Aluminum Clad Steel for OPGW: Design Considerations
RAYTRON Technical Team1
1RAYTRON Group, China
发布日期: March 2026版本: 1.0
DOI:10.1000/raytron.WP-06-08
1. Introduction
1.1 OPGW Function
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Figure fig1 Figure 1: OPGW cross-section showing fiber unit and ACS strands
OPGW serves dual purposes:
Function
Description
Ground wire
Lightning protection
Communication
Fiber optic data transmission
1.2 Why ACS for OPGW
Requirement
ACS Benefit
Strength
Steel core provides
Corrosion resistance
Al cladding provides
Conductivity
Better than steel alone
Compatibility
Works with fiber units
2. OPGW Structure
2.1 Typical Configuration
Layer
Material
Function
Center
Fiber unit + buffer
Communication
Inner strands
ACS or Al
Strength, conductivity
Outer strands
ACS or Al
Protection, conductivity
2.2 Fiber Unit Design
Type
Description
Stainless steel tube
Most common
Aluminum tube
Lighter
Plastic tube
Lower cost
2.3 Strand Materials
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Figure fig2 Figure 2: OPGW strand material options and their properties
Material
Use Case
Aluminum
Conductivity priority
ACS
Strength + corrosion
AAAC (aluminum alloy)
Balance
3. ACS Role in OPGW
3.1 Mechanical Contribution
Property
ACS Contribution
Tensile strength
High
Modulus
Stiffens cable
Sag control
Better than Al alone
3.2 Electrical Contribution
Property
ACS Contribution
Fault current
Moderate conductivity
Lightning protection
Adequate
Grounding
Good
3.3 Environmental Protection
Factor
ACS Benefit
Corrosion
Al surface protects
UV resistance
Excellent
Temperature
Stable
4. Design Considerations
4.1 Fiber Protection
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Figure fig3 Figure 3: Fiber protection requirements in OPGW design
Design Factor
Requirement
Temperature
Fiber limited to ~85°C
Strain
<0.25% for fiber
Crush
Protect from compression
4.2 Short-Circuit Current
Parameter
Design Requirement
I²t
Calculate fault energy
Temperature rise
Keep fiber safe
Material selection
Adequate cross-section
4.3 Sag-Tension
Factor
Consideration
Span length
ACS reduces sag
Wind/ice loading
Strength needed
Creep
ACS low creep
4.4 Installation
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Video 1: OPGW installation procedures and best practices
Factor
ACS OPGW Consideration
Minimum bending radius
Larger than Cu
Pulling tension
Follow specifications
Splicing
Special procedures
5. Performance Requirements
5.1 Standards
Standard
Scope
IEC 60794-4-10
OPGW specification
IEEE 1138
OPGW design
5.2 Testing Requirements
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Figure fig4 Figure 4: OPGW testing setup and procedures
Test
Purpose
Tensile
Mechanical strength
Vibration
Fatigue resistance
Short circuit
Fault current capacity
Temperature
Fiber performance
Lightning
Surge withstand
5.3 Quality Parameters
Parameter
Requirement
Fiber attenuation
Per fiber spec
Splice loss
<0.1 dB typical
Strength
Per design
6. Conclusion
6.1 Summary
ACS Role
Benefit
Strength
High-strength core
Corrosion
Al surface protection
Conductivity
Better than steel
Fiber protection
Stable environment
6.2 Design Summary
ACS in OPGW provides:
Structural integrity
Environmental protection
Adequate conductivity
Long service life
7. References
IEC 60794-4-10. (2022). OPGW Specifications.
IEEE 1138. (2020). Design of OPGW.
FAQ
Why is ACS preferred for OPGW over other materials?
ACS offers the optimal combination of high strength (for structural integrity), moderate conductivity (for fault current handling), excellent corrosion resistance (for long-term reliability), and compatibility with fiber units. Pure aluminum lacks strength; steel alone lacks conductivity and corrosion resistance.
How does OPGW protect the fiber optic cables?
OPGW protects fibers through: stainless steel or aluminum tube housing the fibers; ACS strands providing mechanical protection; aluminum cladding preventing corrosion; and design maintaining fiber strain below 0.25% and temperature below 85°C under all operating conditions.
What standards govern OPGW design and testing?
Key standards include IEC 60794-4-10 for OPGW specifications and IEEE 1138 for OPGW design. Testing requirements cover tensile strength, vibration fatigue, short-circuit current, temperature performance, and lightning withstand capability.
What are the installation considerations for ACS OPGW?
Key considerations include: larger minimum bending radius than copper cables; controlled pulling tension per specifications; specialized splicing procedures for fiber termination; and careful handling to avoid damaging the aluminum cladding. Proper training and equipment are essential.
