Wire drawing: High-purity aluminum alloy rods (diameter 9.5mm) are fed into a continuous wire-drawing machine. The rods pass through a series of diamond dies with decreasing diameters (from 9.5mm to 1.0mm) to form thin wires. The drawing process is lubricated with mineral oil to reduce friction and prevent surface damage. The drawn wires are annealed in a nitrogen-protected furnace at 350℃-400℃ to soften them, improving ductility for subsequent stranding.
Stranding: The annealed aluminum alloy wires (1.0mm diameter) are stranded into 17.5mm² cores using a 19-strand concentric stranding machine. The machine twists 1 central wire, surrounded by 6 wires in the first layer and 12 wires in the second layer, at a controlled pitch of 15-20 times the core’s outer diameter (≈18mm pitch for a 10mm outer diameter core). Tension control systems ensure each strand is pulled evenly, preventing loose or tight strands that could cause current imbalance or mechanical weakness. After stranding, the cores are inspected for diameter (±0.2mm tolerance), roundness, and surface defects (e.g., scratches, kinks).
Insulation extrusion: The stranded aluminum alloy cores are fed into a single-screw extruder (screw diameter 65mm) equipped with a cross-head die. The extruder heats XLPE pellets (dried to ≤0.05% moisture) to 160℃-220℃, melting and mixing the material. The cross-head die applies a uniform XLPE layer (1.2mm thickness) around each core, with a thickness tolerance of ±0.1mm. The extrusion speed is synchronized with the core pulling speed (typically 60m-80m per minute) to ensure consistent thickness.
Peroxide cross-linking: The Insulated Cores are passed through a high-temperature vulcanization (HTV) tube, where they are heated to 200℃-230℃ for 3-5 minutes. The heat activates the peroxide initiator in the XLPE, triggering cross-linking of the polyethylene molecules. After exiting the HTV tube, the cores are cooled in a water bath (20℃-30℃) to solidify the cross-linked insulation. QC tests at this stage include insulation thickness measurement, insulation resistance testing (≥100MΩ at 1000V), and dielectric strength testing (≥10kV/mm for 1 minute).
Core bundling: Four insulated cores (three phase cores + one neutral core) are fed into a cabling machine, which twists them into a single cable at a pitch of 30-40 times the cable’s expected outer diameter (≈800mm-1000mm pitch). A filling material (polypropylene yarn) is added between the cores to fill gaps, ensuring a round cable shape and preventing core movement during installation. A semi-conductive tape may also be wrapped around the bundled cores to improve sheath adhesion and electromagnetic shielding (though shielding is not critical for low-voltage rural cables).
Sheath extrusion: The bundled cores are fed into a larger extruder (screw diameter 90mm) for outer sheath application. Weather-resistant PVC or HDPE pellets (modified with additives) are melted at 160℃-200℃ (for PVC) or 180℃-220℃ (for HDPE) and extruded over the bundled cores to form a 2.0mm-thick sheath. The extruded cable is cooled in a water bath and then passed through a diameter measuring device to ensure the outer diameter (25mm-28mm) meets specifications. The sheath is also inspected for surface defects (e.g., bubbles, cracks) and adhesion to the inner cores.
Comprehensive testing: Each cable length undergoes a series of tests, including:
DC resistance test (conductor resistance ≤1.83Ω/km per core at 20℃)
Insulation resistance test (≥100MΩ at 1000V)
Dielectric strength test (10kV for 5 minutes without breakdown)
Tensile strength and elongation test (sheath tensile strength ≥10MPa, elongation ≥150%)
Weather resistance test (UV exposure for 1000 hours, with no significant sheath degradation)
Spooling: Qualified cables are wound onto wooden or steel spools (diameter 1.2m-1.5m) with a maximum length of 500m per spool (to facilitate transportation and installation). Each spool is labeled with product information (model, specification, length, batch number, production date) and QC pass certification.
Inner layer: A thin polyethylene (PE) film (0.05mm thickness) is wrapped tightly around the spooled cable to create a moisture barrier. This film prevents rain, dew, or humidity from penetrating the cable sheath during outdoor storage or transportation.
Middle layer: A layer of heavy-duty kraft paper (80g/m²) is wrapped over the PE film to add mechanical protection. The kraft paper resists tearing and provides a buffer against minor impacts (e.g., during loading/unloading).
Outer layer: For outdoor storage or long-distance transportation, an additional layer of woven polyethylene fabric (100g/m²) is applied. This fabric is UV-resistant and water-repellent, protecting the cable from direct sunlight and heavy rain. It is secured with plastic straps (width 25mm) to prevent unraveling.
Pallet material: The pallets are made of heat-treated wood (compliant with ISPM 15 standards for international shipping) to prevent pest infestation. Each pallet has a load capacity of ≥1000kg, sufficient to support the weight of the spools (≈250kg-300kg per spool).
Securing method: The spools are placed on the pallet in a staggered pattern to maximize stability. They are secured with steel straps (width 32mm, tensile strength ≥5000N) and plastic edge protectors (to prevent strap damage to the spool flanges). For additional stability, foam blocks (50mm thickness) are placed between spools to prevent movement during transit.
Labeling: Each pallet is labeled with a shipping label containing the consignee’s address, shipper’s information, total weight (≈1000kg-1800kg), number of spools, and a "Handle with Care" warning. A separate QC label lists the batch number and test certification details for traceability.
Smaller spools: Instead of 500m spools, 200m-300m spools (weight ≈100kg-180kg) are used to reduce the weight per spool, making them easier to unload and transport via rural vehicles (e.g., small trucks, tractors) with limited load capacity. The smaller spools also have reinforced wooden flanges (thickness 25mm-30mm) to withstand rough handling, such as being lifted by hand or dragged short distances.
Waterproof crating: For spools destined for areas with frequent rain or flooding, additional waterproof crates made of corrugated plastic (thickness 5mm) are used. The crates fully enclose the spools, with rubber gaskets around the lid to prevent water ingress. Ventilation holes (diameter 10mm) are added to avoid moisture buildup inside the crate, which could lead to mold growth on the cable sheath.
Handling aids: Each small spool is equipped with two wooden handles (length 150mm, diameter 30mm) attached to the flanges, allowing workers to carry the spools without damaging the cable. For larger spools, metal lifting lugs (tensile strength ≥1000N) are welded to the steel flanges, enabling safe lifting with small cranes or hoists commonly used in rural construction sites.
Road transportation:
Vehicles: Heavy-duty trucks (load capacity 10-15 tons) with flatbeds or enclosed trailers are used. Flatbeds are preferred for palletized spools, as they allow easy loading/unloading with forklifts; enclosed trailers are used for shipments to areas with extreme weather (e.g., heavy rain, sandstorms) to provide additional protection. The truck beds are lined with non-slip rubber mats (thickness 10mm) to prevent pallet movement during transit.
Securing: Pallets of spools are secured to the truck bed using steel chains (tensile strength ≥8000N) and turnbuckles, with wooden blocks (height 100mm) placed between pallets to prevent shifting. For small spools (200m-300m), they are packed into metal cages (size 1200mm×800mm×600mm) with foam padding, which are then secured to the truck bed.
Route planning: Routes are planned to avoid roads with excessive potholes, steep slopes, or narrow passages that could damage the cargo. For remote rural areas with unpaved roads, the truck speed is limited to 20-30km/h to minimize vibration, which could loosen spool wrapping or damage the cable sheath.
Rail transportation:
Application: Rail is used for bulk shipments (≥20 pallets) to rural regions with rail access, as it is more cost-effective and stable than long-distance road transport. The spools are loaded into rail freight cars (covered hopper cars or flatcars) with the same securing methods as road transport.
Coordination: The manufacturer coordinates with rail operators to ensure the freight cars are scheduled to arrive at the nearest railway station to the rural grid project site. Local trucking companies are then contracted to transport the spools from the station to the final destination, with last-mile delivery often using small tractors or utility vehicles for areas with no road access.
Sea transportation:
Containerization: Palletized spools are loaded into 20-foot or 40-foot shipping containers (ISO standard). The containers are inspected for water tightness and structural integrity before loading. Pallets are stacked no more than 2 layers high to avoid crushing the bottom pallets, with dunnage (wooden boards) placed between layers for support. The containers are also equipped with moisture absorbers (500g per container) to prevent condensation damage during the voyage.
Documentation: The manufacturer works with freight forwarders to prepare all required documents, including the bill of lading, commercial invoice, packing list, certificate of origin (to comply with import tariffs), and certificate of quality (proving compliance with IEC/GB standards). For countries with strict import regulations, additional testing reports (e.g., weather resistance test results) are provided.
Transit time: Sea transit typically takes 2-6 weeks, depending on the destination. The manufacturer provides the customer with a tracking number to monitor the container’s location via the shipping line’s website. Upon arrival at the destination port, the freight forwarder coordinates with local customs brokers to clear the shipment, and arranges for truck transport to the rural project site.
Air freight:
Application: Air freight is used for urgent orders (e.g., emergency grid repairs) or small quantities (≤2 spools). The spools are packed into lightweight, reinforced cardboard boxes (with foam insulation) to meet air cargo weight limits (typically ≤50kg per package).
Regulations: The packages comply with IATA (International Air Transport Association) regulations for hazardous goods (though the cable is non-hazardous, the packaging must meet size and weight restrictions). The manufacturer provides an air waybill and necessary documentation for quick customs clearance at the destination airport.
Order verification: The logistics team cross-verifies the order details (quantity, length per spool, delivery address, and special requirements) with the sales contract to ensure accuracy. Any discrepancies (e.g., incorrect spool length) are resolved before shipment.
Documentation preparation: A complete shipment document package is prepared, including:
Commercial Invoice: Details the product name, model, quantity, unit price, total amount, payment terms, and currency.
Packing List: Lists the number of spools, length per spool, gross/net weight per package, and total shipment weight/volume.
Certificate of Quality: Includes test results from the final testing stage, signed by the QC manager.
Shipping Label: Contains the consignee’s name, address, contact information, and shipment tracking number.
Customer notification: The customer is notified 3-5 business days before shipment, providing the expected departure date, transportation mode, and tracking number. The customer is also asked to confirm the delivery address and arrange for personnel to receive the shipment.
Loading supervision: A logistics supervisor oversees the loading process to ensure the spools are handled correctly (e.g., no dragging, no dropping) and secured properly to the transport vehicle. Photos of the loaded vehicle are taken and shared with the customer as proof of shipment.
In-transit monitoring: For road and rail shipments, GPS tracking devices are attached to the transport vehicles or containers, allowing the manufacturer and customer to monitor the shipment’s real-time location and estimated arrival time (ETA). For sea shipments, the manufacturer receives regular updates from the shipping line on the container’s status (e.g., departed port, arrived at transshipment hub).
Delay management: In case of delays (e.g., bad weather, road closures, customs hold-ups), the logistics team immediately notifies the customer and takes corrective action—such as rerouting the shipment, arranging alternative transportation, or expediting customs clearance—to minimize the impact on the rural grid project timeline.
Delivery notification: The transport driver contacts the customer 24 hours before arrival to confirm the delivery time. For rural areas with limited communication, the driver may coordinate with local project supervisors instead.
Unloading inspection: The customer or their representative inspects the shipment upon delivery, checking for:
Package integrity: No damage to spool wrapping, crates, or pallets.
Quantity verification: The number of spools matches the packing list.
Visible damage: No scratches, cracks, or deformation of the cable sheath or spools.
Sign-off: If no damage is found, the customer signs a delivery receipt (with a copy provided to the manufacturer) to confirm receipt. If damage is detected, the customer documents the issue with photos and notifies the manufacturer within 24 hours. The manufacturer then coordinates with the transport company to file a damage claim and arranges for replacement spools if necessary.
Product specification (70mm², 0.6/1kV, 4-core aluminum alloy ABC cable).
Purpose of the sample (e.g., testing, project approval, comparison with other products).
Delivery address and contact information.
Sample size: Each sample is a 2m-5m length of the cable, sufficient for visual inspection, dimensional measurement, and basic performance testing.
Sample quality: Samples are manufactured using the same materials, production processes, and QC standards as bulk cables—no "special" materials are used to ensure the sample accurately represents the final product.
Packaging: The sample is packed in a small cardboard box (250mm×150mm×100mm) lined with foam to prevent damage during transit. The box is labeled with the sample specification, production date, batch number, and manufacturer’s contact information.
Test guide: A detailed test guide is included with the sample, outlining recommended tests (e.g., insulation thickness measurement, tensile strength testing) and the corresponding standards (e.g., IEC 60502-1, GB/T 12706.1). The guide also includes expected test results (e.g., insulation thickness ≥1.2mm, sheath tensile strength ≥10MPa) for reference.
Technical support: The manufacturer’s technical team is available via phone, email, or video call to answer questions about the sample—such as explaining the alloy composition, insulation cross-linking process, or weather resistance additives. If the customer lacks testing equipment, the manufacturer can arrange for third-party testing (at a nominal cost) and provide the test report.
Feedback collection: The sales team asks the customer about their evaluation of the sample’s quality, performance, and suitability for the rural grid project. Any concerns (e.g., doubts about weather resistance, questions about installation) are addressed promptly.
Customization discussion: If the customer requests modifications (e.g., thicker sheath for extreme cold, different alloy composition for higher tensile strength), the manufacturer discusses the feasibility and cost of customization, and may provide a modified sample if needed.
Order conversion: If the customer is satisfied with the sample, the sales team assists with bulk order placement—confirming quantity, delivery timeline, pricing, and any special requirements (e.g., specialized packaging for remote areas). The sample cost (if any) is often deducted from the bulk order total as an incentive.
Pre-installation guidance: The manufacturer provides an installation manual tailored to rural grid scenarios, including:
Aerial laying guidelines (e.g., maximum span between poles, tension requirements, compatibility with rural grid hardware like insulators and clamps).
Environmental considerations (e.g., avoiding installation near pesticide storage areas, protecting the cable from livestock damage).
Safety precautions (e.g., using insulated tools, ensuring proper grounding to prevent lightning damage).
On-site troubleshooting: If issues arise during installation (e.g., difficulty in tensioning the cable, sheath damage during laying), the customer can contact the technical support team via a dedicated hotline (available 24/7 for rural grid emergencies). The team provides real-time guidance via phone or video call; if necessary, a technical engineer is dispatched to the rural project site (within 48-72 hours for domestic locations) to resolve the issue.
Post-installation monitoring: For large rural grid projects, the manufacturer offers optional post-installation monitoring services—such as periodic inspections (every 6 months for the first 2 years) to check the cable’s condition (e.g., sheath integrity, conductor temperature during peak load). The technical team provides a monitoring report with recommendations for maintenance or adjustments (e.g., adding additional supports in high-wind areas).
Complaint registration: When a customer reports a quality issue (e.g., sheath cracking, conductor overheating), the after-sales team records detailed information—including the order number, batch number, installation date, issue description, and photos/videos of the problem. The customer is assigned a complaint reference number for tracking.
Investigation: The after-sales team collaborates with the QC and technical departments to investigate the issue:
Batch review: The QC department reviews the production and test records of the relevant batch to check for any deviations from standards.
Sample testing: If needed, the manufacturer requests a sample of the defective cable for laboratory testing (e.g., insulation resistance, tensile strength, alloy composition) to identify the root cause (e.g., manufacturing defect, improper installation, environmental damage).
Resolution: Based on the investigation findings, the manufacturer proposes a resolution to the customer:
Manufacturing defect: If the issue is caused by a manufacturing defect (e.g., insufficient insulation thickness, faulty cross-linking), the manufacturer provides free replacement of the defective cable, covers all transportation costs, and dispatches engineers to assist with replacement installation.
Installation/environmental cause: If the issue is due to improper installation (e.g., excessive tension) or environmental factors (e.g., prolonged exposure to concentrated pesticides), the technical team provides guidance to correct the issue, and may offer a discounted replacement cable if needed.
Warranty coverage: The warranty covers issues such as:
Insulation breakdown due to faulty XLPE material or cross-linking.
Sheath cracking or degradation due to defective weather-resistant additives.
Conductor breakage due to subStandard Aluminum alloy or stranding.
Warranty claim process: To file a warranty claim, the customer provides:
The warranty certificate (issued upon delivery).
Proof of purchase (commercial invoice).
Evidence of the defect (photos, test reports, or the defective cable sample).
Regular maintenance checklist: The maintenance manual includes a checklist for rural grid operators, covering:
Monthly visual inspections (checking for sheath damage, bird nests near the cable, or tree branches touching the cable).
Quarterly insulation resistance testing (using a megohmmeter to ensure insulation resistance ≥50MΩ at 1000V).
Annual tension checks (adjusting tension if the cable sags excessively due to temperature changes).
Seasonal maintenance tips: The manual also provides seasonal guidance, such as:
Winter: Inspecting the cable for ice buildup (which can increase weight and cause sagging) and clearing snow from around the cable poles.
Summer: Monitoring the cable’s temperature during peak load (e.g., during agricultural irrigation season) to prevent overheating.
Rainy season: Checking for waterlogging near cable poles (which can corrode the poles and affect cable support) and inspecting the sheath for water damage.
Hongtai Cable Technology Co.,Ltd
E-mail:export@qlcables.com
sales@qlcables.com
Tel/whatsapp:+86-18032066271
ADD：Xiaokou Industrial Development Zone, Ningjin County, Xingtai City，Hebei Province, China
Copyright © Hongtai Cable Technology Co.,Ltd Technical Support: Ronglida Technology
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