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66kV HV Grid Reinforcement Aerial Conductors

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Aerial Bundled Conductors (ABC) are insulated overhead power distribution systems designed for safe and efficient electricity transmission in urban, rural, and industrial areas. Unlike traditional bare conductors, ABC systems bundle multiple insulated phase conductors with a neutral or messenger wire, reducing installation costs, minimizing faults, and enhancing reliability in harsh weather conditions.
cross sectional area:
16-150
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  • ABC


Product Overview

East Energy Electrical Engineering Co., Ltd. specializes in the manufacturing of high-performance Aerial Bundled Conductors (ABC) with XLPE insulation, engineered for safe, reliable, and efficient overhead power transmission across urban, rural, and industrial sectors.

Our ABC Products Integrate:

Component Material Key Property
Phase conductors High-purity aluminum (H68 Al) Excellent electrical conductivity
Neutral messenger Aluminum alloy Mechanical strength + corrosion resistance
Insulation Cross-linked polyethylene (XLPE) –40°C to +90°C temperature range

Ideal Applications:

  • Overhead power distribution networks

  • Rural electrification projects

  • Urban infrastructure upgrades

  • Industrial power supply systems

Quality and Precision

We prioritize precision in every production step, adhering to strict international standards:

Standard Description
IEC 60502 Power cables with extruded insulation
CENELEC HD 626 Aerial bundled cables for overhead distribution
ASTM B231 Aluminum conductors for electrical purposes

Manufacturing Process Ensures:

Parameter Specification
Conductor diameter tolerance ±0.1mm
Concentric stranding (≤ 50mm²) 7-core
Concentric stranding (50–150mm²) 19-core
Bundle design Integrated – eliminates separate support structures

Customization Options

To meet diverse project requirements, we offer full customization for:

Parameter Range / Options
Cross-sectional areas 10mm² to 400mm²
Bundle configurations Duplex (2×16+1×16), Triplex (3×25+1×25), Quadruplex, custom
Insulation materials XLPE or HDPE
Voltage rating LV (0.6/1kV) to MV (11kV / 33kV)

OEM Services:

  • Regional standards (AS/NZS, NBR, GOST)

  • Client branding (custom printing and packaging)

  • Special environmental conditions (tropical, desert, coastal)

Detailed Product Profile

Technical Specifications & Design

Parameter Value Standard
Rated Voltage 0.6/1kV (LV) / 11kV–33kV (MV) CENELEC HD 626
Conductor Material H68 Al (phase), Al alloy (neutral) ASTM B231
Insulation XLPE / PE (max 90°C) IEC 60502
Bundle Configurations Duplex, Triplex, Quadruplex Customizable
Cross-Section Range 10 – 400 mm² HD 626
Operating Temperature –40°C to +90°C EN 50618
Short Circuit Temperature 250°C (max 5 sec) IEC 60502
Insulation Thickness 0.7 – 3.5 mm IEC 60502
Outer Sheath Color Black, gray, blue, or custom (UV-stabilized) Customer request

Stranding Structure

Conductor Size Number of Wires Stranding Type
10 – 50 mm² 7 wires Concentric
50 – 150 mm² 19 wires Concentric
150 – 400 mm² 37 wires (optional) Concentric

Competitive Advantages

Attribute HD 626 ABC Traditional Cables
Installation Speed 30% faster Slower
Tower Load 40% reduction Higher cost
Lifespan 25+ years 15–20 years
Safety Compliance CENELEC HD 626 / IEC 60502 Variable
Maintenance Low Higher
Tree Contact Risk Reduced High
Aesthetics Compact and neat Visible wiring

Applications

Architectural & Urban Applications

Scenario Technical Fit Benefit
Building Complexes Facade-integrated distribution Aesthetic + reduced sag
Historic Districts Narrow street lines Compact design
Coastal Resorts Salt-air exposure 25-year corrosion resistance
Renewable Microgrids Solar-powered lighting UV-resistant XLPE
Industrial Parks High-density networks Fast installation
Airports Runway/terminal lighting Reliable power
Railway Stations Platform/concourse distribution Durable & weather-resistant

Rural and Remote Applications

Scenario Technical Fit Benefit
Village Electrification Long-span distribution Reduced tower count
Agricultural Irrigation Pumping station supply Weather-resistant
Mountainous Terrain Steep-slope lines Flexible & easy to handle
Island Power Supply Coastal/marine environment Corrosion-resistant
Remote Mining Sites Temporary/permanent lines Fast deployment

Compliance and Certifications

Standard Scope Status
IEC 60502 Power cables with extruded insulation Compliant
CENELEC HD 626 Aerial bundled cables Compliant
ASTM B231 Aluminum conductors Compliant
EN 50618 XLPE insulation Compliant
ISO 9001 Quality management Certified
ISO 14001 Environmental management Certified

Testing and Quality Assurance

Test Method Acceptance Criteria
High voltage test 4 kV AC for 5 min No breakdown
Insulation resistance 500 V DC ≥ 100 MΩ·km
Conductor resistance Kelvin bridge ≤ IEC 60228 limits
Tensile strength Tensile tester ≥ 12.5 MPa
Elongation at break Tensile tester ≥ 350%
Thermal aging 135°C / 168h Retention ≥ 80%
UV resistance Accelerated weathering No cracking/fading
Water absorption 70°C / 168h ≤ 5% weight increase

Installation Guidelines

Parameter Value
Minimum bending radius 8 × cable diameter (during installation)
Recommended pulling tension ≤ 50 N/mm²
Maximum operating tension 20% of rated breaking strength
Hardware compatibility ABC-specific clamps, dead-ends, suspension fittings

Packaging and Delivery

Packaging Type Length
Wooden drum 500m – 2000m
Plastic reel 100m – 200m
Custom packaging Available

Shipping methods: Sea freight / Air freight / Land freight

Documentation included:

  • Packing list

  • Commercial invoice

  • Test reports (routine & type)

  • Quality certificate

  • Installation manual

FAQ

Q: What is the difference between ABC and bare conductor?
A: ABC cables have insulated phase conductors, reducing electrocution risk, allowing smaller clearances, and providing better reliability during storms.

Q: Can ABC cables be installed on existing poles?
A: Yes. Lightweight design reduces pole load by up to 40%, often reusing existing infrastructure.

Q: What is the maximum span length?
A: Typical spans are 50–80 meters, depending on conductor size, tension, and weather conditions.

Q: Are ABC cables suitable for coastal areas?
A: Yes. Corrosion-resistant aluminum alloy messengers and UV-stabilized XLPE insulation make them ideal for coastal and marine environments.

Q: Do you provide installation training?
A: Yes. We offer on-site training, technical documentation, and remote support.


66kV HV Grid Reinforcement Aerial Conductors



Code: ABC 0.6/1kV.

Standards:HD 626  S1:1996  Part5-Section D,AMKA(SFS 2200).

Construction: Phase  Conductors:Aluminum conductors with XLPE insulation.

Neutral Messenger:Aluminum conductors.

Application: Aerial Bundled Conductors are used for tributary networks of power buildings and their internal networks.

Installation: These cables are not allowed to be buried, even in conduits.

Dimensions of Phase Conductors


Cross Section

Conductor

Diameter

Thickness of Insulation

Core Diameter

Current Carrying Capacity

Breaking

Load

(mm²)

min.

tolerance

nom.

min.

min.

max.

(A*)

(kN)

(mm)

(mm)

(mm)

(mm)

(mm)


16

4.4

±0.05

1.4


7.1

7.3

70


25

5.9

±0.02

1.4


8.3

9.1

95


35

6.9

±0.02

1.6


9.7

10.5

115


50

8.1

±0.25

1.6


10.8

11.8

140


70

9.7

±0.25

1.8


12.8

13.8

180


120

12.8

±0.30

2.0


16.2

17.4

250


*  Defined  for  ambient  temperature  of 25℃  and  max.conductor  temperature  of 70℃.

Cross Section

Conductor Diameter

Thickness of Insulation

Core Diameter

Current Carrying Capacity

Breaking Load

(mm²)

min.

tolerance

nom.

min.

min.

max.

(A*)

(kN)

(mm)

(mm)

(mm)

(mm)

(mm)


25

5.9

±0.02



5.5

6.3


7.4

35

6.9

±0.02



6.5

7.3


10.3

50

8.1

±0.25



7.6

8.6


14.2

70

9.7

±0.25



9.2

10.2


20.6

95

11.4

±0.30



10.8

12.0


27.9


Dimensions of Cable Bundle


Number of Phase Cores× Cross Section +Public Lighting Conductors

+ Neutral Cross Section

(mm²)

Bundle Diameter

Approx.

(mm)

1×16+25

15

3×16+25

22

4×16+25

22

3×25+35

26

4×25+35

26

3×35+50

30

3×50+70

35

3×70+95

41

3×120+95

47

LV-ABC Lines with Insulated Neutral Messenger

Code: ABC 0.6/1kV.

Standards:HD 626 S1:1996 Part 6-Section E,AMKA(SFS 2200)

Construction: Aluminum conductors with XLPE  insulation.

Application:Aerial Bundled Conductors are used for tributary networks of power buildings and their internal networks.

Installation:These cables are not allowed to be buried,even in conduits.

Dimensions of Phase Conductors

Cross Section

Conductor

Diameter

Thickness of

Insulation

Core Diameten

Current Carrying Capacity

Breaking Load

(mm²)

min.

max.

nom.

min.

min.

max.

(A*)

(kN)

(mm)

(mm)

(mm)

(mm)

(mm)


16

4.6

5.1

1.2


7.0

7.8



25

5.8

6.3

1.4


8.6

9.4

112


35

6.8

7.3

1.6


10.0

10.9

138


50

7.9

8.4

1.6


11.1

12.0

168


70

9.7

10.2

1.8


13.3

14.2

213


95

11.0

12.0

1.8


14.6

15.7

258


120

12.0

13.1

1.8


15.6

16.7

306


150

13.9

15.0

1.7


17.3

18.6

344


* Defined for ambient temperature of 30℃ and max. conductor temperature of 90℃.

Dimensions of Neutral Messenger Conductors

Cross Section

Conductor

Diameter

Thickness of

Insulation

Core Diameter

Current Carrying Capacity

Breaking

Load

(mm²)

min.

tolerance

nom.

min.

min.

max.

(A*)

(kN)

(mm)

(mm)

(mm)

(mm)

(mm)


54.6

9.2

9.6

1.6


12.3

13.0


16.6

70

10.0

10.2

1.5


12.9

13.6


20.5

95

12.2

12.9

1.6


15.3

16.3


27.5

* Defined for ambient temperature of 30℃ and max.conductor temperature of 90℃.

Dimensions of Cable Bundle

Number of Phase Cores× Cross Section +Public Lighting Conductors

+Neutral Cross Section

(mm²)

Bundle Diameter

Approx.

(mm)

3×25+54.6

30.0

3×35+K×16+54.6

33.0

3×50+K×16+54.6

36.0

3×70+K×16+54.6

37.5

3×70+K×25+54.6

40.0

3×70+K×16+70

41.0

3×95+K×16+70

44.0

3×120+K×16+70

46.0

3×120+K×16+95

47.0

3×150+K×16+70

48.0

3×150+K×16+95

49.0

* Note: K number of public lighting conductors(K can be equal to 0.1.2.or 3).


MV-ABC Lines with Insulated Neutral Messenger

Code: ABC 11kV.

Standards:SANS 1713.

Construction:Phase  Conductors:Aluminum conductors with XLPE insulation.

Neutral  Messenger:A  stranded  galvanized  steel  conductor  with  XLPE insulation.

Application: The Aerial Bundled Conductors shall suitable for continuous operation outdoors in tropical areas at altitudes of up to 2200m above sea level, humidity of up to 90%, average ambient temperature of+30℃ with a minimum of - 1℃ and a maximum of +4℃ in direct  sunlight, heavy saline conditions along the coast and isoceraunic levels of up to 180 thunderstorm days per year.

Installation:These cables are not allowed to be buried,even in conduits.


Phase Conductor Characteristics


1

Conductor size

mm²

70

95

185

2

Diameter over conductor.nominal

mm

9.3-10.2

11.6

16.4


3

Thickness   of   dielectric.nominal

mm

3.4

3.4

3.4

Minimum  at  a  point

mm

2.96

2.96

2.96

4

Diameter  over  insulation.  nominal

mm

16.1-17.0

21.3

25.9

5

Diameter  over  semi-conducting  core  screen.  nominal

mm

18.1-19

23.3

27.9

6

Thickness  of  copper  tape.nominal

mm

0.15

1.15

2.15


7

Thickness   of   sheath.nominal

mm

1.8

1.8

1.8

Minimum  at  a  point

mm

1.43

1.43

1.51

8

Catenary   size

mm²

50

50

70

9

Overall   diameter   of   bundle.nominal

mm

55.7

67.8

79.2

10

Nominal  mass

kg/m

2.64

3.25

4.65


Supporting Catenary Characteristics


1

Catenary size

mm²

50

70

2

Number of wires


7

7

3

Wire size(diameter)

mm

3.0

3.6

4

Minimum tensile strength of each wire

kN

9.26

13.13

5

Elongation at break. minimum

%

3.5

4.0


6

Thickness of protective covering




Nominal

mm

1.2

1.2

Minimum at a point

mm

0.96

1.96

7

Impusewhsandvoag        e1.250s


21kV/5min

21kV/5min


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