{"id":30987,"date":"2026-08-06T12:47:15","date_gmt":"2026-08-06T12:47:15","guid":{"rendered":"https:\/\/doingcable.com\/?p=30987"},"modified":"2026-08-06T12:47:17","modified_gmt":"2026-08-06T12:47:17","slug":"what-is-aluminum-sheath-corrugated-pipe-continuous-extrusion-line","status":"publish","type":"post","link":"https:\/\/doingcable.com\/tr\/what-is-aluminum-sheath-corrugated-pipe-continuous-extrusion-line\/","title":{"rendered":"Al\u00fcminyum K\u0131l\u0131fl\u0131 Oluklu Boru S\u00fcrekli Ekstr\u00fczyon Hatt\u0131"},"content":{"rendered":"

Al\u00fcminyum K\u0131l\u0131fl\u0131 Oluklu Boru S\u00fcrekli Ekstr\u00fczyon Hatt\u0131<\/a><\/strong> is a continuous rotary extrusion (Conform\/Conklad\/SheathEx-type) production system that converts high-purity aluminum rods into a seamless, loose-fitting aluminum tube around a cable core, followed by in-line corrugation to produce a metallic sheath for low-voltage to extra-high-voltage (EHV) power cables.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

This process eliminates longitudinal welds, delivers uniform wall thickness, and provides radial moisture barrier, short-circuit current capacity, and mechanical protection required by IEC 60840, IEC 62067 and related national standards.<\/p>\n\n\n\n

What Is an Aluminum Sheath Corrugated Pipe Continuous Extrusion Line and How Does It Work?<\/h2>\n\n\n\n

An Aluminum Sheath Corrugated Pipe Continuous Extrusion Line feeds multiple clean aluminum rods (typically \u03a69.5 mm or \u03a612\u201315 mm, GB\/T 3954 A2 or equivalent 99.5 %+ purity) into a rotating extrusion wheel (or dual wheels) with circumferential grooves. Frictional heat and pressure plasticize the aluminum at approximately 450\u2013500 \u00b0C. The metal flows into an extrusion chamber surrounding a cooled portal mandrel through which the cable core passes at synchronized speed. A seamless aluminum tube is formed around the core as a loose sheath, immediately water-cooled to protect the XLPE insulation, then corrugated (helical or annular) to the required pitch and depth before take-up.<\/p>\n\n\n\n

Ba\u015fl\u0131ca Teknik Avantajlar<\/h3>\n\n\n\n
    \n
  • Truly seamless aluminum tube \u2013 no weld line, no bead, no risk of weld-related corrosion or cracking.<\/li>\n\n\n\n
  • Uniform wall thickness and superior concentricity thanks to balanced multi-rod feeding and double-groove Conform technology.<\/li>\n\n\n\n
  • In-line water-cooled core protection ensures insulation integrity even at high extrusion temperatures.<\/li>\n\n\n\n
  • Precision adjustable corrugation improves flexibility, bend radius and crush resistance while maintaining excellent radial moisture barrier performance.<\/li>\n\n\n\n
  • High production efficiency and lower scrap rates compared with welding lines.<\/li>\n\n\n\n
  • Compatible with standard continuous-cast and rolled (CCR) aluminum rod \u2013 lower raw-material cost than aluminum sheet or lead.<\/li>\n\n\n\n
  • Robust design for 24\/7 industrial operation with advanced PLC + HMI control, recipe management and real-time monitoring.<\/li>\n\n\n\n
  • Customizable for smooth or corrugated sheath according to project requirements.<\/li>\n<\/ul>\n\n\n\n

    Typical process flow:<\/strong><\/p>\n\n\n\n

      \n
    1. Multiple high-purity aluminum rods (normally 4 \u00d7 \u03a69.5 mm or 2 \u00d7 \u03a612 mm, A2 grade per GB\/T 3954) are paid off, surface-cleaned and fed into the main extrusion unit.<\/li>\n\n\n\n
    2. The Conform extrusion machine with dual-groove wheel structure plasticizes and extrudes a seamless aluminum tube of the required diameter and wall thickness.<\/li>\n\n\n\n
    3. The pre-manufactured cable core is paid off from a large gantry stand at synchronized linear speed and passes through a water-cooled insertion tube and extrusion die. A protective cooling jacket prevents thermal damage to the insulation while a loose-fitting aluminum sheath is formed around the core.<\/li>\n\n\n\n
    4. Immediately after the die the aluminum tube is quenched by water cooling to stabilize dimensions and protect the core.<\/li>\n\n\n\n
    5. The sheathed cable enters the corrugation unit where precise helical or annular corrugations (pitch 10\u201350 mm, depth 2\u20138 mm) are formed according to IEC, GB or customer specifications.<\/li>\n\n\n\n
    6. Final cooling, inspection and take-up onto large bobbins (up to 4500 mm) complete the process.<\/li>\n<\/ol>\n\n\n\n

      This continuous method supports long-length production without stop marks, high material utilization and consistent quality suitable for demanding underground, submarine and extra-high-voltage applications.<\/p>\n\n\n\n

      \"\"<\/figure>\n\n\n\n

      Key process stages:<\/p>\n\n\n\n

        \n
      1. Aluminum rod payoff \u2192 surface cleaning\/polishing.<\/li>\n\n\n\n
      2. Continuous extrusion (single-wheel double-groove or four-channel dual-wheel configurations).<\/li>\n\n\n\n
      3. Synchronized cable-core payoff through water-cooled mandrel.<\/li>\n\n\n\n
      4. Immediate post-die cooling.<\/li>\n\n\n\n
      5. In-line corrugation unit (pitch 10\u201350 mm, depth 2\u20138 mm typical).<\/li>\n\n\n\n
      6. Caterpillar haul-off and large-drum take-up.<\/li>\n<\/ol>\n\n\n\n

        Compared with traditional argon-arc longitudinal welding of aluminum tape, the continuous extrusion method produces zero weld defects, superior concentricity (roundness typically \u226599 %), and thickness deviation within \u00b15 %.<\/p>\n\n\n\n

        Technical Comparison: Continuous Extrusion Seamless vs. Welded Aluminum Sheath<\/h3>\n\n\n\n
        Parametre<\/th>Continuous Extrusion Seamless<\/th>Longitudinal Welded Aluminum Tape<\/th><\/tr><\/thead>
        Weld \/ Seam<\/td>Hi\u00e7biri<\/td>Longitudinal weld + bead<\/td><\/tr>
        Wall thickness uniformity<\/td>Excellent (\u00b15 % typical)<\/td>Variable; weld zone critical<\/td><\/tr>
        Roundness<\/td>\u226599 % achievable<\/td>Lower; dependent on forming<\/td><\/tr>
        Short-circuit performance<\/td>Homogeneous conductivity<\/td>Potential weak points at weld<\/td><\/tr>
        Bending radius<\/td>Typically 25\u00d7 overall diameter<\/td>Often 30\u201335\u00d7 (smooth) or higher after corrugation stress<\/td><\/tr>
        Production length<\/td>Continuous, very long lengths<\/td>Limited by tape coil and stop-start<\/td><\/tr>
        Energy & material efficiency<\/td>Lower energy (approx. 440 kWh\/t reported); uses standard CCR rod<\/td>Higher scrap risk at weld; tape preparation<\/td><\/tr>
        Typical OD range<\/td>60\u2013180 mm<\/td>Broad, but weld integrity limits large sizes<\/td><\/tr>
        Reference processes<\/td>Conform, Conklad, SheathEx, SSLB500 four-channel<\/td>Argon-arc + corrugation<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

        Typical Technical Parameters of Current Production Lines<\/h2>\n\n\n\n
        Model<\/th>Inlet Al Rod Dia. (mm)<\/th>Ekstr\u00fczyon \u00c7ark\u0131 \u00c7ap\u0131 (mm)<\/th>Al Tube OD (mm)<\/th>Wall Thickness (mm)<\/th>Corrugation Pitch (mm)<\/th>Corrugation Depth (mm)<\/th>Typical Pay-off \/ Take-up<\/th><\/tr><\/thead>
        LBF350\u00d72<\/td>9.5<\/td>350<\/td>60\u2013120<\/td>1.5\u20133.0<\/td>10\u201350<\/td>2\u20138<\/td>4500 mm<\/td><\/tr>
        LBF420\u00d72<\/td>9.5 \u00b10.3<\/td>420<\/td>60\u2013170<\/td>1.5\u20135.0<\/td>10\u201350<\/td>2\u20138<\/td>4500 mm<\/td><\/tr>
        LBF540\u00d72<\/td>12 \u00b10.3<\/td>540<\/td>60\u2013180<\/td>1.5\u20135.0<\/td>10\u201350<\/td>2\u20138<\/td>4500 mm<\/td><\/tr>
        SSLB500 (4-channel)<\/td>4\u00d715<\/td>2\u00d7500<\/td>60\u2013180<\/td>2\u20134 (up to 8)<\/td>Configurable<\/td>Configurable<\/td>Large drums<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

        Line speed is generally limited by thermal protection of the cable core (typically up to 12 m\/min for large EHV sizes). Output can exceed 1000 kg\/h aluminum on advanced SheathEx configurations.<\/p>\n\n\n\n

        Selection Logic and Application Guidelines<\/h3>\n\n\n\n

        Select continuous-extrusion corrugated aluminum sheath when the cable requires:<\/p>\n\n\n\n