Material: High-purity aluminum (99.5% minimum purity) alloyed with 0.5–1.0% magnesium and silicon. This alloy enhances tensile strength (110–130 MPa) and corrosion resistance, critical for withstanding mechanical stress during installation and prolonged outdoor exposure.
Stranding Design: Each 16mm² conductor consists of 19 stranded Aluminum Wires (diameter 1.0mm each), twisted concentrically to form a flexible yet durable core. The stranding pattern ensures uniform current distribution and allows the cable to bend easily around poles or obstacles without cracking the insulation.
Electrical Conductivity: ≥61% IACS (International Annealed Copper Standard), resulting in a low resistance of ≤1.15Ω/km per conductor at 20°C. This minimizes power loss during transmission, with efficiency exceeding 97% at full load.
Current-Carrying Capacity: 70–85A per conductor at 30°C ambient temperature; derated to 55–65A at 40°C to account for increased thermal resistance in hot climates. The total current capacity of the 4-core bundle supports three-phase systems up to 400V with a maximum power output of approximately 50kVA.
Thickness: 1.0–1.2mm per conductor, applied uniformly via extrusion to ensure complete coverage and dielectric protection. The insulation thickness is optimized to balance Flexibility and durability, avoiding excessive weight while meeting safety standards.
Thermal Performance: Continuous operating temperature range of -40°C to 90°C, with short-circuit tolerance of 250°C for up to 5 seconds. This exceeds the capabilities of PVC Insulation (60–70°C continuous) and makes the cable resilient to transient overloads from motor startups or equipment faults.
Dielectric Strength: ≥20kV/mm, ensuring reliable insulation even over spans up to 50m. This property prevents electrical leakage and reduces the risk of arcing between conductors, a common cause of outages in bare conductor systems.
Water Treeing Resistance: Tested per IEC 61442, with no visible treeing after 10,000 hours of immersion in water. This confirms suitability for humid environments, coastal regions, or areas with frequent rainfall.
Material: Low-density polyethylene (LDPE) or linear low-density polyethylene (LLDPE) with a melt flow rate of 0.5–2.0g/10min, ensuring flexibility and impact resistance. LLDPE is preferred for applications requiring enhanced puncture resistance (e.g., rural areas with wildlife).
Thickness: 0.8–1.0mm, applied as a continuous outer layer over the bundled Insulated Conductors. The sheath binds the four cores together while adding a protective barrier against physical damage.
UV Stability: Formulated with 2–3% carbon black additives to absorb ultraviolet radiation, preventing degradation from sunlight exposure. This extends the sheath’s service life to 20+ years in outdoor conditions.
Color Coding: Standard color-coding per IEC 60446: Three Phase Conductors (brown, black, gray) and one neutral conductor (blue). Custom colors are available upon request for specific regional standards.
Overall Diameter: 25–30mm, including insulation and sheath, making it compact enough for installation in space-constrained areas (e.g., urban alleyways, dense vegetation).
Tensile Strength: 2.5–3.0kN (cable alone), sufficient for spans up to 40m between poles. An optional galvanized steel messenger wire (3mm diameter) can be integrated, increasing tensile strength to 5.0–6.0kN for spans up to 60m.
Bending Radius: Minimum 10× outer diameter (static) and 15× outer diameter (dynamic), allowing flexible routing during installation without compromising performance.
Impact Resistance: Withstands 10J impact at -20°C without insulation or sheath damage, tested per IEC 60811-1-2.
Chemical Resistance: Resistant to industrial pollutants, salt spray (500 hours per ASTM B117 with ≤5% weight loss), and ozone (100ppm at 40°C for 1000 hours with no cracking).
IEC 60502-1: Low-voltage Power Cables with extruded insulation.
ASTM B230: Standard specification for aluminum Electrical Conductors, stranded.
UL 44: Safety standard for rubber-Insulated Wires and cables (for flame-retardant variants).
CE Marking: Conforms to EU Directive 2014/35/EU for low-voltage equipment.
Small Manufacturing Units: Powers machinery, compressors, and assembly lines in industries such as textiles, electronics, and food processing. The three-phase configuration ensures balanced power for motors, reducing wear and extending equipment life.
Workshops and Garages: Supports power tools, welding equipment, and automotive lifts, where reliable three-phase supply is essential for consistent performance. The cable’s durability withstands the harsh conditions of industrial environments, including exposure to oil, dust, and mechanical vibration.
Retail and Wholesale Outlets: Supplies power to large shopping centers, supermarkets, and warehouses, supporting HVAC systems, refrigeration units, and lighting. The 4x16mm² capacity handles peak loads during business hours without voltage drops.
Multi-Story Apartments: Delivers three-phase power to buildings with 10–20 units, supporting elevators, communal heating/cooling systems, and individual household loads. The bundled design reduces installation space, making it suitable for urban areas with dense housing.
Gated Communities: Connects clubhouses, swimming pool pumps, and security systems, ensuring reliable power for shared amenities. The insulated design minimizes the risk of accidents in populated areas.
Farms and Plantations: Powers irrigation pumps, grain mills, and dairy processing equipment, where three-phase motors are common. The cable’s corrosion resistance withstands exposure to fertilizers, moisture, and rural pollutants.
Rural Electrification: Integrates into grid extension projects, connecting remote villages to three-phase power for community centers, schools, and small businesses. Its lightweight design simplifies installation in areas with limited access to heavy machinery.
Sports Facilities: Supplies power to stadiums, gymnasiums, and outdoor fields, supporting lighting, scoreboards, and HVAC systems during events. The cable’s UV resistance ensures reliability in constant outdoor exposure.
Transport Hubs: Powers bus terminals, train stations, and small airports, where three-phase equipment (e.g., baggage handlers, fuel pumps) requires stable power. The safety features reduce the risk of outages in high-traffic areas.
Tinned Aluminum Conductors: For coastal or high-salt environments (e.g., seaside towns, fishing villages), conductors are coated with a 0.02–0.05mm layer of tin to enhance corrosion resistance. This variant extends service life by 30% compared to Standard Aluminum in salt-spray conditions.
High-Strength Alloys: For applications requiring increased tensile strength (e.g., long spans over rivers or valleys), conductors are alloyed with 1.0–1.5% magnesium, raising tensile strength to 140–160 MPa.
Flame-Retardant XLPE: In fire-prone areas (e.g., forested regions or near chemical plants), insulation is blended with magnesium hydroxide additives to achieve a UL94 V-0 flame rating, preventing flame spread in case of damage.
Rodent-Resistant PE Sheath: For rural areas with high rodent activity, the PE sheath is infused with capsaicin (a natural repellent) to deter gnawing, reducing the risk of insulation damage.
Low-Smoke Zero-Halogen (LSZH) Sheath: In enclosed spaces (e.g., underground ducts for short spans), LSZH sheaths minimize toxic fume emission during combustion, enhancing safety for maintenance workers.
Armored Variant: A 0.3mm galvanized Steel Tape is applied over the PE sheath for installations in high-risk areas (e.g., near construction sites or wildlife corridors), providing additional protection against physical impact.
Messenger Wire Integration: For long spans (40–60m), a 3mm galvanized steel messenger wire is twisted with the cable bundle, reducing sag and ensuring stable performance under wind or ice loads.
Conductor Stranding:
High-purity aluminum rods are heated to 300–400°C and drawn through diamond dies to form individual strands of 1.0mm diameter.
Strands are twisted into four 16mm² conductors using a planetary stranding machine, with a lay length of 12–16 times the conductor diameter to balance flexibility and strength.
XLPE Insulation Extrusion:
Each Stranded Conductor is preheated to 80–100°C to ensure proper adhesion of the insulation.
Molten XLPE (melt temperature 180–200°C) is extruded over each conductor using a cross-head die, forming a uniform 1.0–1.2mm layer.
The insulated conductors undergo cross-linking via steam curing (180°C, 10 bar pressure for 2 hours) to enhance thermal and chemical resistance.
Bundling and Sheath Application:
The four XLPE-insulated conductors (three phase, one neutral) are twisted together into a bundle with a lay length of 20–25 times the overall diameter.
The bundled conductors are cooled to 60–80°C before entering a second extrusion line, where LDPE or LLDPE is applied as a 0.8–1.0mm outer sheath. Color pigments are added to the PE melt for phase identification.
Quality Testing:
Electrical Testing: Each cable undergoes a 10kV AC voltage test for 1 minute to check for insulation defects, followed by an insulation resistance test (≥1000 MΩ at 500V DC).
Mechanical Testing: Samples are subjected to tensile testing (conductor elongation ≥15%), impact testing (-20°C, 10J), and bending tests (10× diameter) to verify durability.
Environmental Testing: Accelerated aging tests (1000 hours at 100°C) and UV exposure tests (ASTM G154) confirm long-term performance.
Spooling:
Cables are wound onto wooden or steel spools (diameter 800–1200mm) in lengths of 200m, 500m, or 1000m, based on customer requirements. Each spool is labeled with conductor size, insulation type, length, batch number, and manufacturing date for traceability.
Spool Materials: Standard spools are made from high-density plywood (thickness 18–22mm) with steel flanges (diameter 300–400mm) to prevent cable damage. For export or reusable applications, galvanized steel spools are available to resist corrosion.
Cable Protection: The outermost layer of cable on each spool is wrapped with a UV-resistant polyethene film (0.1mm thickness) to shield against dust, moisture, and sunlight during storage.
Labeling: Each spool features a weatherproof label with:
Product details (4x16mm², Aluminum Conductors, XLPE insulation, PE sheath).
Electrical specifications (current capacity, voltage rating, resistance).
Compliance marks (IEC, ASTM, CE).
Batch number and manufacturing date for quality tracking.
Palletization: For bulk orders, spools are secured onto wooden pallets (1200×800mm) using steel straps (25mm width). Each pallet holds 4–6 spools (maximum weight 1000kg) and is shrink-wrapped to prevent movement during transit.
Land Transportation:
Domestic deliveries use enclosed or flatbed trucks, with spools secured upright to prevent rolling. For lengths over 500m, spools are placed horizontally on pallets to distribute weight evenly.
Temperature-controlled trucks are recommended for PE-Sheathed Cables in regions with extreme heat (≥40°C) to avoid sheath softening.
Sea Freight:
Export orders are shipped in 20ft or 40ft containers, with pallets stacked to a maximum height of 2.4m. Dunnage (wooden blocks) is placed between layers to absorb shocks during rough seas.
Desiccants (500g per cubic meter) are added to containers to control humidity, preventing condensation damage to wooden spools.
Air Freight:
For urgent orders, cables are shipped via air in smaller spools (200m length) to meet weight restrictions. Spools are packed in corrugated cardboard boxes with foam padding to minimize vibration damage.
Handling Guidelines:
Spools must be lifted using forklifts or cranes with slings (avoiding direct contact with the cable).
Cables should not be dragged or dropped, as this may damage the insulation or conductor.
Storage during transit must be in covered areas to prevent exposure to rain, snow, or direct sunlight.
Minimum Order Quantity: 200m per order, with no maximum limit. Custom lengths (e.g., 300m) are available with a 5% surcharge.
Lead Times:
Standard configurations: 7–10 business days from order confirmation.
Custom variants (e.g., tinned conductors, Flame-Retardant Insulation): 12–15 business days.
Export orders: Additional 3–5 days for documentation (certificates of conformity, packing lists, customs declarations).
Shipping Terms: Available under EXW, FOB, CIF, or DDP terms, with partnerships with major logistics providers (DHL, FedEx, Maersk, and local carriers). Customers may specify preferred carriers for domestic deliveries.
Tracking and Notifications: Once shipped, customers receive a tracking number and automated updates via email or SMS, including estimated delivery times and any delays.
Sample Availability: Standard samples (1m length) are provided free of charge, including XLPE insulation and color-coded PE sheath. Custom samples (e.g., tinned conductors, flame-retardant insulation) are available for a fee of \(80–\)120.
Shipping Costs: Customers cover shipping expenses, which typically range from \(30 (domestic) to \)150 (international) via express courier (DHL, FedEx).
Processing Time: Samples are shipped within 3 business days of request, with delivery in 3–5 days for domestic orders and 7–10 days for international orders.
Sample Kit: Each sample includes a technical data sheet, compliance certificates, and a test report (voltage test, insulation resistance) for quality verification.
Installation Assistance:
A 40-page installation manual (available in English, Spanish, French, and Mandarin) is provided with each order, covering pole mounting, tensioning, termination, and safety procedures.
Virtual support via video call (Zoom, Teams) is available for complex installations, with engineers guiding contractors through setup steps.
Warranty Coverage:
10-year warranty against manufacturing defects, including insulation breakdown, conductor corrosion, or sheath cracking under normal operating conditions (≤90°C, spans ≤40m).
Warranty excludes damage from improper installation (e.g., over-tensioning), natural disasters (lightning, floods), or unauthorized modifications.
Replacement and Repair:
Defective cables identified within the warranty period are replaced free of charge, with the manufacturer covering return shipping costs.
Repair kits (insulation sleeves, conductor splices) are available for purchase, with step-by-step guides for on-site repairs.
Hongtai Cable Technology Co., Ltd
E-mail: export@qlcables.com
sales@qlcables.com
Tel/Whatsapp:+86-18032066271
Adicionar: Zona de Desenvolvimento Industrial Xiaokou, Ningjin County, Cidade de Xingtai ， Hebei Província, China
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