Español
Português
لالعربية
Русский
Bahasa Indonesia
Français
Türkçe
Bahasa Melayu
OPGW Fiber Cable with Aluminum PBT Tube for Transmission Lines
Dual‑function – Replaces overhead ground wire while providing fiber optic communication.
Protected fibers – Optical fibers sealed in metal tube with water‑blocking compound.
High strength – Designed with metallic armor for excellent tensile and impact resistance.
EMI immunity – Unaffected by high‑voltage line interference, ensuring stable signals.
Long life – Corrosion‑resistant construction, service life 25+ years.
Easy deployment – Directly replaces existing ground wires – no extra infrastructure needed.
What is OPGW Fiber Optic Cable?
OPGW, or Optical Ground Wire, is a fiber optic cable that combines optical fiber communication with the overhead ground wire used on power transmission lines. It provides both grounding and lightning protection for the power line while enabling high-speed optical communication for power grid monitoring, control and data transmission.
In this aluminum tube OPGW design, optical fibers are placed inside PBT loose buffer tubes filled with water-blocking gel. The optical unit is protected by an FRP strength unit, thermal barrier and aluminum tube, while the outer aluminum-clad steel wires provide mechanical strength, electrical conductivity, grounding and lightning protection for overhead transmission lines.
Compared with installing a separate communication cable, OPGW can replace or be installed as the overhead ground wire, helping power utilities build a reliable communication backbone without adding a separate cable route. It is commonly used on high-voltage transmission lines, including 110 kV and above power grid projects, and can be designed and tested according to standards such as IEEE 1138 and IEC 60794-4-10.
OPGW Aluminum PBT Tube cable Specification parameters
- Specification parameters
- OPTICAL CHARACTERISTICS
Mechanical and Environmental Test Characteristics:
| Item | Test Method | Requirements |
|---|---|---|
| Tension | IEC 60794-1-2-E1. Load: cable length ≥10m, linked ≥100m, time: 1min | 40% RTS: no strain (0.01%) or attenuation (0.03dB); 60% RTS: ≤0.25% strain, attenuation ≤0.05dB |
| Crush | IEC 60794-1-2-E3, three-point load, duration: 10min | Attenuation at 1550nm ≤0.05dB/fiber; no damage |
| Water Penetration | IEC 60794-1-2-F5B: 1hr, 0.5m sample, 1m water height | No water leakage |
| Temperature Cycling | IEC 60794-1-2-F1: -40°C to +65°C, 2 cycles, 12h dwell | Attenuation change ≤0.1 dB/km at 1550nm |
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 |
Typical Design for OPGW Cable:
| Specification | Fiber Count | Diameter (mm) | Weight (kg/km) | RTS (KN) | Short Circuit (KA²s) |
|---|---|---|---|---|---|
| OPGW-113 (87.9;176.9) | 48 | 14.8 | 600 | 87.9 | 176.9 |
| OPGW-70 (81; 41) | 24 | 12 | 500 | 81 | 41 |
| OPGW-66 (79;36) | 36 | 11.8 | 484 | 79 | 36 |
| OPGW-77 (72;36) | 36 | 12.7 | 503 | 72 | 67 |
Product Structure & Composition
Optical Fiber - Glass core for signal transmission.
Water Blocking Gel - Prevents moisture migration inside the tube.
PBT Loose Buffer Tube - Houses fibers loosely for stress relief and protection.
FRP Strength Unit - Adds tensile strength without conductivity.
Thermal Barrier - Protects fibers from short‑circuit heat.
Aluminum Tube - Hermetically seals and protects the core.
Aluminum Clad Steel - Outer armor providing strength and conductivity.
Benefits of OPGW Aluminum PBT Tube cable
High Mechanical & Electrical Strength
Outer layers of aluminum-clad steel or aluminum alloy wires provide excellent tensile strength, crush resistance, and conductivity to withstand wind, ice, and short-circuit currents.Corrosion-resistant design offers 25–30 years of life, suitable for ≥110kV lines and long spans, meeting IEEE 1138. IEC 60794-4-10. and GB/T 7424.4 standards.
Immune to EMI & Thermal Protection
Optical fibers are protected inside a metal tube with water-blocking gel and a thermal barrier, ensuring stable transmission even under high-voltage and lightning strike conditions.Combines overhead ground wire (lightning protection) with fiber optic communication in a single cable, replacing traditional shield wires.
Engineering Applications OPGW Aluminum PBT Tube cable
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:
1、 Protective plastic wrapping layer
2、 Reinforcing wooden slats for stability
3、 Minimum 1m of free cable end for testing purposes
4、 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:
1、 Product code and fiber count
2、 Manufacturer identification
3、 Production date (month/year)
4、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 Aluminum PBT Tube cable Selection Guide
Choose Aluminum PBT Tube OPGW for medium to high-voltage lines (110kV-220kV) where corrosion resistance and moderate cost are priorities. Its seamless aluminum structure provides excellent anti-corrosion and vibration fatigue resistance, and it is the most economical choice for low fiber counts (≤24 cores). However, avoid if ultra-lightweight or extreme short-circuit temperature performance is required.
Choose Stainless Steel Tube OPGW (Stranded) for EHV/UHV lines (500kV-1100kV) where compact design, light weight, and easy ground wire replacement are critical. It offers the smallest diameter, fastest heat dissipation, and best mechanical match to traditional ground wires. The trade-off is higher cost and maintenance needs due to weld corrosion risks.
Choose Stainless Steel Tube OPGW (Central Tube) for EHV/UHV retrofit projects where tower load capacity is limited and fiber count is moderate (≤48 cores). Its simple central tube design is lightweight, highly side-pressure resistant, and offers lower manufacturing cost than stranded types. However, fiber slack is limited, and core capacity is lower.
Choose Aluminum Spacer OPGW only for specialized medium-voltage lines, anti-icing applications, or unique span designs requiring high fiber density and side-pressure resistance. Its complex spiral groove structure provides ample fiber slack and acts as a high-efficiency conductor, but high manufacturing cost and poor short-circuit current resistance limit its general use.
Quick summary:
110-220kV, corrosion resistance, low cost → Aluminum PBT Tube
500-1100kV, compact & lightweight → Stainless Steel Tube (Stranded)
EHV retrofit, limited tower load → Stainless Steel Tube (Central Tube)
Specialized/anti-icing applications → Aluminum Spacer
OPGW Fiber Cable with Aluminum PBT Tube — Brief Installation Instructions
Inspect the Cable — Confirm no damage and test fiber continuity.
Tension Laying — Tension laying must be used, maintaining constant tension throughout and avoiding friction with obstacles.
Bending Radius — Minimum bending radius during pulling: ≥ 30 times the cable diameter; after installation: ≥ 15 times.
Pulling — Use anti-torsion devices and rotating connectors; do not exceed the rated tensile force.
Grounding — The outer metal wire (aluminum-clad steel or aluminum alloy) is grounded at each tower leg as designed, forming a low-impedance fault current path.
Hardware Installation — Use matching tension or suspension clamps to avoid flattening the aluminum tube or twisting the PBT loose tube.
Connection and Sealing — Carefully peel off the PBT sleeve without damaging it; clean and seal the junction box.
Post-Installation Testing — Perform OTDR, insulation resistance, and water leakage tests according to standards.
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 Aluminum PBT Tube cable FAQ
1. What is an OPGW fiber optic cable used for?
OPGW (Optical Ground Wire) cables are used in overhead power transmission lines. They serve dual functions: grounding the power line and providing high-speed fiber optic communication, often used by utilities and telecom providers.
2. What are the available fiber counts for this cable?
This OPGW cable supports configurations from 12 to 144 cores, depending on your network capacity requirements. It’s compatible with G.652D and G.655C single-mode fibers.
3. What is the cable structure?
The cable uses a central PBT loose tube filled with gel to protect optical fibers, enclosed within an aluminum or aluminum-clad steel layer. This ensures strong mechanical strength and protection against environmental hazards.
4. How does OPGW compare with ADSS cables?
While both are used in aerial installations, OPGW is specifically designed for installation on high-voltage power lines and serves as a grounding conductor. ADSS cables are self-supporting and used below power lines or in non-electrical environments.
5. Is the cable resistant to lightning and electrical interference?
Yes, OPGW cables are designed to conduct lightning current and shield the optical fibers from electrical interference. The metal sheath provides grounding capability while keeping fibers isolated and stable.
Send Your Inquiry
Fill out the form below and we'll get back to you within 24 hours.
