CAIRO AAAC Conductor Cable
CAIRO AAAC (All Aluminum Alloy Conductor) cables comply with ASTM B399 standards and offer high tensile strength, good conductivity, and resistance to corrosion. Named "Cairo" for its 600 mm² nominal area with 61-strand configuration, it offers superior conductivity (53% IACS) and tensile strength (295 MPa min) compared to ACSR. Made from heat-treated aluminum-magnesium-silicon alloy (6201-T81), this cable provides excellent corrosion resistance, low weight, and reduced sag for longer spans. Compliant with ASTM B398, B399, IEC 61089, and BS EN 50182 standards, it supports voltages up to 33kV with ampacity up to 1000A at 75°C. The homogeneous alloy construction eliminates bimetallic corrosion and ensures uniform mechanical properties. The Cairo AAAC Conductor Cable minimizes line losses, withstands harsh weather, and requires minimal maintenance. Ideal for rural electrification, urban upgrades, and renewable energy integrations, it delivers reliable, cost-effective power in overhead lines worldwide, outperforming traditional conductors in corrosive or coastal environments.
- Voltage Rating Up to 33kV (typical)
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Temperature Rating
Operating: -15°C to +95°C
Short-circuit (5s): up to 280°C
Construction
Technical Specifications
Quality Control
Application
Construction
CAIRO AAAC Conductor Cable Construction
Conductor
Stranded 1350-H19 aluminum alloy (Class AA or A)
Armour
Optional galvanized steel wire for enhanced mechanical protection
Insulation
Bare aluminum conductor (AAAC type)
Manufacturer Standard
ASTM B399, IEC 61089, BS 3242
Application
CAIRO AAAC cables meet ASTM B399 standards and are ideal for overhead power transmission and distribution in urban, industrial, and coastal areas, especially where lightweight, high corrosion resistance, and excellent electrical conductivity are essential for reliable performance in challenging environments.
Technical Specifications
CAIRO AAAC Conductor Cable
CAIRO AAAC Conductor Cable
| Construction characteristics | |
| Conductor material | aluminum alloy |
| Type of conductor | Circular, stranded |
| Type of cable | Cairo |
| Conductor flexibility | Class AA |
| Conductor shape | Circular non compacted |
| Dimensional characteristics | |
| Conductor cross-section | 465.4 kcmil |
| Conductor cross-section | 236.38 mm² |
| Wire diameter | 3.98 mm |
| Conductor diameter | 19.9 mm |
| Approximate weight | 651 kg/km |
| Average geometric radius | 0.00753 m |
| Diameter of aluminium alloy 6201 wires | 3.98 mm |
| Nominal diameter of wires | 3.98 mm |
| Nominal outer diameter | 19.9 mm |
| Number of aluminium alloy 6201 wires | 19 |
| Number of cores | 1 |
| Electrical characteristics | |
| Max. DC resistance of the conductor at 20°C | 0.1417 Ohm/km |
| Max. electric resistance AC 60Hz 75°C | 0.17 Ohm/km |
| Inductive reactance | 0.3687 Ohm/km |
| Capacitive reactance | 0.2201 MOhm.km |
| Ampacity | 590.0 A |
| Mechanical characteristics | |
| Hardness type | T81 |
| Rated breaking load | 7106.3 kgf |
| Usage characteristics | |
| Length | 2090 m |
| Reel net weight | 1350 kg |
| Packaging | Reel 150/80 |
Quality Control
CAIRO AAAC Conductor Cable
Raw Material Test
Raw material testing for the Cairo AAAC Conductor Cable ensures compliance with ASTM B398 and IEC 61089 standards. Aluminum alloy ingots (6201-T81) are inspected for chemical composition (Mg 0.6-0.9%, Si 0.5-0.9%, Fe <0.5%) using spectrometry. Wires undergo conductivity (>53% IACS), tensile strength (295-325 MPa), and elongation (>3.5%) checks with universal machines. Samples are subjected to heat treatment simulation at 180°C for aging verification and impurity analysis via microscopy. Corrosion resistance is tested in salt spray chambers for 1000 hours. The step-by-step process: incoming batch verification, random sampling, physical/mechanical testing (diameter tolerance ±0.03mm, weight per length), chemical confirmation, accelerated aging trials, and material release decision.
Process inspection
During the manufacturing of the Cairo AAAC Conductor Cable, process inspection adheres to ASTM B399. Alloy wire drawing ensures diameter tolerance (±0.03mm) and surface smoothness with micrometers. Heat treatment furnace controls temperature (180-200°C) and time for T81 temper via thermocouples. Stranding line monitors 61-wire lay ratio (12-16 times diameter), compactness, and tension balance using optical sensors. Real-time checks for ovality and strand continuity occur at multiple points. Final reeling verifies coil integrity. Key steps: pre-stranding material annealing confirmation, parameter logging (speed, tension), intermediate sampling for tensile testing, defect rejection (breaks/cracks), and post-stranding dimensional verification.
Finished Product
The finished Cairo AAAC Conductor Cable undergoes comprehensive testing to ASTM B399 standards. Routine tests include overall diameter (28.5mm approx.), weight per length (1660 kg/km approx.), and DC resistance (0.057 Ω/km at 20°C). Mechanical tests cover ultimate tensile strength (48 kN min) and elongation using universal machines. Electrical withstand and partial discharge checks confirm integrity. The process steps: reel sampling, preparation with grips, gradual load application to break point, timed hold for creep, post-test fracture analysis, and documentation. Additional verifications include corrosion resistance (1000-hour salt spray), lay length, and weather simulation (UV/ice loading).
Application
Cairo AAAC Conductor Cable is ideal for overhead transmission and distribution lines in utility networks, rural electrification, and industrial power grids. Commonly used for spans up to 500m in corrosive or coastal areas, connecting substations to transformers for efficient high voltage service.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
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What are the advantages of power cables and overhead lines?(1) Reliable operation, because it is installed in a hidden place such as underground, it is less damaged by external forces, has less chance of failure, and the power supply is safe, and it will not cause harm to people; (2) The maintenance workload is small and frequent inspections are not required; (3) No need to erect towers; (4) Help improve power factor.
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Which aspects should be considered when choosing the cross section of a power cable?(1) The long-term allowable working current of the cable; (2) Thermal stability once short circuited; (3) The voltage drop on the line cannot exceed the allowable working range.
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What are the measures for cable fire prevention?(1) Use flame-retardant cables; (2) Use fireproof cable tray; (3) Use fireproof paint; (4) Fire partition walls and fire baffles are installed at cable tunnels, mezzanine exits, etc.; (5) Overhead cables should avoid oil pipelines and explosion-proof doors, otherwise local pipes or heat insulation and fire prevention measures should be taken.
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What should be paid attention to during the transportation and handling of cables?(1) During transportation, loading and unloading, cables and cable reels should not be damaged. It is strictly forbidden to push the cable reels directly from the vehicle. Generally, cables should not be transported and stored flat. (2) Before transporting or rolling the cable reel, ensure that the cable reel is firm, the cable is wound tightly, the oil pipe between the oil-filled cable and the pressure oil tank should be fixed without damage, the pressure oil tank should be firm, and the pressure indication should meet the requirements.
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What inspections should be carried out for the acceptance of cable lines?(1) The cable specifications should meet the regulations, the arrangement should be neat, no damage, and the signs should be complete, correct and clear; (2) The fixed bending radius of the cable, the related distance and the wiring of the metal sheath of the single-core power cable should meet the requirements; (3) The cable terminal and the middle head should not leak oil, and the installation should be firm. The oil pressure of the oil-filled cable and the meter setting should meet the requirements; (4) Good grounding; (5) The color of the cable terminal is correct, and the metal parts such as the bracket are completely painted; (6) There should be no debris in the cable trench, tunnel, and bridge, and the cover should be complete.
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