From long-shot science experiments to an essential element in modern life, electricity is one of the greatest engineering marvels of all time. With electricity transmitted through numerous lines that criss-cross along areas far and wide, what lies at the core of these lines is the conductor. The conductor is considerably the most important component of an overhead power line because of its function to transfer electric power and the significance of its contribution toward the total cost of the line. Most overhead conductors utilize steel core wires surrounded by aluminium strands, whose electrical resistance causes the conductor to heat up under increased levels of electrical current. For an overhead conductor, when these lines heat up, the coefficient of thermal expansion causes the steel wires to stretch, resulting in conductor sag. While keeping a desired sag in overhead transmission and distribution power lines is an important consideration to permit safe tension in a conductor, too much sag in a transmission line could be problematic as it can cause short circuit events, which can then start fires and also create blackouts.

Lighter Than Steel

But unlike most overhead conductors, CTC Global’s ACCC^® Conductors tell a different narrative. Founded with the goal of building more efficient technologies for the transmission of electricity, CTC Global replaced the steel core wires with a carbon-fibre glass-fibre hybrid composite core. And the advantage of this composite core is that it has a very low coefficient of thermal expansion that does not result in conductor sag when the power lines carry an increased level of current. “Our high-capacity, high-efficiency, low-sag, patented and extensively tested ACCC^® Conductor has a core so much lighter than steel that it can incorporate about 28 percent more aluminium in the same diameter without a weight penalty,” says J.D. Sitton, CEO of CTC Global.

The added aluminium content not only carries more electrical current, but it also reduces the electrical resistance of the wire, which serves to reduce transmission line losses. “The transmission line loss reduction is profound in the fact that the reduction in the electrical resistance, as well as the line losses, helps to also reduce the amount of electricity that needs to be generated, which can save fuel,” says Sitton. Burning less fuel means that there are less CO2 and other emissions typically associated with fossil fuel plants like natural gas, coal, and more.

“With places in the U.S. and Australia suffering from severe and intense firestorms and wildfire, CTC Global is happy to be contributing to combating the effects of climate change,” says Sitton. Besides fulfilling environmental goals, CTC Global is trying to accommodate the growing demand for this much cleaner and more efficient source of electrical energy by using its advanced composite core technology. CTC Global produces the ACCC^® Core in Irvine, California and also has core production facilities in Indonesia and China serving those regions.

The composite core of CTC Global has been rigorously tested and certified, and produced to ASTM standards. The company manufactures the finished conductor or the finished power line wires in association with more than 30 different manufacturing partners spread all over the world.