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OPGW Cable with Central Stainless Steel Tube – EMI Shielded Overhead Fiber
Small cable diameter, light weight, low additional load to the tower;
The steel tube locates at the center of the cable, no second mechanical fatigue damage.
Low resistance to side pressure, torsion and tensile (single layer).
OPGW - The Dual-Function Overhead Fiber Optic Ground Wire
OPGW (Optical Ground Wire), specifically the OPGW cable with a stainless steel tube and EMI shielded overhead fiber, is a specialized composite cable used in power transmission systems. It simultaneously serves as a conventional overhead ground wire (providing lightning protection and a fault current return path) and as a high‑capacity optical communication link. The stainless steel tube securely houses the optical fibers, offering excellent mechanical strength, corrosion resistance, and thermal stability, while the metallic structure inherently provides electromagnetic interference (EMI) shielding - crucial for maintaining signal integrity in the high‑voltage environment of power lines. By replacing traditional ground wires with OPGW, utilities can build a dedicated, resilient communication backbone for smart grid applications (e.g., teleprotection, SCADA, and real‑time monitoring) without requiring additional towers or right‑of‑way, making it an efficient and space‑saving solution for modern electric infrastructure.
OPGW Fiber Optic Cable Specification parameters
- Specification parameters
- OPTICAL CHARACTERISTICS
Standard:
| Standard | Description |
|---|---|
| ITU-TG.652 | Characteristics of a single mode optical fiber. |
| ITU-TG.655 | Characteristics of a non-zero dispersion -shifted single mode fibers optical. |
| EIA/TIA598 B | Col code of fiber optic cables. |
| IEC 60794-4-10 | Aerial optical cables along electrical power lines-family specification for OPGW. |
| IEC 60794-1-2 | Optical fiber cables -part test procedures. |
| IEEE1138-2009 | IEEE Standard for testing and performance for optical ground wire for use on electric utility power lines. |
| IEC 61232 | Aluminum -Clad steel wire for electrical purposes. |
| IEC60104 | Aluminum magnesium silicon alloy wire for overhead line conductors. |
| IEC 61089 | Round wire concentric lay overhead electrical stranded conductors. |
Colors -12 Chromatography:
| No. | 1 | 2 | 3 | 4 | 5 | 6 |
|---|---|---|---|---|---|---|
| Color | Blue | Orange | Green | Brown | Gray | White |
| No. | 7 | 8 | 9 | 10 | 11 | 12 |
| Color | Red | Black | Yellow | Violet | Pink | Aqua |
Technical Parameter:
Typical Design for Single Layer:
| Specification | Fiber Count | Diameter (mm) | Weight (kg/km) | RTS (KN) | Short Circuit (KA2s) |
|---|---|---|---|---|---|
| OPGW-32 (40.6;4.7) | 12 | 7.8 | 243 | 40.6 | 4.7 |
| OPGW-42 (54.0;8.4) | 24 | 9 | 313 | 54 | 8.4 |
| OPGW-42 (43.5;10.6) | 24 | 9 | 284 | 43.5 | 10.6 |
| OPGW-54 (55.9;17.5) | 36 | 10.2 | 394 | 67.8 | 13.9 |
| OPGW-61 (73.7;17.5) | 48 | 10.8 | 438 | 73.7 | 17.5 |
| OPGW-61 (55.1;24.5) | 48 | 10.8 | 358 | 55.1 | 24.5 |
| OPGW-68 (80.8;21.7) | 54 | 11.4 | 485 | 80.8 | 21.7 |
| OPGW-75 (54.5;41.7) | 60 | 12 | 459 | 63 | 36.3 |
| OPGW-76 (54.5;41.7) | 60 | 12 | 385 | 54.5 | 41.7 |
Typical Design for Double Layer:
| Specification | Fiber Count | Diameter (mm) | Weight (kg/km) | RTS (KN) | Short Circuit (KA2s) |
|---|---|---|---|---|---|
| OPGW-96 (121.7;42.2) | 12 | 13 | 671 | 121.7 | 42.2 |
| OPGW-127 (141.0;87.9) | 24 | 15 | 825 | 141 | 87.9 |
| OPGW-127 (77.8;128.0) | 24 | 15 | 547 | 77.8 | 128 |
| OPGW-145 (121.0;132.2) | 28 | 16 | 857 | 121 | 132.2 |
| OPGW-163 (138.2;183.6) | 36 | 17 | 910 | 138.2 | 186.3 |
| OPGW-163 (99.9;213.7) | 36 | 17 | 694 | 99.9 | 213.7 |
| OPGW-183 (109.7;268.7) | 48 | 18 | 775 | 109.7 | 268.7 |
| OPGW-183 (118.4;261.6) | 48 | 18 | 895 | 118.4 | 261.6 |
Product Structure & Composition
Aluminum Clad Steel or Aluminum Alloy Wires - Outer conductors for grounding, strength, and corrosion resistance.
Optical Fiber - Core for high-speed data transmission.
Sealed Stainless Steel Tube - Protects fibers from moisture, stress, and temperature.
Benefits of OPGW Fiber Optic Cable
Easy to install
Small cable diameter, lightweight, low additional load on the tower pole;
Good mechanical performance
The steel pipe is located at the center of the cable, without secondary mechanical fatigue damage. Low resistance to lateral pressure, torsion, and tension (single layer).
Engineering Applications OPGW Fiber Optic Cable
Overhead Ground Wire & Lightning Protection
OPGW replaces traditional ground wires, combining line support, lightning shielding, and EMI protection. The stainless steel tube conducts fault currents while safeguarding internal fibers, ensuring power safety and communication integrity.
Power Communication Backbone Network
OPGW provides a dedicated, secure data highway for smart grids, carrying relay protection, dispatch automation, and stability control with ultra‑low latency and zero error. It supports massive bandwidth (10G to 400G per wavelength) for real‑time monitoring and teleprotection.
Large‑Span & Complex Terrain Installations
Stainless steel tube construction offers high tensile strength (>150 kN) for long‑span crossings over rivers, canyons, or mountains. Its compact design reduces wind/ice loads and simplifies tower design. Excellent corrosion resistance ensures 30+ years service life in harsh environments (coastal, desert, industrial).
Ultra‑High Voltage (UHV) & Extreme Environments
For UHV lines, 304L stainless steel offers superior electrochemical corrosion resistance, withstanding severe electrical/chemical stresses. The cable maintains stable signal transmission from –60 °C to +65 °C and exhibits low temperature rise under short‑circuit surges, ensuring communication continuity during faults.
Shipping & Packaging
Packaging Requirements:
1：All cables shall be wound on treated wooden spools that are not returnable
2：Cable ends must be firmly secured to the spool and protected with waterproof shrink caps
3：Each spool must include: Protective plastic wrapping layer ，Reinforcing wooden slats for stability，Minimum 1m of free cable end for testing purposes， Standard spool length: 3000mm (±2% tolerance allowed)
Cable Identification:
The outer jacket must display:
1、Unique sequential numbering every 1m (±1% variance permitted)
2、 Additional repeating markings at 1m intervals showing: Product code and fiber count， Manufacturer identification， Production date (month/year)，Total cable length
Standard Packaging Dimensions:
| Length | Container | Size (L×W×H) | Net Mass | Total Mass |
|---|---|---|---|---|
| 2 km | Wood spool | 90×75×90 cm | 156 kg | 220 kg |
| 3 km | Wood spool | 100×68×100 cm | 240 kg | 280 kg |
| 4 km | Wood spool | 109×75×109 cm | 300 kg | 368 kg |
| 5 km | Wood spool | 129×72×129 cm | 400 kg | 480 kg |
Technical Reference:
1、 Standard cable diameter: 10.0mm
2、Maximum span distance: 100m
3、Contact sales team for complete technical specifications
Spool Marking Standards:
Permanent markings (minimum 25-30mm height) must appear on both sides of each spool:
1、 Company name and trademark
2、Contained cable length
3、Cable specifications (type/fiber count)
4、Winding orientation
5、Weight measurements (gross/net)
Note: All wooden packaging materials must undergo proper fumigation treatment prior to use.
Product Comparison：
| Feature / Dimension | Aluminum PBT Tube OPGW | Stainless Steel Tube OPGW (Stranded) | Stainless Steel Tube OPGW (Central Tube) | Aluminum Spacer OPGW |
|---|---|---|---|---|
| Structural Features | Optical fibers are placed in a PBT loose tube, which is then encased in a seamless aluminum tube and stranded with steel/aluminum alloy wires. Aluminum tube is part of the conductive cross-section and serves as an optical unit protector. | Optical fibers are placed in a hermetically sealed stainless steel tube (laser-welded), which is stranded with aluminum-clad steel wires (ACS) and/or aluminum alloy wires. Stainless steel tube replaces one or more metal wires. | Stainless steel tube is placed at the cable's center, surrounded by one or more layers of stranded ACS/aluminum wires. No stranded optical units. | Optical fibers or loose tubes are placed in the spiral grooves of an aluminum alloy spacer, with a surrounding aluminum tube; all metal parts are fully metallic. |
| Typical Applications | Suitable for medium to high-voltage (110kV-220kV) transmission lines, general new construction, and environments requiring high corrosion resistance. | Preferred for 500kV-1100kV EHV/UHV transmission lines, new line construction, and projects needing compact design and easy ground wire matching. | Ideal for EHV/UHV lines, especially retrofitting projects where tower load capacity is limited, requiring direct replacement of traditional ground wires. | Used for medium-voltage lines, specialized anti-icing lines, and specific designs for special spans. |
| Pros in Engineering | Excellent corrosion resistance and vibration fatigue resistance due to seamless, uniform aluminum structure. Superior heat insulation protects fibers, and aluminum's low resistivity enhances short-circuit current capacity. | Most compact structure, smallest diameter, and lightest weight; mechanically matches traditional ground wires for easy replacement. Fastest heat dissipation with minimal impact on fibers during short-circuit events. | Very compact diameter, lightweight (minimal tower load), and highly resistant to side pressure and impact. Features good overall temperature performance, high production efficiency, and strong lightning resistance. | High fiber density and good side pressure resistance; spiral groove design provides ample fiber slack. Acts as a high-efficiency conductor, reducing transient current and industrial frequency overvoltage. |
| Cons in Engineering | Heavier and larger diameter than steel tube OPGW; fibers are more sensitive to short-circuit temperatures. For aluminum alloys, creep may occur under long-term tension, altering sag. | Welded seams pose corrosion risks, requiring protective gel. Stainless steel has poor galvanic compatibility with ACS wires, leading to galvanic corrosion. Welds also create stress points vulnerable to vibration fatigue. | Limited fiber capacity; with a 48-core design, it is less compact than stranded types. Fibers depend solely on tube-internal slack, limiting overall fiber slack. | Poor resistance to short-circuit currents; high heat transmission to the optical unit risks fiber damage. Complex manufacturing process results in higher costs and limited application. |
| Cost (Relative) | Aluminum PBT Tube OPGW has a moderate material cost, lower than steel tube OPGW. For low fiber counts (e.g., 24 cores), it is the most economical choice. | Higher material and manufacturing costs (including stringent production processes). However, due to its thin wall, the unit fiber cost may be lower for high fiber counts (e.g., 48 cores). | Comparable to stranded steel tube OPGW; manufacturing costs are relatively lower due to a simpler structure, but fiber slack design is more challenging. | High due to the complex structure requiring precise manufacturing and specialist design expertise for dedicated applications. |
| Maintenance Difficulty | Lower maintenance; the uniform material structure and high corrosion resistance reduce maintenance needs. | Higher maintenance; requires monitoring of weld integrity and corrosion at weld points. Protective gel may be needed but can affect grounding. | Lower maintenance; the simple central structure and high corrosion resistance keep maintenance costs low. Preventive inspections are still necessary for the long-term health of the stranded layers. | Lower maintenance; the metallic construction offers good durability. However, potential "ice shedding" risks during ice melting may require more frequent sag inspections. |
| Diameter / Weight (relative) | Larger diameter and heavier weight; a larger metal cross-section is needed for equivalent RTS. | Smallest diameter and lightest weight; under identical tensile strength, its total cross-section is minimized, imposing the smallest wind load and tower load. | Smallest diameter and lightest weight; similar to stranded type. | Larger diameter and heavier weight. |
| Ground Wire Compatibility | Moderate; while aluminum tube is part of the conductive cross-section, matching with ACS wires is not ideal and may require mechanical adjustments. | Excellent; best mechanical similarity to conventional ground wires, making it the preferred choice for replacing existing ground wires on older lines. | Excellent; similar to stranded type. | Moderate; primarily used in specialized applications rather than general replacement. |
OPGW Fiber Optic Cable Selection Guide
Choose Aluminum PBT Tube OPGW for 110–220 kV lines where corrosion resistance and cost efficiency are priorities. Its seamless aluminum structure offers excellent anti-corrosion and vibration fatigue resistance, and it is the most economical option for low fiber counts (≤24 cores). However, avoid if lightweight design or extreme short-circuit tolerance is required.
Choose Stainless Steel Tube OPGW (Stranded) for 500–1100 kV EHV/UHV lines requiring compact size, light weight, and easy ground wire replacement. It offers the smallest diameter, fastest heat dissipation, and best mechanical match to traditional ground wires. Higher cost and weld corrosion monitoring are trade-offs.
Choose Stainless Steel Tube OPGW (Central Tube) for EHV/UHV retrofit projects with limited tower load capacity and moderate fiber needs (≤48 cores). Its simple central design is lightweight, side-pressure resistant, and lower-cost than stranded types—but fiber capacity and slack are restricted.
Choose Aluminum Spacer OPGW only for specialized medium-voltage, anti-icing, or unique span applications. Its spiral groove design provides high fiber density and slack, but poor short-circuit performance and high manufacturing cost limit widespread use.
Quick summary:
110–220 kV, corrosion-resistant, low cost → Aluminum PBT Tube
500–1100 kV, compact & lightweight → Stainless Steel (Stranded)
EHV retrofit, limited tower load → Stainless Steel (Central Tube)
Specialized/anti-icing applications → Aluminum Spacer
OPGW Cable Installation Instructions (Concise)
Inspect cable – Check for any shipping damage. Verify length and fiber continuity before installation.
Use proper tension – Follow rated tensile strength. Avoid over‑bending (minimum bend radius: 20× cable diameter during pulling, 10× after installation).
Pulling – Use swivels and anti‑twist devices. Maintain even tension; never exceed max pulling force.
Grounding – Connect the metallic outer wires and stainless steel tube to tower ground at every span or as per design. Ensure low‑impedance path for fault currents.
Hardware installation – Use matched tension or suspension clamps. Do not crush the cable or distort the stainless steel tube.
Fiber splicing – Clean and seal splice closures properly. Protect fibers from moisture and dust.
Test after installation – Perform OTDR and insulation resistance tests to confirm no damage.
Download YRTFIBER Product Catalog
Factory Real Shot
Cable Sheathing
Loose tubes, reinforcing members, and filler ropes are stranded into a cable core at specific pitches, then extruded into a PE or LSZH sheath. Armored models are further reinforced with steel strips and undergo a second extrusion. The production line is equipped with a deviation measurement and cooling system to ensure a uniform and smooth sheath.
Loose Tube Extrusion Line
Colored fibers are fed into extrusion lines where PBT or PE material forms protective loose tubes, filled with water‑blocking gel.
Quality Control Laboratory
Routine tests include tensile strength, crush resistance, temperature cycling, and water penetration to ensure compliance with industry standards.
Final Coiling & Packaging Zone
Finished cables are precisely coiled onto wooden or steel reels, wrapped with protective materials, and labeled for shipment.
Frequently Asked Questions & Quick Inquiry
OPGW Fiber Optic Cable FAQ
1. What is the OPGW central stainless steel tube fiber cable used for?
OPGW is designed for installation in high-voltage power transmission networks. It provides dual functionality: grounding protection and high-capacity fiber optic communication, making it ideal for utility and telecom applications.
2. What is the structure of this cable?
This cable uses a central stainless steel loose tube to house and protect the optical fibers. Surrounding layers typically include aluminum or aluminum-clad steel wires for mechanical strength and conductivity.
3. What fiber types and core counts are supported?
The OPGW cable supports 12 to 144 fiber cores using G.652D or G.655C single-mode fibers, ensuring compatibility with modern communication systems and long-haul transmission.
4. What are the mechanical and environmental benefits of this design?
The stainless steel tube offers excellent crush resistance, corrosion protection, and thermal stability, while the outer layer provides electrical conductivity and grounding during lightning strikes.
5. What makes this cable suitable for aerial installation on power lines?
Its robust construction and dielectric protection allow for direct installation on overhead transmission towers, with no separate grounding wire needed. It resists EMI, lightning, and harsh weather conditions.
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