01
Copper wire rod casting (UPCAST)
Oxygen-free copper wire rod with a diameter of 8 mm (grade M00) is produced from cathode copper by continuous upward casting (UPCAST). In-house casting with a capacity of 6 000 t/year covers the bulk of the plant's needs and provides end-to-end quality control from the very first processing stage.
Technology: UPCAST
Wire rod Ø: 8 mm
Capacity: 6 000 t/year
02
Wire drawing
Copper or aluminium wire rod with a diameter of 8–9.5 mm is drawn through a series of dies, reducing the diameter to 0.2–3.5 mm. Multi-die drawing machines with automatic tension control are used.
Initial Ø: 8–9.5 mm
Final Ø: 0.2–3.5 mm
Materials: Cu, Al, Al alloy
03
Conductor stranding
Individual wires are twisted together into stranded conductors on stranding machines. A round or sector-shaped conductor cross-section is formed. For flexible cables (KGtp, PVS), class 5 high flexibility is used. For fire-resistant cables (FR), mica tape resistant to high temperatures of up to +1000 °C is wound over the conductor.
Depending on requirements, a semi-conducting tape is also wound over the conductor.
Classes: 1, 2, 5
Cross-sections: 0.5–800 mm²
Shape: round, sector, trapezoidal, Z-shaped layer
04
Insulation application
Insulation is applied on extrusion lines by continuous extrusion. Depending on the cable type, the following materials are used: PVC compound, cross-linkable polyethylene (XLPE), halogen-free compounds (HFC), UV-stabilised PE, thermoplastic elastomer.
PVC – up to 1 kV
XLPE – up to 35 kV
HFC – up to 35 kV
05
Cabling and sheathing
The insulated cores are laid up into a cable with the interstices filled. The outer sheath is then applied. For armoured types (VBShv, AVBShv), steel tape armour or armour of aluminium / steel wires is additionally applied. Depending on requirements, nylon, water-blocking and semi-conducting tapes are also applied.
Sheath: PVC, PE, HF
Armour: steel tape
Screen: copper foil / tape
Nylon, water-blocking, semi-conducting tape
06
Testing and inspection
Every batch is tested in our own accredited laboratory: voltage testing, measurement of insulation and conductor resistance, checking the insulation and sheath material for mechanical changes and for compliance with cold and heat resistance requirements. Checking of geometric parameters, fire resistance testing, and measurement of gas and smoke emission during combustion (for NG / HF / HFZH, ZHFR, FRLS).
High-voltage testing
Resistance testing
Fire resistance (GOST)
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