Contact UsInterlocked armor is a specialized metallic armor structure for cables. Aluminum alloy strip is formed into a specific S-shaped or Z-shaped cross-section using dedicated forming dies and is then helically wrapped around the cable core. Adjacent edges mechanically interlock with each other, creating a continuous, strong, and flexible metallic protective layer.
This construction is particularly common in the North American and Canadian markets and is widely used in cable product families such as AC90, MC, and Teck90 cables.
Compared with traditional steel strip armor, interlocked aluminum alloy armor offers three major advantages: lower weight, better flexibility, and good resistance to lateral compression and impact. Aluminum has a density of approximately one-third that of steel, which can significantly reduce the weight of the finished armored cable.
Some industry studies indicate that cables using aluminum alloy conductors combined with aluminum alloy interlocked armor can reduce overall cable weight by more than 40% compared with conventional copper cables with steel strip armor, and by more than 60% compared with copper cables with steel wire armor, depending on the cable construction. Compared with traditional steel strip armor, aluminum alloy interlocked armor can also simplify cable installation and, in suitable applications, eliminate the need for cable trays, potentially reducing installation costs.
Main Alloys and Specifications
The main aluminum alloy grades used for interlocked armored cable strips are concentrated in the 5xxx series. Depending on the applicable cable standard and manufacturer's specifications, common alloy grades include 5052, 5754, 5154, and 5154A. Certain 1xxx and 3xxx series aluminum alloys may also be used for specific applications.
5052 Aluminum Alloy
5052 aluminum alloy is one of the most widely used grades. Magnesium is its principal alloying element, providing good corrosion resistance, moderate strength, and excellent formability.
The interlocking armor process requires the aluminum alloy strip to withstand repeated bending and forming without cracking or breaking while maintaining sufficient strength to resist external mechanical loads. 5052 offers a good balance between formability, strength, and corrosion resistance, making it a practical choice for many interlocked armor applications.
5154 Aluminum Alloy
5154 aluminum alloy offers excellent corrosion resistance and good mechanical properties. It can be considered for cable armor applications in marine and offshore environments where resistance to moisture and corrosive conditions is important.
5754 O Aluminum Alloy
5754 O contains a higher magnesium content than 5052 and can provide a combination of strength, corrosion resistance, and formability suitable for demanding cable constructions. It can be considered for large cross-section single-core cables and applications requiring enhanced mechanical protection.
Specifications of Aluminum Alloy Strip for Interlocked Armored Cables
| Parameter | Specification |
| Alloy | 5052, 5754, 5154, 5154A |
| Temper | O, H24, H18, etc. |
| Thickness | 0.2–1.0 mm |
| Common Thicknesses | 0.3, 0.4, 0.5, 0.6, 0.8 mm |
| Width | 20–60 mm |
| Thickness Tolerance | ±0.01 mm |
| Width Tolerance | ±0.20 mm |
| Length | 1,000–16,000 mm |
| Coil ID | 150, 200, 300, 500 mm |
| Surface | Bright, clean, free from obvious defects |
| Packaging | Wooden cases, pallets, or export-standard packaging |
Why Are Aluminum Alloy Strips Used for Interlocked Cable Armor?
Aluminum alloy strip is not simply a substitute for steel strip. It has been developed to address the requirements of cable weight reduction, corrosion resistance, flexibility, and forming performance.
1. Lightweight
The density of aluminum is significantly lower than that of steel; therefore, using aluminum alloy strip for the armor layer effectively reduces the overall weight of the cable.
Lightweighting offers distinct advantages for long-distance installations, large-cross-section cables, and projects requiring high construction efficiency.
2. Good Corrosion Resistance
Aluminum naturally forms a dense oxide layer on its surface, providing inherent protection.
Aluminum alloy strip typically demonstrates excellent corrosion resistance in humid environments, industrial settings, and various outdoor applications.
3. Good Formability
Interlocking armor requires the continuous forming of flat metal strip into a specific geometric structure, necessitating material with stable plasticity and bending characteristics.
Proper selection of the aluminum alloy and temper helps minimize issues such as cracking or strip breakage during the forming process.
4. Excellent Overall Processability
Aluminum alloy strip is suitable for slitting, forming, stamping, and other processing operations, making it compatible with various types of interlocking armor production lines.
What Is the Price per Ton of Aluminum Alloy Strip for Interlocked Cable Armor?
This is one of the most common questions asked by cable manufacturers.
It is important to understand that aluminum alloy strip does not have one fixed market price per ton. The final quotation is normally influenced by the aluminum raw material price, alloy grade, processing costs, specifications, order quantity, and delivery terms.
In general, the price of aluminum alloy strip can be understood as:
Aluminum Alloy Strip Price ≈ Aluminum Benchmark Price + Alloy/Melting Cost + Rolling Cost + Slitting Cost + Surface Treatment Cost + Packaging Cost + Other Charges
For export orders, additional costs may include:
Ocean Freight + Insurance + Port Charges + Exchange Rate Fluctuations + Other Logistics Costs
Therefore, even when two customers both purchase "aluminum strip for interlocked cable armor," their final price per ton may be significantly different if their requirements for alloy, temper, thickness, width, quantity, tolerances, packaging, and delivery terms are different.
For an accurate quotation based on your specific requirements, please contact HAOMEI. Our sales team can recommend a suitable aluminum alloy strip and provide a competitive quotation based on your specifications and order quantity.
