How to Making Outdoor Optical Fiber Composite Ground Wire (OPGW)?

Optical Fiber Composite Ground Wire (OPGW)​​ is a dual-function cable used in high-voltage power transmission lines. It serves as:

​A ground wire​ (for lightning protection and electrical grounding).

​A fiber optic communication cable​ (for data transmission).

​1. Design & Material Selection​

Before production, engineers must determine:

​Voltage level​ (e.g., 110kV, 220kV, 500kV)

​Mechanical strength​ (tensile load, wind/ice resistance)

​Fiber count​ (typically 12, 24, 48, or 96 fibers)

​Conductor material​ (usually aluminum-clad steel or all-aluminum alloy)

2. Manufacturing Process​

​Step 1: Fiber Unit Preparation​

Stainless steel loose tube production line SSLT making machine

Optical fibers are placed inside a ​loose tube​ (stainless steel or aluminum).

The tube is filled with ​water-blocking gel​ to prevent moisture damage.

Fibers are color-coded for identification.

​Step 2: Stranding the Outer Conductors​

The central fiber tube is surrounded by ​aluminum or steel wires​ in a helical pattern.

Common stranding methods:

​Single-layer stranding​ (for smaller OPGW)

​Double-layer stranding​ (for higher mechanical strength)

The most suitable machine here is the “Planetary stranding machine",

The 500 model is faster and cheaper than the 630 model.

​Step 3: Final Assembly​

The stranded conductors are compacted to ensure tightness.

A ​corrosion-resistant coating​ (e.g., grease or polymer) is applied.

​Markings & labeling​ are printed for identification.

​Step 4: Quality Testing​

Before delivery, OPGW undergoes:

​Optical Testing​ (attenuation, bandwidth, continuity).

​Mechanical Testing​ (tensile strength, bending, crush resistance).

​Electrical Testing​ (DC resistance, short-circuit current capacity).

Conclusion​

"tubular stranding machines", and the appropriate equipment should be selected according to the number of conductors.

Check video of OPGW cable manufacture process: