Material: High-purity aluminum (minimum 99.5% aluminum content), often alloyed with trace amounts of magnesium (Mg) or silicon (Si) to enhance mechanical strength. This alloying prevents conductor deformation under tension (critical for overhead installation) while preserving electrical conductivity.
Stranding Structure: Stranded Conductors (Class 2 or Class 5 per IEC 60228) are standard, as they offer superior Flexibility compared to solid conductors. A typical 2*16mm² conductor (common for residential service) consists of 7 strands of 1.7mm diameter Aluminum Wire, twisted at a pitch of 12–15 times the conductor diameter to minimize fatigue from thermal cycling.
Cross-Sectional Area (CSA): Available in a range of sizes to match load requirements:
Small-scale residential: 26mm², 210mm² (for single-family homes with low power demand, e.g., <10kW)
Medium residential/commercial: 216mm², 225mm² (for multi-dwelling units or small shops with 10–30kW demand)
Industrial light-duty: 235mm², 250mm² (for small factories or agricultural facilities with 30–50kW demand)
Current-Carrying Capacity (CCC): Dependent on CSA and installation environment. For example:
2*16mm² conductor: 85A (free air, 30°C ambient temperature); 70A (enclosed overhead ducts, 40°C ambient)
2*25mm² conductor: 110A (free air); 90A (enclosed ducts)
DC Resistance: Maximum 1.83Ω/km for 16mm² Aluminum Conductors at 20°C (per IEC 60228), ensuring minimal power loss over transmission distances (typically 50–200 meters for service drops).
Material Grade: Medium-density cross-linked polyethylene (XLPE) with a density of 0.92–0.94 g/cm³. The cross-linking process (either via peroxide, silane, or electron beam) creates a three-dimensional molecular network, eliminating the thermoplastic properties of standard PE and enhancing thermal stability.
Thickness: Insulation thickness varies by voltage rating and CSA:
0.6/1kV rated cable: 1.2mm (for 6–10mm² conductors); 1.4mm (for 16–25mm² conductors)
1.8/3kV rated cable (industrial variant): 1.8mm (for 35–50mm² conductors)
Thermal Performance:
Long-term operating temperature: -40°C to +90°C (continuous use)
Short-term overload temperature: Up to +130°C (for 8 hours, maximum 10 times per year)
Thermal shock resistance: Withstands 50 cycles of -40°C (2 hours) to +90°C (2 hours) without insulation cracking
Electrical Properties:
Dielectric strength: ≥20kV/mm (at 25°C, 50Hz AC)
Volume resistivity: ≥10¹⁴ Ω·cm (at 20°C)
Partial discharge: ≤10pC at 1.73 times the rated voltage (ensures no internal arcing, a common cause of insulation failure)
Environmental Resistance:
UV resistance: Passes 1000-hour exposure to Xenon arc lamps (per ISO 4892-2) with no significant color fading or mechanical degradation
Ozone resistance: Withstands 100pphm ozone concentration at 40°C for 72 hours (per IEC 60811-403) without cracking
Chemical Resistance: Resists dilute acids (10% HCl), alkalis (10% NaOH), and mineral oils (per IEC 60811-404)
Bundling Configuration: Two Insulated Conductors twisted together at a pitch of 300–500mm (varies by cable length). The twist direction (left or right) is consistent throughout the cable to ensure uniform mechanical stress distribution.
Reinforcement (Optional): Some variants include a galvanized steel (GS) or aluminum-clad steel (ACS) strength member (diameter 1.5–2.5mm) placed between the two conductors. This member increases tensile strength:
Standard (no reinforcement): Maximum tensile load = 1.2kN (for 2*16mm²)
With GS reinforcement: Maximum tensile load = 2.5kN (for 2*16mm²)
Outer Sheath (Optional): While most LV ABC duplex cables rely on XLPE insulation alone, industrial variants may include a thin (0.8–1.0mm) LSOH (Low Smoke Zero Halogen) sheath for enhanced chemical resistance. The sheath is colored for phase identification (e.g., red for line conductor, blue for neutral).
Overall Diameter:
2*10mm² (1.2mm XLPE insulation): 12.4mm
2*25mm² (1.4mm XLPE insulation): 16.8mm
2*25mm² with LSOH sheath: 18.6mm
Tensile Strength: Minimum 12N/mm² for aluminum conductors (per IEC 60228 Class 2)
Elongation at Break: ≥15% for conductors; ≥200% for XLPE insulation (ensures flexibility under stress)
Impact Resistance: Passes the drop weight test (per IEC 60811-301): 1kg weight dropped from 1m height onto the cable, with no insulation damage
Weather Resistance: Complies with IEC 60811-502 for outdoor exposure: 2000 hours of UV, temperature cycling (-25°C to +70°C), and humidity (95% RH) with no performance degradation
Weight Advantage: Aluminum has a density of 2.7g/cm³, compared to copper’s 8.9g/cm³. A 2*16mm² Aluminum Cable weighs ~0.45kg/m, while a copper equivalent weighs ~1.3kg/m. This reduces the mechanical load on utility poles (extending pole lifespan) and simplifies installation (contractors can handle longer lengths without additional equipment).
Cost Efficiency: Aluminum is 60–70% less expensive than copper (per unit weight), making the cable more affordable for large-scale utility projects—critical for rural electrification initiatives where budget constraints are common.
Corrosion Resistance: Aluminum forms a thin, stable oxide layer (Al₂O₃) on its surface, which prevents further oxidation. For coastal areas (high salt exposure), conductors are treated with a zinc coating (galvanized aluminum) to enhance corrosion resistance.
Conductivity Balance: While copper has higher conductivity (58 MS/m vs. aluminum’s 37 MS/m), aluminum’s lower density means that a larger CSA aluminum conductor can match copper’s performance at a lower cost. For example, a 16mm² aluminum conductor has the same current-carrying capacity as a 10mm² Copper Conductor.
Thermal Stability: PVC softens at 60°C and degrades above 80°C, limiting its use in hot climates. XLPE maintains its mechanical properties up to 90°C, making it suitable for regions with ambient temperatures exceeding 40°C (e.g., Middle East, Southeast Asia).
Longevity: PVC insulation typically lasts 10–15 years in outdoor environments, while XLPE can last 25–30 years—reducing replacement frequency and lifecycle costs for utilities.
Environmental Safety: In the event of a fire, PVC releases toxic hydrogen chloride (HCl) gas and dense smoke, which pose risks to humans and equipment. XLPE is inherently flame-retardant (self-extinguishing per IEC 60332-1) and releases minimal smoke (smoke density <200 optical density units per IEC 61034) with no halogen gases.
Reduced Hardware: Traditional Overhead Lines require separate insulators, spacers, and tie wires for each conductor. ABC cables integrate conductors into a single bundle, eliminating the need for 50–70% of hardware. For example, a 100-meter service drop using ABC cable requires only 2 insulators (at pole and building) versus 4 insulators for separate conductors.
Lower Fault Risk: Bundled conductors reduce the chance of conductor sway (a common cause of short circuits in windy conditions) and prevent accidental contact with trees or debris. Studies by utility companies show that ABC cables have a 40% lower fault rate than traditional overhead lines.
Easy Identification: Color-coded insulation (e.g., red for line, blue for neutral) simplifies installation and maintenance, reducing the risk of phase reversal or incorrect wiring.
Single-Family Homes: The 26mm² to 216mm² variants are ideal for powering homes with standard electrical loads (lighting, appliances, HVAC systems up to 5 tons). The lightweight design allows installation over spans of 20–50 meters (between utility poles and roof-mounted service entrances).
Multi-Dwelling Units (MDUs): For apartments or townhouses, the 2*25mm² variant is used to supply power to a central distribution panel, which then feeds individual units via smaller cables. The duplex structure simplifies routing through narrow roof spaces or wall cavities.
Small Commercial Buildings: Retail stores, offices, and restaurants use 216mm² to 235mm² cables to handle loads from POS systems, refrigeration, and lighting. The XLPE insulation’s UV resistance makes it suitable for installation on exposed building exteriors (e.g., storefront awnings).
Rural Electrification: In remote areas with limited infrastructure, the cable’s lightweight design and low cost make it the preferred choice for extending power to villages. The 210mm² variant is commonly used for service drops to farmhouses, while the 235mm² variant powers small irrigation pumps (up to 7.5kW).
Agricultural Facilities: Greenhouses and livestock farms use the cable to supply power to climate control systems (heaters, fans) and irrigation equipment. The aluminum conductor’s corrosion resistance is critical in humid, high-moisture environments.
Light Industrial Use: Small factories (e.g., textile mills, workshops) use the 235mm² to 250mm² variants for powering machinery with low to medium loads (10–30kW). The optional steel reinforcement ensures the cable can withstand vibrations from nearby equipment.
Temporary Power: Construction sites and outdoor events (concerts, festivals) use the cable for temporary service drops to portable generators or distribution boxes. The flexible Stranded Conductors allow easy routing around construction barriers, and the XLPE insulation resists damage from dust and debris.
High-Temperature Regions: In desert climates (e.g., Saudi Arabia, Arizona), the cable’s 90°C operating temperature ensures it can handle heat buildup from direct sunlight. The UV-resistant XLPE insulation prevents cracking from prolonged sun exposure.
Coastal Regions: For areas near the ocean (e.g., Florida, Southeast Asia), zinc-coated aluminum conductors and LSOH sheaths are used to resist corrosion from salt spray. These variants comply with ISO 12944-5 for C5-M (severe marine) corrosion environments.
Aluminum Rod Melting: High-purity aluminum rods (99.5% Al) are melted in a induction furnace at 700–750°C. Trace alloys (Mg, Si) are added to the molten aluminum to form AA 1350 or AA 6201 aluminum alloy (common for conductors).
Continuous Casting: The molten aluminum is cast into 9.5mm diameter rods using a continuous casting machine. The rods are cooled with water to prevent oxidation and ensure uniform grain structure.
Wire Drawing: The 9.5mm rods are drawn through diamond dies (gradually reducing diameter) to form 1.0–2.0mm Aluminum Wires. A lubricant (mineral oil-based) is used to reduce friction and prevent wire breakage.
Stranding: The drawn wires are twisted together using a tubular stranding machine to form the final conductor (e.g., 7 wires for 16mm²). The stranding pitch is set to 12–15 times the conductor diameter to ensure flexibility.
QC Testing: Conductors are tested for:
Diameter and ovality (using a laser micrometer)
Tensile strength and elongation (using a universal testing machine)
DC resistance (using a micro-ohmmeter)
Material Preparation: XLPE compound (base polyethylene + cross-linking agent + antioxidants + UV stabilizers) is mixed in a high-speed mixer and melted in an extruder (temperature set to 120–140°C). The cross-linking agent (typically dicumyl peroxide) is added at a concentration of 1–2% to ensure proper cross-linking.
Extrusion: The melted XLPE compound is extruded over the stranded conductor using a tandem extruder (two extruders in series). The first extruder applies a thin inner layer (0.2–0.3mm) for primary insulation, and the second extruder applies the outer layer to reach the required thickness (e.g., 1.2mm for 6–10mm² conductors). The extrusion speed is synchronized with the conductor feeding speed (10–15m/min) to ensure uniform insulation thickness.
Cross-Linking: The insulated conductor is passed through a vulcanization tube (temperature 200–220°C) to activate the cross-linking agent. The cross-linking process takes 5–10 minutes, depending on the insulation thickness, and transforms the thermoplastic PE into thermoset XLPE.
Cooling & Sizing: The cross-linked insulated conductor is cooled in a water bath (temperature 20–30°C) to stabilize the insulation. A sizing die ensures the insulation diameter meets specifications, and any surface defects (e.g., bubbles, scratches) are inspected visually.
Twisting: Two insulated conductors (line and neutral) are fed into a twisting machine and twisted together at a pitch of 300–500mm. The twisting speed is set to 8–12 twists per meter to ensure the bundle is tight but flexible.
Reinforcement Integration (Optional): If the cable requires a strength member, a galvanized steel or aluminum-clad steel wire (diameter 1.5–2.5mm) is fed into the twisting machine alongside the two insulated conductors. The strength member is positioned between the two conductors to distribute tension evenly.
Outer Sheathing (Optional): For industrial variants requiring an LSOH sheath, the bundled cable is passed through a second extruder to apply a thin LSOH layer (0.8–1.0mm). The sheath is colored using non-toxic pigments (e.g., red for line, blue for neutral) for phase identification.
Final Curing: The bundled cable is placed in a curing oven (temperature 80–100°C) for 2–4 hours to ensure the sheath (if present) adheres to the XLPE insulation and any residual moisture is removed.
Electrical Testing: Each cable is tested for dielectric strength (using a high-voltage tester—2kV AC for 1 minute), partial discharge (≤10pC at 1.73 times rated voltage), and insulation resistance (≥1000MΩ using a megohmmeter).
Mechanical Testing: Samples are subjected to tensile load testing (to verify maximum tensile strength), impact testing (drop weight test per IEC 60811-301), and bending testing (100 cycles of bending around a mandrel of 10 times the cable diameter) to ensure flexibility.
Environmental Testing: Samples are exposed to UV radiation (1000 hours per ISO 4892-2), temperature cycling (-40°C to +90°C for 50 cycles), and salt spray (5% NaCl solution for 1000 hours per ASTM B117) to verify weather resistance.
Certification: Only cables passing all tests receive certification from global bodies (e.g., CE for European markets, UL for North America, CCC for China) before being packaged and shipped.
Cable Drums: For bulk orders (typically 500m, 1000m, or 2000m lengths), the cable is wound onto wooden or steel cable drums. Wooden drums are made from pine or oak (treated with anti-fungal chemicals to prevent rot) and have a diameter of 800–1200mm (depending on cable length). Steel drums (used for Heavy-Duty Cables or long-term storage) are galvanized to resist rust and have a load capacity of 500–1000kg.
Drum Protection: The cable is covered with a polyethylene (PE) film to prevent dust and moisture ingress. The drum ends are sealed with cardboard or metal covers, and a label is affixed to the drum containing key information: cable model (e.g., XLPE-Al-ABC-Duplex-2*16mm²), length, batch number, manufacturing date, certification marks (CE/UL/CCC), and handling instructions (e.g., “Do not stack more than 2 drums”).
Palletization: For smaller bulk orders (2–5 drums), the drums are placed on wooden pallets (size 1200*1000mm) and secured with stretch film and steel straps. This ensures stability during transportation and makes it easy to load/unload using forklifts.
Coils: For small lengths (10m, 20m, 50m), the cable is wound into compact coils (diameter 300–500mm) and wrapped in PE film. Each coil is placed in a corrugated cardboard box (printed with product details and safety warnings) to prevent damage during handling.
Accessory Kits: For contractor orders, optional accessory kits are available, including cable clamps (for pole mounting), insulation tape (XLPE-compatible), and cable cutters. These kits are packaged in durable plastic cases and shipped with the cable coils.
Indoor Storage: Cables should be stored in a dry, well-ventilated warehouse with a temperature range of -5°C to +40°C. Avoid storing near heat sources (e.g., heaters) or chemicals (e.g., solvents) that could damage the XLPE insulation.
Outdoor Storage (Temporary): If outdoor storage is necessary, drums should be placed on elevated pallets (to prevent waterlogging) and covered with waterproof tarpaulins. Storage time should not exceed 3 months to avoid UV damage to the PE film.
Handling: When moving cable drums, use Drum Rollers or forklifts (for steel drums) to avoid dragging—dragging can damage the cable insulation or loosen the windings.
Truck Shipping: For domestic orders, the cable is transported via flatbed trucks or enclosed trucks. Flatbed trucks are used for large drum orders (1000m+), with drums secured using steel straps and wooden blocks to prevent rolling. Enclosed trucks are used for small coils or LSOH-sheathed variants (to protect against weather and dust).
Delivery Timelines: Domestic delivery typically takes 2–5 business days, depending on the distance from the manufacturing facility. For urgent orders (e.g., utility emergency repairs), expedited shipping (next-day delivery) is available at an additional cost.
Tracking: Customers receive a tracking number once the order ships, allowing them to monitor the shipment’s progress via the logistics provider’s website or mobile app.
Container Shipping: For international orders, the cable is packed into 20ft or 40ft shipping containers. Wooden drums are treated with methyl bromide (per ISPM 15) to meet international phytosanitary standards, preventing the spread of pests. The containers are climate-controlled (temperature 10–30°C) for shipments to extreme climate regions (e.g., Siberia, the Middle East).
Customs Documentation: The following documents are provided with international shipments to facilitate customs clearance: commercial invoice, packing list, certificate of origin, product certification (CE/UL/CCC), and test reports (electrical and mechanical testing).
Freight Options: Customers can choose between sea freight (cost-effective for large orders, 2–4 weeks transit time) or air freight (expedited for small orders, 3–5 days transit time). For landlocked countries, intermodal transportation (sea + rail + truck) is used.
Risk Mitigation: All international shipments are insured against damage or loss (coverage up to the order value) to protect customers from logistics-related risks.
Standard Orders (500–2000m):
Order confirmation (within 24 hours of placement, including a detailed proforma invoice).
Production scheduling (3–5 business days, depending on inventory levels; if custom specifications are required, e.g., LSOH sheathing or special color coding, production extends to 7–10 business days).
Quality control and certification (1–2 business days).
Packaging and shipping preparation (1 business day).
Dispatch (within 7–15 business days of order confirmation for domestic orders; 10–20 business days for international orders, including customs documentation preparation).
Urgent Orders (≤500m):
Priority processing (order confirmation within 12 hours).
Rush production (1–3 business days, utilizing dedicated production lines).
Expedited quality control (same-day testing).
Next-day dispatch for domestic orders (via express carriers like DHL or FedEx); international urgent orders are shipped via air freight within 3 business days.
Commercial Invoice: Details order value, product specifications, quantity, unit price, and payment terms (e.g., L/C, T/T).
Packing List: Itemizes each package (e.g., “Drum 1: 1000m XLPE-Al-ABC-Duplex-2*16mm², Batch No. 20240508-01”), package dimensions, and gross/net weight.
Certificate of Conformity (CoC): Confirms the product meets applicable standards (e.g., IEC 60502-1, UL 44) and includes test results summary.
Handling & Safety Guide: Provides on-site handling instructions (e.g., “Maximum bending radius: 10× cable diameter”) and safety warnings (e.g., “Wear insulating gloves when cutting live cables”).
Tracking Information: A digital tracking link (sent via email/SMS) that updates in real time, including estimated delivery date, current location, and delivery status (e.g., “In transit,” “Out for delivery”).
Pre-Delivery Notification: Customers receive a notification 24–48 hours before delivery, including the carrier’s contact information and delivery window (2–4 hours for domestic orders).
On-Site Assistance: For bulk orders (≥1000m), we offer optional on-site delivery support—our team coordinates with the customer’s contractors to unload drums (using specialized equipment like drum lifters) and verify package integrity.
Damage Claims: If a shipment arrives damaged, customers must notify us within 48 hours of delivery (with photos of the damage and packaging). We initiate an insurance claim within 24 hours and arrange for a replacement shipment (at no cost) or a full refund, depending on the customer’s preference.
Standard Samples: Available for all regular specifications (e.g., 26mm², 216mm², 2*25mm² XLPE-Al-ABC Duplex Cable) with lengths of 5m or 10m (customer’s choice). Samples include both ZR-RVS (flame-retardant) and NH-RVS (fire-resistant) variants.
Custom Samples: For customers requiring specialized specifications (e.g., LSOH sheathing, custom color coding, or reinforced strength members), we produce custom samples within 5–7 business days. The minimum length for custom samples is 10m.
Sample Kit Inclusions: Each sample kit includes the cable sample, a detailed technical datasheet (with electrical/mechanical parameters), a test report (summarizing dielectric strength and tensile strength results), and a small accessory pack (1 roll of XLPE-compatible insulation tape and 2 cable clamps).
Request Submission: Customers can request samples via email, our website, or through their account manager. The request must include: desired specifications (CSA, insulation type, optional features), sample length, quantity, delivery address, and intended use (e.g., “Testing for residential service drop in coastal areas”).
Sample Confirmation: We confirm the request within 24 hours, including a sample quote (standard samples are free of charge; custom samples incur a nominal fee, which is refundable if a bulk order of ≥500m is placed within 30 days).
Production & Dispatch: Standard samples are dispatched within 2–3 business days; custom samples are dispatched within 7–10 business days. Samples are shipped via express carriers (DHL/FedEx) for fast delivery (3–5 days internationally, 1–2 days domestically).
Post-Sample Support: Our technical team is available for 1-on-1 consultations (via video call or email) to assist with sample testing—e.g., guiding customers on conducting flame-retardancy tests (per GB/T 19666-2019) or verifying current-carrying capacity.
24/7 Technical Hotline: A dedicated team of electrical engineers is available 24 hours a day, 7 days a week to address urgent issues (e.g., “Cable insulation damage during installation,” “Unexpected current loss”). Customers can reach the hotline via phone, email, or our mobile app.
On-Site Technical Assistance: For large-scale projects (e.g., rural electrification projects with ≥10,000m of cable), we send technical engineers to the site for installation guidance—including:
Demonstrating proper cable mounting (using pole clamps to maintain a minimum 0.2m distance from other cables).
Advising on weatherproofing (e.g., applying heat-shrinkable sleeves at cable joints in wet environments).
Troubleshooting installation issues (e.g., resolving conductor tangling during unspooling).
Training Programs: We offer free online training webinars (monthly) and on-site workshops (for customers with bulk orders) covering:
Cable installation best practices (per IEC 60364-5-52).
Routine inspection and maintenance (e.g., checking insulation for UV damage every 2 years).
Safety protocols (e.g., using insulated tools when working near live cables).
Standard Warranty: All XLPE Insulated Aluminum ABC Duplex Cables come with a 10-year warranty from the date of delivery. The warranty covers:
Defects in materials (e.g., faulty XLPE insulation, subStandard Aluminum conductors).
Manufacturing defects (e.g., uneven insulation thickness, loose conductor stranding).
Performance failures (e.g., insulation breakdown below the rated voltage, conductor overheating within the specified current-carrying capacity).
Warranty Exclusions: The warranty does not cover damage caused by:
Improper installation (e.g., bending the cable below the minimum bending radius).
Misuse (e.g., using the cable for voltages exceeding its rated voltage).
Environmental damage beyond normal conditions (e.g., direct exposure to seawater, chemical spills).
Natural disasters (e.g., hurricanes, earthquakes).
Warranty Claim Process:
Customers submit a claim via email, including the order number, batch number, photos/videos of the issue, and a detailed description of the problem.
Our technical team reviews the claim within 48 hours and may request additional information (e.g., test reports from a third-party lab).
If the claim is approved, we offer:
A replacement cable (shipped within 3–5 business days for domestic orders).
A full or partial refund (based on the extent of the issue).
On-site repair (for large-scale installations, e.g., replacing a damaged section of cable in a rural electrification project).
Maintenance Guidelines: We provide a comprehensive maintenance manual (included with bulk orders) that outlines:
Routine inspection schedules (quarterly visual checks for insulation damage; annual electrical testing for insulation resistance).
Cleaning procedures (using a dry cloth to remove dust/debris from the cable surface; avoiding harsh chemicals that could degrade XLPE).
Repair methods for minor damage (e.g., using heat-shrinkable tubes to fix small insulation cracks).
Lifespan Extension Services: For customers looking to extend the cable’s lifespan beyond 30 years, we offer:
Periodic professional inspections (every 5 years) by our technical team—including electrical testing (megohmmeter readings) and mechanical checks (tensile strength verification).
Insulation rejuvenation treatment (for cables aged 15+ years): Applying a specialized XLPE-compatible coating to restore insulation elasticity and UV resistance, extending the lifespan by 10–15 years.
Hongtai Kablo Teknoloji Co., Ltd
E-posta: Export@qlcables.com
sales@qlcables.com
Tel/whatsapp:+86-18032066271
Ekle ： Xiaokou Endüstriyel Kalkınma Bölgesi, Ningjin County, Xingtai City ， Hebei Eyaleti, Çin
Telif Hakkı © Hongtai Cable Technology Co., Ltd Teknik Destek:Ronglida teknolojisi
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