Catenary Catlogue

Member of the NKT Group
Catalogue
Railway catenary systems
www.nktcables.com
Foreword
Content
Our passion brings power to life

Electrical energy is the lifeblood of our modern society,
It affects every aspect of our daily lives, providing heat
and light, acting as a driving force and supporting communication, as well as setting electric trains in motion.
Electrical energy must therefore be in constant supply
and we have to be able to put it to use cost-effectively.
nkt cables has set itself the aim of helping its customers
in energy supply and industry to meet this challenge by
providing creative ideas and tailor-made energy transmission media.
Contact Wires (Trolley Wires)

Drums for contact wire
4
12
Copper and copper-magnesium

cable conductors
13
Flexible cable conductors made of copper
16
Flexible cable conductors made
Contact wires with a service life at least two times longer

than that of conventional copper contact wires and
demonstrably more cost-effective than copper/silver contact wires are our most recent development innovation.
of copper-magnesium
18
Cable conductors made of cooper-clad steel
19
The name of this new contact wire is: VALTHERMO
Cable conductors made of AL1/AL3
21
VALTHERMO has already demonstrated its impressive

properties on several reference routes. These references,
which you will find on the last few pages of this catalogue,
speak for themselves.
Drums and delivery lengths
Working in close collaboration with the Technical University of Dresden, we have created a rigorous economic
efficiency calculation. The result is the reward for many
years of dedicated development work from which you,
our customers, can now benefit.
for cable conductors
26
New BB high-speed Lower Inn Valley

Railway in Austrias Tyrolean Unterland.
28
German Unity Transport Project No. 8

(VDE 8): Berlin Munich in 4 hours
30
Gotthard Base Tunnel

The longest railway tunnel in the world
24
References26
VALTHERMO32
But the VALTHERMO range does not just feature

contact wires. It also includes catenary wires and
dropper wires. You will find all of these in this catalogue.
We hope that you will enjoy working with the products in
the VALTHERMO range and we look forward to hearing
from you.
The nkt cables Railway Team
32
Dr. Jan Siebert
2
VALTHERMO
The economic alternative to Cu- and
Cu/Ag-Overhead Catenary Systems
Survey of contact wires according to EN 50149
Contact wire made of pure copper (Cu-ETP),

CuAg, CuMg and CuSn according to EN 50149
Areas of Application:
Contact wire for all ranges of speed on main and side
lines, for all electrical systems AC or DC as well as for
Metros, Trolley buses and Mining.
Packing:
Different drums according
to the specific application
Construction and weights

nominal wire- construction
nominal
cross section
AC
BC
BF
nominal
weight
mm 2
mm
mm
mm
kg/km
80
10.60
710
100
12.00
12.00
11.04
890
107
12.30
12.24
11.35
952
120
13.20
12.85
12.27
1070
150
14.80
14.50
13.60
1335
Other constructions:
e.g. international standards or customer specification can be manufactured according to customers request
Contact wires for every speed and application

Survey of materials (selection) and speed
material
speed
typical
conductivity
min.
tensile strength
min.
breaking load
max. km/h
m/*mm 2
N/mm 2
kN
Cu-ETP (normal tensile strength)
160
56.3
330
38.4
CuAg0.1 (high tensile strength)
250
56.3
360
41.9
CuSn0.2 (normal conductivity)
350
41.8
420
48.9
CuMg0.2 (normal conductivity)
350
44.6
430
50.1
CuMg0.5
400
36.0
490
57.0
250
56.3
360
41.9
VALTHERMO
(high tensile strength)
Values are based on a cross section of 120 mm2 according to EN 50149
Identification marks according to EN 50149
Contact wires made of

pure copper (Cu-ETP)
do not have identification grooves. Speciality
in UK: Contact wires
made of coppercadmium alloy are not
allowed to have identification grooves.
Contact wires made

of copper-silver alloy
have two identical
identification grooves
on the top of the wire.
Contact wires made

of copper-tin alloy
have one identification
groove on the top of
the wire at an angle of
24 from the vertical.
Contact wires made

of copper-magnesium
alloy have three identification grooves on the
top of the wire.
VALTHERMO contact
wires have two identification grooves, one
offset at an angle of 24
and one in the middle
of the curve at the top
of the wire.
Contact wire made of pure copper Cu-ETP according to EN 50149
Contact wire made of CuAg0.1 according to EN 50149
Values for ETP copper (normal tensile strength)
Values for CuAg0.1 (normal tensile strength)
technical data
nominal cross section
technical data
80
100
107
120
150
80
100
107
120
150
min. tensile strength R m 2)
N/mm2
355
355
350
330
310
N/mm2
365
360
350
350
350
min. breaking load1) Fm
kN
27.5
34.4
36.3
38.4
45.1
kN
28.3
34.9
36.3
40.7
50.9
Percentage Elongation after fracture A 200
3 10
3 10
3 10
3 10
3 10
3 10
3 10
3 10
3 10
3 10
Modulus of elasticity E
kN/mm2
120
120
120
120
120
kN/mm2
120
120
120
120
120
Half-hard point
180
180
180
180
180
Half-hard point
300
300
300
300
300
Electrical conductivity at 20C
m/(Ohm*mm2)
56.3
56.3
56.3
56.3
56.3
m/(Ohm*mm2)
56.3
56.3
56.3
56.3
56.3
% IACS
97
97
97
97
97
% IACS
97
97
97
97
97
Specific electrical resistance el at 20C
10 -8Ohm*m
1.777
1.777
1.777
1.777
1.777
10 -8Ohm*m
1.777
1.777
1.777
1.777
1.777
Electrical resistance R
Ohm/km
0.229
0.183
0.171
0.153
0.122
Ohm/km
0.229
0.183
0.171
0.153
0.122
Temperature coefficient el of electrical resistance
10 -3/K
3.8
3.8
3.8
3.8
3.8
10 -3/K
3.8
3.8
3.8
3.8
3.8
Linear coefficient of thermal expansion
10 -5/K
1.7
1.7
1.7
1.7
1.7
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
1)
2)
1)
calculation based on the minimum cross section

different tensile strengths on request
2)
Values for ETP copper (high tensile strength)

technical data

Values for CuAg0.1 (high tensile strength)

technical data
80
100
107
120
150
N/mm2
375
375
360
360
360
N/mm2
80
100
107
120
150
375
375
360
360
360
kN
29.1
36.4
37.4
41.9
52.4
kN
29.1
36.4
37.4
41.9
52.4
38
38
38
38
38
38
38
38
38
38
kN/mm2
120
120
120
120
120
kN/mm2
120
120
120
120
120
Half-hard point
180
180
180
180
180
Half-hard point
300
300
300
300
300
m/(Ohm*mm2)
56.3
56.3
56.3
56.3
56.3
m/(Ohm*mm2)
56.3
56.3
56.3
56.3
56.3
% IACS
97
97
97
97
97
% IACS
97
97
97
97
97
10 -8Ohm*m
1.777
1.777
1.777
1.777
1.777
10 -8Ohm*m
1.777
1.777
1.777
1.777
1.777
Ohm/km
0.229
0.183
0.171
0.153
0.122
Ohm/km
0.229
0.183
0.171
0.153
0.122
10 -3/K
3.8
3.8
3.8
3.8
3.8
10 -3/K
3.8
3.8
3.8
3.8
3.8
10 -5/K
1.7
1.7
1.7
1.7
1.7
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
1)
2)

1)
2)

Contact wire made of VALTHERMO according to EN 50149
Contact wire made of CuMg0.2 according to EN 50149
Values for VALTHERMO (high tensile strength)
Values for CuMg0.2 alloy (normal conductivity)
technical data
technical data
80
100
107
120
150
80
100
107
120
150
N/mm2
375
375
360
360
360
N/mm2
460
450
440
430
420
kN
29.1
36.4
37.4
41.9
52.4
kN
35.7
43.7
45.7
50.1
61.1
38
38
38
38
38
3 10
3 10
3 10
3 10
3 10
kN/mm2
120
120
120
120
120
kN/mm2
120
120
120
120
120
Half-hard point
300
300
300
300
300
Half-hard point
370
370
370
370
370
m/(Ohm*mm2)
56.3
56.3
56.3
56.3
56.3
m/(Ohm*mm2)
44.6
44.6
44.6
44.6
44.6
% IACS
97
97
97
97
97
% IACS
77
77
77
77
77
10 -8Ohm*m
1.777
1.777
1.777
1.777
1.777
10 -8Ohm*m
2.240
2.240
2.240
2.240
2.240
Ohm/km
0.229
0.183
0.171
0.153
0.122
Ohm/km
0.289
0.231
0.216
0.192
0.154
10 -3/K
3.8
3.8
3.8
3.8
3.8
10 -3/K
3.1
3.1
3.1
3.1
3.1
10 -5/K
1.7
1.7
1.7
1.7
1.7
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
1)
2)
1)

2)

Values for CuMg0.2 alloy (high conductivity)

technical data
80
100
107
120
150
460
450
440
430
420
N/mm2
kN
35.7
43.7
45.7
50.1
61.1
3 10
3 10
3 10
3 10
3 10
kN/mm2
120
120
120
120
120
Half-hard point
370
370
370
370
370
m/(Ohm*mm2)
46.4
46.4
46.4
46.4
46.4
% IACS
80
80
80
80
80
10 -8Ohm*m
2.155
2.155
2.155
2.155
2.155
Ohm/km
0.278
0.222
0.208
0.185
0.148
10 -3/K
3.1
3.1
3.1
3.1
3.1
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
1)
2)

Contact wire made of CuMg0.5 according to EN 50149
Contact wire made of CuSn0.2 according to EN 50149
Values for CuMg0.5 alloy
Values for CuSn0.2 alloy (normal conductivity)
technical data
technical data
80
100
107
120
150
80
100
107
120
150
N/mm2
520
510
500
490
470
N/mm2
460
450
430
420
420
kN
40.4
49.5
51.9
57.0
68.4
kN
35.7
43.7
44.6
48.9
61.1
3 10
3 10
3 10
3 10
3 10
28
28
28
28
28
kN/mm2
120
120
120
120
120
kN/mm2
120
120
120
120
120
Half-hard point
375
375
375
375
375
Half-hard point
330
330
330
330
330
m/(Ohm*mm2)
36.0
36.0
36.0
36.0
36.0
m/(Ohm*mm2)
41.8
41.8
41.8
41.8
41.8
% IACS
62
62
62
62
62
% IACS
72
72
72
72
72
10 -8Ohm*m
2.778
2.778
2.778
2.778
2.778
10 -8Ohm*m
2.395
2.395
2.395
2.395
2.395
Ohm/km
0.358
0.286
0.268
0.239
0.191
Ohm/km
0.309
0.247
0.231
0.206
0.165
10 -3/K
2.7
2.7
2.7
2.7
2.7
10 -3/K
3.2
3.2
3.2
3.2
3.2
10 -5/K
1.7
1.7
1.7
1.7
1.7
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.89
8.89
8.89
8.89
8.89
Specific mass
103 kg/m3
8.92
8.92
8.92
8.92
8.92
1)
2)

1)
2)

Values for CuSn0.2 alloy (high conductivity)

technical data
80
100
107
120
150
460
450
430
420
420
N/mm2
kN
35.7
43.7
44.6
48.9
61.1
28
28
28
28
28
kN/mm2
120
120
120
120
120
Half-hard point
330
330
330
330
330
m/(Ohm*mm2)
46.4
46.4
46.4
46.4
46.4
% IACS
80
80
80
80
80
10 -8Ohm*m
2.155
2.155
2.155
2.155
2.155
Ohm/km
0.278
0.222
0.208
0.185
0.148
10 -3/K
3.2
3.2
3.2
3.2
3.2
10 -5/K
1.7
1.7
1.7
1.7
1.7
Specific mass
103 kg/m3
8.92
8.92
8.92
8.92
8.92
1)
2)
10

11
Wooden drums similar to DIN 46139 for Contact Wire

Survey 1)
survey 1)
identification number
flange-
d1
mm
mm
mm
mm
kg
kg
F14
1400
1000
700
560
180
2000
core-
d2
width
winding
width
drum
weight
load
capacity
F16
1600
1000
700
560
270
3000
F18
1800
1500
700
560
320
2000
1)
different drum specification on request
Cable Conductors made of pure Copper Cu-ETP

and Bz II (CuMg) according to DIN 48201 part 1 and 2
Applications/versions:
Catenary wire (Messenger wire)
Jumpers
Bare Cable conductors
Cross span Cable conductors
Anchoring cables
Stitch wire
Lightning protection cables (earthing wire)
Design:
bare, hard drawn, thermally treated,
tinned, insulated
Packing:
in coils, on drums or
spools of wood and steel
Load capacity for wooden drums

according to DIN 46139 for Contact Wire
Lengths in m for drums with identification number
cross section of contact wire
F14
F16
F18
mm
65
3400
5100
3400
80
2770
4160
2770
100
2200
3320
2200
107
2060
3100
2060
120
1840
2760
1840
150
1470
2210
1470
50 mm distance to edge of flange according to VDE 0276
12
13
Cable Conductors made of pure Copper Cu-ETP

according to DIN 48201 part 1
Cable Conductors made of Bronze BzII (CuMg)

Survey
Survey
nominal
cross section
calculated
cross section
mm 2
mm 2
10
10.02
number
of wires
wire
conductor
weight
calculated
breaking load
continuous currentcarrying capacity
nominal
cross section
calculated
cross section
mm
mm
kg/km
kN
mm 2
mm 2
1.35
4.1
90
4.02
90
10
10.02
number
of wires
wire
conductor
weight
calculated
breaking load
mm
mm
kg/km
kN
1.35
4.1
90
5.88
75
16
15.89
1.70
5.1
143
6.37
125
16
15.89
1.70
5.1
143
9.33
100
25
24.25
2.10
6.3
218
9.72
160
25
24.25
2.10
6.3
218
14.24
130
35
34.36
2.50
7.5
310
13.77
200
35
34.36
2.50
7.5
310
20.17
160
50
49.48
3.00
9.0
446
19.84
250
50
49.48
3.00
9.0
446
28.58
200
50
48.35
19
1.80
9.0
437
19.38
250
50
48.35
19
1.80
9.0
437
28.39
200
70
65.81
19
2.10
10.5
596
26.38
310
70
65.81
19
2.10
10.5
596
38.64
245
95
93.27
19
2.50
12.5
845
37.39
380
95
93.27
19
2.50
12.5
845
54.76
305
120
116.99
19
2.80
14.0
1060
46.90
440
120
116.99
19
2.80
14.0
1060
67.57
350
150
147.11
37
2.25
15.8
1337
58.98
510
150
147.11
37
2.25
15.8
1337
86.37
410
185
181.62
37
2.50
17.5
1649
72.81
585
185
181.62
37
2.50
17.5
1649
106.63
465
240
242.54
61
2.25
20.3
2209
97.23
700
240
242.54
61
2.25
20.3
2209
142.40
560
300
299.43
61
2.50
22.5
2725
120.04
800
300
299.43
61
2.50
22.5
2725
175.80
635
400
400.14
61
2.89
26.0
3640
160.42
960
400
400.14
61
2.89
26.0
3640
231.12
765
500
499.83
61
3.23
29.1
4545
200.38
1110
500
499.83
61
3.23
29.1
4545
288.70
880
Remark: The outer layer has to be right handed (Z-rotation)
Remark: The outer layer has to be right handed (Z-rotation)
Reference values for continuous currentcarrying capacity are valid up to 60 Hz at the given wind velocity of 0.6 m/s and sun impact (for Germany)
for a starting ambient temperature of 35C and a final temperature of the conductor of 70C. For special environmental conditions (calm) the values
have to be reduced by about 30%.
Reference values for continuous currentcarrying capacity are valid up to 60 Hz at the given wind velocity of 0.6 m/s and sun impact (for Germany)
for a starting ambient temperature of 35C and a final temperature of the conductor of 70C. For special environmental conditions (calm) the values
have to be reduced by about 30%.
Other designs: for example international standards or customer specifications on request
Other designs: for example international standards or customer specifications on request
14
15
Flexible cable conductors made of pure copper Cu-ETP

according to DIN 43138
Flexible Cable Conductors made of pure Copper

Cu-ETP and BzII (CuMg) according to DIN 43138
Applications/versions:
Bare conductors
flexible cables
flexible strands
Jumpers
Alloys:
Cu- ETP, Bz, CuAg and
other copper alloys
according to customer request
Design:
bare, hard drawn, thermally treated
Packing:
in coils, on drums or spools
of wood and steel
Survey
nominal
cross section
calculated
cross section
mm 2
mm 2
16
16.3
25
35
50
number
of wires
diameter
wire
cable
weight
tensile strength
single wires
continuous currentcarrying capacity A
mm
mm
kg/km
N/mm 2
49
0.6 m/s
1 m/s
0.65
5.9
152
< 300
135
155
26.1
37.6
133
0.50
7.5
246
< 300
180
205
133
0.60
9.0
353
< 300
225
255
51.2
133
0.70
10.5
482
< 300
280
310
70
72.7
189
0.70
13.0
685
< 300
340
370
95
99.7
259
0.70
14.7
935
< 300
420
460
120
118.5
336
0.67
16.4
1120
< 300
485
535
150
150.9
392
0.70
18.3
1420
< 300
570
625
185
185.1
525
0.67
20.4
1745
< 300
660
720
210
209.8
595
0.67
21.5
1980
< 300
720
780
240
245.2
367
0.70
23.1
2320
< 300
785
850
300
296.6
637
0.77
25.4
2800
< 300
895
970
Remarks: The outer layer has to be right handed (Z-rotation)
Reference values for continuous current load are valid up to 60 Hz at the given wind velocity and sun impact
for a starting ambient temperature of 40C and a final temperature of the conductor of 80C.
Other constructions: e. g. international standards and customer specifications on request
16
17
Flexible cable conductors made of Bronze II (CuMg)

according to DIN 43138
Cable conductors made of copper-clad steel

Survey
nominal
cross section
calculated
cross section
mm 2
mm 2
10
9.6
16
16
number
of wires
diameter
wire
cable
weight
tensile strength
single wires
mm
mm
kg/km
N/mm 2
49
0.50
4.5
89
589
16.3
16.3
49
0.65
5.9
152
589
84
0.50
6.2
152
589
25
26.1
133
0.50
7.5
246
589
35
37.6
133
0.60
9.0
353
589
Applications/variants:
Anchoring cables
Cable conductors (messenger wire)
Lightning protection cables
Feeder cables
Rail and track connectors
Anchoring systems for street lighting
Other constructions: e.g. international standards or customer specifications on request
Design:
Bare
Packing:
In coils, on drums made
of wood or steel
Optimized high bending

resistance
Fatigue test
18
19
Cable conductors made of copper-clad steel (Staku)

Dimensions, mechanical values for Staku I or lI/30 (appr. 30% electrical conductivity)
Staku I
Staku II
weight1)
calculated
breaking load
continuous currentcarrying capacity 3)
mm
kg/km
kN
3.7
56
4.32
40
2.10
4.5
85
6.58
56
1.70
5.1
131
10.07
75
2.10
6.3
200
25.76
90
34.36
2.50
7.5
284
33.95
112
49.48
3.00
9.0
409
47.05
140
nominal
cross section
calculated
cross section
mm 2
mm 2
6.81
10
10.39
16
15.89
25
35
50 2)
number
of wires
diameter
wire
cable
mm
1.70
3
7
24.25
48.35
19
1.80
9.0
400
51.80
140
70
65.81
19
2.10
10.5
545
69.90
170
95
93.27
19
2.50
12.5
774
92.15
213
120
116.99
19
2.80
14.0
971
115.59
244
Cable conductors made of AL1/AL3

according to EN 50182
Applications/variants:
Conductors
Overhead lines
OCS cable conductors (feeder)
Earthing conductor
Return conductor
Design:
Bare, hard drawn, thermally treated,
with optical fibre
Packing:
In coils, on drums
made of wood or steel
1)
The cable weights are calculated on a density of 8.15 kg/dm3 for Staku I and II with a conductivity of 30% of a wire made of soft annealed copper;
on a density of 8.20 kg/dm3 for Staku I and II with a conductivity of 40% of a wire made of soft annealed copper and a medium regular twist length of lay.
The medium regular twist length of lay is defined by the arithmetic average of minimum and maximum values of the values for the regular twist length of lay
in the standards concerned.
2)
For cables with a nominal cross section of 50 mm2 the number of wires has to be specified in the order.
3)
eference values for continuous current-carrying capacity valid up to 60 Hz at a wind velocity of 0.6 m/s and sun intensity (for Germany) for a starting
R
ambient temperature of 35C and a final temperature of the conductor of 80C. For special environmental situations (calm) the values have to be
decreased by about 30%.
Other constructions: e.g. Staku II/30, Staku I/40, Staku II/40 or international standards and customer specifications on request.
Steel core
Copper layer
20
21
Cable conductors made of AL 1 according to EN 50182
Cable conductors made of AL 3 according to EN 50182
Survey
Survey
nominal
cross section
calculated
cross section
mm 2
mm 2
16-AL1
15.9
number
of wires
diameter
wire
cable
weight
mm
mm
1.70
5.1
calculated
breaking load
nominal
cross section
calculated
cross section
kg/km
kN
mm 2
mm 2
43.4
3.02
110
16-AL3
15.9
number
of wires
diameter
wire
weight
mm
mm
kg/km
kN
1.70
5.1
43.4
4.69
105
cable
calculated
breaking load
24-AL1
24.2
2.10
6.3
66.3
4.36
145
24-AL3
24.2
2.10
6.3
66.3
7.15
135
34-AL1
34.4
2.50
7.5
93.9
6.01
180
34-AL3
34.4
2.50
7.5
93.9
10.14
170
49-AL1
49.5
3.00
9.0
135.2
8.41
225
49-AL3
49.5
3.00
9.0
135.2
14.60
210
48-AL1
48.3
19
1.80
9.0
132.9
8.94
225
48-AL3
48.3
19
1.80
9.0
132.9
14.26
210
66-AL1
65.8
19
2.10
10.5
180.9
11.85
270
66-AL3
65.8
19
2.10
10.5
180.9
19.41
255
93-AL1
93.3
19
2.50
12.5
256.3
16.32
340
93-AL3
93.3
19
2.50
12.5
256.3
27.51
320
117-AL1
117.0
19
2.80
14.0
321.5
19.89
390
117-AL3
117.0
19
2.80
14.0
321.5
34.51
365
147-AL1
147.1
37
2.25
15.8
405.7
26.48
455
147-AL3
147.1
37
2.25
15.8
405.7
43.40
425
182-AL1
181.6
37
2.50
17.5
500.9
31.78
520
182-AL3
181.6
37
2.50
17.5
500.9
53.58
490
243-AL1
242.5
61
2.25
20.3
674.1
43.66
625
243-AL3
242.5
61
2.25
20.3
674.1
71.55
585
299-AL1
299.4
61
2.50
22.5
828.5
52.40
710
299-AL3
299.4
61
2.50
22.5
828.5
88.33
670
400-AL1
400.1
61
2.89
26.0
1107.1
68.02
855
400-AL3
400.1
61
2.89
26.0
1107.1
118.04
810
500-AL1
499.8
61
3.23
29.1
1382.9
82.47
990
500-AL3
499.8
61
3.23
29.1
1382.9
147.45
930
626-AL1
626.2
91
2.96
32.6
1739.7
106.45
1140
626-AL3
626.2
91
2.96
32.6
1739.7
184.73
1075
802-AL1
802.1
91
3.35
36.9
2228.3
132.34
1340
802-AL3
802.1
91
3.35
36.9
2228.3
236.62
1255
1000-AL1
999.7
91
3.74
41.1
2777.3
159.95
1540
1000-AL3
999.7
91
3.74
41.1
2777.3
294.91
1450
Reference values for continuous current-carrying capacity valid up to 60 Hz at a wind velocity of 0.6 m/s and sun intensity (for Germany) for a starting
ambient temperature of 35C and a final temperature of the conductor of 80C. For special environmental situations (calm) the values have to be
decreased by about 30%.
Reference values for continuous current-carrying capacity valid up to 60 Hz at a wind velocity of 0.6 m/s and sun intensity (for Germany) for a starting
ambient temperature of 35C and a final temperature of the conductor of 80C. For special environmental situations the values have to be decreased
by about 30%.
Other constructions: e.g. international standards and customer specifications on request
Other constructions: e. g. international standards and customer specifications on request
22
23
Wooden drums according to DIN 46391, e.g. for cable conductors
Capacity of wooden drums according to DIN 46391

for cable conductors
Survey
identification
number
Length in m for drums according to size
flange-
d1
core-
d2
d4-
d5-
s1
winding
width I2
appr. drum
weight
maximum load
capacity
in mm
in mm
in mm
in mm
in mm
in mm
in mm
in kg
in kg
cable-
81
800
400
80
40
66
200
450
31
400
mm
101
1000
500
80
50
66
320
560
71
900
121
1250
630
80
50
70
320
630
144
1700
6441
15077
4077
9746
81
101
11481
27181
121
141
1400
710
80
50
70
320
750
175
2000
161
1600
900
80
60
80
600
900
280
3000
2847
6753
13986
2050
4951
10406
181
1800
1120
80
60
80
600
1120
380
4000
202
2000
1250
125
60
90
600
1120
550
5000
161
1540
3737
7923
1223
2270
6191
10
2413
5008
6515
11
1976
4011
5326
9127
12
1608
3366
4321
7577
13
1402
2992
3663
6541
14
1219
2486
3270
5634
181
15
2205
2750
4830
5676
16
1954
2456
4360
5119
17
1728
202
2189
3712
4364
6098
18
1950
3343
3929
5471
19
1732
20
3008
3535
4907
2699
3172
4393
21
2421
2846
3920
22
2161
2524
3492
23
2091
2455
3099
24
1867
25
24
141
2194
2995
1945
2648
26
1888
2566
27
1671
2261
28
1626
2188
29
1429
1916
30
1391
1864
25
References
New Lower Inn Valley Railway

BB high-speed rail link
in Austrias Tyrolean Unterland
The project:
New Lower Inn Valley Railway BB high-speed rail link
in Austrias Tyrolean Unterland.
Providing access to the Brenner Base Tunnel from the
north, the New Lower Inn Valley Railway is part of TEN
axis no. 1 which links Berlin and Palermo.
The aim:
Along with other construction projects (e.g. the new
Brenner Base Tunnel), the New Lower Inn Valley Railway
will reduce the journey time between Munich and Innsbruck from 1 hour 50 minutes to 55 minutes and between
Munich and Verona from 5 hours 20 minutes to 2 hours
20 minutes.
The contract:
Retention for nkt cables as new supplier and party to
the BB framework contract in the first major project.
In 2012, BB named nkt cables as its new supplier of
contact wires and catenary wires.
Between January and September 2012, nkt cables
supplied a total of 95 km of CuAg0.1 120 mm contact
wire and CuAg0.1 70 mm catenary wire for this project
via its distributor HC-ELECTRIC of Vienna, Austria.
In meeting the expectations of BB, the first major
task for us as a manufacturer was posed by short
lead times and very varied batch sizes.
26
TEN stands for Trans-European Networks, an initiative

funded by the European Union to transform and
develop the single market and improve the economic
and social cohesion of the EU. The programme is also
designed to unify transport systems in the EU.
Key Facts:
40 km double-track stretch between Kundl and
Baumkirchen
At the heart of this section of the route is the
16 km long Mnsterer tunnel between Radfeld
and Jenbach
Total project costs EUR 2.4 billion
The new section of track was handed over
for scheduled operations to commence on
29 November 2012
27
References
German Unity Transport Project No. 8 (VDE 8):

Berlin Munich in 4 hours
The project:
From 2017, high-speed trains capable of speeds of
up to 300 km/h will reduce the journey time between
Germanys two biggest cities, Berlin and Munich,
to less than 4 hours.
The project will make the train a genuine and

ecofriendly alternative to travelling by air and car.
Work on the project to improve the transport link

between East and West was approved back in 1991
by the then Federal Government.
The aim:
Before construction work commenced, the journey time
between Berlin and Munich was approximately 7 hours.
However, of equal priority to reducing the journey time
between these two major cities was establishing a link to
the new German states. The journey time from Dresden
and Leipzig in the East to Frankfurt-am-Main and the
Rhine-Main region in the West, for example, is significantly reduced.
The contract:
nkt cables was selected to supply contact wires and
cables from one of the route to the other, with particular
involvement in the provision of high-speed contact wires.
Key Facts:
Track length 200 km including for goods traffic
At the heart of the project and also a challenge
was crossing the Saale Valley and the Thuringian
Forest
Total costs EUR 10 billion
Modern, high-performance rail hubs which also
integrate regional traffic are being created in
Erfurt, Halle and Leipzig
With short and reliable lead times, nkt cables showed

itselt to be a helpful project partner along the entire route
for Spitzke SE, Europten, SPL and BBR, the companies
responsible for the construction work.
Until the end of 2016, a total of 400 t of contact wire and
300 t of cable will have been supplied to the project.
From Cologne to Rhine-Main, Nuremberg to Ingolstadt
and before that from Berlin to Hanover, nkt cables has
played a vital role on all major high-speed routes in
Germany.
28
29
References
Gotthard Base Tunnel

The longest railway tunnel in the world
The project:
This construction connects the northern side of the Alps
with Erstfeld in the Uri Valley with Bodio in the Canton of
Tessin on the south side. At 57 km, it is the longest railway
tunnel in the world. A continuous track runs through each
of the east and west tubes. As the tunnel is what is known
as a flat route, it is suitable for use by high-speed trains.
The contract:
To develop and deliver innovative conductive
products for railways
The construction of the Gotthard Base Tunnel has
involved the installation of 2800 km of cables for power
supply and data transmission, 170 km each of CuAg
contact wire (120 mm2) and Bz catenary wire (70 mm2)
as well as 850 km of copper cable and more than 100 km
of aluminium cable in various cross-sections for feed
and return purposes.
All contact wires and cables are being supplied by
nkt cables. In collaboration in this, the largest railway
tunnel project in the world, nkt cables was yet again
able to demonstrate its skills as a technology leader.
Many years of trustful cooperation with our contractors,
thorough preparation for projects with the flexibility to
adapt planning and installation schedules all of these
features set us apart and are valued by our customers.
Key Facts:
At 57 km, it is the longest railway tunnel in the
world.
Construction work commenced in 1999 and the
tunnel went into operation in December 2016
Approximate costs approx. CHF 12 billion
nkt cables contracted by the Transtec Gotthard
Consortium
Building contractor is AlpTransit AG
Installation of 228 km of track and 190,000
concrete sleepers
Installation of 2800 km of cables for power supply
and data transmission
Supply of 170 km of CuAg contact wire 120 mm2
Supply of 170 km of Bz catenary wire 70 mm2
Supply of 850 km of copper cable and more than
100 km of aluminium cable for feed and return
purposes
30
31
VALTHERMO
The economic alternative to

Cu- and CuAg-Overhead Catenary Systems
VALTHERMO is the new contact wire material from
nkt cables. Copper and copper-silver contact wires
can now be replaced by the economic alternative
VALTHERMO.
Compared with copper contact wires, VALTHERMO
provides higher wear resistance, higher thermal resistance and lower creep elongation while achieving the
same high conductivity as copper and copper-silver
contact wires.
Application areas for VALTHERMO
In the first instance, VALTHERMO is used as a cost efficient alternative to CuAg0,1 while being fully compatible
with EN 50149.
With increasingly stringent requirements on contact
line system availability and power transmission capability replacing copper contact wires (Cu-ETP) with
VALTHERMO is also strongly recommended. The
permissible constant temperature of 80C for Cu-ETP
can be increased to a minimum of 100C in the case of
VALTHERMO without any thermal softening.
Thermal resistance as well is significantly higher when

subjected to short duration thermal stresses and
local overheating (e.g. pantograph stationary). Similar
to CuAg0,1 the half hard point is 300C, see also
EN 50119.
In the long-term, other products made of VALTHERMO,
such as messenger wires, are as well the preferred
economic alternative when compared with copper or
copper-silver cables because of their high thermal
resistance and lower creep elongation.
That means:
1. A saving of one or a number of contact wire
replacements over the systems life.
5. By increasing contact line system availability,

VALTHERMO is making a significant contribution to long-term development strategies of
railways.
2. The lower creep elongation cuts the cost of

adjusting the initial contact wire installations, or
even avoids the cost altogether. VALTHERMO
exhibits exactly the same creep elongation as
CuAg0,1. The adjustment cost savings means
that VALTHERMO pays for itself in the very first
year. The remaining installation characteristics
are the same as for Cu-ETP and CuAg0,1.
The most important advantages of VALTHERMO

The VALTHERMO contact wire has been in commercial
operation with the DB rail network since 2012 on a comparison basis alongside other materials.
6. VALTHERMO contact wires are mechanically

(tensile strength, hardness, modulus of elasticity,
torsional characteristics, coefficient of expansion
etc.) and electrically (conductivity, thermal coefficient of electrical resistance) fully compatible
with Cu-ETP and CuAg0,1- contact wires. The
clamps and other accessories used for Cu-ETP
can also be used unchanged for VALTHERMO.
3. An analysis by Dresden University of Technology

based on the Net Present Value method demonstrates that for a train frequency of 160 trains
per day, for example, an overhead contact wire
system can be operated for more than 70 years
without replacement. This means significant
economies in terms of operation and maintenance.
This demonstrated two major advantages for

VALTHERMO compared with Cu-ETP contact wire:
at least twice the service life
a lower creep elongation by a factor of approximately
1:3 to 1:2
Profile/
Nominal Cross Section
Tensile
strength
Min. Breaking
Load
Breaking
Elongation
Electrical
Resistivity
Electrical
Conductivity
mm 2
N/mm 2
kN
10 -8 x m
% IACS
m/( x mm)
/km
AC 80
375
29.1
38
1.777
97
56.3
0.229
AC 100
375
36.4
38
1.777
97
56.3
0.183
AC 107
360
37.4
38
1.777
97
56.3
0.171
AC 120
360
41.9
38
1.777
97
56.3
0.153
BC 100
375
36.4
38
1.777
97
56.3
BC 107
360
37.4
37
1.777
97
56.3
BC 120
360
41.9
38
1.777
97
BC 150
360
52.4
38
1.777
97
CF 100
375
36.75
2.5 7
1.777
CF 120
370
43.5
2.5 7
1.777
32
4. The longer service life and lower adjustment cost

translates into significantly higher contact line
system availability.
Electrical Resistance
per length
Torsion
7. The DB assessed the field test and awarded

VALTHERMO technical release. VALTHERMO
is now listed as approved product.
8. VALTHERMO-contact wires comply with
EN 50149.
Bending test
Weight
per length
Half hard point
kg/km
710
300
890
300
952
300
1070
300
0.183
890
300
0.171
952
300
56.3
0.153
1070
300
56.3
0.122
1333
300
97
56.3
0.183
889
300
97
56.3
0.153
1067
300
33
VALTHERMO
VALTHERMO
Success that speaks for itself
April 2012: First presentation at DB Netz
Estonia
September 2012: In service testing in the field of DB Netz

(VALTHERMO compared with Cu, CuAg0.1 and CuMg0.2)
Local transport
Main line transport
October November 2012:
Germany
Creep measurement within the

In service testing
From January 2013: Tests of Component

Compatibility (system specific)
Austria
May 2014: First comparative wear

measurement in the context of
In service testing
August 2014: Approval by DB Netz,

inclusion in the Ebs-Zeichnungswerk of the DB.
Delivery orders from Germany and abroad for
AC and DC railways have arrived at nkt cables
34
Switzerland
France
VALTHERMO has already

successfully established itself:
The Deutsche Bahn and many
other rail operators in Germany,
Austria, Switzerland and France
have recognised these advantages
and opted for VALTHERMO.
35
Dsseldorfer Strae 400

Chempark
51061 Kln
Germany
Tel: +49 221 676 3460
info@nktcables.com
www.nktcables.com
36
Printversion 08/2016
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Member of the NKT Group

Railway catenary systems

Our passion brings power to life

Contact Wires (Trolley Wires)

Copper and copper-magnesium

Flexible cable conductors made of copper

Flexible cable conductors made

Contact wires with a service life at least two times longer

Cable conductors made of cooper-clad steel

The name of this new contact wire is: VALTHERMO

Cable conductors made of AL1/AL3

VALTHERMO has already demonstrated its impressive

Drums and delivery lengths

for cable conductors

New BB high-speed Lower Inn Valley

German Unity Transport Project No. 8

Gotthard Base Tunnel

But the VALTHERMO range does not just feature

Survey of contact wires according to EN 50149

Contact wire made of pure copper (Cu-ETP),

Construction and weights

Contact wires for every speed and application

Cu-ETP (normal tensile strength)

CuAg0.1 (high tensile strength)

CuSn0.2 (normal conductivity)

CuMg0.2 (normal conductivity)

(high tensile strength)

Values are based on a cross section of 120 mm2 according to EN 50149

Identification marks according to EN 50149

Contact wires made of

Contact wires made

Contact wires made

Contact wires made

Contact wire made of pure copper Cu-ETP according to EN 50149

Contact wire made of CuAg0.1 according to EN 50149

Values for ETP copper (normal tensile strength)

Values for CuAg0.1 (normal tensile strength)

nominal cross section

nominal cross section

min. tensile strength R m 2)

min. tensile strength R m 2)

min. breaking load1) Fm

min. breaking load1) Fm

Percentage Elongation after fracture A 200

Percentage Elongation after fracture A 200

Electrical conductivity at 20C

Electrical conductivity at 20C

Electrical conductivity at 20C

Electrical conductivity at 20C

Specific electrical resistance el at 20C

Specific electrical resistance el at 20C

Temperature coefficient el of electrical resistance

Temperature coefficient el of electrical resistance

Linear coefficient of thermal expansion

Linear coefficient of thermal expansion

calculation based on the minimum cross section

Values for ETP copper (high tensile strength)

calculation based on the minimum cross section

Values for CuAg0.1 (high tensile strength)

nominal cross section

min. tensile strength R m 2)

min. tensile strength R m 2)

min. breaking load1) Fm

Contact Wires (Trolley Wires)

Flexible cable conductors made of copper

Cable conductors made of cooper-clad steel

Cable conductors made of AL1/AL3

for cable conductors