In an era where durability and reliability are essential, galvanised steel wire braid cables have emerged as a critical solution across various industries.
These cables, also known as GSWB cables, are reinforced with a protective layer of galvanised steel wire – offering exceptional strength, flexibility, and resistance to harsh environmental conditions. From construction sites to automotive applications, their versatility makes them indispensable in a wide variety of settings.
In this comprehensive guide, we will explore what galvanised steel is and then delve into the specifics of galvanised steel wire braid cables. We’ll discuss their benefits, common applications and manufacturing processes, to provide you with a well-rounded understanding of these vital components.
Whether you are an engineer, contractor, or simply curious about industrial materials, this guide aims to equip you with valuable insights into galvanised steel wire braid cables and their significant role in modern technology and infrastructure.
What is galvanised steel?
Galvanised steel is a type of steel that has been coated with a layer of zinc to protect it from corrosion and rust. The process of galvanisation involves applying the zinc coating through one of several methods, with hot-dip galvanising being the most common.
Galvanised steel has a wide range of common uses, including:
- Cables: Galvanised steel wire braid cables.
- Construction: Steel beams, roofing, and supports.
- Automotive industry: Car bodies and frames.
- Fencing and gates: Used in outdoor environments due to its rust resistance.
- Piping: Water and gas pipelines.
- Appliances: Metal components of washers, refrigerators, etc.
Key benefits of galvanised steel
There are many benefits to galvanising steel, including:
1. Corrosion resistance
The zinc coating acts as a barrier to prevent moisture and oxygen from reaching the steel, significantly slowing down the rusting process.
2. Durability
The protective layer of zinc makes galvanised steel more durable and resistant to harsh environmental conditions like rain, humidity, and saltwater.
3. Self-healing
If the zinc coating gets scratched or damaged, the exposed steel is still protected because zinc will corrode preferentially – protecting the underlying steel through a process called cathodic protection.
4. Cost-effective
Galvanisation is generally a more affordable and low-maintenance solution for long-term protection, compared to using paints or other coatings.
What are galvanised steel wire cables?
Galvanised steel wire braid cables, also known as GSWB cables, refer to electrical cables that have an outer layer or cable sheathing made of braided galvanised steel wire. This braided layer provides additional strength, protection, and durability to the cables. These cables are commonly used in demanding environments where flexibility, mechanical protection, and resistance to corrosion are needed.
Benefits of galvanised steel wire braid cables
Galvanised steel wire braid cables offer a range of benefits that make them highly suitable for various demanding applications. Here are some of the key advantages:
1. Corrosion resistance
The zinc coating on the steel braid provides excellent protection against rust and corrosion. This makes these cables ideal for outdoor or harsh environments, such as coastal areas, chemical plants, or marine applications, where exposure to moisture and corrosive substances is common.
2. Mechanical strength
The braided galvanised steel layer adds significant mechanical strength, making the cables resistant to physical damage such as cuts, abrasions, or crushing. This is crucial in industrial and construction settings where the cables may face rough handling or environmental wear.
3. Flexibility
Despite the protective steel braid, GSWB cables are considered to be flexible cables. The braided construction allows the cable to bend and move without breaking, making them suitable for applications that require both durability and flexibility, such as in machinery or moving parts.
4. Protection of internal components
The steel wire braid shields the inner components of the cable (such as electrical conductors) from external stress, ensuring the integrity of the internal components is maintained over time.
5. Electromagnetic interference (EMI) shielding
In electrical applications, the steel braid can act as a shield against electromagnetic interference (EMI), helping to prevent signal disruption or noise in sensitive systems like data transmission cables or control cables.
6. Resistance to high temperatures
Galvanised steel can withstand higher temperatures than many other materials, providing an extra layer of protection when the cable is used in environments with extreme heat, such as manufacturing plants or near machinery that generates heat. This allows GWSB cables to be considered high temperature cables.
7. Chemical resistance
The zinc coating also provides some level of resistance to chemical reactions, making galvanised steel wire braid cables suitable for environments where exposure to mild chemicals, oils, or fuels is possible, such as in refineries or chemical plants. These are more commonly known as harsh environment cables.
8. Longevity and cost-effectiveness
The combination of mechanical protection and corrosion resistance results in cables that last longer than standard unprotected cables. This reduces the need for frequent replacements and maintenance, making them a cost-effective solution over the long term.
9. Versatility
These cables can be used in a wide variety of environments, from industrial machinery and automotive systems to power plants, telecommunications, and marine applications. Their versatility and ability to withstand harsh conditions make them ideal for both static and dynamic applications.
10. Grounding and electrical safety
In electrical systems, the steel braid can provide a grounding path, enhancing electrical safety. Additionally, the braid can also reduce the risk of electrical shocks or short circuits in case of damage to the inner conductors.
11. Resistance to UV radiation
Galvanised steel provides additional resistance to ultraviolet (UV) radiation, making these cables suitable for prolonged outdoor exposure where UV damage could otherwise weaken other types of protective coatings.
Common applications of galvanised steel wire braid cables
Galvanised steel wire braid cables are highly versatile and used in a wide variety of applications due to their durability, flexibility, and protective properties. Below are some of the most common applications:
1. Industrial equipment and machinery
The GSWB design can be used to protect electrical power cables in industrial environments where heavy machinery, moving parts, and harsh conditions require robust protection against abrasion, vibration, and mechanical damage. These cables are also commonly used for control systems in industrial machinery, ensuring stable operation while resisting wear and tear from constant movement and mechanical stress.
2. Automotive and aerospace applications
Galvanised steel wire braid cables are used in the automotive industry for electrical wiring that needs protection from heat, vibration, and potential damage from moving parts. In aerospace, these cables are used for both electrical wiring and hydraulic systems, as they offer strength and reliability under high-pressure and high-temperature conditions.
3. Construction and infrastructure
GSWB cables are often used in elevators, hoists, and cranes, where they protect the electrical systems from wear caused by friction and mechanical stress. In construction, these cables can be used to protect electrical systems, especially in outdoor settings or in buildings with high exposure to harsh conditions.
4. Marine and offshore applications
Galvanised steel wire braid cables are ideal for use on ships, oil rigs, and other marine structures, where the cables are exposed to saltwater, humidity, and corrosive environments. They are also used in subsea wiring, where corrosion resistance and high mechanical strength are necessary for operating under water pressure.
5. Energy and power generation
These cables are widely used in oil rigs, refineries, and pipelines to protect electrical systems from corrosive chemicals, high pressure, and extreme temperatures. In wind farms and solar installations, galvanised steel wire braid cables provide protection to electrical wiring and control systems that are exposed to the elements.
6. Telecommunications
In environments where data transmission cables are vulnerable to electromagnetic interference (EMI), the steel braid acts as a shield, protecting the integrity of signals in telecommunications equipment and network installations. Galvanised steel wire braid cables are also used in outdoor or underground telecommunications installations, where they need protection from physical damage and environmental conditions.
7. Mining and tunnelling
In the mining industry, these cables are used to protect electrical systems on mining equipment that operate in dusty, abrasive, and high-impact environments. The steel braid provides resistance to wear and tear, ensuring safety and reliability.
8. Defence and military applications
GSWB cables are used in military vehicles, aircraft, and naval vessels, where reliable protection against extreme environmental conditions, mechanical stress, and EMI shielding is critical. Furthermore, in field communication systems or portable military equipment, the steel braid ensures that cables can withstand rough handling and harsh terrain.
9. Fire safety and emergency systems
Galvanised steel wire braid cables are often used in fire detection and alarm systems, as they can withstand high temperatures and remain operational in emergency situations. Moreover, in critical infrastructures, such as hospitals or data centres, these cables ensure the reliability of backup power systems during power outages or emergencies.
10. Agricultural machinery
In agriculture, the cables are used to protect electrical wiring in tractors, combine harvesters, and other farming machinery that operate in dusty, wet, or abrasive conditions.
11. Robotics and automation
In automated systems and robotics, the flexibility of galvanised steel wire braid cables allows them to move freely, whilst providing the necessary protection from mechanical stress – ensuring uninterrupted performance of electrical or fluid systems.
What is the difference between GSWB and SWA cables?
Curious about the difference between GSWB and SWA cables?
Galvanised steel wire braid (GSWB) cables and steel wire armoured (SWA) cables serve distinct purposes in various applications, primarily determined by their construction and protective features, but are often compared.
GSWB cables consist of a core of conductors surrounded by a braided layer of galvanised steel wire, offering excellent flexibility and corrosion resistance. This makes them ideal for applications where bending and movement are required, such as in industrial machinery, automotive systems, and telecommunications. Their lighter weight also facilitates easier handling and installation – especially in dynamic environments.
In contrast, SWA cables feature a core of conductors encased in insulation, with a layer of steel wires arranged in a spiral for robust protection. This construction provides superior mechanical strength against physical impacts, making SWA cables suitable for fixed installations in harsh environments, such as underground wiring and outdoor power distribution. Whilst SWA cables are typically heavier and less flexible than GSWB cables, they are designed to withstand severe conditions where additional protection is critical.
How are galvanised steel wire braid cables made?
The manufacturing process of galvanised steel wire braid cables involves several key steps, from the preparation of the steel wire to the final braiding and galvanization. Here’s an overview of the process:
Step 1: Wire production
The first step involves producing the steel wire itself. Steel rods are drawn through a series of dies to reduce their diameter and increase their length. This process creates thin strands of steel wire, which will be used in the braiding process.
Then, the drawn wire undergoes quality checks to ensure it meets the necessary specifications for strength and flexibility.
Step 2: Galvanisation
Next, the drawn steel wire is cleaned to remove any surface contaminants like oil, grease, or rust. This is typically done using chemical baths or mechanical cleaning methods.
The cleaned steel wire is then submerged in molten zinc. This process forms a protective zinc coating on the wire, which enhances corrosion resistance. The galvanised wire is allowed to cool, resulting in a strong bond between the steel and the zinc.
After galvanisation, the wire is cooled and inspected to ensure the coating is uniform and free from defects.
Step 3: Braiding process
Then, the galvanised steel wires are fed into braiding machines, which intertwine multiple strands to create the braided structure. The machines can create various braid patterns, such as single, double, or triple braids, depending on the required strength and flexibility of the final product.
During the braiding process, the tension of the wire is carefully controlled to ensure that the braiding is tight enough to provide strength, whilst allowing for flexibility.
Step 4: Assembly
Depending on the application, the braided cable may include additional materials as a core, such as electrical conductors. These components are inserted into the braided structure during assembly. The ends of the cables are often terminated with connectors, terminals, or fittings, which are crimped or soldered to ensure a secure connection.
Step 5: Final inspection and testing
Finally, the finished galvanised steel wire braid cables undergo rigorous testing and inspection to ensure they meet industry standards for performance, strength, and flexibility. This may include tensile strength tests, flexibility tests, and electrical insulation tests (if applicable).
Once inspected and approved, the cables are packaged for shipping, ready to be distributed for various applications.
Step 6: Optional customisations
Depending on the intended use, additional protective coatings or insulations may be applied to the braided cable for enhanced resistance against environmental factors or electrical insulation. This is known as custom cable design.
Cables are also often labelled with specifications and certifications, providing essential information for users regarding their performance characteristics and compliance with industry standards.
When it comes to cables, we’re the experts. To learn more about all the different types of cables, their benefits and uses, you can find more resources and information on our blog, or get in touch with our helpful team today for expert advice.
