Exel Composites Promotes Multi-Wire Composite Conductor Cores for Future Power Grids

Updated on June 03, 2026 • 6 min read

As global electricity demand continues to accelerate, utilities and transmission system operators are under increasing pressure to expand grid capacity without the cost and delays associated with building new transmission corridors. According to projections from the International Energy Agency (IEA), global electricity demand is expected to increase by approximately 3.5% by 2030, driven by industrial electrification, renewable energy integration, artificial intelligence infrastructure, and rapidly expanding data centers.

Against this backdrop, Exel Composites is highlighting the role of polymeric matrix composite (PMC) conductor cores as a practical solution for upgrading existing overhead transmission lines while avoiding large-scale infrastructure investments.

Growing Demand Requires Smarter Grid Solutions

Modern transmission networks face a difficult challenge. Electricity consumption is rising faster than many grid expansion projects can be completed. Securing permits, land access, environmental approvals, and funding for new transmission corridors can take years.

As a result, many utilities are focusing on technologies that can increase the capacity of existing transmission lines.

Composite conductor cores have emerged as one of the most promising options. Compared with conventional steel-core conductors, composite-core technologies provide:

• Higher strength-to-weight ratios
• Lower thermal expansion
• Reduced line sag
• Increased current carrying capacity
• Lower transmission losses
• Improved operating temperatures

These advantages allow utilities to transport more electricity using existing towers and infrastructure.

Evolution from Single-Wire to Multi-Wire Composite Cores

The first generation of composite conductor cores typically relied on a single carbon fiber core protected by a glass fiber outer layer.

While these conductors offered significant performance advantages over traditional aluminum conductor steel reinforced (ACSR) systems, they also presented challenges.

Single-core designs can be relatively stiff and may be more vulnerable to installation damage if handling procedures are not strictly followed.

To address these limitations, manufacturers developed multi-wire composite core technology.

Instead of relying on one large structural element, multi-wire designs utilize multiple smaller composite rods stranded together.

This architecture provides several advantages:

• Greater flexibility during installation
• Improved damage tolerance
• Better handling characteristics
• Reduced risk of catastrophic failure
• Mechanical behavior closer to traditional ACSR conductors

Perhaps most importantly, the load is distributed across multiple strands rather than concentrated in a single structural member.

New CIGRE Study Demonstrates Damage Tolerance

A recently published study presented through the CIGRE examined how multi-wire PMC conductor cores perform when individual strands are damaged.

The research was conducted in collaboration between Exel Composites, De Angeli Prodotti, and Belgian transmission operator ELIA.

To simulate realistic field damage, researchers intentionally weakened a single strand by applying transverse compression, reducing its tensile strength by approximately 30%.

The damaged strand was then incorporated into a 6+1 multi-wire conductor core assembly and subjected to tensile loading until failure occurred.

Key Findings

The study found that:

• The damaged strand failed as expected
• Surrounding strands remained unaffected
• Overall conductor integrity was preserved
• Core strength remained above required specification levels
• No progressive damage occurred within the remaining structure

The results demonstrated that localized strand failure does not compromise the overall performance of the conductor.

For transmission operators, this provides an important level of redundancy and operational confidence.

Flexibility Testing Confirms Installation Robustness

A second CIGRE study focused on installation and handling performance.

Researchers compared traditional single-wire composite cores against newer multi-wire designs by subjecting conductors to severe bending conditions designed to replicate worst-case installation scenarios.

The findings showed that multi-wire composite cores maintained exceptionally high residual tensile strength even when bent beyond recommended operational limits.

The results indicate that multi-wire PMC cores possess bending characteristics that exceed the minimum requirements established for conventional ACSR conductors.

This flexibility is particularly important during:

• Installation operations
• Stringing procedures
• Maintenance activities
• Transportation and handling

Reduced sensitivity to bending damage lowers operational risk and simplifies deployment.

Benefits for Transmission Operators

The growing interest in high-temperature low-sag (HTLS) conductors is being driven by a common industry objective: increasing transmission capacity without building new power lines.

Multi-wire composite cores support this goal by enabling:

Higher Transmission Capacity

Lower thermal expansion allows conductors to operate at higher temperatures while maintaining acceptable sag clearances.

Reduced Energy Losses

Advanced conductor designs can improve efficiency and lower operating costs throughout the system’s lifetime.

Increased Reliability

The multi-wire architecture provides redundancy and resilience against localized damage.

Easier Installation

Flexibility comparable to traditional conductors simplifies field deployment and reduces installation risk.

Longer Service Life

Composite materials are resistant to corrosion and fatigue, helping improve long-term durability.

Strategic Importance for Grid Modernization

The timing of these developments is significant.

Global power systems are simultaneously dealing with:

• Renewable energy integration
• Electrification of transportation
• Industrial decarbonization
• Data center expansion
• Artificial intelligence infrastructure growth

These trends are creating unprecedented demand for transmission capacity.

Building entirely new transmission corridors remains expensive, politically complex, and time-consuming.

Consequently, utilities are increasingly evaluating technologies that maximize existing infrastructure.

Composite conductor core systems represent one of the few solutions capable of delivering substantial capacity increases without requiring new tower construction.

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This article is developed based on real engineering experience, machine testing data, and practical production knowledge from Jota Machinery’s work in advanced composite manufacturing.

All technical explanations—including material structure, processing methods, and performance characteristics—are reviewed and verified by our engineering team to ensure accuracy and real-world relevance.

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Industry Outlook

The latest CIGRE studies provide additional evidence supporting the adoption of composite conductor cores for modern transmission networks.

The demonstrated ability of multi-wire PMC cores to maintain structural integrity even after localized damage addresses one of the key concerns utilities have historically expressed regarding composite-core technologies.

As transmission operators continue searching for practical ways to accommodate growing electricity demand, multi-wire composite conductors are likely to play an increasingly important role in grid modernization strategies worldwide.

For companies such as Exel Composites, the focus now shifts from proving technical feasibility to accelerating large-scale deployment across utility networks seeking greater capacity, reliability, and efficiency without major infrastructure expansion.