Aluminum Alloy Conductor Plastic Insulated Power Cable for Medium- and Low-Voltage Networks

Reliable power transmission depends on cable systems that combine electrical conductivity, insulation performance, mechanical strength, installation practicality, and long-term environmental resistance. The aluminum alloy conductor plastic insulated power cable, with rated voltage applications up to 26/35kV, is designed to address these requirements in medium- and low-voltage transmission and distribution systems. It uses an aluminum alloy conductor as the conductive core, plastic insulation as the primary electrical protection, and an external sheath to protect the cable from mechanical and environmental influences.

This cable type is suitable for fixed installation in urban power networks, industrial distribution systems, commercial buildings, public infrastructure, transportation projects, and energy facilities. Its design is particularly useful where a balance is required between dependable electrical performance, reduced cable weight, installation efficiency, and controlled material consumption.

Compared with conventional cables using heavier conductor materials, aluminum alloy conductor cables can reduce overall cable weight while maintaining stable current transmission performance. The resulting benefits may include easier handling, lower installation labor requirements, simplified transportation, and improved practicality for projects involving long cable routes or difficult construction conditions.

The product is manufactured for applications ranging from low-voltage systems at 0.6/1kV to medium-voltage systems reaching 26/35kV within the applicable product family. Cross-linked polyethylene is commonly used as the insulation material because it provides strong electrical insulation, high operating-temperature capability, heat resistance, and resistance to aging. The exact construction can be selected according to voltage level, installation environment, number of cores, shielding requirements, and project specifications.

Wuxi Guanghuan Cable Co., Ltd. manufactures this product as part of a wider portfolio of power cables, electrical equipment wires and cables, bare conductors, overhead insulated cables, rail transit cables, and cables for renewable energy and energy storage applications. Its production capabilities, testing resources, technical personnel, quality systems, and experience in cable manufacturing support the development of cable solutions for domestic and international engineering projects.

1. Product Overview

The aluminum alloy conductor plastic insulated power cable is a fixed-installation power cable intended for the transmission and distribution of electrical energy. Its main function is to carry electrical current from power sources to distribution equipment, buildings, production facilities, public infrastructure, and other electrical loads while maintaining insulation between the conductor and surrounding structures.

The conductive core is produced from aluminum alloy material rather than ordinary aluminum or heavier metallic conductor materials. Alloying and conductor design are used to improve the balance between conductivity, tensile strength, flexibility, and weight. The conductor may be manufactured in a compacted or otherwise optimized structure to reduce unnecessary voids and provide a practical external diameter.

The insulation system is based on plastic insulating materials, commonly cross-linked polyethylene. This insulation is designed to withstand the electrical stress associated with the specified rated voltage and to maintain reliable performance during long-term operation. In medium-voltage designs, additional semiconductive layers and metallic shielding arrangements may be included according to the cable construction and applicable technical standard.

The outer sheath provides protection against moisture, abrasion, impact, chemicals, and other environmental influences. Sheath material and structure can be adapted to the installation environment. For example, a cable installed indoors may require a different protection profile from one installed in a tunnel, underground facility, industrial plant, or outdoor distribution route.

The product can be supplied in different core configurations and cross-sectional areas. Single-core cables are often selected for particular high-current or installation arrangements, while three-core cables are commonly used in three-phase distribution systems. The appropriate selection depends on current capacity, voltage, short-circuit requirements, route length, installation method, ambient conditions, and the requirements of the electrical design.

2. Main Construction

2.1 Aluminum Alloy Conductor

The aluminum alloy conductor is the central component responsible for transmitting electrical energy. Aluminum-based conductors have a lower density than many conventional conductor materials, making them useful where cable weight is an important design consideration. The alloy composition and manufacturing process are controlled to provide stable conductivity together with improved mechanical performance.

A properly designed aluminum alloy conductor can provide a practical combination of electrical and mechanical properties. Its lower weight can make cable drums easier to transport and cable sections easier to position during installation. This is valuable in high-rise buildings, underground facilities, long industrial routes, bridges, tunnels, and projects where lifting equipment or access space is limited.

The conductor may be compacted to create a smooth and relatively dense structure. This can help reduce the overall cable diameter compared with a less compact conductor of the same nominal area. A controlled conductor geometry also supports consistent insulation extrusion and stable dimensional quality during production.

2.2 Semiconductive Components and Electrical Field Control

Medium-voltage cable designs generally require careful control of the electrical field around the conductor. Semiconductive layers may be applied over the conductor and beneath the main insulation to reduce localized electrical stress and support a more uniform field distribution.

Uniform interfaces are important for long-term insulation reliability. Manufacturing equipment must control extrusion conditions, material cleanliness, concentricity, and surface quality. Defects, contamination, excessive eccentricity, or irregular interfaces can increase local electrical stress. For this reason, online monitoring and high-voltage testing are important parts of a professional cable manufacturing process.

2.3 Cross-Linked Polyethylene Insulation

Cross-linked polyethylene, commonly known as XLPE, is widely used in medium- and low-voltage power cables. It offers strong dielectric performance, a maximum permissible long-term conductor operating temperature of 90°C under the stated operating conditions, and good resistance to heat and aging.

During a short-circuit event lasting no more than five seconds, the maximum allowable conductor temperature can reach 250°C under the specified cable design and standard requirements. This temporary temperature capability allows the cable to withstand short-duration fault conditions while protective equipment operates to clear the fault.

Insulation thickness and construction are determined by rated voltage and applicable standards. Medium-voltage cables require greater insulation coordination and more rigorous testing than low-voltage cables. Production parameters must therefore be adjusted according to the voltage class rather than applying a single manufacturing approach to all products.

2.4 Metallic Shielding and Protective Layers

Depending on the design, medium-voltage cable may include metallic screens or shields. These components help manage electrical fields, provide a path for fault current, and support the safe operation of the cable system when properly connected to the grounding arrangement.

Additional layers may include fillers, binding tapes, armor, water-resistant components, or other protective structures. The selected arrangement depends on whether the cable will be installed directly underground, in ducts, in cable trays, indoors, outdoors, in industrial facilities, or in locations exposed to mechanical forces.

2.5 Outer Sheath

The outer sheath is the cable’s first line of defense against the surrounding environment. It protects internal components from abrasion, moisture, sunlight, chemicals, and general handling damage. Sheath material selection must correspond to the expected operating conditions.

A reliable sheath also supports installation quality. During pulling, bending, positioning, and fixing, the sheath must tolerate reasonable mechanical stress without cracking or losing protective function. The cable should nevertheless be installed according to the specified minimum bending radius and pulling requirements.

Component	Primary Function	Typical Material or Design Feature	Project Benefit
Aluminum alloy conductor	Transmits electrical current	Optimized aluminum alloy stranded or compacted conductor	Reduced weight with stable conductivity and mechanical strength
Conductor screen	Supports electrical field control	Semiconductive extruded layer where required	Improved field uniformity around the conductor
Main insulation	Electrically separates the conductor from other components	Cross-linked polyethylene or other specified plastic insulation	Heat resistance, insulation stability, and aging resistance
Metallic screen or shield	Controls electrical stress and supports fault-current paths	Metallic tape, wire screen, or specified shielding structure	Improved medium-voltage system protection and grounding compatibility
Outer sheath	Protects the cable from the installation environment	Environmental-resistant plastic sheath	Mechanical protection and improved service durability

3. Electrical and Operating Performance

The product family covers medium-voltage and low-voltage applications. Operating performance depends on the selected voltage class, conductor cross-sectional area, installation method, ambient temperature, number of loaded circuits, thermal conditions, and applicable technical standard.

3.1 Medium-Voltage Operating Characteristics

For cross-linked polyethylene insulated cables in the range from 3.6/6kV to 35kV, the maximum permissible long-term operating temperature of the conductor is 90°C under the stated requirements. This allows the cable to carry its designed load while maintaining stable insulation performance during normal operation.

In short-circuit conditions lasting no more than five seconds, the maximum allowable conductor temperature is 250°C. This value is used in the design and verification of the conductor and insulation system. Actual protection coordination must be completed by the system designer so that fault currents are cleared within the required time.

During installation, the ambient temperature should not be lower than 0°C. Low temperatures can reduce the flexibility of plastic materials and increase the risk of sheath or insulation damage during bending. If installation must take place under colder conditions, appropriate technical measures should be considered in accordance with the cable manufacturer’s instructions and the applicable project standard.

For three-core medium-voltage cables, the minimum bending radius should generally be no less than 10 times the cable outer diameter. For single-core cables, the minimum bending radius should generally be no less than 15 times the cable outer diameter. These requirements help preserve the geometry of the insulation, shielding, conductor, and sheath during installation.

3.2 Low-Voltage Operating Characteristics

For cross-linked polyethylene insulated low-voltage cables rated at 0.6/1kV, the conductor’s maximum permissible long-term operating temperature is also 90°C under the stated product requirements. This makes the cable suitable for long-term power distribution in buildings, industrial plants, public facilities, and other low-voltage networks.

Under a short-circuit condition lasting no more than five seconds, the conductor temperature may reach 250°C. The actual permissible fault current depends on conductor size, initial temperature, fault duration, and cable construction. Electrical protection must be selected to ensure that the cable is not exposed to fault conditions beyond its verified capability.

The recommended minimum installation temperature is 0°C. The minimum bending radius is generally no less than seven times the cable outer diameter for the stated low-voltage construction. Installation personnel should confirm the specific technical data for the selected cable before beginning work, because special structures may have different requirements.

3.3 Voltage Adaptability

One of the product’s important strengths is its availability for several voltage classes. This allows project engineers to select an appropriate cable from a related product family rather than treating each voltage level as an entirely separate solution. The cable can support low-voltage distribution and medium-voltage feeder applications when the correct insulation system, conductor size, shielding arrangement, and test requirements are specified.

The rated voltage should always be selected according to the electrical network. A cable rated for a lower voltage must not be used in a higher-voltage system merely because the conductor cross-sectional area appears adequate. Voltage stress, insulation thickness, screen design, accessories, termination methods, and testing must all be evaluated together.

4. Advantages of Aluminum Alloy Conductor Cable

4.1 Lower Cable Weight

Lower weight is one of the most visible advantages of aluminum alloy conductor cable. The reduced density of aluminum alloy can decrease the mass of a cable with an equivalent current-carrying design. This can simplify transportation, storage, drum handling, lifting, and positioning.

Weight reduction is especially valuable in projects with restricted access. High-rise construction sites, underground stations, tunnels, industrial plants, and renovation projects may have limited lifting capacity or narrow cable routes. A lighter cable can help reduce the burden on installation teams and may allow more practical use of available handling equipment.

Lower cable weight may also reduce logistical requirements over long distances. Fewer handling resources may be needed for moving cable drums from a delivery point to the installation area. However, the final cable drum weight, drum dimensions, route conditions, and lifting plan must still be reviewed before construction.

4.2 Installation Convenience

A lighter cable can improve installation convenience without compromising the need for proper technical control. Installation teams may find it easier to arrange cable routes, position cables in trays, and prepare sections for termination. Reduced weight can also be beneficial when cables must be installed at height or in locations where mechanical access is limited.

Installation convenience does not mean that normal cable handling requirements can be ignored. The cable should not be dragged over sharp surfaces, crushed under heavy equipment, bent below its specified radius, or pulled beyond the permitted tension. Proper rollers, pulling devices, temporary supports, and route preparation remain necessary.

4.3 Efficient Material Utilization

Aluminum alloy is widely available and offers a practical resource option for power cable manufacturing. The use of aluminum alloy conductors can support material diversification and help project owners select a cable based on a broader combination of electrical, mechanical, weight, and cost considerations.

Resource utilization should be evaluated through the entire project life cycle. The conductor material, insulation system, sheath, accessories, installation method, operating losses, maintenance requirements, and expected service life should all be considered. A technically appropriate cable is one that provides reliable performance over the complete operating period rather than simply offering the lowest initial purchase price.

4.4 Stable Mechanical Performance

Aluminum alloy conductors are designed to provide improved mechanical strength compared with basic aluminum conductor designs. This supports cable handling and installation while maintaining stable performance during long-term service. The precise mechanical properties depend on alloy composition, conductor structure, cross-sectional area, and manufacturing process.

Mechanical strength is particularly important when cables are pulled through ducts, arranged in complex routes, or installed in areas subject to vibration or thermal movement. The cable must still be supported correctly and protected from excessive external force. Cable strength does not replace good engineering practice.

4.5 Reliable Thermal and Insulation Performance

The XLPE insulation system supports a maximum long-term conductor operating temperature of 90°C under the stated conditions. Its short-circuit temperature capability of up to 250°C for a duration of no more than five seconds provides a useful margin for temporary fault conditions.

XLPE also offers stable electrical insulation, heat resistance, and resistance to aging. These properties are important in distribution systems where cables may operate continuously for many years. The insulation must be produced with controlled cleanliness, thickness, concentricity, and extrusion quality to achieve the expected performance.

4.6 Broad Application Range

The cable can be applied in buildings, public facilities, industrial plants, energy projects, transportation systems, and special engineering environments. Its broad application range allows it to serve as a feeder cable, distribution cable, internal power cable, or infrastructure power connection, depending on the selected structure and voltage class.

The same basic product concept can therefore support multiple project categories while allowing customization in conductor size, number of cores, shielding, sheath, armor, and applicable standard. This flexibility helps engineering contractors and electrical designers coordinate cable selection with the rest of the power system.

Aluminum Alloy Conductor Plastic Insulated Power Cable (Rated Voltage up to 26/35kV)

5. Comparison with Conventional Cable Selection

Cable comparison should be based on the complete technical requirement rather than on conductor material alone. A cable with a lower weight may offer installation advantages, but it must still meet the required current-carrying capacity, voltage rating, short-circuit performance, insulation level, mechanical conditions, and environmental requirements.

Compared with heavier conductor cable designs, aluminum alloy conductor cables may provide a lower mass for a similar electrical application. This can reduce handling difficulty and improve installation efficiency. Compared with basic aluminum conductors, the alloy design can offer an improved balance of strength and conductivity. Compared with underspecified low-cost cables, a properly manufactured product provides better assurance through controlled materials, tested construction, and documented quality procedures.

Competitor comparison should also consider manufacturing control. Important factors include conductor resistance, dimensional accuracy, insulation eccentricity, sheath thickness, partial discharge performance, high-voltage withstand results, short-circuit capability, production traceability, and compliance with the specified standard. A cable supplier with modern online monitoring and complete testing capabilities can provide greater confidence than a supplier that only performs limited final inspection.

Evaluation Factor	Aluminum Alloy Conductor Cable	Key Selection Consideration
Conductor weight	Generally lower than heavier conductor alternatives for comparable applications	Review complete cable mass and drum handling requirements
Mechanical strength	Supported by alloy composition and optimized conductor structure	Confirm pulling tension, bending, support, and termination requirements
Electrical conductivity	Stable when conductor design and material quality are properly controlled	Verify conductor resistance and ampacity for the selected size
Insulation performance	XLPE provides stable dielectric properties and heat resistance	Confirm voltage class, insulation thickness, and test results
Installation efficiency	Lower weight can simplify transportation and positioning	Prepare suitable rollers, pulling equipment, and route protection
Environmental adaptability	Can be configured with suitable sheath and protection structures	Match sheath construction to moisture, chemicals, sunlight, and mechanical exposure
International project suitability	Can be manufactured and tested according to multiple standards	Define the governing standard before production begins

6. Manufacturing Process and Quality Control

6.1 Material Preparation

Reliable cable quality begins with material control. Aluminum alloy rod, insulation compounds, semiconductive materials, sheath compounds, metallic components, and auxiliary materials must be checked before entering production. Material identification and batch management help maintain traceability throughout the manufacturing process.

Conductor materials are selected according to the required electrical and mechanical properties. Insulation materials must be suitable for the specified voltage class and processing conditions. The material preparation process should control storage temperature, humidity, cleanliness, and contamination risk because plastic insulation performance can be affected by improper handling.

6.2 Conductor Stranding and Compaction

Aluminum alloy wires are stranded to form the conductor. The stranding process controls wire arrangement, pitch, surface condition, and dimensional stability. Compaction may be used to create a denser and more uniform conductor profile.

Process control at this stage affects electrical resistance, flexibility, surface smoothness, and compatibility with subsequent insulation extrusion. Excessive deformation, loose strands, damaged wires, or uneven compaction can create defects that influence the final cable. Production personnel therefore monitor conductor dimensions and appearance during operation.

6.3 Insulation Extrusion

The insulation is applied through an extrusion process. For medium-voltage cable, the conductor screen, insulation, and insulation screen may be extruded in a controlled arrangement to improve interface quality and electrical field uniformity. Clean production conditions are particularly important for medium-voltage insulation systems.

Extrusion temperature, pressure, line speed, cooling conditions, and material flow must be controlled. The objective is to achieve consistent insulation thickness, stable concentricity, smooth interfaces, and the required dimensional tolerances. Online eccentricity monitoring can identify deviations during production, allowing corrective action before a long cable length is completed.

6.4 Cross-Linking and Cooling

When cross-linked polyethylene is used, the insulation undergoes a controlled cross-linking process. This changes the polymer structure and provides the thermal and electrical properties required for power cable service. The cross-linking process must be properly controlled to avoid defects such as inadequate curing, excessive thermal exposure, voids, or dimensional instability.

After cross-linking, the cable is cooled under controlled conditions. Cooling must be sufficiently uniform to maintain cable geometry and prevent stress concentration. The completed insulation is then evaluated through dimensional inspection and electrical testing.

6.5 Shielding, Sheathing, and Final Assembly

Metallic screens, tapes, fillers, armor, and other components are applied according to the specified design. The outer sheath is then extruded over the cable structure. Sheath thickness, surface condition, concentricity, color, marking, and dimensional stability are monitored.

Cable marking provides important information for identification, installation, maintenance, and traceability. Depending on the project requirements, marking may include manufacturer information, voltage rating, conductor size, standard, production batch, meter marking, and other technical identifiers.

6.6 Testing and Inspection

Testing verifies whether the finished product satisfies the applicable technical requirements. Typical inspection activities may include conductor resistance measurement, dimensional inspection, insulation thickness measurement, sheath thickness measurement, voltage withstand testing, insulation resistance testing, partial discharge testing for suitable medium-voltage designs, and other routine or type tests.

High-voltage series resonance testers can be used for high-voltage withstand testing. Partial discharge detectors support the evaluation of insulation quality in medium-voltage cable systems. Online eccentricity monitors help control insulation geometry during extrusion rather than relying only on inspection after production.

Testing requirements depend on the governing standard and contract specification. A project may require routine tests for every manufactured length, sample tests at defined intervals, or type tests for a particular cable design. The test plan should be agreed before production so that documentation is complete and aligned with the customer’s requirements.

7. Manufacturing Strengths of the Supplier

Wuxi Guanghuan Cable Co., Ltd. was founded in 1998 and is headquartered in Guanlin Town, Yixing City, Jiangsu Province, a region known for its cable manufacturing industry. The company covers more than 100,000 square meters, including more than 45,000 square meters of building area, and operates more than 70 production and testing lines.

The company employs more than 140 people, including more than 30 technical professionals. Its reported annual sales revenue is approximately RMB 2 billion, while annual output value exceeds RMB 3 billion. These resources support large-scale production, product development, quality management, technical service, and project coordination.

The company offers more than 100 product categories and over 30,000 specifications under the registered Liguang brand. Its product portfolio includes power cables, electrical equipment wires and cables, bare conductors, overhead insulated cables, high-speed railway and urban rail transit cables, and cables for energy storage, photovoltaic, and wind power applications.

A broad product portfolio can benefit customers that need coordinated cable procurement across different parts of an electrical or infrastructure project. The supplier’s experience in multiple cable categories may also support technical communication when a project includes medium-voltage feeders, low-voltage distribution, control wiring, overhead lines, renewable energy connections, or specialized infrastructure cables.

7.1 Production Equipment

Advanced production equipment supports consistent product quality. Online eccentricity monitors can detect deviations in insulation and sheath geometry during extrusion. High-voltage series resonance testers can perform high-voltage testing with controlled test conditions. Partial discharge detectors can help identify insulation defects that may not be visible through ordinary visual inspection.

The use of these technologies demonstrates an approach that combines process monitoring with final product testing. Process monitoring helps prevent defects from continuing through the production line, while final testing confirms whether the finished cable meets the required electrical and dimensional criteria.

7.2 Management Systems and Certifications

The company has obtained ISO 9001 quality management, ISO 14001 environmental management, ISO 45001 occupational health and safety, and ISO 50001 energy management certifications. It has also obtained certifications or management system recognition related to intellectual property, green management, social responsibility, and after-sales service.

These systems provide a framework for managing production quality, environmental responsibilities, energy use, workplace safety, innovation, customer service, and post-delivery support. Management system certification does not replace product testing, but it can strengthen organizational control when properly implemented.

The company’s products have received CCC, TÜV, product carbon footprint, China Energy-Saving and Environmentally Friendly Product, and other certifications. The relevance of each certification depends on the cable type, market, project, and contract requirement. Customers should confirm which certificates apply to the selected product and intended destination.

7.3 Technical and Project Support

Cable projects often require more than manufacturing. Customers may need conductor sizing, voltage selection, cable structure recommendations, test documentation, packing plans, delivery coordination, installation guidance, and after-sales support. A supplier with technical professionals and a broad manufacturing base can provide assistance across these stages.

For international projects, communication about standards is especially important. The product can be manufactured and tested according to GB/T requirements and, when specified, according to relevant International Electrotechnical Commission, British, or American standards. The selected standard should be clearly identified in the technical agreement because requirements for conductor resistance, voltage tests, dimensions, marking, routine tests, and type tests may differ.

8. Applicable Standards and Project Compliance

The product is manufactured in accordance with GB/T 31840-2025 according to the supplied product information. This standard provides the technical basis for the design and manufacture of the applicable power cable product. Quality control procedures are implemented throughout design, material preparation, production, testing, and delivery.

For projects outside the domestic market, the cable may also be produced and tested according to applicable IEC standards, British standards, or American standards. International projects should define the required standard at the inquiry and design stage. The cable supplier can then confirm whether the requested conductor, insulation system, sheath, test program, labeling, and documentation are available.

Standards compliance should be supported by technical documents. These may include product datasheets, construction drawings, standard declarations, routine test reports, type-test reports, material certificates, inspection records, packing lists, and certificates of conformity. The exact document package should be agreed with the customer before shipment.

8.1 Standard Selection Procedure

The first step is to identify the electrical network and rated voltage. The second step is to define the installation method, including direct burial, duct installation, cable tray, tunnel, building shaft, underground facility, or industrial route. The third step is to determine current demand, short-circuit level, ambient temperature, grouping conditions, and required service life.

The fourth step is to select the cable construction, including conductor size, number of cores, insulation, shielding, armor, sheath, and water or fire protection features where required. The fifth step is to agree on the governing standard and testing requirements. Finally, the technical specification should be reviewed and approved before production.

9. Application Fields

9.1 Building Engineering

The cable is suitable for power distribution systems in high-rise buildings, residential developments, hotels, hospitals, theaters, conference centers, libraries, museums, and other buildings. It can be used for connections between transformers, switchboards, distribution panels, and major electrical loads.

In large buildings, cable weight and installation access can be significant concerns. Aluminum alloy conductor cables may help simplify handling in vertical shafts, plant rooms, underground parking areas, and long horizontal routes. Cable selection must still account for fire protection, emergency power requirements, smoke control, installation grouping, and local building regulations.

9.2 Public Facilities

Government buildings, financial centers, broadcasting and television centers, sports complexes, and public service facilities require dependable power distribution. These projects may include multiple voltage levels, backup systems, large mechanical loads, and complex cable routes.

The cable can be selected for feeder and distribution applications where its voltage rating, conductor size, insulation type, sheath, and installation method meet the project design. Public facilities may also require strict documentation, inspection procedures, and delivery coordination because electrical systems are often integrated with other construction activities.

9.3 Industrial and Energy Facilities

Industrial and mining enterprises, petrochemical plants, power facilities, and steel smelting projects may use the cable for power distribution between substations, switchgear, production lines, motors, auxiliary systems, and process equipment.

Industrial environments can expose cables to heat, vibration, oil, chemicals, mechanical impact, and electromagnetic influences. The cable structure should therefore be selected according to the actual environment. Additional armor, special sheath materials, separation measures, or protective conduits may be required.

9.4 Transportation Infrastructure

Airports, tunnels, metro systems, light rail systems, underground parking facilities, and civil defense structures require organized and dependable electrical networks. Cable routes may be long, enclosed, congested, or difficult to access after construction.

In these applications, reduced cable weight can support installation efficiency, while the plastic insulation and protective sheath provide the basic electrical and mechanical functions required by the project. Fire performance, smoke characteristics, water resistance, and emergency power requirements should be reviewed separately where applicable.

9.5 Special Engineering Environments

Ships, offshore oil platforms, large commercial complexes, shopping centers, and parking facilities may require specially selected cable structures. The product concept can be adapted to different installation conditions, but the final design must satisfy the specific environmental, fire, mechanical, and regulatory requirements of the project.

Offshore and marine applications may require resistance to salt spray, moisture, vibration, oil, and movement. Commercial complexes may require stringent fire performance and smoke control. Parking facilities may require consideration of water, vehicle impact, ventilation, and emergency systems. These requirements should be incorporated before the cable is manufactured.

10. Installation Recommendations

Before installation, the cable drum should be inspected for damage, moisture ingress, deformation, missing markings, or other transportation problems. Cable ends should remain sealed until the cable is ready for termination. The route should be checked for sharp edges, obstructions, excessive bends, water accumulation, and insufficient support.

During pulling, the installation team should use suitable rollers and pulling equipment. Pulling tension should remain within the specified limit, and the cable should not be twisted. For long routes, the pulling direction, intermediate access points, bending areas, and communication arrangements should be planned in advance.

The minimum bending radius must be respected. For the stated medium-voltage construction, three-core cables generally require a bending radius of at least 10 times the outer diameter, while single-core cables generally require at least 15 times the outer diameter. For the stated low-voltage construction, the minimum bending radius is generally at least seven times the outer diameter.

Installation should not normally be performed at ambient temperatures below 0°C. If the cable has been stored in a cold environment, it may require suitable conditioning before bending. The installation team should follow the manufacturer’s instructions and the approved project method statement.

After installation, the cable should be supported and fixed according to its construction and route. Single-core cables require particular attention to electromagnetic effects, cleat arrangement, spacing, and short-circuit forces. Terminations and joints must be made using accessories compatible with the cable’s conductor, insulation, voltage class, screen, and sheath.

Testing after installation should be performed according to the applicable standard and project requirements. Test methods must be selected carefully so that the cable and accessories are not damaged by inappropriate voltage or duration. Test records should be retained as part of the project commissioning documentation.

11. Cable Selection Checklist

When selecting the aluminum alloy conductor plastic insulated power cable, the project team should first confirm the rated voltage. The cable voltage must correspond to the nominal network voltage and insulation coordination requirements.

The required current-carrying capacity should then be calculated. This calculation should consider conductor cross-sectional area, installation method, ambient temperature, cable grouping, thermal resistance of surrounding materials, and permissible conductor temperature.

The short-circuit current and clearing time should be reviewed. The cable must withstand the expected short-circuit thermal and mechanical stresses until the protection system clears the fault.

Installation conditions should be defined, including indoor or outdoor use, direct burial, ducts, trays, tunnels, shafts, machinery areas, wet locations, chemical exposure, vibration, sunlight, and mechanical impact.

The cable construction should then be specified. This may include single-core or three-core design, conductor size, insulation, metallic screen, armor, sheath, water resistance, flame performance, and special environmental features.

Finally, the customer should confirm the required standard, testing program, documentation, packaging, delivery conditions, and after-sales service. A complete technical specification reduces the risk of misunderstanding and supports efficient production.

12. Frequently Asked Questions

Q1: What is the main purpose of this cable?

The cable is designed for fixed power transmission and distribution in medium- and low-voltage systems. It can connect substations, switchgear, distribution panels, buildings, industrial facilities, public infrastructure, and other electrical loads.

Q2: Why use an aluminum alloy conductor?

An aluminum alloy conductor can reduce cable weight while maintaining stable electrical performance and providing practical mechanical strength. The lower weight can support easier transportation, handling, and installation, especially on long routes or construction sites with restricted access.

Q3: What insulation material is commonly used?

Cross-linked polyethylene is commonly used as the main plastic insulation material. It provides stable electrical insulation, heat resistance, aging resistance, and a maximum permissible long-term conductor operating temperature of 90°C under the stated requirements.

Q4: What is the short-circuit temperature capability?

For the stated cable designs, the maximum allowable conductor temperature can reach 250°C during a short-circuit condition lasting no more than five seconds. The actual short-circuit capability must be confirmed for the selected cable construction and governing standard.

Q5: What is the minimum installation temperature?

The ambient temperature during installation should generally not be lower than 0°C. Cold conditions can reduce material flexibility and increase the risk of damage during bending or pulling.

Q6: What bending radius is required?

For the stated medium-voltage construction, the minimum bending radius is generally at least 10 times the outer diameter for three-core cable and at least 15 times the outer diameter for single-core cable. For the stated low-voltage construction, the minimum bending radius is generally at least seven times the outer diameter.

Q7: Can the cable be manufactured according to international standards?

Yes. In addition to GB/T requirements, the product can be manufactured and tested according to applicable IEC, British, or American standards when specified by the project. The governing standard should be confirmed before production.

Q8: Is this cable suitable for buildings?

Yes. It can be used in power distribution systems for high-rise buildings, residential buildings, hotels, hospitals, theaters, conference centers, libraries, museums, shopping centers, and other commercial or public buildings. Fire, smoke, emergency power, and local building requirements must be reviewed separately.

Q9: Is the cable suitable for industrial facilities?

Yes. It may be used in industrial and mining enterprises, petrochemical plants, power facilities, steel projects, and other industrial environments. The sheath, armor, and other protective features should be selected according to chemical exposure, heat, vibration, impact, moisture, and other site conditions.

Q10: What quality controls are important during production?

Important controls include conductor material inspection, conductor resistance measurement, stranding and compaction control, insulation extrusion monitoring, eccentricity monitoring, sheath dimensional inspection, high-voltage testing, partial discharge testing where applicable, and final product documentation.

Q11: What information should be provided when requesting a quotation?

The customer should provide the rated voltage, conductor size or required current, number of cores, cable length, installation method, environmental conditions, shielding or armor requirements, applicable standard, test requirements, packaging requirements, delivery destination, and expected delivery schedule.

Q12: What makes the manufacturer suitable for large projects?

The manufacturer has operated since 1998, maintains more than 70 production and testing lines, employs technical professionals, offers a broad product portfolio, and holds several management system and product certifications. Its equipment includes online eccentricity monitoring, high-voltage series resonance testing, and partial discharge detection capabilities.

13. Conclusion

The aluminum alloy conductor plastic insulated power cable with rated voltage applications up to 26/35kV provides a balanced solution for modern power transmission and distribution systems. Its aluminum alloy conductor supports weight reduction, installation convenience, and practical mechanical performance. Its plastic insulation, commonly cross-linked polyethylene, provides stable electrical insulation, heat resistance, and aging resistance for long-term operation.

The cable is suitable for low-voltage and medium-voltage applications across buildings, public facilities, industrial plants, energy projects, transportation infrastructure, and special engineering environments. Its value is determined not only by conductor material, but also by the quality of insulation extrusion, conductor design, shielding, sheath protection, testing, documentation, and installation support.

Wuxi Guanghuan Cable Co., Ltd. combines cable manufacturing experience, a broad product portfolio, modern production and testing equipment, technical personnel, and certified management systems. These strengths support the production of cable solutions for projects requiring stable performance, controlled quality, multiple standards, and dependable service.

For best results, customers should define the electrical, mechanical, environmental, installation, and regulatory requirements before ordering. When the cable construction is correctly selected and professionally installed, the product can provide reliable service in a wide range of power infrastructure applications.

References

GB/T 31840-2025, Power Cables with Extruded Insulation and Their Accessories for Rated Voltages.

International Electrotechnical Commission, IEC standards for power cables with extruded insulation and cable testing.

International Electrotechnical Commission, IEC guidance for cable current-carrying capacity and installation conditions.

Relevant British Standards for insulated power cables, cable construction, testing, and installation.

Relevant American Standards for power cables, electrical insulation systems, conductor requirements, and cable testing.

Cross-Linked Polyethylene Insulated Power Cable Technical Requirements, manufacturer technical documentation.

Power Cable Installation and Commissioning Practices, engineering reference material.

Product: Aluminum Alloy Conductor Plastic Insulated Power Cable (Rated Voltage up to 26/35kV)