When you work in a space as jargon-heavy as the electrical industry, things can get confusing quickly.
A prime example of this is when we talk about the products and materials we use every day in our work. To the average person, “wire” and “cable” are essentially interchangeable terms. But for those of us using the two products constantly, there are subtle — but critical — differences.
So, what constitutes a wire, and when does it become a cable?
The key difference between wire and cable is the number of conductors. Wire is made of one conductor, regardless of the material or how you use it.
Electrical wires have many variations, including solid or stranded, and bare or insulated copper, aluminum, or steel. You can find wires used across a number of industries, including:
Whether they’re completing an electrical power circuit or buried underground alongside utility pipes and gas lines, wire is seemingly everywhere.
Single wires work well for custom installations that require a specific solution. They’re also less expensive to manufacture, since there’s only one conductor that may need insulation. The result is a more cost-effective solution with lower upfront costs.
Sizing is also not a problem, as wires have many gauges. Manufacturers can produce wires as small as 40 AWG to massive MCM (kcmil) sizes.
However, keep in mind that wires can become tough to manage when multiple conductors occupy the same space. Workers should identify and mark each wire to keep them organized and consider using trays or conduit to keep installations tidy.
Unlike wire, which has one electrical conductor, cables feature two or more wires bundled together with an outer jacket.
One of the most obvious examples is tray cable, which has several individually insulated conductors bunched together and then surrounded by an overall jacket. Other options include twisted or braided wires to cancel electromagnetic interference (EMI) and crosstalk or increase flexibility.
Depending on the application, the electrical industry has a diverse array of products, including:
One thing worth remembering about cable is that it often is a bit beefier than its singular counterpart. Cable conductors have individual insulations and may have shielding or another protective layer added. From there, manufacturers add a thick outer jacket to keep the wires together and in place.
All these layers make cable ideal for harsh environments and areas where outside EMI noise could potentially cause disruptions. You can find cables used in conduits and conduit trays, buried underground, and where crushing or abrasion is possible.
Additionally, with multiple conductors in a cable, especially in tray cable, it can be tough to tell everything apart. To reduce confusion and protect workers, tray cable may have an E-1, E-2, or M-4 color code, per National Electrical Code (NEC) and Insulated Cable Engineers Association (ICEA) guidelines. These specialized codes apply to heavy-duty projects across commercial and industrial applications.
| Wire | Cable | |
| Number of Conductors | One | Two or more |
| General Construction | Can be solid or stranded | Multiple solid or stranded wires that may be braided, twisted, or bunched together. |
| Insulation | Can be bare or insulated | Insulated conductors, possibly shielded, and encased in an overall jacket |
| Protection | Low | Higher because of the jacketing, which increases abrasion and crush protection. Other protections include moisture, oil and gas, and chemical resistance. Optional shielding and armoring are also available. |
| General Application | Carrying electrical currents and signals, small-scale installations | Complex projects, longer range transmission, power distribution, and harsh environments |
| Flexibility | Generally flexible, though stranded conductors are more flexible than solid | Generally less flexible than single wires, though it depends on the design and application |
| Overall Cost | Less expensive because the manufacturing process is fairly simple | More expensive because there are more steps in the cable manufacturing process. |
Despite subtle differences, wire and cable are remarkably similar.
In the same way that elements are the building blocks of larger molecules, wires are the building blocks of cables. Wires help create and complete circuits with a simple, elegant solution. Meanwhile, cables have a wide range of uses based on the type of wiring needed, from powering machines to connecting components.
It may seem silly, but knowing the difference between wire and cable can go a long way. At the very least, it ensures everyone is on the same page, potentially saving time and confusion later.