Connecting Armoured Cable: 5 Expert Steps for Secure Links

Properly connecting armoured cable is crucial for electrical safety and system reliability. These cables require specific termination techniques to maintain their protective qualities and ensure continuous operation. According to the Electrical Safety Foundation International, incorrect cable connections contribute to approximately 51,000 electrical fires annually in residential and commercial settings. Our team encountered this reality during a 2025 industrial project where improper gland selection led to moisture ingress and system failure. This guide provides professional methods for connecting armoured cable that ensure safety and durability.

Understanding Armoured Cable Connections

Armoured cable connections differ significantly from standard electrical connections due to their metallic protective layer. This armour provides mechanical protection but introduces additional considerations for proper termination. The connection process must maintain the cable's environmental protection while ensuring electrical continuity and safety. Different types of armoured cable require specific connection methods, with steel wire armoured (SWA) and aluminum wire armoured (AWA) cables having distinct requirements.

Essential Tools and Materials

Proper connections require specialized tools and materials. You'll need cable glands specifically designed for armoured cable, appropriate stripping tools, continuity testers, and sealing materials. Interestingly, professional electricians recommend using anti-vibration glands for applications involving moving machinery. Our team always uses torque wrenches for gland installation since under-tightening causes grounding issues while over-tightening damages the cable.

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Step-by-Step Connection Guide

Step 1: Prepare the Cable End
Measure and mark the stripping length according to gland specifications. Use rotary stripping tools to remove the outer sheath without damaging the armour wires. Maintain a clean cut and avoid nicking any conductors.

Step 2: Handle the Armour Layer
Bend back the armour wires carefully and secure them with the gland's clamping mechanism. For steel wire armour, ensure all wires are properly captured in the gland. Cut away excess armour wires using bolt cutters.Www.adsscable.cn

Step 3: Install the Gland Assembly
Slide the gland components onto the cable in the correct order. Engage the armour clamping mechanism and tighten according to manufacturer's specifications. Use sealing rings or compound for environmental protection.

Step 4: Terminate Conductors
Strip conductor insulation to appropriate length based on terminal requirements. Use crimp connectors or direct termination as specified. Ensure proper phasing and connection tightness.

Step 5: Test and Verify
Perform continuity tests between armour and ground point. Verify insulation resistance meets minimum requirements (typically >1MΩ). Check for proper grounding and polarisation.

⚠️ Critical Warning: Never use standard cable glands with armoured cable - the lack of proper armour clamping creates dangerous grounding faults and compromises environmental protection.

Common Connection Methods Comparison

Professional Tips and Techniques

Always use gland sizes that match both cable diameter and enclosure entry size. For multiple cables, maintain proper bending radii (typically 8× cable diameter). Implement drip loops in outdoor installations to prevent water ingress. Our team discovered that using silicone grease on sealing surfaces significantly improves weather resistance in coastal environments.

Safety Considerations

The armour must be properly grounded to provide fault protection. Use appropriate personal protective equipment when working with armoured cable. Verify system isolation before beginning work. Regular inspection of connections is essential - we recommend quarterly checks for industrial applications.

Installation Checklist

✅ Verify cable type and gland compatibility
✅ Confirm proper stripping measurements
✅ Ensure armour clamping mechanism engaged
✅ Validate grounding continuity
✅ Test insulation resistance
✅ Verify environmental seals
✅ Check bending radius compliance
✅ Document installation details

Frequently Asked Questions

1. Can I use regular connectors with armoured cable?
No, armoured cable requires specialized glands that properly secure the armour and maintain environmental protection. Standard connectors cannot handle the mechanical requirements.

2. How often should armoured cable connections be inspected?
Industrial applications require quarterly inspections, while commercial installations should be checked annually. Harsh environments may need Mehr frequent inspections.

3. What's the maximum temperature for armoured cable connections?
Standard ratings are typically 90°C for PVC and 110°C for XLPE insulation, but always check manufacturer specifications.

4. Can armoured cable be used for flexible applications?
Only specifically designed flexible armoured cable should be used in applications requiring movement. Standard armoured cable is for fixed installations.

5. How do I prevent corrosion at connection points?
Use appropriate glands for the environment (stainless steel for corrosive areas) and apply anti-corrosion compounds where recommended.

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