The Advantages of Steel

Conductor materials have undergone quite a transformation over the years. With decades of improvements and updates, today's materials are stronger and more durable than ever before.

The 1900s welcomed the development of the Aluminum Conductor, Steel Reinforced (ACSR) conductor. With this method, the core is constructed of galvanized steel conductor wires that fit into one of the following corrosion resistance categories:

• Class A
• Class B
• Class C

The ACSR conductor replaced copper wires until growing electricity needs inspired a new manufacturing method. In the 1970s, the utility industry started utilizing a conductor design called Aluminum Conductor, Steel Supported (ACSS), created and patented by Reynolds Metals.

When manufacturing ACSS, the individual aluminum strands are annealed before stranding them around the steel core. The annealing process includes heating and cooling the aluminum to reduce tensile strength and boost conductivity.

However, the process is imperfect. The stranding method often causes irregularities, such as having strands with uneven tensile strengths and hardened aluminum. In the 1990s, a new manufacturing process called batch-annealing combatted these issues. It involves completing the annealing process after the aluminum strands go around the steel core. The method is highly beneficial for creating uniform aluminum tensile strength.

ACSS proved to be more useful than steel reinforced distribution cables in terms of tension and sag.

Though steel was around in ancient times, bulk steel production was impossible until 1855. English inventor Henry Bessemer established a pneumatic steelmaking process that led to worldwide production by the early 1900s. Thanks to Bessemer, a stream of advancements in steel production led to the modern steel industry, including:

• The open-hearth furnace in the 1860s
• Oxygen steelmaking in the 1940s
• Electric steelmaking throughout the 1900s

Steel quickly became in demand worldwide. Further improvements made it possible to add strength and corrosion resistance to steel through alloying processes. The growing need for power and telecommunication lines throughout the 1900s led to the use of steel cables.

Today, steel is still one of the most used metals because of its history of sturdiness and dependability.

Utilizing steel for power cables can have many benefits, including the following:

1. Lower costs: One of the greatest advantages of steel cables is their low costs. Steel's strength-to-weight ratio makes it a cost-effective choice because less material can handle more strain than alternative metal options.
2. Easier installation: A steel reinforced conductor often offers more flexibility, making it easier to work with during installation and removal. Steel is also less likely to break during installation than other conductor types.
3. Durability:  When working with a steel conductor cable with a core made up of multiple wires, you can enjoy more durability and a lower chance of failure if damage occurs. Steel is also less likely to bend and warp when an external force and weight are applied.
4. Weather resistance: Another key advantage of using steel for power cables is its ability to withstand a wide range of weather conditions. Steel can withstand ice loads better than other types of metals and is less likely to warp due to heat.
5. Corrosion resistance: Galvanized steel cables are highly resistant to corrosion and rust. The zinc coating layer protects against oxygen and moisture, which can lead to rust damage over time. Steel can withstand the elements for years with the proper coating.
6. Increased conductor breaking strength: Another way steel is an advantageous material for power cables is its increased conductor breaking strength paired with its minimal increase in weight per unit length.
7. Smaller sag: Whether you are dealing with high temperatures or high ice loading, steel cables can withstand the elements with a smaller sag increase than other power cable materials.
8. Less blowout: When you work with steel reinforced power cables, you can enjoy less blowout and smaller right-of-way width, two crucial factors for any utility or highway line.
9. Reduced plastic elongation: Steel is a great option for utility cables because it reduces plastic elongation over time, making it more resistant to stress and strain that could damage other materials more quickly.
10. Less reduction in conductor strength at high temperatures: Steel cables can also maintain conductor strength at temperatures exceeding 100 degrees Celsius (212 degrees Fahrenheit), making them suitable for regions with especially hot climates.
11. Steel tensile strength: Since steel cable tensile strength is high, this material has excellent tension and fatigue resistance against certain stress levels.
12. Conductivity: When it comes to the conductivity of power and telecommunication lines, steel-supported transmission is an economical and effective option.

To ensure that steel is the right material for your application and that your power cable's performance is supported, you should consider the following:

• Tensile strength: Tensile strength of steel is an important deciding factor in avoiding failure and damage to the utility cable for your application.
• Wires per strand: You must ensure you choose enough wires per strand to achieve the flexibility necessary for the job.
• Breaking strength: When considering steel cables, select the right size to accommodate the breaking strength that your application requires.
• Environmental conditions: You must also consider the climate and temperatures you are working with. Galvanized steel cables are best for corrosive environments.

Common applications for steel cables include:

• Power lines
• Telecommunication lines
• Railway signals
• Towers
• Wind turbines
• Masts
• Reinforcing overhead power conductors