In modern power cable production, the metallic sheath plays a decisive role in providing long-term radial moisture protection, mechanical strength, and chemical resistance — particularly in underground, submarine, and high-voltage applications. The Aluminum Sheath Corrugated Pipe Continuous Extrusion Line delivers a state-of-the-art seamless aluminum sheath solution that outperforms traditional welded aluminum processes by ensuring uniform wall thickness, zero weld defects, and superior concentricity.
Using high-purity aluminum rods (Φ9.5 mm or Φ12 mm per GB/T 3954), this Aluminum continuous extrusion and cladding/sheathing line produces corrugated aluminum tubes with outer diameters from Φ60 mm to Φ180 mm and wall thicknesses from 1.5 mm to 5.0 mm. The resulting sheaths offer excellent flexibility, lightweight construction, and reliable long-term performance for low-voltage through extra-high-voltage cable cores.
Core Technology & Engineering Advantages
Advanced Continuous Extrusion Process (Conform-Type)
Four aluminum rods undergo surface cleaning before entering the main extrusion unit, which features an upper-and-lower single-wheel double-groove structure. This Conform-type rotary extrusion technology ensures homogeneous material flow, high production efficiency, and complete elimination of weld seams that are inherent in traditional longitudinal welding methods.
In-Line Cable Core Integration
The cable core pays off at precisely synchronized speed and passes through the extrusion die equipped with a protective water-cooling jacket. This prevents thermal damage to the insulation while forming a loose-fitting aluminum sheath around the core.
Immediate Cooling & Precision Corrugation
Post-extrusion water cooling protects both the sheath and the cable core. The tube then enters the corrugation unit, where precise helical or annular corrugations are formed (pitch 10–50 mm, depth 2–8 mm) according to international standards or specific customer requirements. Corrugation significantly enhances flexibility and crush resistance while maintaining excellent radial water-blocking performance.
Robust Pay-Off & Take-Up Systems
Large-capacity gantry-type pay-off and take-up units (up to 4500 mm bobbins) ensure stable, high-speed operation and easy handling of long-length cables typical in HV/EHV and submarine projects.
Intelligent Full-Line Control
Advanced MMI + PLC system provides real-time monitoring, recipe storage, automatic synchronization, and comprehensive data logging for consistent quality and minimal downtime.
Compared with traditional welded aluminum sheaths, continuous extrusion delivers more even metal distribution, eliminates weld-related defects (a common source of corrosion and mechanical weakness), and provides superior corrosion resistance and mechanical flexibility — making it the preferred choice for demanding MV/HV/EHV cable applications.
Technical Specifications
| Model | Inlet Al. Rod Dia. (mm) | Extrusion Wheel Dia. (mm) | OD of Al. Tube (mm) | Thickness of Al. Tube (mm) | Pitch of Corrugation (mm) | Depth of Corrugation (mm) | Pay-off / Take-up Bobbin (mm) |
|---|
| LBF420x2 | 9.5 ± 0.3 | 420 | 60–170 | 1.5–5.0 | 10–50 | 2–8 | 4500 / 4500 |
| LBF540x2 | 12 ± 0.3 | 540 | 60–180 | 1.5–5.0 | 10–50 | 2–8 | 4500 / 4500 |
Custom configurations for specific voltage classes or corrugation profiles are available upon request.
Production Process Flow
- Aluminum rod pay-off and surface cleaning
- Multi-rod feeding into Conform-type rotary extrusion unit
- In-line extrusion of seamless aluminum tube around synchronized cable core (with protective cooling jacket)
- Immediate water cooling of the sheath
- Precision corrugation unit (helical or annular as required)
- Final cooling and quality inspection
- Large-capacity gantry take-up
This integrated continuous process ensures high efficiency, excellent concentricity, and consistent quality from rod to finished corrugated aluminum sheath.
Primary Applications in Power Cable Industry
- Low-Voltage to Extra-High-Voltage Cables: Seamless aluminum sheath for MV, HV, and EHV cable cores
- Underground & Submarine Power Cables: Radial moisture barrier and mechanical protection
- Oil-Filled & Specialized Cables: Enhanced chemical and corrosion resistance
- Renewable Energy & Grid Infrastructure Projects: Lightweight, flexible sheathing for long-distance transmission
This Aluminum Sheath Corrugated Pipe Continuous Extrusion Line is engineered for manufacturers seeking consistent, high-quality metallic sheathing that meets or exceeds IEC 60840, IEC 62067, and GB standards while reducing material waste and production costs.
Engineered for Reliability, Efficiency & Long-Term ROI
Manufactured by RLB (Jiangsu Reliable Industry Co., Ltd.) — a trusted specialist with decades of experience in wire and cable machinery — every component of this Aluminum Sheath Corrugated Pipe Continuous Extrusion Line is built for 24/7 continuous operation with minimal maintenance.
Measurable advantages over traditional welded aluminum or lead sheathing:
- Uniform aluminum distribution with complete elimination of weld defects
- Superior flexibility and crush resistance thanks to precision corrugation
- Significantly lighter weight and lower material cost compared with lead sheathing
- Higher production efficiency and substantially reduced scrap rates
- Excellent long-term corrosion resistance and radial water-blocking performance
This continuous extrusion and cladding/sheathing solution meets or exceeds IEC 60840, IEC 62067, and GB standards while delivering the reliable quality, customized configurations, and long-term technical partnership that modern cable producers require.
Built for Global Standards & Turnkey Partnership
RLB provides complete turnkey solutions including engineering design, equipment supply, installation supervision, commissioning, operator training, and ongoing technical support. Custom configurations are available to match your specific voltage class, cable construction, corrugation requirements, and factory layout needs.
Ready to upgrade your metallic sheathing capabilities with advanced seamless aluminum technology?
Inquiry Now for a detailed technical quotation, custom configuration options, layout design recommendations, or factory visit arrangement. Our engineering team provides full turnkey solutions, installation support, operator training, and long-term technical partnership tailored to your production goals.
Frequently Asked Questions
What are the main advantages of continuous extruded aluminum sheath versus traditional welded aluminum sheath?
Continuous extrusion produces a truly seamless tube with uniform wall thickness and no weld seams — eliminating potential weak points for corrosion or mechanical failure while providing superior concentricity and flexibility, especially when corrugated.
Why is corrugation important for aluminum sheathed power cables?
Corrugation greatly improves the flexibility and bend radius of the cable, reduces mechanical stress during installation and operation, and enhances crush resistance while maintaining excellent radial water-blocking performance — critical for long-length HV/EHV and submarine cables.
Which cable types benefit most from this Aluminum Sheath Corrugated Pipe Continuous Extrusion Line?
The line is particularly suitable for medium-, high-, and extra-high-voltage power cables (MV/HV/EHV), underground and submarine cables, oil-filled cables, and renewable energy transmission projects where lightweight, flexible, and highly reliable metallic sheathing is required.
What standards does the line comply with?
The equipment is designed to produce aluminum sheaths meeting or exceeding IEC 60840, IEC 62067, and relevant GB standards for power cables.
Can the line produce both smooth and corrugated aluminum sheaths?
Yes. The corrugation unit can be configured or bypassed to produce either smooth or corrugated aluminum sheaths according to project requirements.
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