About Tokyo Rope Innovative HTLS Transmission Conductor With ® Core

Tokyo Rope was established in 1887

and has been the leader in Japan's wire
rope industry. Our global operations
are expanding. Our main products are
Steel Wire Rope, Fiber Rope, Steel Cord
for tire, and CFCC.

ALUMINUM CONDUCTOR FIBER REINFORCED

Low Loss
China
● Shanghai office
● Hong Kong office
Russia
●Moscow Office
High
Capacity
USA
● Detroit Office
Japan Head Office ● Michigan CFCC Plant
●
●
Gamagori CFCC Plant
Tsuchiura Plant
●Kitakami Plant
Low Sag
●Kitakami Works
●Sakai Plant
●Tokyo Seiko Rope
●Ako Rope

Kazakhstan
●
Astana City Office Vietnam Brazil
●
Almaty Plant ●Binh Duong Plant ●Rio de Janeiro Office
Thailand
● Bangkok Office

Click here

TOKYO ROPE MFG. CO., LTD.

NIHONBASHI FRONT BLDG. 6-2 NIHONBASHI 3-CHOME CHUO-KU TOKYO 103-8306 JAPAN
Tel.: + 81 3 6366 7731, Fax: +81 3 3278 6870
http://www.tokyorope.co.jp/english/product/acfr/index.html
E-mail: inquiry_cfcc@tokyorope.co.jp

TOKYO ROPE MFG. CO., LTD.

17-03-SA
 Today's Overhead Conductor's market

Current Status Challenge

Transmission Owners are facing
ACSR is a conventional type
the following requirements:
of conductor which has
● Huge Electric Demand
three drawbacks as follows:
● Environmental Concern(CO2)
● Heavy steel core ● Sag Violations
● Large Thermal Expansion ● Right of Way Issue
● Corrosion
● Construction Cost & Period

● Lower Life Cycle Cost

Solution
Next generation conductor
cable=
● Low Transmission Loss
● High Transmission Capacity
● Low Sag

● Longevity

● Easy Handling

ACFR Structure
ACFR stands for Aluminum Conductor Fiber Reinforced

Core Light Weight and Small Thermal Expansion

Trapezoidal Aluminum Wire Large Cross Sectional Area

Core
Annealed Aluminum Wire
(or TAL / Hard Drawn Wire)
Trapezoidal Shape

ALUMINUM CONDUCTOR FIBER REINFORCED

 ALUMINUM CONDUCTOR FIBER REINFORCED

Case Study Accessories (Dead End Clamp and Mid Span Joint)
Performance Example compared to ACSR Basic Design is the same as those for the conventional ACSR conductor,
Design Concept Transmission Loss Transmission Capaicty Sag except for using an aluminum buffer which grabs the CFCC core securely.
Low Loss 27% Less Same Same
High Capacity More 120% More Same
Low Sag-Low Loss 9% Less Same 12% Less
*This figure depends on design
Low Sag-High Capacity More 103% More 10% Less and operating conditions.

ACSR
Low 27% Less

Loss
100A 90A 100A 93A

Dead End Clamp Mid Span Joint

*These pictures are for example purposes. Actual design to be decided by the customer's requirements.
ACSR
High Supply Scheme
Capacity 100A 200A
Tokyo Rope provides CFCC to local conductor producer which will make ACFR.
100A
Twice capacity using Reference
exsiting tower
Advisor: ACFR Design

Longer span Lower tower’s height Accessories Local

development
Low Reduction of total construction cost includig land,
foundation and tower.
Deduction of tower structual cost Conductor
Producer
Sag ACSR TOKYO ROPE Contractor
Transmission
Owner
Accessories
Producer
ACSR
Advisor: Accessories Installation Training
Conductor Stringing Training

Standard ACFR Design Example

The following is standard ACFR Design Example. Final design should be agreed with the conductor's manufacturer.
Equivalent conventional ACSR Hawk Drake Curlew Bison Zebra
Type of design Low Loss Low Sag Low Loss Low Sag Low Loss Low Sag Low Loss Low Sag Low Loss Low Sag
Size 310/40 290/55 520/55 470/95 660/70 570/140 490/45 430/95 540/55 440/140

8/TW(4.44) 10/TW(3.97) 8/TW(4.82) 12/TW(3.90) 8/TW(4.13) 8/TW(4.38)

10/TW(3.88) 10/TW(5.01) 10/TW(4.75) 12/TW(4.46)
Aluminum No./mm
12/TW(4.43) 14/TW(3.98) 12/TW(4.83) 16/TW(3.90) 12/TW(4.14) 12/TW(4.38)
Stranding *1 14/TW(3.90) 14/TW(5.02) 14/TW(4.77) 16/TW(4.47)
18/TW(3.98) 16/TW(4.83) 20/TW(3.90) 16/TW(4.16) 16/TW(4.38)
Core No./mm 7/2.6 7/3.2 7/3.2 7/4.2 7/3.6 7/5.1 7/2.9 7/4.2 7/3.2 7/5.1
Rated Tensile Strength kN 95.15 135.47 147.44 228.03 186.39 331.05 126.63 225.66 148.48 324.22
Conductor mm 21.79 21.79 28.14 28.14 31.62 31.62 27.00 27.00 28.62 28.62
Diameter
Core mm 7.80 9.60 9.60 12.50 10.80 15.20 8.80 12.50 9.60 15.20
Conductor mm2 309 285 522 474 659 573 486 427 542 439
Cross Sectional Area Core mm2 37.2 56.3 56.3 95.4 71.3 141 47.3 95.4 56.3 141
Total mm2 346 342 578 570 730 714 533 523 599 580
Weight kg/km 917.3 884.6 1540.2 1461.0 1938.4 1811.0 1425.1 1331.1 1597.1 1437.1
DC Resistance at 20°C Ω/km 0.0910 0.0985 0.0539 0.0593 0.0426 0.0490 0.0578 0.0658 0.0518 0.0641
*2
at 75°C A 678 652 932 890 1074 1006 892 838 954 861
Current Carrying Capacity
at 175°C A 1250 1202 1748 1668 2032 1900 1668 1565 1791 1614
Conductor GPa 74.7 79.0 74.5 77.2 73.7 79.6 73.6 78.0 74.3 82.4
Modulus of Elasticity
Core GPa 130 135 135 123 126 127 131 123 135 127
Conductor ×10-6/ °C 18.9 16.8 19.1 17.1 19.3 16.1 19.5 16.7 19.2 14.7
Coefficient of Thermal Expansion
Core ×10-6/ °C 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Notes *1: TW(X.XX) stands for Trapezoidal Shaped Wires for which the equivalent outside diameter is X.XX mm.
*2: Current Carrying Capacity is solved using the Cigre Method.
Calculation Conditons: Ambient temperature: 35°C, Wind: 0.9 m/s, Wind direction: 45°, Solar radiation: 0.1 W/cm2,
Absorptivity and Emmisivity of conductor surface: 0.5, Frequency: 50 Hz, Sea level: 0m
 CFCC Development History CFCC Advantage
CFCC core's development was started in the 1980s. Initially, CFCC was used for civil engineering CFCC core is uniquely stranded CFRP and has eight advantages:
applications. In 2002, Tokyo Rope supplied CFCC core to conductor partners which produce ACFR,
and since then, more than 10 years have passed with satisfactory operations. Non-magnetic No Iron Loss

Lightweight 1/5 of Steel

High Flexibility Can be wound to the small Drum

1980s Started development of CFCC
High Corrosion resistance Against acid, alkali, water and UV　
1986 Supplied for PC Bridge project in Japan
High Tensile Fatigue Able to withstand wind vibration
2001 Supplied for PC Bridge project in Michigan/USA.
Small Thermal Expansion 1/10 of Steel (CFCC: 1.0×10-6; Steel : 11.5×10-6)
2002 Supplied for ACFR project in Japan High Modulus Superior to other FRP

2002 ACFR presentation in CIGRE* session 2002 Low Creep Similar to Steel

2007 Supplied for ACFR project in Korea

2011 Established Gamagori CFCC Plant in Japan

(First full-scale integrated CFCC factory.) Standard Characteristics
2012
Supplied for ACFR project in China Properties Item 1×7 7.8φ HT Type
2015 Tensile strength (kN/mm2) *1 2.14
Supplied for ACFR project in Indonesia General mechanical Tensile elastic modulus (kN/mm2) *1 130
2016
properties Elongation at break (%) 1.70
Established Michigan CFCC Plant in USA
(First overseas CFCC production facility.) Specific gravity 1.60
Relaxation (%) *2 1.3
*CIGRE is international council on Large Electric System Creep strain *3 0.07×10-3
Static properties Coefficient of linear expansion (×10-6/℃) *4 Less than 1
Specific resistance (µΩcm) 3,000
Creep failure load ratio *5 0.85
Fatigue capacity(Stress range) (N/mm2) *6 780
Bending stiffness (kN・cm2) 56.9
Others 175℃(Operating)
Heat resistance (℃)
200℃(Emergency)
Acid resistance Superior to steel
Alkaline resistance Almost the same as steel
*1: Calculated by nominal cross sectional area
*2: 0.7pu, 1000hrs(20±2℃), according to JSCE-E534.
*3: 0.6pu, 1000hrs(20±2℃)
*4: 20℃～200℃, according to JSCE-E536.
*5: Tests of CFCC 1×12.5φ according to JSCE-E533 “Test Method for Creep Failure of Continuous Fiber Reinforcing
Materials” gave a load ratio of 0.85 at 1 million hours.
Tendons of the prestressed concrete pier *6: Average load is 75% of breaking load. The number of cycles is 2×106, according to JSCE-E535.
(Partly used) pu: breaking load
“Excellent construction resistances”

Standard Specification of CFCC

Designation Nominal cross Breaking Nominal mass Tensile elastic

Diameter
(Configuration diameter) sectional area load density* modulus*
(mm) (mm2) (kN) (g/m) (kN/mm2)

U 5.0φ 5.0 19.6 41.9 30 135

1×7 6.8φ 6.8 28.2 60.3 45 122

1×7 7.8φ 7.8 37.2 79.5 61 130

Gamagori CFCC Plant Michigan CFCC Plant in USA 1×7 8.3φ 8.3 42.1 90.0 69 131

1×7 9.6φ 9.6 56.3 121 93 135

1×7 10.8φ 10.8 71.3 153 111 126

1×7 12.5φ 12.5 95.4 204 146 123

1×7 15.2φ 15.2 141 302 221 127

1×7 20.9φ 20.9 267 571 412 129

*Reference value

®
CARBON FIBER COMPOSITE CABLE