Composite conductor cores
Transforming power transmission with composite conductor cores
The demand for more efficient, reliable, and sustainable electricity transmission is greater than ever. Transmission System Operators (TSOs) need cutting-edge solutions to meet the challenges of increased and centralized electricity consumption combined with the aging infrastructure. Enter Exel Composites’ carbon fiber composite cores — a revolutionary technology that increases transmission capacity, enhances efficiency, decreases transmission losses, and reduces environmental impact.
Advanced conductors also known as HTLS (High Temperature Low Sag) conductors with composite cores outperform traditional ACSR conductors, making them the preferred choice for modern power grids. Learn how we can help future-proof your electrical infrastructure with composites.
Why choose HTLS composite conductors?
Upgrade aging infrastructure
Over 40% of Europe’s overhead power lines are more than 40 years old, struggling to meet today’s electricity demands. HTLS conductors with Exel’s composite cores modernize existing lines through reconductoring; boosting grid capacity and efficiency without costly new construction.
Eliminate transmission bottlenecks
Building new power lines is a time-consuming regulatory challenge, especially in densely populated areas. Additional challenges are brought by the fast implementation of renewable power plants. Reconductoring with Exel’s composite cores offers a fast-track solution to increase transmission capacity even sectionally while using the existing infrastructure.
Power longer distances with less loss
Renewable energy and urban expansion demand efficient long-distance transmission. Exel’s carbon fiber composite cores support high-voltage applications, minimizing energy loss for a smarter, more sustainable grid.
Support the growth of renewable energy
Wind and solar farms are becoming more widespread and change the layout of the grid rapidly. HTLS composite conductors boost capacity to accommodate these decentralized energy sources without overhauling existing networks.
Stay compliant & reduce carbon footprint
Stricter regulations require maintaining sag clearances at elevated temperatures. Exel’s minimal-elongation composite cores help TSOs meet compliance standards while cutting line losses by up to 50% — resulting in lower emissions and energy savings.
Exel Composites’ conductor core offering
Exel Composites’ innovative composite conductor cores provide a high-performance, cost-effective solution for modern power grids. By replacing traditional steel core conductors with ones having carbon fiber reinforced cores, utilities can significantly improve transmission capacity and efficiency without the need for completely new infrastructure. Our composite cores are stronger, lighter, and safer – resulting in more efficient conductors. Use of composite core conductors enables lower energy losses and minimal sag in the grid, while supporting longer spans between towers. This allows TSOs to increase capacity and enhance grid resilience while reducing maintenance and operational costs.
Multi-wire and single-wire PMC conductor cores
Exel Composites’ Polymer Matrix Composite (PMC) cores are pultruded, spoolable carbon fiber rods, designed for use in both multi-wire and single-wire core structures. Our continuous pultrusion manufacturing technology enables efficient, high-quality production of long-length, spooled products, offering an optimal balance of strength, flexibility, and minimal thermal elongation. These properties make our cores the preferred choice for reliable, long-lasting power transmission. Learn more about pultrusion here.
Single-wire vs. multi-wire cores
While single-wire cores remain the most economical option, multi-wire cores are gaining popularity among TSOs. Traditional carbon fiber single-wire cores require careful handling during installation, as they can be prone to breakage, if mishandled. In contrast, multi-wire cores provide enhanced flexibility, allowing them to behave similarly to traditional steel-core conductors, making installation safer and eliminating the risk of damage.
Exel Composites has decades of technical expertise to support TSOs and conductor manufacturers with different core options. To share this knowledge and shape the common future of power grids, we also take actively part in industry committees of IEC and CIGRE.
Key benefits of composite conductor cores
More capacity
~2x more transmission capacity without major expansions.
Less losses
Transmission loss reduction of up to 50%, lowering operational costs and environmental impact.
Stronger product
50% stronger than steel with virtually zero elongation, reducing sag and allowing for longer spans.
Lower infra costs
Lower infrastructure costs by enabling reconductoring instead of building new lines.
Fast installation
Faster installation and permitting, reducing project delays and regulatory challenges.
Customizable and high-quality production with pultrusion
Our composite core offering is fully customizable in terms of size, shape, and performance characteristics. With decades of expertise in composite materials, Exel provides tailored solutions, ensuring:
- Typical Tg values of 210-215°C for adjusted operating temperatures
- Tensile strengths exceeding 3000 MPa
- Flexible, global manufacturing capacity to meet project-specific demands
By combining carbon fiber (CF) or hybrid carbon and glass fiber (CF/GF) epoxy matrix designs, we provide solutions that fit the unique needs of conductor manufacturers and TSOs alike.
Our conductor core production lines are fully specified and designed for continuous, high-quality manufacturing. The continuous pultrusion process is constantly monitored, ensuring full traceability of all the reels shipped out from our sites. Read more about pultrusion here.
Grid upgrades made easy with reconductoring
Reconductoring means replacing old power lines with new, higher-performance conductors—without changing the existing towers or routes. It’s a fast, cost-effective way to increase transmission capacity using the grid you already have.
At Exel Composites, we supply carbon fiber composite conductor cores that make this possible. Lighter and stronger than steel, our cores enable HTLS (High Temperature Low Sag) conductors that:
- Carry more power
- Reduce line sag
- Cut transmission losses by up to 50%
Read more about reconductoring in this article by our Product Manager Heini Kloster here.
Case Study: Advanced conductors by De Angeli Prodotti
De Angeli Prodotti, a global leader in electrical conductors, partnered with Exel Composites to develop high-performance carbon fiber conductor cores that help utilities boost grid capacity—without building new lines.
By replacing steel with carbon fiber, the advanced conductors can double ampacity while maintaining sag compliance, even at high temperatures. Unlike new infrastructure projects that can take a decade, reconductoring with Exel’s composite cores takes just 12–24 months.
Key benefits:
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Faster grid upgrades without new towers
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Higher ampacity for increased capacity
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Lower energy losses and emissions
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Improved safety with multi-wire cores
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Proven support for modernization goals
This partnership shows how composite cores can deliver a faster, cleaner, and more cost-effective grid.
Why carbon fiber composite cores are the future
Carbon fiber composite cores are redefining power transmission by offering higher capacity, exceptional strength, and long-term durability. Their lightweight structure allows for increased aluminum content and use of better conducting aluminum grades, enhancing overall transmission capacity and efficiency. Unlike traditional materials, carbon fiber composites resist thermal expansion, ensuring consistent performance and low sag under extreme temperatures. As a conclusion, these cores significantly reduce maintenance costs while maximizing grid reliability.
As the energy industry shifts toward more sustainable solutions, carbon fiber composite cores stand at the forefront of modern grid advancements.
Why work with Exel Composites?
Carbon fiber composite cores redefine what is possible in power transmission. Greater capacity, unmatched efficiency, and lower costs make Exel Composites the ideal partner for your electrical grid modernization.
With decades of expertise in pultruded composite solutions, we provide TSOs and conductor manufacturers with reliable, high-performance composite cores — engineered for the future of power transmission.
Our continuous pultrusion manufacturing expertise ensures high-quality, with consistent performance, strength, and durability. This scalable production method allows us to meet growing industry demands efficiently, supporting the global transition to more sustainable and robust power infrastructure.
Let’s power the grid of tomorrow— get in touch with us today!