How Is SWA Cable Made? Inside The Manufacturing Process

In modern power transmission, industrial construction, and infrastructure projects, cables are the core medium for electricity delivery. Their performance directly impacts system safety and reliability. With the rapid expansion of urban construction, industrial parks, and energy projects, the demand for high-performance cables is growing.

SWA Cable, or Steel Wire Armoured Cable, is known for its excellent mechanical protection and stable electrical performance. It is widely used in underground installations, power transmission, and industrial applications.

This article provides an in-depth analysis of the manufacturing process of SWA cables, from conductor selection to final quality inspection. It also compares SWA Cable with NYY Cable, helping customers understand why SWA Cable is advantageous in specific projects and how to select the right SWA Cable specification based on engineering requirements.

What Is SWA Cable

SWA Cable, short for Steel Wire Armoured Cable, is a high-performance cable with a steel wire armour layer added to the standard power cable structure. Its core structure includes:

• Conductor – The core medium for current transmission, usually made of copper or aluminum;
• Insulation Layer – Made of PVC or XLPE, ensuring electrical insulation and heat resistance;
• Bedding Layer – Provides a smooth support for the armour layer, reducing mechanical stress on the insulation;
• Steel Wire Armour – Provides strong compressive, tensile, and mechanical impact resistance, which is the most distinctive feature of SWA Cable;
• Outer Sheath – Protects internal structures from environmental damage, offering weather resistance, oil resistance, and corrosion resistance.

SWA Cable is widely applied in underground installations, industrial parks, mines, infrastructure, and energy projects, performing exceptionally in high-mechanical-stress and harsh environments.

SWA Cable Specifications and Applications

• Common Specifications

SWA cables cover a wide range of models, suitable for both small distribution and large-scale projects:

 1.Conductor Cross-Section: 16mm² – 630mm², suitable for different current requirements;

 2.Conductor Material: Copper (high conductivity and reliability) or Aluminum (cost-effective and lightweight);

 3.Voltage Ratings: Low voltage 600/1000V, Medium voltage 6/10kV, 8.7/15kV;

 4.Insulation Materials: PVC (cost-effective), XLPE (high-temperature resistance and high breakdown voltage);

 5.Sheath Colors: Standard black, customizable red, blue, yellow, etc.

• Application Scenarios

 1.Underground Direct Burial – Steel wire armour resists soil pressure and mechanical damage;

 2.Industrial Parks & Factories – Resistant to mechanical wear and tear, suitable for heavy machinery;

 3.Mining Projects – Designed for mines, high mechanical stress, and damp environments;

 4.Infrastructure Construction – Airports, ports, and subway power supply systems;

 5.Energy Projects – Wind farms, solar farms, oil and gas pipelines, providing stable, safe power transmission.

SWA Cable Manufacturing Process

The manufacturing of SWA Cable follows strict international standards, with each step affecting the final performance.

• Conductor Selection and Stranding

The conductor is the core of the cable, determining electrical conductivity and long-term performance. SWA cables commonly use copper or aluminum conductors, employing compacted or concentric stranding to ensure density, flexibility, and reduced resistance.

Compared with NYY Cable, SWA cables are better suited for harsh environments and high mechanical stress because NYY lacks steel wire armour and is prone to conductor damage under external force.

• Insulation Extrusion

The insulation layer, typically XLPE or PVC, is extruded evenly around the conductor using precision equipment.

 1.XLPE Insulation – High-temperature and breakdown voltage resistance, ideal for medium to high voltage and underground projects;

 2.PVC Insulation – Cost-effective, suitable for standard low-voltage distribution.

Each cable undergoes thickness measurement and electrical testing to ensure uniform insulation without voids or defects.

• Bedding Layer

The bedding layer, located between the insulation and armour, cushions the insulation from external mechanical stress. Commonly made of PVC or LSZH, it ensures the armour layer is tightly applied without puncturing the insulation, enhancing overall durability.

• Steel Wire Armour

The steel wire armour is the key feature of SWA Cable:

 1.Made of galvanized steel wires, providing tensile, compressive, and impact resistance;

 2.Armour process: continuous stranding → compacting → surface treatment;

 3.Wire diameter, density, and layers can be adjusted according to the application environment.

Compared with NYY Cable, SWA Cable offers superior mechanical protection, ideal for direct burial, high-impact industrial sites, and harsh outdoor environments.

• Outer Sheath Extrusion

The outer sheath protects internal layers and is usually PVC or LSZH:

 1.Offers weather, corrosion, and oil resistance;

 2.Customizable colors to meet project identification requirements;

 3.Inspected for defects, bubbles, or scratches after extrusion.

• Testing and Quality Inspection

Finished cables undergo rigorous testing:

 1.Electrical Tests – Voltage withstand, insulation resistance, and conductor continuity;

 2.Mechanical Tests – Tensile, bending, and impact resistance;

 3.Flame Retardant & Weather Tests – Ensures stability under fire or extreme conditions;

 4.Compliant with IEC 60502, BS 5467 international standards.

How to Select the Right SWA Cable Specification

Selecting the appropriate SWA cable requires considering project requirements, environmental conditions, and electrical needs:

1.Application Environment

• Direct burial → Choose a thicker armour layer with higher compressive strength;
• Outdoor installation → Consider weather-resistant and UV-resistant sheath materials.

2.Voltage Rating

• Low voltage distribution → 600/1000V;
• Medium/high voltage transmission → 6/10kV or higher for safety margin.

3.Conductor Material

• Copper → High conductivity for critical circuits;
• Aluminum → Lightweight, cost-effective for large-scale projects.

4.Engineering Design Needs

• Long-distance transmission → Consider voltage drop and cable cross-section;
• High mechanical risk → Choose higher steel wire density and thicker armour.
• Proper selection ensures optimal durability, mechanical strength, and safety.

SWA Cable vs. NYY Cable

SWA Cable is ideal for high-mechanical-risk environments, underground installations, and industrial applications, while NYY Cable is suitable for indoor and general industrial wiring.

Expanded Applications of SWA Cable

• Commercial Buildings – Underground distribution for offices and shopping centers;
• Infrastructure – Airports, ports, subways;
• Industrial Sector – Factories, chemical plants, heavy machinery environments;
• Energy Projects – Wind farms, solar farms, oil & gas pipelines;
• High-Risk Environments – Areas subject to mechanical damage, ensuring long-term stability.

Our Advantages

• We produce IEC-standard cables with a complete product range

Including SWA Cable, NYY Cable, N2XY Cable, RV-K Cable, STA Cable, U-1000 R2V Cable, covering industrial, energy, and building applications.

• Products meet the Americas market standards

Strict compliance with IEC and local standards ensures compatibility with project regulations.

• Full range of specifications, covering 16mm² and above

Ample stock for standard sizes, with custom options for special models.

• Strong delivery capability for large and small orders

Own factories with sufficient monthly production capacity, meeting urgent and large-scale project requirements.

• Professional technical support and pre/post-sales service

Engineering team provides selection advice and installation guidance, with full project support.

• Extensive international cooperation experience

Clients across Europe, Americas, Asia, and Africa, supplying airports, universities, mining, and energy projects.

• IEC-certified cables ensure quality and reliability

Manufactured strictly according to IEC 60502, ensuring safety and long-term performance.

• Comprehensive customization services

Materials, specifications, lengths, colors, performance, marking, and packaging can all be tailored to meet specific project requirements.

Company Information

Dongguan Greater Wire & Cable Co., Ltd.

• Tel/WhatsApp/Wechat: +86 135 1078 4550 / +86 136 6257 9592
• Email: manager01@greaterwire.com