| Customization: | Available |
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| Application: | Overhead |
| Voltage: | Low and Medium Voltage Cable |
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CAAI (Aluminum Alloy Conductor) and CAAI-S (Aluminum Alloy Conductor with Steel Reinforcement) are high-performance overhead conductors designed for power transmission and distribution networks. These conductors combine excellent electrical properties with superior mechanical strength.
Key Characteristics:
CAAI: All-aluminum alloy conductor (no steel core)
CAAI-S: Aluminum alloy conductor with steel reinforcement
Temperature Range: -40°C to +150°C (continuous operation)
Short Circuit Rating: 200°C for 5 seconds
Primary Applications:
Overhead power transmission lines (33kV to 230kV)
Distribution networks (11kV to 33kV)
River crossings and long spans
Areas with high ice/wind loading
Coastal regions with corrosion concerns
Advantages:
20-30% higher strength-to-weight ratio vs conventional ACSR
Better sag characteristics at high temperatures
Superior corrosion resistance
Reduced electrical losses (up to 10% lower than ACSR)
Longer service life (40+ years)
3.1 CAAI Conductor (All Aluminum Alloy)
Outer Strands: 6201-T81 aluminum alloy (ASTM B399)
Core: None (homogeneous aluminum alloy construction)
Stranding: Concentric lay, typically 7, 19, or 37 strands
Standard Sizes: 150mm² to 800mm²
3.2 CAAI-S Conductor (Steel Reinforced)
Outer Strands: 6201-T81 aluminum alloy (ASTM B399)
Core Strands: High-strength galvanized steel (ASTM B416)
Stranding Configuration:
Typical: 6 Al/1 St (7-strand) to 54 Al/7 St (61-strand)
Compact designs available
Standard Sizes: 70mm² to 1250mm²
3.3 Key Construction Parameters
| Parameter | CAAI | CAAI-S |
|---|---|---|
| Tensile Strength (MPa) | 290-330 | 1100-1400 (steel core) |
| Elongation at Break | ≥4% | ≥1.5% (steel) |
| DC Resistance (Ω/km) | Lower by 5-8% vs ACSR | Comparable to ACSR |
| Weight | 15-20% lighter than ACSR | Similar to ACSR |
4.1 International Standards
IEC 61089: Round wire concentric lay overhead conductors
ASTM B399: Aluminum-Alloy 6201-T81 Wire
ASTM B416: Concentric-Lay-Stranded Steel Core Wire
BS 215: Aluminum alloy conductors for overhead lines
IEEE 524: Guide for Overhead Conductor Installation
4.2 Testing Requirements
Mechanical Tests:
Tensile strength
Stress-strain characteristics
Torsion tests
Electrical Tests:
DC resistance
Current-temperature relationship
Corrosion Tests:
Salt spray (5000 hours)
Galvanic compatibility
Maximum Span: 400-600m (depends on loading)
Sag-Tension: 15-18% of breaking load at 60°C
Recommended Clamps: Special alloy clamps required
Creep Characteristics: 0.05-0.1% per decade
| Parameter | CAAI | CAAI-S | ACSR |
|---|---|---|---|
| Corrosion | ★★★★★ | ★★★★ | ★★ |
| Strength | ★★★ | ★★★★★ | ★★★★ |
| Conductivity | ★★★★ | ★★★ | ★★★ |
| Weight | ★★★★★ | ★★★ | ★★★ |
| Cost | Higher | Comparable | Lower |
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