''UNISTAR'' Aerial Bunched Conductor are furnished in this Catalogue:

(ABC) is a very novel concept for Over Head

Table 1 & 1 A : 1.1 kV Aerial Bunched
power distribution. When compared to the Cables generally to
conventional bare conductor over head IS:14255
distribution system, ABC provides higher (Three phase and one
safety and reliability, lower power losses insulated reduced neutral
and ultimate system economy by reducing conductor around bare
installation, maintenance and operative steel messenger).
cost. This system is ideal for rural
Table 2 & 2 A : 1.1 kV Aerial Bunched
distribution and specially attractive for
Cables generally to
installation in difficult terrains such as hilly
IS:14255
areas, forest areas, coastal areas etc.
(Three phase and one
ABC is also considered to be the best insulated neutral
choice for power distribution in congested conductor around bare
urban areas with narrow lanes and by- steel messenger).
lanes. In developing urban complex, ABC
Table 3 & 3 A : 11 kV Aerial Bunched
is the better choice because of flexibility for
Cables generally to
re-routing as demanded by changes in
IS:7098/Part-2
urban development plan.
(Three phase conductors
CONSTRUCTION OF ABC around bare steel
XLPE insulated power conductors of messenger).
Aluminium ( neutral conductor and street STRINGING
lighting conductors, if and when necessary )
No difficulty is envisaged during stringing of
are laid together (twisted) around a high
ABC in the conventional method but care
tensile stranded and galvanized steel
shall be taken that insulated conductors do
(Aluminium Alloy may be used but
not get damaged during installation.
sparingly) bare or insulated messenger wire
Dragging the ABC on the ground is to be
to form the Aerial Bunched Cable. This
avoided. Tension to be applied during
assembly is directly strung on to distribution
stringing shall be 25% of the breaking load
pole / towers by means of standard
of the messenger wires. This will allow line
hardwares available in the market.
to have sag within specified limit of 1.5% of
XLPE is cross-linkable low density the span at the lowest ambient temperature.
polyethylene which is made thermoset by
JOINTING
special formulation from base polymer of
thermoplastic low density polyethylene. While mid-span jointing is permissible for
XLPE combines the best electrical 1.1 KV ABC system by conventional
properties of LDPE and superior thermo technique, our recommendation will be to
mechanical properties. draw the line in such a way as to bring the
joints at the supports. Mid-span jointing is
Details of common types and sizes of ABC
not at all recommended in the case of HT ADVANTAGES
lines. Under unavoidable circumstances,
In comparison to bare overhead power
line tapping at the support points may be
distribution lines, ABC has very high
allowed through suitably designed clamp
reliability in maintaining services because
connectors/PG clamps. The semi
power and neutral conductors are insulated
conducting screen continuity shall be
with the best dielectric medium, resulting in
maintained at all joints as far as possible to
the following advantages :
avoid fluctuations during system
disturbances. The 3-phase screens may be 1) Less fault rate on account of good
shorted and earthed through suitable non- protection against line and ground faults
linear surge arrestor. Attempting to make a by high winds or falling trees or birds
tap-off from power conductors in the region especially in hilly areas & forests as
where catenary is under tension is not encountered in Rural distribution net-
recommended. works.

SURGE / LIGHTNING ARRESTORS 2) High insulation resistance to earth in all

seasons and polluted atmospheres.
The usage of conventional surge / lightning
Negligible leakage currents and low
arrestors on the main line is recommended
losses.
as in the case of bare conductor lines to
protect line and equipment, especially at 3) Multiple circuits of Power and Telephone
terminal ends and at open tap-off poles (At cables could be strung in the same set of
least one set in every KM span). poles or any other supports.

APPLICATION 4) Better adaptability to run concurrently

with existing over-head bare conductor
ABC can be conveniently used :
system without any interference.
a) as replacement of bare lines in Rural
5) High capacitance and low inductance
areas, in woods and in other localities
leading to low impedance of lines.
where the spare is limited,
6) Lower voltage drop, higher current
b) as replacement of bare lines where
capacities. VIS-À-VIS Better Voltage
reliability of supply is of prime
Regulation.
importance,
7) Longer spans and longer distance lines
c) as replacement of bare lines where high
are possible with better system stability.
degree of stability of supply voltage is of
importance,
d) in hilly terrains where cost of erection of
overhead lines or under ground cable
becomes very high,
e) for temporary supplies.
C. Dead end clamp

D. Suspension Clamp with running out Device

A. Riser

B. FUSE Switch

E. Insulation piercing connector

 G
K
H J
F

G. Dead end clamp

H. Suspension Clamp

I. Distance nail

J. Cable protection

K. Hook plates
L. Dead end clamp

N. Suspension Clamp

O. Tension splice connector

M. Universal brackets
Suspension construction
Straight lines

It consists of

1. Suspension hook.
2. Insulator
3. Suspension clamp.
4. Rubber insert.
Suspension Construction
Angles up to 900

It Consists of

1. Connection Plate
2. Insulatar
3. Suspension Clamp (2 pcs)
4. Rubber Insert (2 pcs)
Dead. End Construction

It Consists of

1. Steel hook
2. Insulator
3. Dead end clamp
 Jointing Construction

It Consists of

1. Dead-end clamp (2 pcs)

2. Insulator (2 pcs)
3. Fork Plate (2 pcs)
4. Cable joing (3 pcs)
 Suspension Construction
Angles UP to 600

It Consists of

1. Steel hook
2. Insulator
3. Suspension Clamp
4. Rubber insert
 TABLE 1
1.1 KV AERIAL BUNCHED CABLES GENERALLY TO IS:14255
(Three phase and one insulated reduced neutral conductor around bare steel messenger).
Phase Conductor 3x25 3x35 3x50 3x70 3x95
Neutral Conductor 1x16 1x16 1x25 1x35 1x50
Messenger Conductor 1x35 1x35 1x35 1x55 1x55
1 Trade Name UNISTAR
2 Rated Voltage Volts 1100 1100 1100 1100 1100
3 Reference Standard Generally to IS 14255/1995
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 25 35 50 70 95
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 1.2 0.868 0.641 0.443 0.32
4.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.2 1.2 1.5 1.5 1.5
iii) Nominal dia over insulation mm 8.8 9.9 11.7 13.4 15.3
5 NEUTRAL CONDUCTOR
5.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 16 16 25 35 50
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 1.91 1.91 1.2 0.868 0.641
5.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.2 1.2 1.2 1.2 1.5
iii) Nominal dia over insulation mm 7.7 7.7 8.8 9.9 11.7
6 MESSENGER CONDUCTOR (BARE)
i) Material High Tensile galvanized steel strand to IS 398 (Part 2)/96
ii) Nominal cross-sectional area Sqmm 35 35 35 55 55
iii) Shape of conductor Stranded Circular
iv) Min. Breaking load KN 41 41 41 62 62
v) Approx. messenger diameter mm 7.8 7.8 7.8 9.5 9.5
7 Number of Conductor
i) Phase conductors 3 3 3 3 3
ii) Neutral conductor 1 1 1 1 1
iii) Bare Steel messenger 1 1 1 1 1
8 Identification of Conductors
i) Phase conductors By providing one, two & three ridges
ii) Neutral conductor By providing four ridges
9 Assembly Phase & Neutral conductors twisted around Bare messenger in RH
lay not exceeding 35 times the diameter of insulated Phase conductor
10 Approx Cable weight Kg/km 630 720 895 1260 1545
11 Continuous current carrying Amps 85 105 130 165 200
capacity of cable when laid
freely in air at 50oC ambient
air temperature
12 Short circuit rating of conductor KA 2.4 3.3 4.7 6.6 9.0
for one second duration
 TABLE 1A
1.1 KV AERIAL BUNCHED CABLES GENERALLY TO IS:14255
(Three phase and one insulated reduced neutral conductor around bare steel messenger).
Phase Conductor 3x120 3x150 3x185 3x240
Neutral Conductor 1x70 1x70 1x95 1x120
Messenger Conductor 1x55 1x55 1x55 1x55
1 Trade Name UNISTAR
2 Rated Voltage Volts 1100 1100 1100 1100
3 Reference Standard Generally to IS 14255/1995
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 120 150 185 240
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 0.253 0.206 0.164 0.125
4.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.8 1.8 1.8 2.0
iii) Nominal dia over insulation mm 17.2 18.6 20.2 23.0
5 NEUTRAL CONDUCTOR
5.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 70 70 95 120
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded Compacted Circular
v) Max. DC resistance at 200C Ω
/km 0.443 0.443 0.32 0.253
5.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.5 1.5 1.5 1.8
iii) Nominal dia over insulation mm 13.4 13.4 15.3 17.2
6 MESSENGER CONDUCTOR (BARE)
i) Material High Tensile galvanized steel strand to IS 398 (Part 2)/96
ii) Nominal cross-sectional area Sqmm 55 55 55 55
iii) Shape of conductor Stranded Circular
iv) Min. Breaking load KN 62 62 62 62
v) Approx. messenger diameter mm 9.5 9.5 9.5 9.5
7 Number of Conductor
i) Phase conductors 3 3 3 3
ii) Neutral conductor 1 1 1 1
iii) Bare Steel messenger 1 1 1 1
8 Identification of Conductors
i) Phase conductors By providing one, two & three ridges
ii) Neutral conductor By providing four ridges
9 Assembly Phase & Neutral conductors twisted around Bare messenger in RH lay
not exceeding 35 times the diameter of insulated Phase conductor
10 Approx Cable weight Kg/km 1870 2120 2520 3160
11 Continuous current carrying Amps 235 270 315 380
capacity of cable when laid
freely in air at 50oC ambient
air temperature
12 Short circuit rating of conductor KA 11.3 14.2 17.5 22.6
for one second duration
 TABLE 2
1.1 KV AERIAL BUNCHED CABLES GENERALLY TO IS:14255
(Three phase and one insulated neutral conductor around bare steel messenger).
Phase Conductor 3x16 3x25 3x35 3x50 3x70 3x95
Neutral Conductor 1x16 1x25 1x35 1x50 1x70 1x95
Messenger Conductor 1x35 1x35 1x35 1x35 1x55 1x55
1 Trade Name UNISTAR
2 Rated Voltage Volts 1100 1100 1100 1100 1100 1100
3 Reference Standard Generally to IS 14255/1995
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 16 25 35 50 70 95
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 1.91 1.2 0.868 0.641 0.443 0.32
4.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.2 1.2 1.2 1.5 1.5 1.5
iii) Nominal dia over insulation mm 7.7 8.8 9.9 11.7 13.4 15.3
5 NEUTRAL CONDUCTOR
5.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 16 25 35 50 70 95
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 1.91 1.2 0.868 0.641 0.443 0.32
5.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.2 1.2 1.2 1.5 1.5 1.5
iii) Nominal dia over insulation mm 7.7 8.8 9.9 11.7 13.4 15.3
6 MESSENGER CONDUCTOR (BARE)
i) Material High Tensile galvanized steel strand to IS 398 (Part 2)/96
ii) Nominal cross-sectional area Sqmm 35 35 35 35 55 55
iii) Shape of conductor Stranded Circular
iv) Min. Breaking load KN 41 41 41 41 62 62
v) Approx. messenger diameter mm 7.8 7.8 7.8 7.8 9.5 9.5
7 Number of Conductor
i) Phase conductors 3 3 3 3 3 3
ii) Neutral conductor 1 1 1 1 1 1
iii) Bare Steel messenger 1 1 1 1 1 1
8 Identification of Conductors
i) Phase conductors By providing one, two & three ridges
ii) Neutral conductor By providing four ridges
9 Assembly Phase & Neutral conductors twisted around Bare
messenger in RH lay not exceeding 35 times the diameter of
insulated Phase conductor
10 Approx Cable weight Kg/km 540 660 780 970 1370 1692
11 Continuous current carrying Amps 65 85 105 130 165 200
capacity of cable when laid
freely in air at 50oC ambient
air temperature
12 Short circuit rating of conductor KA 1.5 2.4 3.3 4.7 6.6 9.0
for one second duration
 TABLE 2A
1.1 KV AERIAL BUNCHED CABLES GENERALLY TO IS:14255
(Three phase and one insulated neutral conductor around bare steel messenger).
Phase Conductor 3x120 3x150 3x185 3x240
Neutral Conductor 1x120 1x150 1x185 1x240
Messenger Conductor 1x55 1x55 1x55 1x55
1 Trade Name UNISTAR
2 Rated Voltage Volts 1100 1100 1100 1100
3 Reference Standard Generally to IS 14255/1995
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 120 150 185 240
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded, compacted circular
v) Max. DC resistance at 200C Ω
/km 0.253 0.206 0.164 0.125
4.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.8 1.8 1.8 2.0
iii) Nominal dia over insulation mm 17.2 18.6 20.2 23.0
5 NEUTRAL CONDUCTOR
5.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 120 150 185 240
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2
iv) Shape of conductor Stranded Compacted Circular
v) Max. DC resistance at 200C Ω
/km 0.253 0.206 0.164 0.125
5.2 Insulation
i) Material Cross-linked Polyethylene to IS 14255/95, Black colour
ii) Nominal thickness mm 1.8 1.8 1.8 2.0
iii) Nominal dia over insulation mm 17.2 18.6 20.2 23.0
6 MESSENGER CONDUCTOR (BARE)
i) Material High Tensile galvanized steel strand to IS 398 (Part 2)/96
ii) Nominal cross-sectional area Sqmm 55 55 55 55
iii) Shape of conductor Stranded Circular
iv) Min. Breaking load KN 62 62 62 62
v) Approx. messenger diameter mm 9.5 9.5 9.5 9.5
7 Number of Conductor
i) Phase conductors 3 3 3 3
ii) Neutral conductor 1 1 1 1
iii) Bare Steel messenger 1 1 1 1
8 Identification of Conductors
i) Phase conductors By providing one, two & three ridges
ii) Neutral conductor By providing four ridges
9 Assembly Phase & Neutral conductors twisted around Bare
messenger in RH lay not exceeding 35 times the diameter of
insulated Phase conductor
10 Approx Cable weight Kg/km 2040 2365 2800 3530
11 Continuous current carrying Amps 235 270 315 380
capacity of cable when laid
freely in air at 50oC ambient
air temperature
12 Short circuit rating of conductor KA 11.3 14.2 17.5 22.6
for one second duration
 TABLE 3
11 KV(E) AERIAL BUNCHED CABLES GENERALLY TO IS:7098/PART - 2
(Three phase conductors around bare steel messenger).
Phase Conductor 3x25 3X35 3X50 3X70 3X95 3X120 3X150
Messenger Conductor 1X35 1X35 1X35 1X55 1X55 1X55 1X55
1 Trade Name UNISTAR
2 Rated Voltage Kv 6.35/11
3 Reference Standard Generally to IS 7098 (Part 2)/85
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 25 35 50 70 95 120 150
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2
iv) Form of Conductor Stranded Compacted Circular
v) Max. DC resistance at 200C Ω/km 1.2 0.868 0.641 0.443 0.32 0.253 0.206
vi) Approx conductor diameter mm 6.2 7.3 8.4 10.1 12.0 13.2 14.6
4.2 Conductor Screen
i) Material & Type Extruded semi-conducting layer
ii) Min. thickness mm 0.3 0.3 0.3 0.3 0.3 0.3 0.3
4.3 Insulation
i) Material Cross-linked Polyethylene to IS 7098 (Part 2) / 85
ii) Nominal thickness mm 3.6 3.6 3.6 3.6 3.6 3.6 3.6
4.4 Insulation screen (Non-Metallic)
i) Metrial & Type Extruded semi-conducting layer
ii) Min. Thickness of extruded layer mm 0.3 0.3 0.3 0.3 0.3 0.3 0.3
4.5 Insulation screen (Metallic)
i) Material & Type Copper type applied helically with overlap
ii) Approx. thickness of copper tape mm 0.045 0.045 0.045 0.045 0.045 0.045 0.045
4.6 Sheath
i) Material & Type PVC Type ST2 to IS 5831/84, Black Colour
ii) Nom. thickness mm 2.0 2.0 2.0 2.0 2.0 2.0 2.0
4.7 Approx. diameter of Power core mm 20.4 21.5 22.6 24.3 26.2 27.4 28.8
5 Bare Messenger
i) Material High Tensile galvanized steel strand to IS 398 (Part2) / 96
ii) Nom. Cross Sectional Area Sqmm 35 35 35 55 55 55 55
iii) Form of conductor Stranded Circular
iv) Approx. breaking load kn 41 41 41 62 62 62 62
v) Approx. messenger diameter mm 7.8 7.8 7.8 9.5 9.5 9.5 9.5
6 Number of Cores
i) Phase Conductor 3 3 3 3 3 3 3
ii) Bare Messenger 1 1 1 1 1 1 1
7 Identification of Phase conductor By one, two & three ridges on outer sheath
8 Cable assembly Phase conductor laid up around the bare messenger
9 Approx weigh of cable kg/km 1590 1760 1940 2385 2490 3040 3370
10 Continuous current carrying Amps 95 115 140 175 215 250 280
capacity cable when laid freely
in air at 50ºC ambient Air temp.
11 Short circuit rating for one
second duration
i) Phase Conductor KA 2.4 3.3 4.7 6.6 9.0 11.3 14.2
ii) Copper Screen Amp 200 200 200 200 200 200 200

Note:
Copper tape screen has been designed for earth fault current of 200 Amp. for 1 second duration. However if
required it can be suitably redesigned to meet specific requirement if any.
 TABLE 3 A
11 KV(E) AERIAL BUNCHED CABLES GENERALLY TO IS:7098/PART - 2
(Three phase conductors around bare steel messenger).
Phase Conductor 3x185 3x240 3x300
Messenger Conductor 1x90 1x90 1x90
1 Trade Name UNISTAR
2 Rated Voltage Kv 6.35/11
3 Reference Standard Generally to IS 7098 (Part 2) / 85
4 PHASE CONDUCTOR
4.1 Conductor
i) Material Aluminium to IS 8130/84, H4 Grade
ii) Nominal cross-sectional area Sqmm 185 240 300
iii) Flexibility class as per IS 8130 Class 2 Class 2 Class 2
iv) Form of Conductor Stranded Compacter Circular
v) Max. DC resistance at 200C Ω/km 0.164 0.125 0.1
vi) Approx conductor diameter mm 16.2 18.6 20.6
4.2 Conductor Screen
i) Material & Type Extruded semi-conducting layer
ii) Min. thickness mm 0.3 0.3 0.3
4.3 Insulation
i) Material Cross-linked Polyethylene to IS 7098 (Part 2) / 85
ii) Nominal thickness mm 3.6 3.6 3.6
4.4 Insulation screen (Non-Metallic)
i) Metrial & Type Extruded semi-conducting layer
ii) Min. Thickness of extruded layer mm 0.3 0.3 0.3
4.5 Insulation screen (Metallic)
i) Material & Type Copper tape applied helically with overlap
ii) Approx. thickness of Copper Tape mm 0.045 0.045 0.045
4.6 Sheath
i) Material & Type PVC Type ST2 to IS 5831/84, Black Colour
ii) Nom. thickness mm 2.2 2.2 2.2
4.7 Approx. diameter of Power core mm 30.8 33.2 35.2
5 Bare Messenger
i) Material High Tensile galvanized steel strand to IS 398 (Part2) / 96
ii) Nom. Cross Sectional Area Sqmm 90 90 90
iii) Form of conductor Stranded Circular
iv) Approx. breaking load kn 103 103 103
v) Approx. messenger diameter mm 12.3 12.3 12.3
6 Number of Cores
i) Phase Conductor 3 3 3
ii) Bare Messenger 1 1 1
7 Identification of Phase conductor By one, two & three ridges on outer sheath
8 Cable assembly Phase conductor laid up around the bare messenger
9 Approx weigh of cable kg/km 4160 4820 5515
10 Continuous current carrying Amps 325 400 445
capacity cable when laid freely
in air at 50ºC ambient Air temp.
11 Short circuit rating for one
second duration
i) Phase Conductor KA 17.5 22.6 28.3
ii) Copper Screen Amp 200 200 200

Note:
Copper tape screen has been designed for earth fault current of 200 Amp. for 1 second duration. However if
required it can be suitably redesigned to meet specific requirement if any.