs SWA vs STA: How to choose?
| characteristic | AWA (Aluminum Wire Armor) | SWA (Steel Belt Armor) | STA (Steel Wire Armor) |
|---|---|---|---|
| Material | Aluminum wire/aluminum strip | steel strip | galvanized steel wire |
| weight | light | Heavy | heaviest |
| Antimagnetic properties | Excellent (non-magnetic) | Poor magnetic permeability | Poor magnetic permeability |
| Tensile strength | medium | high | Extremely high |
| Applicable Scenarios | Underground pipelines, offshore platforms, and factories | General direct burial, high voltage | Vertical shaft, long-distance hoisting |
| price | medium | Low | high |
Note: If your project involves single-core or is sensitive to magnetic interference, choose AWA; if it is a multi-core conventional control, SWA is more suitable.
How to Choose High-Quality AWA Control Cables?
1. Confirm Requirements: Clarify core count, voltage, and environmental conditions.
2. Choose a Reputable Manufacturer: Look for cables with ISO9001 and CCC certifications.
3. Focus on Materials: Conductor purity and insulation quality.
4. Request Qualifications: Type test reports and product certificates.
5. Compare Prices: High-quality products are reasonably priced; avoid low-priced, low-quality products.
3 Major Factors Affecting AWA Cable Prices
1. Aluminum Cost: Fluctuations in London Metal Exchange (LME) aluminum prices directly affect armor layer costs.
2. Copper Rod Purity: The price difference between oxygen-free copper rods and ordinary copper rods can be 10%-15%.
3. Process Requirements: Whether low-smoke halogen-free (LSZH), flame-retardant (FR), or shielded layers are required.
FAQ
Q1: Are AWA cables waterproof?
A: Standard AWA cables are waterproof and moisture-proof. However, if the cable is to be submerged in water for extended periods, it is necessary to choose a model with longitudinal water-blocking capabilities or increase the thickness of the PE outer sheath.
Q2: What is the minimum bending radius of an AWA cable?
A: It is typically 12 times the cable’s outer diameter (D). Avoid excessive bending during installation to prevent breakage of the aluminum armor.
Q3: Can single-core AWA cables be used in AC systems?
A: Yes. Aluminum is a non-magnetic material, and single-core AWA cables pose no significant eddy current risk in AC systems (a fundamental difference from steel wire armor). IEC 60502-2 explicitly permits this. However, reliable grounding at both ends of the armor layer is required.
Q4: How to identify substandard AWA cables?
A: Three checks: ① Is the armor aluminum wire blackened (severe oxidation)? ② Does the sheath have a pungent odor when burned (not LSOH)? ③ Request the supplier to provide an aluminum wire composition test report (Al ≥ 99.5%).