10 Questions You Should to Know about Airport Cables Manufacturer

When it comes to aircraft hardware, there is no room for cutting corners. Only the highest quality materials must be used to ensure that the aircraft is manufactured correctly. Aircraft cable is a critical piece of equipment that is found in all types of planes, from small two-seaters to Boeing 737s and even military aircrafts.  

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The aircraft hardware cable industry has gone through quite a bit of ups and downs lately. The COVID-19 pandemic caused production and demand to plummet, as airlines cut back on flights and aircraft purchases. However, as travel bans are being lifted, the market is expected to bounce back stronger than ever before, with a projected 6.2% market growth through .  

But this type of cable is high in demand for more than just aircraft production. You may be surprised to see that many industrial hardware distributors have aircraft cable offered in their inventory.  

This extremely durable and strong piece of equipment can be used for many things – so, here’s what you need to know before placing an order with an industrial hardware supplier.  

1. All Hardware Cables Must Meet Specific Aircraft Quality Standards

Aircraft hardware cables are used primarily for tie-downs, as well as for stabilizing, fastening, and lifting extremely heavy pieces of equipment. Therefore, this type of cable has to be constructed to ensure that it is durable and safe. 

Aircraft cable has set quality standards which are determined by the FAA (Federal Aviation Administration) and the USDOT (U.S. Department of Transportation) for any cable produced or used in the United States. These guidances ensure that the cables meet regulatory requirements for aircraft equipment. There are set standards for all types and uses of aircraft cable, depending on the application, structure, and so on. 

The materials used in aircraft cable are quite specific, which is what primarily sets them apart from other types of industrial cables. Traditional hardware has too low of a tensile strength and heat ratings, so aircraft cables are only made from high carbon steel, typically 316 or 302/304 grade.  

2. Aircraft Cable is Similar to Extreme Strength Wire Rope

Due to their appearance, aircraft cables are often mistaken for wire ropes. These are similar in some aspects, such as the overall design of construction. 

 Wire ropes are constructed with several strands of wires which are woven together to create an extremely strong cable. There are multiple configurations, depending on the number of wires and strands used in its construction. The more wires used, the more flexible the wire rope will be.  

There are also several types of cores which are utilized in wire ropes and industrial cables. These may be fiber cores, independent wire ropes, or wire strands. These can provide either added flexibility or strength, depending on the intended use and load limit.  

Aircraft cables are constructed in a similar fashion to wire ropes, but they have their own sizing and construction standards. Aircraft cables can be made from wires ranging between 3/64” to ¼”. 

The configurations for industrial wire ropes compared to aircraft cable are also slightly different. Most aircraft cables are constructed with 7×19, 7×7, 3×7, 1×19, or 1×7 configurations. This refers to the number of strands used as well as the number of wires per strand. Industrial wire ropes are most often offered in 6×15, 6×19, 6×26, or 6×36 configurations. 

Ultimately, you could say that aircraft cables are essentially an extremely strong wire rope – but there are important differences, and these two pieces of hardware cannot be used interchangeably. 

3. Aircraft Cables can be Used for Many Things

Although aircraft cables are primarily used for aircraft construction and transportation, this equipment is quite versatile. Thanks to its extremely durable design and high tensile strength, it can be used for far more than just aircrafts.  

Contact us to discuss your requirements of Airport Cables Manufacturer. Our experienced sales team can help you identify the options that best suit your needs.

Some other common applications for aircraft cables include: 

• Boating and Marine Applications – Stainless steel cables are often used for maritime purposes, since it is naturally corrosion resistant. Aircraft cables may be used for securing boats to the dock, as well as hoisting them out of the water. 
• Pulley Systems – Since pulley wires must resist the natural friction it encounters, the cables must be extremely durable. Aircraft cables are often used in this type of apparatus, particularly for lifting heavy loads. 
• Exercise Equipment and Ziplines – These types of cables can be used for entertainment and recreational purposes, but they must be strong enough to withstand lots of weight and friction, as well as harsh weather environments. This makes aircraft cables the ideal hardware choice. 
• Securing Cargo – Aircraft cables are often used on cargo ships and trucks to tie-down large loads.

4. You Should Only Purchase from a Qualified Industrial Hardware Supplier

Since aircraft cables must meet specific standards and the strength and durability is so important, only buy from a trusted industrial hardware distributor. You should only buy from certified suppliers who provide ample details about the materials, construction, and origin of their cables.  

One thing to look out for is the grade of steel which is used to create the cables. Apart from just the graded number, it is recommended that you only use aircraft cables made from IPS (improved plow steel) or EIPS (extra improved plow steel). This classifies the steel’s tensile strength. 

You should also work with a distributor who offers expert advice and assistance when placing orders. There may be times when you need a specific size or when one type of steel grade will do better than another. An industrial hardware supplier should be able to answer any questions you have about their products and help you find the exact configuration, type, and size of cable you need. 

 Looking for Top-Quality Aircraft Cables?

Airport lighting cable, also known as a Type C airport cable, is a specific type of industrial cable used in airports to sustain runway and taxiway lighting systems that are crucial to the pilots' visibility. These cables are used at all steps of airport lighting, including runway end lights, runway end identifier lights, runway edge lights, centerline lights, touchdown zone lights, and the approaching lighting systems. Airport lighting cables are designed to be extra-durable and long-lasting due to the specifics of the airport's operation and the fact that they are used for safety-critical installations. Airports work like a clock, and a delay of any operation may result in physical and financial risks for everyone involved. Naturally, airfield lighting cables have to work like a clock as well. 

These cables are also designed to prevent overheating because they are exposed to high temperatures. While the recommended temperature for a continuous operation is 90 C, airfield ground lighting cables are prepared to survive more extreme conditions as the maximum operating temperature in short circuits is 250 C. Given the varying weather conditions that airport ground is exposed to, airport lighting cables are also waterproof and resistant to the impact of sunlight and abrasion, as well as the chemicals that may be used in an airport.

Applications of Airport Lighting Cables

While an airport lighting cable's main purpose is to sustain runways and taxiways, they are also used for various lighting applications within an airport. Some of the typical applications include obstruction lighting, navigational aids, and lighting and control circuits of all possible types. 

Airport lighting cables are unique when it comes to installation because they can be installed in a variety of ways. These cables are suitable for direct burial, raceways, installation in metallic and non-metallic conduits and ducts. Moreover, aerial cable installation is also a possibility with airport lighting cables. Because of this versatility, airport lighting cables can be used for any purpose within the airport that calls for these types of installation. However, direct burial and burial in ducts are the most widely used types of installation in runways and taxiways.

Construction of a Type C Airfield Cable

Most type C airport lighting power cables have an annealed stranded bare copper with a class B stranding and an XLPE insulation. Cross-linked polyethylene has superior dielectric strength, better impact resistance, higher temperature range than its counterparts. It also has a better resistance to chemicals, which is essential because de-icing fluid chemicals are regularly used in airports. However, some manufacturers offer airfield lighting cables with an alternative PVC and PE insulation. At Nassau National Cable, we offer type C cables with XLPE insulation because of their overall better quality in these settings.

Airfield ground lighting cables also have semi-conductive tape applied over the insulation. This is done to improve the cable's resistance to heat and moisture, which is crucial in the airport setting. The cables also have an optional outer shielding, usually a PVC, PE, HDPE, or CPE jacket, that helps to prevent unwanted power loss.

Types of Airfield Lighting Cables

The main difference between different types of airport cables is their voltage. Standard voltages of lighting runway cables are 5KV and 600 volts. When you buy a runway lighting cable, make sure it meets or exceeds FAA Specification L-824, which is necessary to legally install a lighting cable in an airport.

Airport Lighting Cable 5KV is suitable for primary circuit high-voltage lighting applications. These cables are placed between current regulators and transformers in runways and taxiways. They are expected to be extremely durable and waterproof. The cable is available in sizes between 8 AWG and 4 AWG, with or without a semi-conductive protective tape.

Airport Lighting Cable 600 V is designed for secondary lighting circuits. For instance, these cables connect the runway and taxiways transformers to electrical lamps. While they are not as durable as their 5KV counterparts, their strength is in their flexibility. The cables are sized between 12 AWG and 4 AWG.

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