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2025-09-03 17
This guide provides five clear, expert-approved steps for cutting armoured cable safely and effectively. We'll cover the essential tools, a step-by-step method, and crucial mistakes to avoid. Whether you're a seasoned electrician or a capable DIYer, getting this right is fundamental to any project involving this robust wiring.
Before you make the first cut, it's helpful to know what you're working with. Armoured cable is designed with a protective layer, typically galvanized steel or aluminum, wound around the inner cores. This armour provides mechanical protection, preventing crushing or damage from impacts. However, this metal sheath is what makes cutting armoured cable different from cutting standard NM or Romex® cable. Using standard wire cutters or a hacksaw carelessly can fray the armour, leaving sharp edges that can damage the inner insulation and compromise safety.
You can't do a professional job without the right tools. Using improper tools is the most common mistake we see. For cleanly cutting armoured cable, you will need a few specific items:
A dedicated armoured cable cutter: This is the ideal tool, providing a clean, square cut without splaying the wires.
A hacksaw with a bi-metal blade: A very common and effective alternative. The key is to use a sharp blade and employ the correct technique.
A rotary cable cutter: For frequent, high-volume work, this power tool is a game-changer.
Tape: Electrical tape or a specialist anti-short bushings are needed to protect the inner cores from the sharp cut armour.
Pliers: For twisting the armour and securing the gland nuts afterwards.
⚠ Warning: Never use an angle grinder or standard wire cutters for the main armour cut. An angle grinder can generate excessive heat, damage the insulation, and create hazardous metal shavings inside the cable. Standard wire cutters will crush and distort the armour, making it unusable.
Follow these five steps for a perfect cut every time.
Step 1: Measure and Mark Precisely
This seems obvious, but measure twice, cut once. Use a tape measure and a permanent marker or a piece of tape to clearly indicate your cutting point. Ensure you have enough cable length for termination and any future servicing.
Step 2: Secure the Cable Firmly
Place the cable securely in a vice or have a colleague hold it steady. This prevents the cable from spinning or moving when you apply pressure, which is crucial for a clean cut and for your safety.
Step 3: Score and Cut the Armour
This is the critical step. If using a hacksaw, position the blade on your mark. Apply light pressure and use a steady, back-and-forth motion to score through the metal armour. You only need to cut through the armour, not the entire cable. Once scored, you can twist the armour to break it off cleanly at the score line.
Fun fact: A study on workshop injuries found that nearly 40% of injuries involving cable occurred during the cutting phase, primarily due to the tool slipping from an unsecured cable (Source: Electrical Safety Foundation International, 2022).
Step 4: Remove the Cut Armour Section
Once the armour is severed, carefully unwind and remove the cut section. You will now see a bare section of inner cores with a conductive plastic layer (the bedding) and the sharp, freshly cut end of the armour.
Step 5: Apply Protection and Terminate
This final step is non-negotiable for safety. The cut end of the armour will be razor-sharp. You must cover it immediately. The best practice is to slide a "cone" from a wiring gland onto the cable before you make the cut. After cutting, slide this cone back over the sharp armour to protect the wires. Alternatively, you can use a specialist red anti-short bushings or even carefully wrap the edge with electrical tape to prevent the armour from slicing into the insulation.
| Feature | Armoured Cable Cutter | Hacksaw |
|---|---|---|
| Cost | Higher initial investment | Very low cost |
| Ease of Use | Very easy; one-handed operation | Requires practice and technique |
| Cut Quality | Clean, square, and perfect crush-free cut | Can be clean if done correctly, but risk of fraying |
| Portability | Bulky to carry | Easy to carry |
| Best For | Professionals who do this daily | DIYers and occasional use |
Before you energize your circuit, run through this list:
The correct cutting tool for the job is selected and sharp.
The cable is measured, marked, and securely held in place.
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The armour has been cut cleanly without damaging the inner cores.
The sharp cut end of the armour is properly protected with a gland cone or anti-short bushing.
The cable is correctly terminated into a suitable armoured cable gland to maintain the earth continuity and IP rating.
Cutting armoured cable safely is a skill that underpins a secure and reliable electrical installation. By respecting the process, using the right tools, and always protecting the inner conductors, you ensure your project is safe and built to last. Remember, taking a few extra minutes to do it right is always faster than fixing a mistake.
Q1: Can I use bolt cutters for cutting armoured cable?
A1: It's not recommended. While bolt cutters can shear through the metal, they tend to crush and distort the armour violently, which can easily damage the inner insulation and compromise the cable's integrity.
Q2: How do I prevent the armour from fraying when using a hacksaw?
A2: The key is to score the armour lightly and consistently around the circumference rather than trying to cut through it aggressively in one spot. Once scored, a sharp twist will usually break it cleanly at the score line.
Q3: Is it necessary to earth the armour?
A3: Yes, absolutely. The steel wire armour is a vital part of the cable's earth continuity. This is why you use a proper metal gland when terminating; it bites into the armour, providing a secure mechanical and electrical connection to earth.
Q4: What is the purpose of the yellow gland ring?
A4: The yellow ring inside a gland is an anti-vibration seal. It helps to keep the gland nut locked in place and maintains the environmental seal, preventing moisture and dust from entering the enclosure.
Q5: Can armoured cable be used outdoors?
A5: Yes, that's one of its primary purposes. The armour provides mechanical protection, and when terminated with weatherproof glands and suitable enclosures, it is perfectly suited for direct burial or outdoor runs.
