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Wires & Cables

MV Power Cables

3.3 to 33KV grade Three Core Copper / Aluminium Conductor cables from sizes 35 to 1200 conforming to IS: 7098/II/85, IEC 60502-2 / BS 6622/ BS 7835.

LV Power Cables

1100 volts grade Power Copper / Aluminium Cables from to and in 2/3/3.5/4 core as per IS 1554 / IS 7098(Part1) 1988 and generally confirming to IEC 605021 / BS 5467 / BS 6724.

LV Control Cables

1110 Volts grade 2 to 100 core in 1.5 and 2.5 as per IS 1554 / IS 7098 (Part 1) 1988 and generally confirming to IEC 60502-1/BS 5467 / BS 6724.

Fire Survival Cables (FS)

Stranded Copper Conductor covered with layers of Mica Glass tape, Fire Survival Cables generally confirming to IEC 60331, BS 7846 & BS 6387 category CWZ.

Multicore Industrial Flexible Cables

2 Core to 61 Core x .050 to 4, 2 Core to 4 Core from 6 to 120

Submersible Flat and Round Cables

Flat : 3 Core x 1.50 to 95,
Round : 3 Core and 4 Core x 1.5 to 120

Solar DC Cable

Class 5 Bare / Tinned Copper Conductor insulated with XLPE / Cross linkable Low Smoke Zero Halogen compound suitable for conductor temperature beyond 120 C and sheathed with UV stabilized Cross linkable Low Smoke Zero Halogen compound – in sizes 1C x 2.5 to 25

LT Aerial Bunched Cables (ABC)

XLPE / Black HDPE insulated Aluminium conductors are laid together(twisted) around Aluminum Alloy / ACSR conductor insulated or bare messenger wire to form the Aerial Bunched Cable.

Building Wires

Energy efficient wires range to 16 with different Insulation properties.

Telephone Cables

Range: 1 Pair to 100 Pair x 0.40 mm, 0.50 mm and 0.63 mm in solid bare conductor with HDPE Insulation and Flame Retardant Jacketing having lower cross talk and attenuation.

LAN Cables

Range: Cat 5e to Cat 6
STP & UTP (Armoured & Unarmoured)

Speaker Cables

Range: Twin Parallel 23/26, 23/38, 40/36, and 40/38 – Polycab provides Speaker Cables with high quality oxygen free copper conductor.

CO – Axial Cables

Range: RG 59, RG 6 F, RG 6 CSS, RG 11 F CSS.

CCTV Cables

Polycab CCTV Cables are offered in two types namely 4+1 CCTV Cable and 3+1 CCTV Cables.

Single Core Industrial Flexibles

Energy Efficient Wires Range to 1000 in Class 5 copper conductors with different insulation properties.

Handling, Storage and Laying of Cables

Cable Inspection

Inspect every cable reel for damage before accepting the shipment. Be particularly alert for cable damage if;

  • A reel is lying flat on its side
  • Several reels are stacked
  • Nails have been driven into reel flanges to secure shipping blocks
  • A reel flange is damaged
  • A cable covering is removed, stained or damaged
  • A cable end seal is removed or damaged. A reel has been dropped (hidden damage likely)

Cable Handling & Storage

Damage to cables can occur due to the incorrect handling to which the drums and cables may be subjected; causing breakdown of the drum flanges and in exceptional cases, movement of the drum barrel takes place. Once this breakdown of the drum occurs, the cable is immediately exposed to damage. Cables damaged during handling & storage can cause service failures when the subject cable is put to use.

Thus the following is a list of Do's & Don'ts that should be followed while handling and storing the cables before it is put to use.

Do's Don'ts
When off loading reels from a truck, lower reels carefully using a hydraulic gate, hoist or forklift truck. Never drop reels. If reels must be rolled, roll in opposite direction of the cable wraps to keep cable from loosening on the reel.
If a fork lift is used, approach the feel from the flange side. Position the forks such that the reel is lifted by both reel flanges. Also Consideration should be given to, Traffic patterns during off – loading & damage during the time in storage. Do not allow the lift forks to contact the cable. Care must be taken by the fork lift operator not to make sudden turns or stops.
Cables reels should be stored on hard surfaces resting on the flanges edge (flanges vertical). Align reels flange to flange and, if possible arrange so that first in is first out. Multiple reels stacked on top of each other("Pancake" storage) is not recommended for cable drums. The weight of the stack can total thousands of kgs. Creating an enormous load on the bottom reel. Also, damage to the reel and/or cable will likely occur when the reel is flipped for transit. A concentration of stress on the reel flange may cause it to break and subsequently damage the cable.
When using a hoist, install a mandrel through the reel arbor holes and attach a sling. Use a spreader bar approximately 6 inches longer than the overall reel width placed between the sling ends just above the reel flanges. This may lead to the bending of the reel flanges and mashing the cable.

Pre- Installation

To ensure the safety during cable installation, following shall be checked prior to installation.

  • The cable is selected is proper for designed application.
  • The cable has not been damaged in transit or storage.

Review all applicable state and national codes to verify that the cable chosen is appropriate for the job. Also consult your local electricity authority. Next, you must identify any existing cable damage and prevent any further damaged from occurring. This is done through proper cable inspection, handling and storage.

Installation & Laying

Mechanical stresses during installation are generally more severe than those encountered while in service. Thus care should be taken as regards to the following while installation and laying of cables:

  • Polycab recommend the lying and installation of cables as per IS: 1255 / 84.
  • Care shall be taken during laying to avoid sharp bending, and twisting.
  • Cable shall be unwound from the drum by lifting the drum on the center.
  • Shaft supported both ends with suitable jacks / stands.
  • Under no circumstances the cable winding shall be lifted off a coil or drum laying flat at the flanges. This would cause serious twist and damages.
  • Suitable protection shall be provided to the cables against mechanical damages, it includes covers, pipes, etc.

Recommended Minimum Bending Radius for Heavy Duty Cables.

  • Single Core: 20 x D
  • Multi Core: 15 x D
  • Where D = diameter of cable in mm

Recommended Safe Pulling Force with Stockings:

  • For Unarmoured Cable: P = 5 D2
  • For Armoured Cable: P = 9 D2
    Where P = Pulling Force
    Where D = Diameter of Cable in mm

Recommended Safe Pulling Force when Pulled with Pulling Eye:

  • For Aluminum Conductor: 30 N / mm2
  • For Copper Conductor: 50 N / mm2