Aerial Bundled 0.6/1kV 3x70+54.6+16mm2 XLPE Insulated Overhead Line Cable

Product Overview

Overhead distribution in rural and peri urban areas usually means long spans, trees, monsoon wind and a crew that wants to finish the line before dark. An aerial bundled cable answers all four: four XLPE insulated cores are twisted around an AAAC messenger, so the bundle supports itself between poles and needs no separate catenary wire, no insulators and no cross arms on straight sections.

The three 70mm2 aluminium phase cores carry the load, the 54.6mm2 alloy messenger takes the mechanical tension, and the 16mm2 core feeds street lighting without adding a second stringing operation. Because the insulation is UV stabilised black XLPE, the bundle tolerates direct sun and ozone, and because the conductors are close together, the reactance is low, which improves voltage regulation at the end of the feeder.

Compared with bare overhead line, the aerial bundled layout removes most phase to phase contact faults caused by wind borne branches, cuts tree trimming costs over the line life, and allows narrower corridors through villages, which is often the deciding factor for the permit.

Technical Specifications

Key Advantages

• Self supporting bundle needs no separate messenger wire or insulators.
• Twisted XLPE cores cut short circuit faults from branches and birds.
• Narrower right of way makes village and roadside permitting faster.
• Integrated 16mm2 lighting core removes one stringing pass per span.
• Low bundle reactance improves voltage at the remote end of long feeders.

Typical Applications

• Rural electrification and village distribution lines
• Suburban street lighting circuits
• Temporary construction power and event supply
• Island and coastal microgrid distribution
• Agricultural pump set feeders

Quality Assurance and Test Data

Bundles are tested for conductor resistance, insulation thickness and twist lay length, and tension tests are performed on the messenger from each production lot. We can supply sag and tension tables for your pole schedule so the installation crew can string to the correct span without field rework. An aerial bundled cable only performs when the messenger and the XLPE insulated phases are twisted at the right lay length, which is controlled on our line for every 3x70 aluminium bundle.

Ordering and Delivery Notes

Aerial bundled orders are driven by the pole schedule rather than by cable metres alone. Send the span lengths, wind zone and the number of street light poles, and we will return a bundle length per section plus the sag and tension table the crew needs. Because the aerial bundled construction includes a self supporting messenger, the hardware list is short: suspension clamps, dead end clamps and one anchoring arrangement per termination pole.

Selection and Test Summary

• For an aerial bundled overhead line the pole hardware is simple, so project cost sits mostly in the XLPE Insulated Cable and the clamps.
• The self supporting messenger carries the tension, and the 3x70 aluminium phases are twisted around it at a controlled lay length.
• Where wind loading is severe the aerial bundled overhead design still works with shorter spans, and we issue the sag table with the drum plan.
• Each self supporting messenger is tension tested per lot, and the XLPE Insulated Cable is spark tested over its full length.
• For a village line the aerial bundled overhead bundle replaces three bare wires and a neutral, which cuts installation time per span.
• The 3x70 aluminium phases are drawn from rod in house, so conductor quality on an aerial bundled overhead order stays traceable.

Frequently Asked Questions

Q: Do I still need insulators with aerial bundled cable?
A: No. Straight sections are supported by clamps on the messenger, so insulators are only needed at dead ends and angle poles.

Q: What span can the 54.6mm2 messenger carry?
A: Around 45 m at 40 percent sag under normal wind load; we will confirm against your local wind and ice assumptions.

Q: Can the lighting core be omitted?
A: Yes, we build three core and four core variants of the same bundle with the same messenger.

Q: Is aluminium suitable for coastal areas?
A: The XLPE insulation and the alloy messenger resist salt atmosphere, and for severe coastal sites we can supply grease filled conductor strands.

Q: Which clamps are needed for the aerial bundled cable?
A: Suspension clamps on straight poles, dead end clamps with guy grips at terminations, and anchoring hardware matched to the self supporting messenger; we quote the set with the drum plan.

Send your pole schedule, span and wind load, and we will return sag and tension tables plus a delivered price for this aerial bundled overhead cable.