New Technology Bare Over Head Conductor

Hydro Aluminium Evy Drange Tel: +47 52 84 71 98 Fax: +47 52 85 40 33 Contact E-Mail: [email protected]

Hydro Aluminium Fabienne Gailledreau Tel: + 33 1 46 46 11 62 Fax: + 33 1 46 46 15 14 Contact E-Mail: [email protected]

One of the world's leaders Hydro is one of the world's largest integrated aluminium companies, holding important market positions in America, Asia and the Pacific region. Our focus on innovation, quality and cost-efficient solutions has led us to achieve market leadership in many of the industry's most important market segments, such as the automotive, packaging, construction and the printing industries. We are also very active in the field of common consumer goods. We are also a global leader in the manufacture of super high purity aluminium, supplying a wide range of modern technical applications. Over 3 million tonnes supplied annually Besides continuously adding to our extensive know-how in downstream activities, we focus on aluminium production as a core business activity. We have been able to improve our market position in this area through important recent acquisitions. With our leading European network of aluminium remelters and third-party alliances, we supply the market with over 3 million tonnes of metal products annually. Moreover, we have established a leading position in recycling worldwide. European base, world wide operations Europe is our home and will be the focus point for most of our business in the near future. However, we will continue to operate globally, and when we enter new markets, our customers can rest assured that we will maintain our high standards as a reliable partner.

Wire rod

Hydro is a major producer of top-quality aluminium wire rod, supported by well-equipped research centres in Norway and strategic partnerships all over the world. In Europe and beyond, cable producers are finding innovative solutions with our wire rod products. In this market of intensive restructuring, requirements for overall quality are growing. We focus on meeting or exceeding the most demanding specifications. Our production system is reliable and flexible, and we have entered partnerships with external suppliers that enable us to meet market demand. We offer delivery precision, commercial service and technical assistance, with meticulous follow-up to all inquiries. We develop partnerships with our customers on projects related to product and process development. Our research has mainly concentrated on improving and developing our own process. In addition, we focus on such customer processes as drawing, stranding and extruding. This research program is part of our long-term strategy for the continuous improvement of product properties and active customer support.

Technical services available • Our highly-skilled technicians are equipped with: • Light optical microscope • Scanning electron microscope (SEM) • Tensile testing machines • Resistivity tester • Corrosion testing • Physical process simulation (Gleeble 3500).. • Facilities for testing hydrogen content (for measurements in melt and in solid material) • Inclusions in Al melt (LIMCA) R&D Projects – processing of wire rod • Melt treatment of 1370-alloys: • Continuously casting of wire rod: modelling and understanding • Rolling Mechanisms • Consistency of product parameters like tensile strength and electrical conductivity • Increase of electrical conductivity • Optimisation of the conform process; modelling and understanding of the drawing process

Dimensions and weight Rod Diameters and Tolerances Diameter target (mm) 9.5 12.0 15.0 19.0 25.0 30.0

Lower Tolerance (mm)

Upper Tolerance (mm)

9.0 (5%) 10.0 11.6 (5%) 12.6 14.2 (5%) 15.8 18.0 (5%) 20.0 23.8 (5%) 26.2 28.5 (5%) 31.5 Coil Inner Diameter = 540 mm

(5%) (5%) (5%) (5%) (5%) (5%)

Ovality (mm) 0.4 0.5 0.6 0.8 1.0 1.2

(4%) (4%) (4%) (4%) (4%) (4%)

Mechanical and electrical properties Designation HAEN1715 Temper. O H11 H11 H11 H12 H12 H12/13 H13 H13/14 H14 H14

HA6 HA8 HA8 HA8 HA10 HA10 HA10/11 HA11 HA11/12 HA12 HA12 **

UTS-Target (MPa)

Elongation (%)**

Min. Conduct. (% IACS)

Max. Resist. (nOhm - m)

MAX. 75* 82.5 87.5 92.5 97.5 102.5 107.5 112.5 117.5 122.5 127.5

25 63.3 27.25 15 61.9 27.85 15 61.9 27.85 15 61.9 27.85 12 61.5 28.01 12 61.5 28.01 10 61.5 28.01 10 61.5 28.01 8 61.5 28.01 8 61.5 28.01 8 61.5 28.01 * Homogenized The elongation is given as approx. values and is not corresponding to EN1715

*** Some tolerances does not correspond to EN1715

UTS-targets (MPa)

Designation EN UTS-range Max. HA-Temper 1715 (MPa) 75 82.5 87.5 92.5 97.5 102.5 107.5 112.5 117.5 122.5 127.5 HA6

0

HA8

H11

60-80 80-95

HA10

H12

95-110

HA11

H13

105-120

HA12

H14

115-130

Alloys Designation EN1715 Chemical AW-EAI AW-EAI AW-EAI AW-EAI AW-EAI AW-EAI AW-EAI AW-EAI

99.7 99.7 99.7 99.7 99.7 99.7 99.5 99.5

Numerical

Hydro Standard

AW-1370 AW-1370 AW-1370 AW-1370 AW-1370 AW-1370 AW-1050A AW-1050A

137015 137011 137006 137005 137005 137004 105041 105045

Olex offers a proud history of cable manufacturing expertise, with more than half a century of experience in the industry. Olex offers market leadership in design, quality engineering excellence, distribution and customer service. Australia’s

cable

spec

World leader in overhead transmission cables

Olex supports Australia’s position as a world leader in overhead transmission line technology, based on more than 50 years of experience in manufacturing bare overhead conductors. Every Olex cable is subject to exacting quality control procedures, ensuring rigid testing to relevant standards at every stage of manufacture. The extensive range of Olex bare overhead conductors includes internationally accepted conductor configurations. All-aluminium, contemporary aluminium alloy and steel-reinforced conductor designs are manufactured to Australian Standards and specific customer requirements, including most international standards. Electrical, mechanical and cost considerations determine the selection of a conductor for a particular application. The values of resistance, inductance and, where applicable, capacitance, should be such that voltage regulation, temperature rise and losses will be within acceptable limits when the conductor is carrying the required current load. On high voltage lines, radio interference characteristics or corona losses often dictate the minimum diameters which may be used. Conductor design and span lengths are also determined by mechanical loads likely to be imposed by wind or ice, as well as by economic considerations. This catalogue presents the standard range of Olex overhead conductors and cables. Information on other power and industrial cable products is available from the Olex office in your state.

Product Range Introduction 1 Bare Overhead Conductors 2 Type AAC 4 Type AAAC/1120 5 Hard Drawn Copper 6 Type ACSR/GZ 7 Type ACSR/AC 8 Type SC/GZ & SC/AC 9

Low Voltage Aerial Bundled Cables 10 LV XLPE Insulated 2/3/4 Core Aluminium 12 LV XLPE Insulated 2/3/4 Core Copper 13 PVC Insulated Single 2/3/4 Core Copper 14 Covered Conductors 16 Type CCT 17

High Voltage Aerial Bundled Cables 18 HV HV HV HV

XLPE XLPE XLPE XLPE

Non Metallic Screened ABC 21 Non Metallic Screened ABC HDPE 22 Metallic Screened ABC 6.35/11kV 23 Metallic Screened ABC 12.7/22kV 24

Contact : Olex Cable Olex has sales offices in each state and two manufacturing sites in Australia. To contact your nearest office, please call 1300 CABLES (1300 222 537) or contact us to send an email.

Sales Locations: Victoria

207 Sunshine Rd, Tottenham, VIC, 3012 Dynamite Distribution & Storage, Shop E, 241 Main Street, Hobart Tasmania TAS 7001 New South Wales 29 Davis Rd, Wetherill Park, NSW, 2164 541 Bilsen Rd, Geebung, QLD, 4034 Queensland 16 Leyland St, Townsville, QLD, 4810 South Australia/ Northern 539 South Rd, Regency Park, SA, 5010 Territory Western Australia 503 Abernethy Rd, Kewdale, WA, 6105

Manufacturing Locations: Tottenham 207 Sunshine Rd, Tottenham, Vic, 3012 Lilydale 55 Main Street, Lilydale, Vic, 3140

Head Office: 207 Sunshine Road, Tottenham, VIC 3012 PO Box 33 West Footscray, VIC 3012 Phone: +613 9281 4444 Fax: +613 9281 4294

About Lamifil Lamifil is a metal processing company located in Hemiksem, Belgium. Our undisputed core activity is the production of wire and cable from aluminium and aluminium alloys, copper and copper alloys. The resulting high-quality products, both semi-finished goods and finished products, are sold in the following markets:

• • • • • •

cable industry (energy and telecom) steel industry railway electrification automotive, robot and aviation industry mechanical industry conform applications (continuous extrusion)

The powerful combination of innovative technology, many years experience and advanced know-how has made Lamifil one of Europe’s biggest, independent aluminium wire rod and wire producers. Lamifil is also a prominent supplier of copper alloys and railway electrification products. Lamifil has a heart for the trade and thus also for its customers. A constant effort has always been devoted to the search for added value for our customers. We are therefore proud to see that our extensive service package and thorough metal knowledge has already generated such a large number of long-term, mutually beneficial partnerships.

Wire rod (electrical and mechanical) Materials: aluminium and aluminium alloys Standards: EN / DIN / BS / NF / NBN / ASTM a.o. Dimensions:diameters 9.5 / 12 / 15 / 19 / 23 / 25mm Condition: rolled / annealed / homogenized / static and in-line tempered coils up to 2.2 T on wooden pallets internal diameter: 550mm Packaging: external diameter: according to coil weight height: 900mm

High Voltage Lamifil is at home in many markets. One of our specialities is the production of cables for high voltage lines. Besides the conventional types such as ACSR, AACSR, AAC, AAAC, Lamifil is constantly searching for solutions to allow specific customer needs to be approached even more effectively. An example? Take the European market, which is mainly a market for the replacement of high voltage lines. This means that customers are increasingly faced with the restrictions of existing pylons as power demand continues to grow. In order to deal with this situation, Lamifil developed a number of special alloys (extra high conductivity alloy, AlZr alloys, Al59, Super B-quality) and special designs (cables with Z or trapezoidal wire, Gap Conductor). The total integration from wire rod to cable enables Lamifil to develop an optimal cable and thus provide a fully customised solution.

Contacts General Lamifil NV Frederic Sheidlaan B-2620 Hemiksem Belgium t + 32 (0)3 8700 611 f + 32 (0)3 8878 059 e [email protected] Route description Plan your route to Lamifil

Sales Manager Aluminium Wire Rod & De-ox

Gwenda Libert t +32 (0)3 8700 715 f +32 (0)3 8700 674 e [email protected] Sheidlaan B-2620 Hemiksem Belgium t + 32 (0)3 8700 611 f + 32 (0)3 8878 059 e [email protected] Route description Plan your route to Lamifil

Shaved wire For certain applications the surface finish of the wires is a critical parameter. For this purpose, Lamifil has developed a special shaving process that removes a thin layer of metal from the wire. This results in reduction of the number of minor surface defects. The shaving process is applied both for aluminium and its alloys and for copper and its alloys. We recommend shaved wire for a number of wire applications, including wire plating, enamelled wire and mechanical wire.

Extra high conductivity Lamifil: always a step ahead. Lamifil has in fact developed a technology that allows the production of aluminiummagnesium-silicon alloys (AA6101) with extra high conductivity. The conductivity of these alloys is well above the value specified in the EN50182 standard. A value of 57.0% IACS with an average tensile strength of 310 MPa is repeatedly achieved. This extra high conductivity alloy has the advantage of reducing the Joule loss by as much as 8% compared with conventional AA6101 alloys. Moreover, no changes are required to the cable design or accessories and ampacity can be improved by 4%. Lamifil is currently working on an alloy with extra-extra high conductivity of 57.5% IACS and a tensile strength of 295 Mpa. This special alloy is already available upon request.

Copper alloys

On an upcaster, Lamifil produces a series of copper alloys that are mainly used in overhead electrification lines of railway tracks, from light rail up to high speed rail. Other uses are in special fine wire for aerospace and electronics, where high strength and good conductivity have to be combined with excellent flexlife. Copper-silver has the same electrical and mechanical characteristics as ETP copper but is able to withstand higher temperatures, because the silver increases the recrystalisation temperature. Copper-cadmium combines high strength with good conductivity. This alloy with its unsurpassed flexlife is frequently used for fine wire. Copper-cadmium-tin increases the strength at the expense of conductivity. This alloy is mainly used in railway applications. Copper-magnesium was developed as an alternative to copper-cadmium and coppercadmium-tin. It is used primarily in railway applications. Special brands are already being used for special fine wire applications. As you may expect from Lamifil, we continue to innovate and expand our product lines! That is why we are focusing our research both on new copper alloys and on optimisation of their characteristics.

Gap conductor In a combined effort with a number of our partners Lamifil has developed the High Temperature Low Sag GAP conductor. This conductor is composed of trapezoidal wires manufactured from a high temperature alloy, resulting in a low noise, smooth body conductor. The advantages of the GAP system are an increase in capacity (+50% to +100%), low sag, no or minimal modification of existing tower structures, thereby avoiding environmental problems that would otherwise occur when new and bigger constructions are erected.

Heat resistant alloys Lamifil has developed aluminium/zirconium alloys that are being used in overhead line conductors: TAL or AT1, ZTAL or AT3, XTAL or AT4, KTAL or AT2 according to IEC 62004. These alloys are applied in our steel reinforced overhead line conductors, allowing the line capacity to be increased by 50 to 100%. Depending on the alloy, the maximum allowable temperatures are between 150 and 230°C. Peak temperatures may vary between 180 and 310°C. Lamifil is currently also studying other types of heat resistant alloys.

Smooth body conductor

Lamifil also produces conductors with shaped wires, such as Z-shaped or trapezoidal wires or customer-specific wires. These wires produce a smooth body closed conductor that has a smaller diameter than conventional conductors. This results in improved wind and ice load characteristics. Another advantage of Lamifil’s smooth body conductors is their extremely low noise level.

Our technology

Lamifil is synonymous with flexible and innovative technology. Our success story is based on three driving forces:

• • •

Improvement and Development driven by customer needs A corporate philosophy based on innovative technology A flat organization structure that enables short development cycles

The great strides forward made by Lamifil in its development are first and foremost the result of the immense flexibility which the company managed to incorporate into its processes. This flexibility is also due to the fact that Lamifil controls the entire liquid metal production process, from raw materials over various semi-finished goods to finished products.

BARE ALUMINUM (ALUMINIUM) ELECTRICAL CONDUCTORS ACSR/TW

Applications | Specifications | Construction

Applications ACSR/TWD is ideal for reconductoring: it offers the same diameter for ice and wind but loading at higher ampacity than traditional ACSR designs. Angle and deadend structures must be carefully evaluated because of the greater weight of the conductor. The same tangent structures may normally be used in installation. This conductor is an outgrowth of the technology developed in the manufacture of self-damping conductor ACSR/SD. Specifications ACSR/TWD is produced to ASTM B-779 Construction ACSR/TW is a concentrically stranded conductor of varying layers, made with trapezoidal-shaped 1350-H19 wires over a high strength steel core. Each conductor is patterned after existing "round strand" ACSR(ASTM B-232), except that trapezoidal aluminum strands replace round strands. An ACSR/TWD design features equivalent diameter, whereas ACSR/TW offers reduced diameter with equivalent circular mil area. The same diameter means an increase in aluminum area of more than 20%. This means a reduction in AC resistance in the order of 15%. The steel core is increased proportionally to the aluminum in order that existing stress-strain data used for sag and tension be applicable to ACSR/TWD. The ACSR/TWD design is different from that of "round strand" ACSR in that the trapezoidal layers are not self-supporting. Intentional gaps between the TW wires are a major part of the design. This allows gripping devices, such as comealongs, to transfer the clamping load through all layers to the core. The increased aluminum and steel area means that larger compression fittings are required than would normally be used on the "round strand" ACSR of the same diameter. Conventional armor rods and suspension shoes, which are diametersensitive, may be used.

BARE ALUMINUM (ALUMINIUM) ELECTRICAL CONDUCTORS ACSR/TWD

Applications | Specifications | Construction

Applications ACSR/TWD is ideal for reconductoring: it offers the same diameter for ice and wind but loading at higher ampacity than traditional ACSR designs. Angle and deadend structures must be carefully evaluated because of the greater weight of the conductor. The same tangent structures may normally be used in installation. This conductor is an outgrowth of the technology developed in the manufacture of self?damping conductor ACSR/SD. Specifications ACSR/TWD is produced to ASTM B-779 Construction ACSR/TW is a concentrically stranded conductor of varying layers, made with trapezoidal-shaped 1350-H19 wires over a high strength steel core. Each conductor is patterned after existing "round strand" ACSR(ASTM B-232), except that trapezoidal aluminum strands replace round strands. An ACSR/TWD design features equivalent diameter, whereas ACSR/TW offers reduced diameter with equivalent circular mil area. The same diameter means an increase in aluminum area of more than 20%. This means a reduction in AC resistance in the order of 15%. The steel core is increased proportionally to the aluminum in order that existing stress-strain data used for sag and tension be applicable to ACSR/TWD. The ACSR/TWD design is different from that of "round strand" ACSR in that the trapezoidal layers are not self-supporting. Intentional gaps between the TW wires are a major part of the design. This allows gripping devices, such as comealongs, to transfer the clamping load through all layers to the core. The increased aluminum and steel area means that larger compression fittings are required than would normally be used on the "round strand" ACSR of the same diameter. Conventional armor rods and suspension shoes, which are diametersensitive, may be used.