Aircraft Cable
Aircraft Cable Size & Strength Chart
Breaking strengths for 1/16″ through 3/8″ aircraft cable in 7x7 and 7x19 construction, plus how to choose between galvanized and stainless cable wire rope for your application.
What is aircraft cable?
Aircraft cable is small-diameter stranded wire rope— sometimes called cable wire rope — typically 3/8″ and under, built in 7x7 or 7x19 construction from galvanized carbon steel or type 304/316 stainless steel. The name comes from its original use in aircraft flight controls, but today the same cable serves rigging, lifelines, garage doors, exercise equipment, and marine hardware. Because it packs many small wires into a compact stranded design, aircraft cable delivers high strength and flexibility for its size — the two properties that separate it from solid wire and from larger crane-class wire ropes. Browse our full aircraft cable catalog for stocked sizes and constructions.
7x7 vs 7x19 aircraft cable
The construction number tells you how the cable is built: strands x wires per strand. More wires means more flexibility; fewer, larger wires means more abrasion resistance.
7x7 Construction
7 strands x 7 wires — 49 wires total
Fewer, larger wires make 7x7 cable stiffer and more abrasion-resistant than 7x19. It holds up better where the cable rubs against guides or fittings, and it is the standard construction for the smallest diameters (1/16″ and 3/32″).
- ✓Straight runs and static loads
- ✓Light-duty control cables
- ✓Abrasive environments
7x19 Construction
7 strands x 19 wires — 133 wires total
Many fine wires make 7x19 cable significantly more flexible, so it can run over pulleys and sheaves without fatiguing. It is the standard construction for aircraft controls and rigging, and for most diameters 1/8″ and up.
- ✓Runs over pulleys and sheaves
- ✓Aircraft controls and rigging
- ✓Repeated flexing and winching
Aircraft cable breaking strength chart
Standard published minimum breaking strengths for galvanized aircraft cable. Stainless steel cable runs slightly lower per size. Working load limits shown assume a common 5:1 design factor.
| Diameter | Construction | Min Breaking Strength | Working Load (5:1) | Typical Use |
|---|---|---|---|---|
| 1/16" | 7x7 | 480 lbs | ~96 lbs | Picture hanging, light lanyards |
| 3/32" | 7x7 | 920 lbs | ~184 lbs | Light controls, trellis, displays |
| 1/8" | 7x19 | 2,000 lbs | ~400 lbs | Aircraft controls, railing infill |
| 5/32" | 7x19 | 2,800 lbs | ~560 lbs | Controls, light rigging |
| 3/16" | 7x19 | 4,200 lbs | ~840 lbs | Garage doors, exercise equipment |
| 7/32" | 7x19 | 5,600 lbs | ~1,120 lbs | Rigging, winch lines |
| 1/4" | 7x19 | 7,000 lbs | ~1,400 lbs | General rigging, lifelines |
| 5/16" | 7x19 | 9,800 lbs | ~1,960 lbs | Heavy rigging, guy lines |
| 3/8" | 7x19 | 14,400 lbs | ~2,880 lbs | Heavy-duty rigging, hoisting |
Never load a cable to its breaking strength. Breaking strength is the minimum load at which a new cable fails under test. Safe working load requires a design factor — commonly 5:1 for general rigging, and higher for lifting people or overhead loads. Fittings, terminations, and wear all reduce the effective strength of an assembly.
Galvanized vs stainless aircraft cable
- Galvanized aircraft cable is the economical workhorse. Zinc-coated carbon steel delivers slightly higher breaking strength per size than stainless and resists rust in dry, indoor, and general outdoor service. See our galvanized aircraft cable line for stocked sizes.
- Type 304 stainless aircraft cable trades a small amount of strength for genuine corrosion resistance. Choose it for architectural railing, food processing, and sustained outdoor exposure where a zinc coating would eventually sacrifice itself. Browse stainless aircraft cable options.
- Type 316 stainless adds molybdenum for resistance to chlorides — the right call for marine rigging, coastal installations, and pool environments where 304 can pit. For a full alloy comparison, see our 304 vs 316 stainless guide.
Common aircraft cable applications
Aircraft cables show up far beyond aviation. The same 7x19 flexibility that suits aircraft flight controls makes it the standard for garage door lift cables, exercise equipment, winch and rigging lines, and safety lifelines. Stiffer 7x7 cable handles straight-run duties like railing infill, display suspension, and light control linkages, while 316 stainless cable is the material of choice for marine rigging and coastal hardware. American Wire Works also supplies custom steel wire rope for aircraft applications and OEM assemblies where a stock construction, coating, or put-up will not do.