Galvanized flat wire from voestalpine Wire Technology as an important part of the global energy supply

15 November 2023 |

Flat wires from the voestalpine Wire Austria production site in Bruck/Mur are used for the armouring of high-voltage cables for deep-sea applications, high-voltage XLPE cables, as well as for offshore wind farms and onshore power plants.

High-voltage direct current transmission, or HVDC for short, is a key technology in the field of electrical power transmission. In contrast to conventional AC transmission, HVDC enables the efficient transmission of large amounts of energy over very long distances. This is done by converting alternating current to direct current at a converter and reconverting it at the destination. HVDC links minimize losses during transmission, making them ideal for transporting electricity across oceans or deserts. This technology plays a crucial role in the integration of renewable energy sources, as it can connect different power grids. HVDC links are an important building block for the future of global energy supply.

Submarine cables have to withstand particularly high demands. The challenges are not only the length of the cables themselves, which is often several 100 km, but also the harsh environment, such as salt water, and the long service life of the cables - they are used under water for about 30 years.

High-quality galvanized flat wire from Bruck an der Mur protects and sheaths deep-sea cables and thus contributes to a secure energy supply,

says Application Engineer Hubert Köberl, summarizing the product application.

Flat wire from the production site of voestalpine Wire Austria in Bruck/Mur is used for the armoring of high-voltage cables for deep-sea applications, high-voltage XLPE cables, as well as in offshore wind farms and onshore power plants. The penultimate production step is the armoring of the cables with the flat wire, which forms a flexible protective layer around the cable and is only supplemented by a bitumen layer (corrosion protection or protection against abrasion).

The reinforcement of the cable is further designed to absorb the enormous forces during laying, which occur when the cable is lowered from the ship onto the sea modes at around 2 km sea depth. The outer diameter of the entire cable is around 20 cm.

Benefits of our flat wire

It is a great feeling to be part of such a big project together with my colleagues from engineering and production. The use of the product pushes the boundaries of the energy transition and is a crucial step towards a sustainable future,

Sales Manager Jana Machacova is pleased with the success of the galvanized flat wire product.

Deep under the sea surface, the galvanized flat wire produced in Bruck an der Mur reliably protects deep-sea cables from mechanical damage, which can also occur during seaquakes. voestalpine Wire Technology makes a significant contribution to global sustainable energy supply with its flat wires for armoring submarine cables.

Involvement in such a project is a long and very intensive process. A particular challenge was the development of a new plant concept to be able to produce flat wires continuously and with a defined zinc coating,

says process engineer Franz Poetzelsberger.

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