ACSR Conductor: Types, Advantages and Uses - ZW Cable

From what we know, aluminum is a lightweight material and very easy to work with as a cable material while steel is superior in strength and has better mechanical support. These two materials are perfectly combined in the ACSR (Aluminum Conductor Steel Reinforced). Next we’ll read more about its type and its advantages in applications.

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What is ACSR conductor?

ACSR conductor is a kind of high capacity and high strength stranded conductor used in overhead transmission lines. ACSR cable consists of two main components: aluminum and steel.

Steel Core: It is located in the center of the conductor and uses galvanized steel wire to enhance the mechanical strength of the wire. The steel core can be solid or twisted. The construction of the steel core may consist of a single, 7 or 19 galvanized steel wires, depending on the strength required and the application.

Stranded aluminum wire: The steel core is surrounded by multiple layers of aluminum wires that are twisted concentrically to form a continuous outer layer. The choice of aluminum allows the ACSR to reduce energy losses when transmitting large amounts of power. The number of stranded aluminum wires and the number of wires per layer can be adjusted according to the current load-carrying requirements.

ACSR exists in a number of different conductor configurations for steel stranded wire and aluminum stranded wire. So in the early days of the wire and cable industry various animal names were used as species and ACSR conductor size identifiers. For example:

ACSR Dog conductor typically consists of six 4.72 mm diameter aluminum strands and seven 1.57 mm diameter steel strands.

ACSR Rabbit conductors typically consist of 6 aluminum strands with a diameter of 3.35 mm and 1 steel strand with a diameter of 3.35 mm.

ACSR Conductor- Common Types

In order to adapt to a variety of applications and performance requirements, more and more ACSR conductor types have emerged in the market, providing users with more flexible and diverse choices. Likewise, the following types of overhead cables are available from ZW Cable:

All Aluminium Conductor –AAC

AAC conductor has a unique all aluminium structure and is made by concentric winch process. The conductor structure is pretty easy, efficient and has high conductivity. Compared with ACSR, AAC may be inferior in strength. However, it performs well in cost-effectiveness, portability and ease of maintenance, especially for low to medium voltage overhead lines and flexible electrical wiring systems.

All Aluminium Alloy Conductors –AAAC

AAAC is made of high-performance aluminum-magnesium-silicon alloy by precise multi-layer stranding process. Compared with traditional AAC, AAAC cable has better tensile strength and weight ratio under the same diameter, which is especially advantageous in long distance transmission.

Aluminium Conductor Aluminium Reinforce –ACAR

ACAR cable uses high strength aluminum alloy core wrapped with aluminum wire concentric layer. ACAR differs from AAC and AAAC in that it uses alloy cores to enhance its performance in overhead transmission and distribution networks, including strength and current carrying capacity.

Aluminium Conductor Steel Reinforced – ACSR

ACSR conductor is wrapped in multi-layer aluminum wire with steel filling core. This is designed for high strength applications. This type of conductor is suitable for overhead grounding lines, as well as installations requiring extra-long spans and river crossings. Unlike Aluminum Conductor Steel Support (ACSS), which relies on a steel core to maintain its strength at varying temperatures, ACSR conductors excel even at high and low temperatures thanks to the high strength of their steel core and the excellent current-carrying capacity of aluminum.

ACSR Conductor– Main Advantages

Why are ACSR conductors specifically chosen for overhead lines? The reason being that overhead transmission requires a conductor that is capable of meeting the needs of a wide variety of applications. Aluminum Conductor Steel Reinforced (ACSR) cables are uniquely suited to meet these diverse requirements.

Weight advantage: aluminum is about one-third the density of steel and ACSR cables are lighter than all-steel or all-aluminum cables with the same conductivity. If a typical high-voltage transmission line uses an all-aluminum conductor, it may need a thicker cross-section or a denser support structure to withstand its own weight and wind. On the other hand, ACSR can achieve this with a smaller diameter and a longer distance between towers, significantly reducing the cost of tower and foundation construction.

High tensile strength: the steel core provides additional strength to the cable to better support its own weight and reduce sag, making it ideal for crossing complex terrain such as rivers and valleys.

High electrical conductivity: the aluminum coating provides good electrical conductivity, ensuring efficient power transmission with minimal loss, contributing to overall energy efficiency.

Corrosion Resistance: although the steel core itself easy to rust, but after galvanizing or other anti-corrosion process, and then with the natural protection of aluminum, ACSR cables exhibit excellent corrosion resistance in the general atmosphere and in non-extreme corrosive environments and maintain long service life even under harsh conditions.

Convenient installation and maintenance: ACSR cable not only strong structure, relatively light weight, more time-saving installation and labor-saving. In addition, its flexibility allows it to easily adjust its shape to suit different overhead line configurations and is more convenient for maintenance.

Economy: because the price of aluminum is relatively low, ACSR cable is very competitive in cost, the overall cost of lines reduced.

ACSR conductor- Widespread applications

ACSR conductor is widely used in power transmission industry in various countries. Here are some concrete examples:

Across large bodies of water. A typical example is the Earl Strait Bridge, which connects Denmark and Sweden. It adopts ACSR cable in overhead transmission system. The application is critical to maintaining power connections between the two countries and demonstrates the ability of ACSR to travel long distances on water.

High-voltage power transmission in China. China’s UHVDC (ultra high voltage direct current) transmission lines, such as the Xiangjiaba-shanghai line, use ACSR conductors in segments requiring high load and strength. These lines transmit power over thousands of kilometers, highlighting the suitability of ACSR for long-distance and high-voltage applications.

Urban and rural distribution networks. Although ACSR is more relevant for long-distance transmission, it is also used for distribution networks in urban and rural areas. For example, overhead lines that power suburban or remote farmhouses often use ACSR conductors to ensure their reliability and cost-effectiveness.

How to select ACSR cable specifications according to application requirements?

Consider mechanical strength

The ACSR steel core provides mechanical strength for support and resistance to tension. According to the span of the line, wind load, ice load and installation conditions to choose the appropriate proportion of steel core.

Consider electrical requirements

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Select the appropriate conductor size according to the line voltage level (e.g. 25kv or 35kV) to ensure voltage regulation and Factor of safety.

Consider environmental factors

In certain specific industrial environments, such as highly contaminated areas, corrosion of ACSR cables is exacerbated. In order to improve the corrosion resistance, all-aluminum alloy conductors (AACSR) are available on the market. AACSR consists of one or more aluminum-magnesium-silicon alloy coils and high strength zinc-coated steel core. In addition, all-aluminum alloy conductors (AAAC and AAC) have better corrosion resistance because they are composed entirely or mainly of aluminum. These types can be considered for use in highly corrosive environments.

Consider International Standards

Ensure cables comply with local, national and international standards such as ASTM B230, B232 and IEC .

There are a lot of factors to consider when it comes to choosing the right type of wire for your project. But, with so many options on the market, it can be difficult to decide which is right for you. In this article, we'll compare ACSR and AAAC to help make your decision easier. Stay tuned!

What is ACSR cable?

The term ACSR refers to "Aluminium Conductor Steel Reinforced is a Stranded conductor comprising a variety of aluminum wire layers atop a core of a steel wire that has been stimulated. The inner steel core of the wire can be described as one wire which will vary in size. The cables are available in various galvanizations, such as classes B, B & C, for safeguarding against corrosion. 

For this type of conductor, the amount of steel and aluminum could be selected based on the capability of the mechanical strength and current carrying capacity, depending on the purpose. In addition, the classification of these conductors could be determined by factors such as reliability, economy weight ratio, and positive strength. This article will provide a comprehensive outline of what constitutes the definition of an ACSR conductor, its types, and how they work.

Aluminium Conductor Steel Reinforced (ACSR) is a concentrically-stranded conductor with several layers of -H19 aluminum wire on a galvanized steel core. Depending on the diameter, the core may be either stranded or single wire. Steel core wire is offered in Class A, B, and Class C galvanization to protect against corrosion. Further protection against corrosion is provided by applying grease to the conductor or by infusion of the complete conductor using grease.

The percentage of aluminium and steel within an ACSR conductor can be chosen according to the strength and the current carrying capacity required by the particular application.

ACSR conductors are renowned for their reputation for economy reliability, reliability, and an excellent strength-to-weight ratio. ACSR conductors blend aluminum's light weight and excellent conductivity with the durability and strength of steel. When designed in line, they can offer higher tensions and less sag, and greater span lengths you cannot get from other kinds of conductors for overhead use.

What is AAAC cable?

AAAC cable is an electrical cable used in a variety of applications. It is made from aluminium and is sometimes also known as aluminium-clad cable. AAAC cables are known for their high conductivity and resistance to corrosion. They are often used in electrical power distribution applications. AAAC cables have a wide range of applications due to their many benefits. 

They can be used in indoor and outdoor applications and are often used in electrical power distribution systems. AAAC cables are also known for their resistance to electromagnetic interference. This makes them ideal for use in electronic equipment and devices.

How are they different?

ACSR cables and AAAC cables may appear similar at first glance, but they are actually quite different. ACSR cables are made of aluminum and steel, while AAAC cables are made entirely of aluminum. As a result, AAAC cables are much lighter than ACSR cables, making them easier to transport and install. 

However, ACSR cables are more robust and durable, better suited for applications where strength is needed. In addition, ACSR cables have a higher resistance to corrosion than AAAC cables. As a result, they are often used in outdoor applications where they will be exposed to the elements. Ultimately, the choice between ACSR cables and AAAC cables depends on the project's specific needs.

How does ACSR cable compare to AAAC cable in terms of performance and price point?

In the electrical industry, two cable types are often compared in terms of performance and price point: ACSR cable and AAAC cable. Both are used extensively in the transmission and distribution of electricity, but how do they stack up against each other? In terms of strength, ACSR cable is typically superior to AAAC cable. 

This is because ACSR cable is made from high-strength steel core strands, while AAAC cable is made from aluminum. As a result, ACSR cables can generally withstand higher loads and tension without breaking. However, in terms of price, ACSR cable is typically more expensive than AAAC cable. This is because the manufacturing process for ACSR cable is more complex, and the materials used are more costly. 

However, the increased price point may be worth it for customers who require a higher level of performance from their cables.

What is the main difference between ACSR cable and AAAC cable?

AAAC: This bare concentric-lay-stranded conductor, made from round aluminum alloy -T81 wires, is constructed with a central core surrounded by one or more layers of helically laid wires. It provides better resistance to corrosion over that of it. stainless steel conductor of aluminum reinforced(ACSR).

In contrast to AAAC cable, ACSR conductors are made from round aluminum -H19 (extra hard) wires and zinc-coated or aluminum-coated steel core wire(s). It provides better strength than AAAC cable.

Pros and cons of each type of cable 

When it comes to electrical cables, there are a few different types that are commonly used. ACSR and AAAC are two of the most popular options. However, both have their own unique set of advantages and disadvantages that should be considered before making a decision.

ACSR cables are made from aluminum and steel, which makes them very strong and durable. They are also resistant to corrosion, which is a major advantage in areas where moisture is present. However, ACSR cables are also much heavier than other cable types, making them difficult to work with. In addition, the aluminum core can be susceptible to electrolysis, which can cause problems down the road.

AAAC cables are also made from aluminum, but they use an alloy instead of steel. This makes them lighter than ACSR cables, which is a major advantage in installation. AAAC cables are also more resistant to corrosion than other cable types, making them a good choice for wet or damp environments. However, the alloy used in AAAC cables can be weaker than steel, which may be a concern in some applications.

So, which type of cable is right for you? The answer depends on your specific needs and application. If you need a strong and durable cable that can withstand corrosion, then ACSR is the way to go. On the other hand, if you need a lighter-weight cable that is easier to work with, then AAAC is the better option. Ultimately, the best way to decide is to consult an expert who can help you assess your specific needs and make the best decision for your application.

Which wire should you choose for your next electrical project - ACSR or AAAC wire?

When it comes to electrical projects, there are various cables to choose from. Two of the most popular options are ACSR and AAAC cable. Both have their own benefits and drawbacks, so selecting the right one for your project is essential. ACSR cable is made from aluminum and steel, which makes it very strong and durable. However, this also makes it heavier than other cable types, making it challenging to work with. AAAC cable is made from aluminum alloy, which makes it lightweight and easy to work with. However, it is not as strong as ACSR cable and is therefore not recommended for use in high-stress applications. Ultimately, your project's best cable type will depend on your specific needs and requirements.

Which is the better value for your money - ACSR or AAAC wiring?

It is crucial to understand the critical differences between these two types of wiring to answer this question. ACSR wiring is made from aluminum strands coated with a steel layer. This gives it a higher weight-to-strength ratio than other types of wiring. Additionally, ACSR is less likely to sag when suspended between poles. 

However, it is also more expensive than AAAC wiring. AAAC wiring is made from aluminum alloy strands that have been crimped together. This gives it superior strength and flexibility, making it ideal for heavily forested areas. 

Additionally, AAAC is less expensive than ACSR. When it comes to electrical wiring, both ACSR and AAAC have their own unique benefits. So, which one is the better value for your money? That ultimately depends on your specific needs and budget. However, both options are sure to give you years of reliable service.

Final Thoughts

There are various types of electrical cables, each with its advantages and disadvantages. When it comes to ACSR vs. AAAC, both have their pros and cons. ACSR is made from aluminum and steel, making it strong and durable. However, this also makes it quite heavy and challenging to work with. 

On the other hand, AAAC is made from aluminum alloy and is much lighter than ACSR. This makes it easier to install and work with, but it also means that it is less strong or durable. Ultimately, the choice between ACSR and AAAC depends on the project's specific needs.

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