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Aluminum Conductors with XLPE Insulation for Overhead Power Line Applications

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.
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  • ABC

Product Description


conductor

Applications

- Rural Electrification: Ideal for remote areas with limited infrastructure.

- Urban Distribution: Overhead lines in densely populated zones.

- Forestry Zones: Fire-resistant and eco-friendly.

- Industrial Complexes: Reliable power supply in harsh environments.

- Renewable Energy: Connects solar/wind farms to grids.

Features

Weatherproof: Resists UV, rain, snow, and pollution.

-Safety: Reduced risk of short circuits and accidental contact.

-Low Maintenance: Minimal sagging and corrosion.

-Space-Saving: Compact design reduces right-of-way requirements.

-Easy Installation: Lightweight and pre-bundled for rapid deployment.

Standards

- IEC 60502 (Power cables up to 30 kV)

- IEC 61089 (Circular concentric lay stranded conductors)

- ASTM B232 (Aluminum conductors, concentric-lay-stranded)

- BS 7870(LV and MV polymeric insulated cables)

- AS/NZS 3560(Australian/New Zealand standards for ABC)

Construction

1. Conductors: High-purity aluminum or aluminum alloy (AAAC) for phase and neutral wires.

2. Insulation: Cross-linked polyethylene (XLPE) or high-density polyethylene (HDPE) for UV and moisture resistance.

3. Messenger Wire: Optional steel or aluminum alloy core for mechanical support.

4. Bundling: Phase conductors and neutral are twisted or bound together with durable UV-resistant tapes.

Key Parameters

- Voltage Rating: 0.6/1 kV (LV) or 11 kV/33 kV (MV)

- Conductor Sizes: 16 mm² to 240 mm² (aluminum)

- Temperature Range: -40°C to +90°C (operational)

- Current Capacity: Up to 600 A, depending on configuration.

Technical Data

Property

Value

Insulation Thickness

1.5 mm – 3.5 mm (XLPE/HDPE)

Tensile Strength

1000–1500 N/mm² (messenger wire)

Resistance

1.12 Ω/km (for 50 mm² Al)

Weight

150–600 kg/km (varies by size)




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).

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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