About Tokyo Rope Group

Innovative HTLS Transmission Conductor With®

Core

Tokyo Rope was established in 1887
and has been the leader in Japan's wirerope industry. Our global operations
are expanding. Our main products are
Steel Wire Rope, Fiber Rope, Steel Cordfor tire, and CFCC.

®
ALUMINUM CONDUCTOR FIBER REINFORCED

Low Loss
China●Shanghai officeHong Kong office●Russia

HighCapacity●Moscow Office
St. Petersburg Plant●St. Petersburg Office●USA
Japan Head Office●Kitakami CFCC Plant
Tsuchiura Plant●Kitakami Plant●Kitakami Works●Sakai Plant●Tokyo Seiko Rope●Ako Rope
●Kazakhstan●Almaty Plant●Michigan CFCC Plant
Michigan Office（TOKYO ROPE USA INC.)

VietnamBrazil●●Binh Duong Plant

Kyrgyzstan

Low Sag●Sao Paulo Office●Bishkek office

Thailand●Bangkok OfficeTOKYO ROPE INTERNATIONALNIHONBASHI FRONT BLDG. 6-2 NIHONBASHI 3-CHOME CHUO-KU TOKYO 103-8306 JAPAN
Tel.: + 81 3 6366 7731, Fax: +81 3 3270 1776
https://tokyorope-intl.co.jp
E-mail: inquiry_cfcc@tokyorope.co.jp
TOKYO ROPE INTERNATIONAL

19-10-SA

Today's Overhead Conductor's market
Challenge

Current StatusTransmission Owners are facing
the following requirements:

ACSR is a conventional typeof conductor which has
three drawbacks as follows:●Huge Electric Demand
Environmental Concern(CO2)● Sag Violations● Right of Way Issue● Construction Cost & Period● Lower Life Cycle Cost●

●Heavy steel core
Large Thermal Expansion● Corrosion●Solution
Next generation conductor
cable=®
●Low Transmission Loss
High Transmission Capacity● Low Sag
● Longevity● Easy Handling●ACFR Structure
ACFR stands for Aluminum Conductor Fiber ReinforcedCore

Light Weight and Small Thermal Expansion

Trapezoidal Aluminum Wire

Large Cross Sectional AreaCore
Trapezoidal Shape®
ALUMINUM CONDUCTOR FIBER REINFORCED

Annealed Aluminum Wire(or TAL / Hard Drawn Wire)®
ALUMINUM CONDUCTOR FIBER REINFORCED

Case Study

Accessories (Dead End Clamp and Mid Span Joint)

Performance Example compared to ACSR
Design Concept
Low LossHigh Capacity
Low Sag-Low Loss
Low Sag-High Capacity

Low
Loss

Transmission Loss
27% Less
More
9% Less
More

Transmission Capaicty
Same
120% More
Same
103% More

SagSameSame
12% Less
10% Less

Basic Design is the same as those for the conventional ACSR conductor,
except for using an aluminum buffer which grabs the CFCC core securely.

*This figure depends on designand operating conditions.

ACSR
27% Less

100A

90A

100A

93A

Dead End Clamp

HighCapacity

ACSR

Supply Scheme
100A

200A

Tokyo Rope provides CFCC to local conductor producer which will make ACFR.

100A

Reference

Twice capacity using
existing tower

Low
Sag

Mid Span Joint*These pictures are for example purposes. Actual design to be decided by the customer's requirements.

Longer span

Advisor: ACFR Design

Accessories
development

Lower tower’s height

Reduction of total construction cost including land,
foundation and tower.

Deduction of tower structual cost

LocalConductor
Producer

ACSRTransmission
Owner

Contractor

Accessories
Producer

ACSR

Advisor: Accessories Installation Training
Conductor Stringing Training

Standard ACFR Design Example
The following is standard ACFR Design Example. Final design should be agreed with the conductor's manufacturer.
ACFR PRODUCT CODE
(Equivalent conventional ACSR)
Mechanical Specifications
Overall Diameter of Conductor
Nominal Aluminum Cross-sectional Area
Nominal Diameter of Composite Core (from CFCC data sheet)
Nominal Cross-sectional Area of Core
Nominal Cross-sectional Area of the Conductor
Ultimate Tensile Strength of Conductor
Rated Strength of CoreCore Nominal Mass per unit length
Aluminum Nominal Mass per unit length
Conductor Nominal Mass per unit length
Maximum Allowable Operating Temperature
Coefficient of Linear Expansion Above Thermal Kneepoint
Coefficient of Linear Expansion Below Thermal Kneepoint
Final Modulus of Elasticity Above Thermal Kneepoint
Final Modulus of Elasticity Below Thermal Kneepoint
Electrical Specifications
Nominal Resistivity of Aluminium at 20°C, DC 63% IACS
Current carrying capacity at maximum operating temperature@180 °C
Emergency operating temperaturemmmm2mm
mm2mm2kN
kN
kg/km
kg/km
kg/km
°C
×10-6/°C×10-6/°C
GPa
GPaohm/km
Amps°CACFR 121/17-FA-TT(Dog equivalent)

ACFR 213/28-FA-TT( Linnet Equivalent )ACFR 267/37-FA-TT( Panther Equivalent )ACFR 410/50-FA-TT(Grosbeak Equivalent )ACFR 492/55-FA-TT( Zebra Equivalent )ACFR 658/66-FA-TTT(Moose Equivalent)

14
121.3
5.3
17.2
138.5
43.7
36.8
27335
362
180
1.0
17.8
122
63.32

18.29
212.7
6.8
28.2
240.9
72.7
60.344588
632
180
1.0
18.0
122
62.85

20.75
267.2
7.8
37.2
304.3
94.8
79.5
60
738
798
180
1.0
17.7
126
63.67

25.15
407.18949.5
456.68
129.1
105.8
78
1124
1202
180
1.0
18.2
126
62.73

28.14
491.8
9.5
55.1
546.94
146.2
117.7
86
1358
1444
180
1.0
18.5
126
62.16

31.6
657.7
10.4
66.1
723.8
179.1
141.3
104
1819
1923
180
1.0
18.9
126
61.48

0.2307674
200

0.1314968
200

0.10471127
200

0.06861476
200

0.05681680
200

0.04262009
200

Note: Current Carrying Capacity is Calculated as per the following Assumptions: Wind Velocity (m/sec) : 0.6, Solar Absorption Co-efficient : 0.5,
Ambient Temperature (°C) : 35, Solar Radiation (Watt/Sq.m) : 1033

Emissivity : 0.5,

CFCC Development History

CFCC Advantage

CFCC core's development was started in the 1980s. Initially, CFCC was used for civil engineering
applications. In 2002, Tokyo Rope supplied CFCC core to conductor partners which produce ACFR,
and since then, more than 15 years have passed with satisfactory operations.

CFCC core is uniquely stranded CFRP and has eight advantages:Non-magnetic

No Iron Loss

Lightweight

1/5 of SteelHigh Flexibility

Can be wound to the small Drum

High Corrosion resistance

Against acid, alkali, water and UVHigh Tensile Fatigue

Able to withstand wind vibration

Small Thermal Expansion

1/10 of Steel (CFCC: 1.0×10-6; Steel : 11.5×10-6)

1980s

Started development of CFCC

1986

Supplied for PC Bridge project in Japan

2001

Supplied for PC Bridge project in Michigan/USA.

2002

Supplied for ACFR project in Japan

High Modulus

Superior to other FRP

2002

ACFR presentation in CIGRE* session 2002

Low Creep

Similar to Steel2011Established Gamagori CFCC Plant in Japan(First full-scale integrated CFCC factory.)

2012

Supplied for ACFR project in China

2015

Supplied for ACFR project in Indonesia

2016Standard Characteristics
Properties

Established Michigan CFCC Plant in USA

General mechanicalproperties(First overseas CFCC production facility.)

2018

2019

Item
Tensile strength
Tensile elastic modulus
Elongation at breakDensity
Relaxation
Creep strain
Coefficient of linear expansion
Specific resistance
Creep failure load ratio
Fatigue capacity(Stress range)
Bending stiffness

Established TOKYO ROPE INTERNATIONAL INC.
Established Kitakami CFCC Plant in Japan
Static properties

Supplied for ACFR project in India, USA*CIGRE is international council on Large Electric System

Others(MPa)*1(GPa)

*1(%)
*2(%)

*3
(×10-6/℃) *4(µΩcm)*5(N/mm2)*6(kN・cm2)

Heat resistance

1×7 7.8φ HT Type
2.137
126
1.70
1.60
1.3
0.07×10-3
Less than 1
3,000
0.85
780
56.9
180℃(Operating)
200℃(Emergency)(℃)

Superior to steel
Almost the same as steel

Acid resistanceAlkaline resistance*1: Calculated by nominal cross sectional area
*2: 0.7pu, 1000hrs(20±2℃), according to JSCE-E534.
*3: 0.6pu, 1000hrs(20±2℃)*4: 20℃～200℃, according to JSCE-E536.
*5: Tests of CFCC 1×12.5φ according to JSCE-E533 “Test Method for Creep Failure of Continuous Fiber Reinforcing
Materials” gave a load ratio of 0.85 at 1 million hours.
*6: Average load is 75% of breaking load. The number of cycles is 2×106, according to JSCE-E535.
pu: breaking load

Installed ACFR（Twin Bundle)

ACFR Installation

Standard Specification of CFCC
Designation(Configuration diameter)Kitakami CFCC Plant

Michigan CFCC Plant in USA®
CARBON FIBER COMPOSITE CABLE

DiameterNominal crosssectional area

Breaking
load

Unit Weight*

Tensile Modulus*

(mm)

(mm2)

(kN)

(g/m)

(GPa)

135

U

5.0φ

5.0

19.6

41.9

30

1×7

5.3φ

5.3

17.2

36.8

27

1×7

6.8φ

6.8

28.2

60.3

44

1×7

7.8φ

7.8

37.2

79.5

60

1×7

8.5φ

8.5

44.1

94.2

69

1×7

9.5φ

9.5

55.1

117.7

86

1×7

9.9φ

9.9

59.9

128.0

95

1×7 10.8φ

10.8

71.3

152.4

112

1×7 12.5φ

12.5

95.4203.9

147

1×7 15.2φ

15.2

141.1

301.5

224

1×7 21.2φ

21.2

274.5

586.6

432

122

126

*Reference value