3rd issue

Telephone Wires & Cables

Designation Code for Telephone CablesYou can order our product by
giving the following informations

1- cable codes as per the catalogue

2- if your requirements is out of our catalogue product range, you can

use the following map to identify the code

Conductor Material Egyptian Standard

D Solid Soft Copper 01 TC 113
02 TC 135
wire Diam. (mm) 03 TC 154
04 TC 450
02 0.4 05 TC 113 JUMBER
03 0.5
04 0.6
06 0.9

Insulation Type

E Polyethylene
P PVC

No. of Paires

U Unarmored
A Armored

Outer Sheathing Type

P PVC
F PVC / FR
H Polyethylene

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Jelly Filled Telephone Cable
Primary and Secondary

6 54 1،2،3

Description Plain solid annealed copper conductor, polyethylene (solid or foam) insulated, twisted pairs or
twisted quads, Jelly filled, screened with ALU laminated PE, CU wire acc. to Egyptian standard
spec. TC 154 & TC 450 Also the cable can be manufacturing according to customer spec.

Construction 1- Solid annealed copper conductor.
Applications 2- Polyethylene (solid or foam) insulation.
3- Filling compound petroleum Jelly.
4- Core wrapping tape.
5- Aluminium moisture barrier (screen).
6- Extruded black Polyethylene sheath.
7- Sheath marking by ink Jet.

Jelly filled cable are used for primary and secondary underground distribution networks and for
long distance communications.

Jelly Filled telephone cable
Dimensions and standard packing

Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
D02E0006UH03 No. x mm mm Meter
D02E0010UH03 58 mm
D02E0016UH03 6 x 2 x 0.4 8 79 1000
D02E0020UH03 10 x 2 x 0.4 9 109 1000 600
D02E0030UH03 16 x 2 x 0.4 10 128 1000 700
D02E0050UH03 20 x 2 x 0.4 11 173 1000 700
D02E0100UH03 30 x 2 x 0.4 12 275 1000 800
D02E0150UH03 50 x 2 x 0.4 15 478 1000 800
D02E0200UH03 100 x 2 x 0.4 19 700 1000 900
D02E0250UH03 150 x 2 x 0.4 22.5 928 1000 1200
D02E0300UH03 200 x 2 x 0.4 26 1133 1000 1200
D02E0400UH03 250 x 2 x 0.4 28.5 1335 1000 1400
D02E0500UH03 300 x 2 x 0.4 30.5 1786 1000 1400
D02E0600UH03 400 x 2 x 0.4 35 2150 1000 1600
D02E0800UH03 500 x 2 x 0.4 38.5 2542 1000 1800
D02E1000UH03 600 x 2 x 0.4 41.5 3348 500 2000
D02E1200UH03 800 x 2 x 0.4 47.5 4122 500 1600
1000 x 2 x 0.4 52 4926 500 1800
1200 x 2 x 0.4 57 500 2000
2000

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Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
D06E0006UH03 No. x mm mm Meter
D06E0010UH03 175 mm
D06E0016UH03 6 x 2 x 0.9 12.5 273 1000
D06E0020UH03 10 x 2 x 0.9 15 402 1000 900
D06E0030UH03 16 x 2 x 0.9 18 487 1000 900
D06E0050UH03 20 x 2 x 0.9 19.5 693 1000 1200
D06E0100UH03 30 x 2 x 0.9 23 1185 1000 1200
D06E0150UH03 50 x 2 x 0.9 30 2205 1000 1400
D06E0200UH03 100 x 2 x 0.9 40 3341 1000 1600
D06E0250UH03 150 x 2 x 0.9 48 4371 500 2000
D06E0300UH03 200 x 2 x 0.9 55 5430 500 1800
D06E0400UH03 250 x 2 x 0.9 61 6450 500 2000
300 x 2 x 0.9 66 8568 300 2200
Product-Code 400 x 2 x 0.9 76 300 2000
Approx. Weight 2200
D03E0006UH03 Cable Size Approx. outer kg/km Shipping lengh
D03E0010UH03 Pair Count diameter ±5% Drum Size
D03E0016UH03 No. x mm mm 69 Meter flange diameter
D03E0020UH03 96
D03E0030UH03 6 x 2 x 0.5 8.5 134 1000 mm
D03E0050UH03 10 x 2 x 0.5 10 158 1000
D03E0100UH03 16 x 2 x 0.5 11 216 1000 600
D03E0150UH03 20 x 2 x 0.5 12 347 1000 700
D03E0200UH03 30 x 2 x 0.5 14 612 1000 800
D03E0250UH03 50 x 2 x 0.5 17 927 1000 800
D03E0300UH03 100 x 2 x 0.5 22 1198 1000 900
D03E0400UH03 150 x 2 x 0.5 27 1492 1000 1000
D03E0500UH03 200 x 2 x 0.5 30 1782 1000 1200
D03E0600UH03 250 x 2 x 0.5 33.5 2315 1000 1600
D03E0800UH03 300 x 2 x 0.5 36.5 2792 1000 1600
D03E1000UH03 400 x 2 x 0.5 41 3336 1000 1800
D03E1200UH03 500 x 2 x 0.5 45 4361 500 1800
600 x 2 x 0.5 49 5415 500 2000
Product-Code 800 x 2 x 0.5 60 6510 500 1800
1000 x 2 x 0.5 62 500 2000
D04E0006UH03 1200 x 2 x 0.5 68 500 2000
D04E0010UH03 2200
D04E0016UH03 Cable Size Approx. outer Approx. Weight Shipping lengh 2200
D04E0020UH03 Pair Count diameter kg/km ±5%
D04E0030UH03 No. x mm mm Meter Drum Size
D04E0050UH03 flange diameter
D04E0100UH03 6 x 2 x 0.6 9 91 1000
D04E0150UH03 10 x 2 x 0.6 10.5 131 1000 mm
D04E0200UH03 16 x 2 x 0.6 12 187 1000
D04E0250UH03 20 x 2 x 0.6 13 224 1000 700
D04E0300UH03 30 x 2 x 0.6 16 322 1000 700
D04E0400UH03 50 x 2 x 0.6 19 511 1000 800
D04E0500UH03 100 x 2 x 0.6 26 949 1000 900
D04E0600UH03 150 x 2 x 0.6 30.5 1412 1000 1000
D04E0800UH03 200 x 2 x 0.6 35 1868 1000 1400
D04E1000UH03 250 x 2 x 0.6 38.5 2318 1000 1600
D04E1200UH03 300 x 2 x 0.6 42 2744 1000 1800
400 x 2 x 0.6 47.5 3618 500 2000
500 x 2 x 0.6 52 4379 500 2200
600 x 2 x 0.6 57 5235 500 2400
800 x 2 x 0.6 64.5 6874 500 1800
1000 x 2 x 0.6 72 8589 500 2000
1200 x 2 x 0.6 79.5 10362 500 2000
2200
N.B.: Intermediate and other sizes are produced upon request 2400
2200
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Electrical and transmission characteristics

1- Conductor resistance at 20O C

Nominal Copper conductor diameter Max. Resistance
mm mm ohm/Km
0.4 Minimum 0.425
0.5 mm 0.525 149
0.6 0.385 0.625 93
0.9 0.485 0.925 64.5
0.585 28
0.885

2- Resistance unbalance
Resistance unbalance shall be calculated with the following formula

R ( %) = R max - Rmin X 100 Resistance unbalance %
CRonmduacxtor+diaRmin
Minimum Max.
mm mm mm
5
0.4 2 5
4
0.5 1.5 4

0.6 1.5

0.9 1.2

3- The tensile strength of conductor is max 26 Kg/mm2

and min 20 Kg/mm2

3- Insulation Resistance

The Insulation Resistance at 20 OC is the following
Min. 10000 Mega ohm km for foam skin insulation

Min. 5000 Mega ohm km for solid insulation

4- Mutual Capacitance at 800 HZ
Max average 45 ± 5 nf/km

Max average 50 nf/km

5- Capacitance unbalance Pair
For 160 meter at 800 HZ to earth
Max avarage 500 PF/km
Max individual 2500 PF/km

Max capacitance unbalance

Kind of Reading Avarage Individual

Side to side (within star quad) 70 300
Side to earth 200 450
150
Side to side adjacent pairs -

N.B.: Intermediate and other sizes are produced upon request

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Jelly Filled Telephone Cable
Primary and Secondary

6 54 1،2،3

Description Plain solid annealed copper conductor, PVC insulated, twisted pairs or twisted quads, and PVC
sheathed also flame retardant PVC sheathed can be applied acc. to Egyptian standard spec. TC
Construction 113 also the cable can be manufacturing according to customer specification.
Applications
1- Solid annealed copper conductor. 2-PVC insulation
3- Polyethylene or polyster tape ( core wrapping tape )..
4- Gray or black PVC Sheath.
5- Sheath marhing by ink jet.

Indoor cables are used for indoor installation in telephone communications networks.
( frame and switch board cables)..

Indoor telephone cable
Dimensions and standard packing

Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
D03P0003UP01 No. x mm mm Meter
D03P0004UP01 35 mm
D03P0005UP01 3 x 2 x 0.5 5.5 43 1000
D03P0006UP01 4 x 2 x 0.5 6 54 1000 500
D03P0010UP01 5 x 2 x 0.5 6.5 62 1000 500
D03P0016UP01 6 x 2 x 0.5 7 99 1000 500
D03P0020UP01 10 x 2 x 0.5 9 142 1000 700
D03P0030UP01 16 x 2 x 0.5 10.5 181 1000 700
D03P0050UP01 20 x 2 x 0.5 12 251 1000 800
D03P0100UP01 30 x 2 x 0.5 14 400 1000 800
D03P0150UP01 50 x 2 x 0.5 17.5 747 1000 900
D03P0200UP01 100 x 2 x 0.5 24 1138 1000 1000
D03P0250UP01 150 x 2 x 0.5 29.5 1507 1000 1400
D03P0300UP01 200 x 2 x 0.5 33.5 1846 1000 1600
D03P0400UP01 250 x 2 x 0.5 37 2254 1000 1800
D03P0500UP01 300 x 2 x 0.5 41 2971 1000 2000
400 x 2 x 0.5 47 3690 1000 2000
500 x 2 x 0.5 52.5 1000 2400
2400

Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
No. x mm mm Meter
44 mm
D04P0003UP01 3 x 2 x 0.6 6.5 55 1000
D04P0004UP01 4 x 2 x 0.6 7 70 1000 500
D04P0005UP01 5 x 2 x 0.6 7.5 80 1000 600
D04P0006UP01 6 x 2 x 0.6 8 129 1000 600
D04P0010UP01 10 x 2 x 0.6 10 189 1000 600
D04P0016UP01 16 x 2 x 0.6 12 239 1000 700
D04P0020UP01 20 x 2 x 0.6 13.5 336 1000 800
D04P0030UP01 30 x 2 x 0.6 16 543 1000 900
D04P0050UP01 50 x 2 x 0.6 20.5 1022 1000 1000
D04P0100UP01 100 x 2 x 0.6 28 1562 1000 1200
D04P0150UP01 150 x 2 x 0.6 34 2071 1000 1600
D04P0200UP01 200 x 2 x 0.6 39 2545 1000 1800
D04P0250UP01 250 x 2 x 0.6 43.5 3099 1000 2000
D04P0300UP01 300 x 2 x 0.6 47.5 4092 1000 2200
D04P0400UP01 400 x 2 x 0.6 55 5088 1000 2400
D04P0500UP01 500 x 2 x 0.6 61 1000 2400
2600
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Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
D06P0003UP01 No. x mm mm Meter
D06P0004UP01 mm
D06P0005UP01 3 x 2 x 0.9 9 92 1000
D06P0006UP01 4 x 2 x 0.9 10.5 117 1000 700
D06P0010UP01 5 x 2 x 0.9 11.5 148 1000 800
D06P0016UP01 6 x 2 x 0.9 12 173 1000 800
D06P0020UP01 10 x 2 x 0.9 15.5 282 1000 800
D06P0030UP01 16 x 2 x 0.9 19 425 1000 900
D06P0050UP01 20 x 2 x 0.9 21.5 537 1000 1200
D06P0100UP01 30 x 2 x 0.9 25.5 771 1000 1400
D06P0150UP01 50 x 2 x 0.9 32.5 1274 1000 1400
D06P0200UP01 100 x 2 x 0.9 45 2432 1000 1600
D06P0250UP01 150 x 2 x 0.9 55 3743 1000 2200
D06P0300UP01 200 x 2 x 0.9 63.5 4971 1000 2400
250 x 2 x 0.9 70.5 6143 500 2600
Product-Code 300 x 2 x 0.9 77.5 7444 500 2400
2400
D03P0010AP01 N.B.: Intermediate and other sizes are produced upon request
D03P0016AP01 Drum Size
D03P0020AP01 Outdoor Armoured Telephone cable flange diameter
D03P0030AP01 Dimensions and standard packing
D03P0050AP01 mm
D03P0100AP01 Cable Size Approx. outer Approx. Weight Shipping lengh
D03P0150AP01 Pair Count diameter kg/km ±5% 800
D03P0200AP01 No. x mm mm Meter 900
D03P0250AP01 234 900
D03P0300AP01 10x2x0.5 12 298 1000 1000
D03P0400AP01 16x2x0.5 13.5 351 1000 1200
20x2x0.5 15 445 1000 1600
Product-Code 30x2x0.5 17 636 1000 1800
50x2x0.5 20.5 1056 1000 2000
D04P0010AP01 100x2x0.5 27 1881 1000 2000
D04P0016AP01 150x2x0.5 34 2345 1000 2200
D04P0020AP01 200x2x0.5 38 2763 1000 2400
D04P0030AP01 250x2x0.5 41.5 3255 1000
D04P0050AP01 300x2x0.5 45.5 4107 1000 Drum Size
D04P0100AP01 400x2x0.5 51.5 1000 flange diameter
D04P0150AP01
D04P0200AP01 Cable Size Approx. outer Approx. Weight Shipping lengh mm
D04P0250AP01 Pair Count diameter kg/km ±5%
D04P0300AP01 No. x mm mm Meter 900
D04P0400AP01 900
D04P0500AP01 10 x 2 x 0.6 13 278 1000 1000
16 x 2 x 0.6 15 361 1000 1200
20 x 2 x 0.6 16.5 429 1000 1400
30 x 2 x 0.6 19 554 1000 1600
50 x 2 x 0.6 23 810 1000 2000
100 x 2 x 0.6 30.5 1375 1000 2200
150 x 2 x 0.6 38.5 2410 1000 2400
200 x 2 x 0.6 43.5 3031 1000 2400
250 x 2 x 0.6 48 3598 1000 2600
300 x 2 x 0.6 52 4250 1000 2200
400 x 2 x 0.6 59.5 5402 1000
500 x 2 x 0.6 65.5 6539 1000

N.B.: Intermediate and other sizes are produced upon request

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Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Drum Size
Pair Count diameter kg/km ±5% flange diameter
D06P0010AP01 No. x mm mm Meter
D06P0016AP01 510 mm
D06P0020AP01 10x2x0.9 18.5 696 1000
D06P0030AP01 16x2x0.9 22 814 1000 1200
D06P0050AP01 20x2x0.9 24 1158 1000 1400
D06P0100AP01 30x2x0.9 29 1758 1000 1400
D06P0150AP01 50x2x0.9 36 3037 1000 1600
D06P0200AP01 100x2x0.9 48 5136 1000 1800
D06P0250AP01 150x2x0.9 60 6559 1000 2200
200x2x0.9 68 7966 1000 2600
250x2x0.9 75.5 1000 2200
2400

Indoor Wires

3 21

Description Plain solid annealed copper conductor, PVC insulated, one pair or one quad, and PVC sheathed.
Construction According to Egyptian local standard spec, TC 113 also can be manufacturing according to
customer specification.

1- copper conductor. 2-PVC insulation
3- PVC sheathed (lightgray).
4- Drain wire (as polyproplene) for easily strippable sheathed.

Applications The indoor wires are used for installations between internal distribution points on subscribers
terminationblocks to wall the telephone sockets.

Dimensions and standard packing

Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Packing
Pair Count diameter kg Meter
No. x mm mm Coil
100 Coil
D03P0001UP01 1 x 2 x 0.5 4 1.8 100 Coil
D03P0002UP01 100 Coil
D04P0001UP01 1 x 4 x 0.5 5 2.6 100
D04P0002UP01
1 x 2 x 0.6 4.5 2.1

1 x 4 x 0.6 5.5 3.2

Electrical and transmission characteristics

1- Loop resistance at 20oC. for both sizes
Max. 192 ohm / Km for 0.5 mm for size 0.5 mm
for size 0.6 mm
Max. 131 ohm / Km for 0.6 mm
1.1 Resistance unbalance
Max. average 1.5
Max. individual 5
Max. individual 4

2- Insulation Resistance
The insulation resistance at 20oC shall not less than
500 mega ohm Km.

3- The tensile strength of conductor is max. 26 kg/mm2 and min. 20 kg/mm2.

4- Mutual capacitance at 800 Hz Max. 100 nf/km.

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Jumper Wires

Description Plain solid annealed copper conductor, solid PE or PVC insulated, tow insulated conductors are
twisted together with short lay to from a pair according to Egyptian local standard spec. TC 113
Construction also can be manufacturing according to customer specification.
Applications
copper conductor.
PVC or PE insulation.

The jumber wires are used generally in outdoor cabinets forcross connections between primary
and secondary terminal block also in main distribution frame in exchange buildings.

Dimensions and standard packing

Product-Code Cable Size Approx. outer Approx. Weight Shipping lengh Packing
Pair Count diameter kg Meter
No. x mm mm Coil
Coil
D03P000105 2 x 0.5 2.1 0.6 100
D04P000105 2 x 0.6 2.4 0.8 100

Electrical and transmission characteristics

1- Loop resistance at 20oC. for both sizes
Max. 192 ohm / Km for 0.5 mm for size 0.5 mm
for size 0.6 mm
Max. 131 ohm / Km for 0.6 mm
1.1 Resistance unbalance
Max. average 1.5
Max. individual 5
Max. individual 4

2- Insulation Resistance
The insulation resistance at 20oC shall not less than
500 mega ohm Km.

3- The tensile strength of conductor is max. 26 kg/mm2 and min. 20 kg/mm2.

4- Mutual capacitance at 800 Hz Max. 100 nf/km.

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358

Special Voltage Cables

INNOVATING
FOR A SAFER WORLD

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TELEPHONE CABLE
TC 154 x0.6

polyethylene outer sheath

Twisted Quad

Drain Wire

Non-Hygroscopic
Polyester Tape

single side coated
aluminum tape

soft mineral
hydrocarbon
filling compound

INTRODUCTION Figure (1) Multi pair Telephone cable 0.6 mm
CABLE DESIGN
APPLICATIONS • Our ofer is duct and direct buried telecommunication coper cables. These cables are
designed for use as a non-presurized distribution and junction cables in local telephone
• networks as wel as in private communications systems. Technical comments are
prepared for our proposed telephone cable which having the folowing characteristics:

• Up to 120 coper pairs with solid conductor size 0.6 mm.
• Foam-skin HDPE insulated wires.
• Insulated wires twisted in Quads.
• Cable core and al interstices are fuly filed.
• Cable core covered with polyester tape.
• Single side coated aluminum tape as a moisture barier.
• Polyethylene outer sheath.

• Distribution cables.
• telephone.
• Transmision of signal.

3

SPECIAL FEATURES intelligent

• High reliability assured by continuous petroleum filling and a laminated sheath.
• Low transmission loss coupled with.
• Suitable for direct burial or for pulling into ducts.
• Laminated aluminum tape acts as additional moisture barrier.

CABLE CONSTRUCTION The conductor is pure annealed solid copper, smoothly drawn, circular in cross section,
CONDUCTOR uniform inquality, and free from defects. The conductor is in full compliance with IEC
60228 and BS 6360. Theconductor has the following electrical and mechanical
INSULATED WIRES properties as follows table (1):

TWINNING PROCESS Parameters Unit Nominal Values

Conductor Dimensions mm 0.6
Conductor dimension mm +0.004
-0.003
tolerance /km
Maximum conductor % 62
N/m/m2
resistance > 18
Conductor Elongation 177<T.S<255
Conductor tensile strength

Each conductor covered with uniformly foam skin high density polyethylene (PE).
The insulation has the following mechanical properties as follows table (2)

Parameters Unit Nominal Values

Insulation thickness mm 0.24
Insulated wire diameter mm 1.08 ± 0.02
%
Insulation Elongation N/mm2 > 200
Insulation tensile strength N ≥5
Insulation adhesive force
2 : 12

Four insulated wires with the appropriate color uniformly twisted together to form a Quad.
Each Quad has its own lay length (different) to reduce both capacitance unbalance
and cross talk characteristics. The identifications of quads are as follows table (3) :

Color of insulation

Sequence of Quads In The Layers (A. wire) (B. wire) (C. wire) (D. wire)

1st White Green Red Black '

2nd White Orange Blue Black

Odd White Red Yellow Black

Even White Brown Blue Black

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(Main unit (26 Quads) The required numbers of the quads are stranded together in one direction to form the main
(50 pairs) or (51 Quads) unit 50 or 100 pairs.
(100 pairs).

Unit identification. One binder of synthetic non-hygroscopic material wound helically around the main-unit.
Assembly The bin der colors will be: WHT,RED,YEL,GRN,BRN,BLU,ORA,BLK,(WHT/RED),
(WHT/GRN),(WHT/BLU),(WHT/BLK),(YEL/RED) WHT,RED,YEL,GRN,BR-
CORE FILLING N,BLU,ORA,BLK,(WHT/RED),(WHT/GRN),(WHT/BLU),(WHT/BLK),(YEL/RED),
CORE WRAPPING (YEL/GRN), (YEL/BLU), (YEL/BLK), (BRN/RED), (BRN/GRN), (BRN/BLU), (BRN/BLK).

The main unit are stranding together to form the cable core .the construction
of the cable core will be as shown in table (4):

Pair Cable Construction
Number
Center 1st Layer 2nd layer 3rd layer
2 1Q 21 Q
4 2Q 7Q 14 Q
6 3Q 8Q 16 Q
8 4Q 11 Q
10 5Q 9Q
16 1Q 10 Q
20 2Q
30 4Q 5 x 50"
50 3Q 6 x 50"
100 4Q 7 x 50"
150 5 x100"
200 3 x 50" 6 x 100"
250 4 x 50" 7 x 100"
300 5 x 50" 8 x 100"
400 1 x 50"
500 2 x 50"
600 3 x 50"
800 1 x 100"
1000 2 x 100"
1200 3 x 100"
4 x 100"

All interstices of the core are filled with a filling compound in order to block any possible
water ingress. The filling compound has homogenous, uniformly mixed, and contain
antioxidants. It has colorless and suitable for service in cable project to temperature
from 0 up to 70 OC.

Above the cable core, one non-hygroscopic dielectric (polyester) tape is longitudinally
applied with an overlap. The core wrapping provide sufficient heat barrier to prevent
visible evidence of the conductor insulation deformation or adhesion between
the conductors caused by the adverse heat transfer during jacketing operation.

SCREENING (SHIELD) A laminated aluminum tape is longitudinally applied over the core with suitable overlap.
AND MOISTURE The polyethylene coating side of aluminum tape will face the polyethylene sheath.
BARRIER And the aluminum face will be in contact with tinned copper drain wire which is used
to make termination easily and to ground electrostatic discharges.

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PE OUTER SHEATH Black PE sheath is extruded over the aluminum tape. Due to the process-heat,
CABLE MARKING both elements are perfectly bonded together providing a barrier against the penetration
of moisture. The thickness of the outer sheath is as shown in table (5)

Diameter of the cable(mm) Nominal Outer sheath thickness (mm)

Up to 10 1.5
10.1 to 20 1.7
20.1 to 30 2.0
30.1 to 40 2.20
40.1 to 50 2.40
50.1 to 60 2.60
60.1 to 70 3.00
70.1 to 80 3.60
80.1 to 85 4.00

Each length of cable has a longitudinal printing on the sheath surface indicating
the manufacturer, the month/year of manufacture, type of cables, number
of pair/conductor
• diameter and the running length.
• The color of marking will be white.

CABLE MECHANICAL Parameters Unit Nominal Values
CHARACTERISTICS.
Number of pairs mm Up to 1200 Pairs
CABLE ELECTRICAL Conductor diameter . 0.6
CHARACTERISTICS
Insulation mm PE - Foam-skin
Type mm 0.24
1.08
Thickness mm
Wire dimension Aluminum
mm 0.12
Screen
Type PE-Black
As table (5)
Thickness
Outer Sheath

Type
Thickness

• Note: The diameters and weights are representative figures and can be varied by 5 %.

Parameters Unit Nominal
Values
• Conductor Dimensions mm 0.6 mm
% 0.6
• Resistance Unbalance (Max) nf/km 1.5
pf/ 160 m 50 ±5
• Mutual Capacitance 150
• Capacitance unbalance (Quad to GΩ.km
10
Quad)@1000Hz volt
• Insulation Resistance @ 225
• Temperature = 20 oC & Testing

voltage 500 VDC
• Rated Voltage (peak)

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Product data

Size Number of Cable weight Overall diameter Size Number of Cable weight Overall diameter
(mm) Pairs Approx.) (Approx.) (mm) Pairs Approx.) (Approx.)
(No.) (kg/km) (mm) (N (kg/k (m
0.6 4 69 8.3 0.6 30 255 41.
6 88 9.2 40 337 46.
8 107 9.9 50 416 51.
10 124 10.6 60 488 5
16 176 12.3 80 641 63.
20 218 13.6 100 804 71.
30 300 15.6 120 973 78.
50 481 19.1
100 894 25.4
150 1315 30.2
200 1732 34
250 2154 38

PACKING Every length will be delivered on non-returnable wooden drum. The wooden drum
will be marked with the manufacturer’s name in Arabic and English and the direction
of rolling. Both ends of the cable shall be sealed to prevent the ingress of moisture
during transportation and storage, physical damage, and sealing of filling compound.
All other information will be identified on metallic tag which fixed to the reel flange.

• Type of cable.
• Number of pairs and conductor size.
• Length and weight of cable per drum.
• Net and gross weight.
• Manufacturer’s name and location
• Customer’s name and destination.
• Production date.
• Purchasing order.

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TELEPHONE CABLE
TC 450 X 0.4

Ldpe Outer Sheath

Twisted Quad

Non-Hygroscopic
Polyester Tape

Double Side Coated
Aluminum Tape
(0٫2 mm thickness)
soft mineral
hydrocarbon
filling compound

INTRODUCTION Figure (1) Multi pair Telephone cable -TC 450

Our offer is duct and direct buried telecommunication copper cables. These cables
are designed for use as a non-pressurized distribution and junction cables in local
telephone networks as well as in private communications systems. Technical comments
are prepared for our proposed telephone cable which having the following characteristics:

CABLE DESIGN • 100, 150 & 200 copper pairs with solid conductor size 0.4 mm.
APPLICATIONS • Foam-skin HDPE insulated wires.
• Insulated wires twisted in Quads.
• Cable core and all interstices are fully filled.
• Cable core covered with polyester tape.
• Double side coated aluminum tape 0.2 mm as a moisture barrier.
• LDPE outer sheath.

• Distribution cables.
• telephone.
• Transmision of signal.

365

intelligent • High reliability assured by continuous petroleum filling and a laminated sheath.
• Low transmission loss coupled with.
SPECIAL FEATURES • Suitable for direct burial or for pulling into ducts.
CABLE CONSTRUCTION • Laminated aluminum tape acts as additional moisture barrier.
CONDUCTOR
The conductor is pure annealed solid copper, smoothly drawn, circular in
INSULATED WIRES cross section, uniform inquality, and free from defects. The conductor is in
full compliance with IEC 60228 and BS 6360. Theconductor has the following
TWINNING PROCESS electrical and mechanical properties as follows table (1):

Parameters Unit Nominal Values

Conductor Dimensions mm 0.40
Conductor dimension mm +0.004
-0.003
tolerance Ω/km
Maximum conductor % 143

resistance N/mm2 ≥ 14
Conductor Elongation 177 < T.S < 255
Conductor tensile strength

Each conductor covered with uniformly foam skin high density polyethylene (PE).
The insulation has the following mechanical properties as follows table (2):

Parameters Unit Nominal Values

Insulation thickness mm 0.175
Insulated wire diameter mm 0.75 ± 0.02
%
Insulation Elongation N/mm2 ≥ 350
Insulation tensile strength N ≥ 19
Insulation adhesive force 2 : 12

Four insulated wires with the appropriate color uniformly twisted together to form a star
quad (see below circuits). Each Quad has its own lay length (different) to reduce both ca-
pacitance unbalance and cross talkcharacteristics. The conductor insulation is identified by
color coding and black ring markers as follow:

Ctrcult 1

Ctrcult 2

Basic colors of the 4conductor’s Item Color
insulation of each star quad of 1st quad Red
2nd Quad Green
the basic Squads sub-unit: 3rd Quad Gray
4th Quad Yellow
366 5th Quad White

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sub unit (S Quads) (10 pairs). Each five quads with in sequence and color coding are stranded together to form a sub unit
10 pairs.

Main unit (S sub unit) • Five sub units are stranded together to form main units 50 pairs.
(50 pairs) & (3+7 sub unit)(100”). • Ten sub units are stranded together to form main units 100 pairs.

Unit identification. • A red color helix binder marks the tracer subunit of every main unit as well as the tracer
Assembly main units of every cable core. The other subunits and main units are marked by white
color helix binder

The main unit are stranding together to form the cable core .the construction of the
cable core will be as in table (3):

Pair Cable Construction
Number
Center 1st Layer 2nd layer 3rd layer
10 1 x 10"
20 2 x 10" 7 x 10"
30 3 x 10"
50 5 x 10" 5 x 50"
100 3 x 10" 6 x 50"
150 3 x 50" 7 x 50"
200 4 x 50" 5 x100"
250 5 x 50"
300 1 x 50"
400 2 x 50"
500 3 x 50"
600 1 x 100"

CORE FILLING All interstices of the core are filled with a filling compound in order to block any possible
CORE WRAPPING water ingress. Thefilling compound has homogenous, uniformly mixed, and contain
antioxidants. It has colorless and suitablefor service in cable project to temperature
from 0 up to 70 OC. This test will be occurred during inspection.

Above the cable core, one non-hygroscopic dielectric (polyester) tape is longitudinally
applied with an’ overlap of 20%. The core wrapping provide sufficient heat barrier
to prevent visible evidence of the’ conductor insulation deformation or adhesion between
the conductors caused by the adverse heat transfer during jacketing operation.

SCREENING (SHIELD) A laminated aluminum tape is longitudinally applied over the core with thickness
AND MOISTURE BARRIER (0.2+ 0.025 mm). The laminated aluminum tape applied with overlap. Both sides
of the outer surface of aluminum tape are coated
with protective polymer (30 μm thick).

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intelligent Black PE sheath is extruded over the aluminum tape. Due to the process-heat,
both elements are perfectly bonded together providing a barrier against the penetration
PE OUTER SHEATH of moisture. The thickness of the outer sheath is tabel 4 column (2):

Diameter of the cable(mm) Nominal Outer sheath thickness (mm)

10" 1.4
20" 1.4
30" 1.4
50" 1.6
100" 1.6
150" 1.6
200" 1.8
250" 1.8
300" 1.8
400" 1.8
500" 1.8
600" 1.8

CABLE MARKING • Each length of cable has a longitudinal printing on the sheath surface indicating
the manufacturer
CABLE ELECTRICAL • GIZA CABLE INDUSTREIS, the month/year of manufacture, type of cables, number of
CHARACTERISTICS.
pair/conductor diameter, contract No. and running length.
CABLE ELECTRICAL
CHARACTERISTICS. Parameters Unit Nominal Values

Conductor Dimensions mm 0.4
Ω/km 300
Loop resistance at 20 oC nf/km ≤ 50

Mutual Capacitance @ GΩ.km 10
800 HZ volt 225

Insulation Resistance @
Temperature = 20 oC &
Testing voltage 500 VDC
Rated Voltage (peak)

Parameters Unit Nominal Values

Number of pairs mm 10 Up to 600
mm 0.4
Conductor diameter mm
mm PE - Foam-skin
Insulation 0.175
Type mm
0.75
Thickness
Aluminum
Wire dimension 0.2

Screen PE-Black
Type As table (4) column (2)

Thickness

Outer Sheath
Type

Thickness

• Note: The diameters and weights are representative figures and can be varied by 5 %.

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Product data Number of Pairs Cable weight Overall diameter
CONDITION (Approx.) (Approx.)
(No.)
PACKING 10 (kg/km) (mm)
20 82 8.5
30 130 10.3
50 170 11.6
100 264 14.3
150 465 18.3
200 666 21.2
250 870 24.2
300 26.5
400 1073 28.5
500 1245 32.2
600 1625 35.4
1995 38.2
2360

Every length will be delivered on non-returnable wooden drum. The wooden drum will
be marked with the manufacturer’s name in Arabic and English and the direction
of rolling. Both ends of the cable shall be sealed to prevent the ingress of moisture
during transportation and storage, physical damage, and sealing of filling compound.
All other information will be identified on metallic tag which fixed to the reel flange.

• Type of cable.
• Number of pairs and conductor size.
• Length and weight of cable per drum.
• Net and gross weight.
• Manufacturer’s name and location
• Customer’s name and destination.
• Production date.
• Purchasing order.

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TELEPHONE CABLE
TC 450 X 0.6

Ldpe Outer Sheath

Twisted Quad

Non-Hygroscopic
Polyester Tape

Double Side Coated
Aluminum Tape
(0٫2 mm thickness)
soft mineral
hydrocarbon
filling compound

INTRODUCTION Figure (1) Multi pair Telephone cable -TC 450
CABLE DESIGN
APPLICATIONS Our offer is duct and direct buried telecommunication copper cables. These
cables are designed for use as a non-pressurized distribution and junction
370 cables in local telephone networks as well as in private communications
systems. Technical comments are prepared for our proposed telephone cable
which having the following characteristics:

• 100, 150 & 200 copper pairs with solid conductor size 0.6 mm.
• Foam-skin HDPE insulated wires.
• Insulated wires twisted in Quads.
• Cable core and all interstices are fully filled.
• Cable core covered with polyester tape.
• Double side coated aluminum tape 0.2 mm as a moisture barrier
• LDPE outer sheath

• Distribution cables.
• telephone.
• Transmision of signal.

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SPECIAL FEATURES • High reliability assured by continuous petroleum filling and a laminated sheath.
CABLE CONSTRUCTION • Low transmission loss coupled with.
CONDUCTOR • Suitable for direct burial or for pulling into ducts.
• Laminated aluminum tape acts as additional moisture barrier.
INSULATED WIRES
The conductor is pure annealed solid copper, smoothly drawn, circular in cross
TWINNING PROCESS section, uniform inquality, and free from defects. The conductor is in full compliance
with IEC 60228 and BS 6360. Theconductor has the following electrical and mechanical
properties as follows table (1):

Parameters Unit Nominal Values

Conductor Dimensions mm 0.60
mm + 0.008
Conductor dimension - 0.003
tolerance /km
% 62
Maximum conductor N/mm2
resistance ≥ 18
177 ≤ T.S ≤ 255
Conductor Elongation

Conductor tensile strength

Each conductor covered with uniformly foam skin high density polyethylene (PE). The
insulation is in full compliance with IEC 708-1. The insulation has the following mechanical
properties as follows:

Parameters Unit Nominal Values

Insulation thickness mm 0.24
Insulated wire diameter mm 1.08 ± 0.02
%
Insulation Elongation N/mm2 ≥ 350
Insulation tensile strength N ≥ 19
Insulation adhesive force 2 : 12

Four insulated wires with the appropriate color uniformly twisted together to form a star
quad (see below circuits). Each Quad has its own lay length (different) to reduce both
capacitance unbalance and cross talkcharacteristics. The conductor insulation is identified
by color coding and black ring markers as follow:

Ctrcult 1

Basic colors of the 4conductor’s Ctrcult 2 Color
insulation of each star quad of Red
Item Green
the basic Squads sub-unit: 1st quad Gray
2nd Quad Yellow
3rd Quad White
4th Quad
5th Quad

371

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sub unit (S Quads) (10 pairs). Each five quads with in sequence and color coding are stranded together to form a sub unit
10 pairs.

Main unit (S sub unit) (50 pairs) • Five sub units are stranded together to form main units 50 pairs.
& (3+7 sub unit)(100”). • Ten sub units are stranded together to form main units 100 pairs.

Unit identification. • A red color helix binder marks the tracer subunit of every main unit as well as the tracer
Assembly main units of every

• cable core. The other subunits and main units are marked by white color helix binder

The main unit are stranding together to form the cable core .the construction of the cable
core will be as in table (3):

Pair Cable Construction
Number
Center 1st Layer 2nd layer 3rd layer
10 1 x 10"
20 2 x 10" 7 x 10"
30 3 x 10"
50 5 x 10" 5 x 50"
100 3 x 10" 6 x 50"
150 3 x 50" 7 x 50"
200 4 x 50" 5 x100"
250 5 x 50"
300 1 x 50"
400 2 x 50"
500 3 x 50"
600 1 x 100"

CORE FILLING All interstices of the core are filled with a filling compound in order to block any possible
CORE WRAPPING water ingress. The filling compound has homogenous, uniformly mixed, and contain
antioxidants. It has colorless and suitablefor service in cable project to temperature
from 0 up to 70 OC. This test will be occurred during inspection.

Above the cable core, one non-hygroscopic dielectric (polyester) tape is longitudinally
applied with an’ overlap of 20%. The core wrapping provide sufficient heat barrier
to prevent visible evidence of the’ conductor insulation deformation or adhesion between
the conductors caused by the adverse heat transfer during jacketing operation.

SCREENING (SHIELD) A laminated aluminum tape is longitudinally applied over the core with thickness
AND MOISTURE BARRIER (0.2+ 0.025 mm). The laminated aluminum tape applied with overlap. Both sides
of the outer surface of aluminum tape are coated with protective polymer
(30 μm thick).

372

PE OUTER SHEATH intelligent
CABLE MARKING
Black PE sheath is extruded over the aluminum tape. Due to the process-heat, both
elements are perfectly bonded together providing a barrier against the penetration
of moisture. The thickness of the outer sheath is as shown in table (4) column (2).

CABLES size / No. Of pairs Nominal Outer sheath thickness (mm)

10" 1.4
20" 1.4
30" 1.6
50" 1.6
100" 1.8
150" 1.8
200" 1.8
250" 1.8
300" 1.8
400" 2
500" 2
600" 2

• Each length of cable has a longitudinal printing on the sheath surface indicating the
manufacturer

• GIZA CABLE INDUSTREIS, the month/year of manufacture, type of cables, number of
pair/conductor diameter, contract No. and running length.

Example:
For 100 pair " GIZA CABLE INDUSTREIS 100 x 2 x 0.6 mm Order NO. TC450 (YEAR)
(METER)”

The length shall be marked at regular interval of one meter along the regular.
The color of marking will be white.

CABLE ELECTRICAL Parameters Unit Nominal Values
CHARACTERISTICS.
Conductor Dimensions mm 0.6
/km 130
Loop resistance at 20 oC nf/km ≤50

Mutual Capacitance @ G .km 10
800 HZ volt 225

Insulation Resistance @
Temperature = 20 oC &
Testing voltage 500 VDC
Rated Voltage (peak)

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intelligent Parameters Unit Nominal Values

CABLE ELECTRICAL Number of pairs mm 10 Up to 600
CHARACTERISTICS. mm 0.6
Conductor diameter mm
mm PE - Foam-skin
Insulation 0.24
Type mm
1.08
Thickness
Aluminum
Wire dimension 0.2

Screen PE-Black
Type As table (4) column (2)

Thickness

Outer Sheath
Type

Thickness

• Note: The diameters and weights are representative figures and can be varied by 5 %.

Product data Number of Pairs Cable weight Overall diameter
PACKING (Approx.) (Approx.)

(No.) (kg/km) (mm)

10 128 10.1
20 216 12.7
30 311 15.1
50 472 18.1
100 880 24.4
150 1296 28.9
200 1675 32.6
250 2054 35.9
300 2428 38.9
400 3380 45.3
500 3986 50.0
600 4708 53.8

Every length will be delivered on non-returnable wooden drum. The wooden drum
will be marked with the manufacturer’s name in Arabic and English and the direction
of rolling. Both ends of the cable shall be sealed to prevent the ingress of moisture
during transportation and storage, physical damage, and sealing of filling compound.
All other information will be
identified on metallic tag which fixed to the reel flange.

• Type of cable.
• Number of pairs and conductor size.
• Length and weight of cable per drum.
• Net and gross weight.
• Manufacturer’s name and location
• Customer’s name and destination.
• Production date.
• Purchasing order.

374

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Telephone Cables 1

We Deliver ... Your Power

intelligent

International Cables Co.

Telephone cables according to telecom Egypt specification TC 154

Copper conductors, PE foam-skin insulated, star quad stranded, Jelly filled, shielded with
laminated Aluminum tape and sheathed with black PE.

Construction:

Bare copper conductor, diameter 0.4 mm, 0.5 mm, 0.6mm, is covered with PE foam-skin insulated or solid Polyethylene insulation for
cables ≤ 250 pairs.

Each 4 conductors are twisted to form star quad, the quads are identified by its conductor insulation colors.

For cables with pair capacity ≤ 100 pairs, the specific number of quads are stranding in concentric layers.

For cables from 150 pairs to 400 pairs, 26 quads are stranding together in concentric layers to form one unit of 52 pairs. For cables
over 400 pairs, 51 quads are stranding together in concentric layers to form one unit of 102 pairs. Units are identified by colored binder
tapes. The needed units are stranding together to form the cable core.

The cable core is fully filled with petroleum jelly and wrapped with one polyester tape. One laminated aluminum tape is longitudinally
applied over the cable core and an outer sheath of black PE which is both UV and stress-crack resistant is applied over the shielding.

Product Data (Standard Products)

Cable Number of quads Number of units 0.4 Overall diameter 0.9
cable or unit 8.1 approx., mm 12.4
Copper diameter 3 10.0 16.5
10 pairs 5 4 11.4 0.5 0.6 19.3
20 pairs 10 5 13.6 8.5 9.2 24.8
30 pairs 15 6 18.0 10.5 11.5 32.9
50 pairs 26 8 21.4 12.0 13.7 40.0
100 pairs 51 5 24.0 15.0 16.8 45.9
150 pairs 26 6 27.0 19.6 22.0 50.6
200 pairs 26 8 29.0 23.3 26.9 55.3
250 pairs 26 10 33.6 27.0 30.3 72.4
300 pairs 26 12 37.0 29.5 33.4 80.7
400 pairs 26 15 40.0 31.9 36.5 87.6
500 pairs 51 18 46.0 41.4 48.8
600 pairs 51 20 50.7 45.8 53.4
800 pairs 51 24 55.0 49.6 58.4
1000 pairs 51 61.3 56.8 67.4
1200 pairs 51 67.4 62.8 74.5
1500 pairs 51 70.6 69.0 82.2
1800 pairs 51 76.7
2000 pairs 51
2400 pairs 51

Telephone Cables according To Telecom Egypt specification TC 450

Copper conductors , PE foam-skin insulted ,star qued stranded , Jelly filled , shielded with
laminated Aluminum tape and sheathed with black PE .

376 We Deliver ... Your Power

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International Cables Co.

Construction:

Bare copper conductor ,diameter 0.4 mm , 0.5 mm , 0.6 mm or For cable over 100 pairs , the needed units of 50pairs or 100 pairs
0.9 mm , is covered with PE Foam-skin insulation . are twisted together to form the cable core , which is fully filled with
petroleum jelly , than wrapped by one or two polyester tapes .
Each 4 conductors are twisted to form star quad , the quads are
identified by its conductor insulation color . The insulated conduc- A red color helix binder marks the tracer sub unit of the cable or
tors are identified by colors coded and black ring markers . The every main unit as well as the tracer main unit in each layer of the
Basic colors of 4 conductors insulation of each star quad of the cable core, the other sub units or main units are marked by white
basic 5 quads sub unit are red ,green , gray ,yellow and white . color helix binder .

Each 5 quads , in sequence and of color coding ,are twisted to One laminated aluminum tape is longitudinally applied over the
form 10 pairs sub unit , the sub units are stranded together to cable core and an outer sheath of black PE which is both UV and
form cable or main units of 50 or 100 pairs . stress – crack resistant is applied over the shielding.

Product Data (Standard Products)

Cable Number of quads cable or unit Number of units Overall diameter approx. .., mm

Copper diameter 3 0.4 0.5 0.6 0.9
4
10 pairs 5 5 7.6 8.7 9.7 12.9
6
20 pairs 10 8 9.4 10.9 12.3 17.2
5
30 pairs 15 6 10.7 12.6 14.9 20.3
8
50 pairs 26 10 13.5 15.9 18.3 25.9
12
100 pairs 51 15 17.3 20.7 24.5 34.5
18
150 pairs 26 20 20.5 25.2 29.5 41.7
24
200 pairs 26 23.1 28.5 33.5 48.0

250 pairs 26 25.7 31.3 36.7 53.0

300 pairs 26 27.8 34.0 40.0 58.5

400 pairs 26 31.4 28.5 45.8 67.0

500 pairs 51 34.5 42.2 50.5 73.5

600 pairs 51 37.5 46.2 54.5 80.5

800 pairs 51 42.5 52.7 63.0

1000 pairs 51 48.7 59.2 70.3

1200 pairs 51 52.5 64.2 77.0

1500 pairs 51 58.0
1800 pairs 51
2000 pairs 51 63.0

66.0

2400 pairs 51 72.0

Electric Characteristics mm 0.4 0.5 0.6 0.9
Ω/km 300 192 130 56.6
Cable Conductor diameter G.Ω.km 10 10 10 10
Conductor loop resistance at 20° C,max . Nf/km 50 50 50 50
Insulation resistance at 20°C foam -skin
Mutual capacitance

Max average

Capacitance unbalance in the quad at 800 Hz for 300 m , (k1) , max . pF 400 400 400 400

Capacitance unbalance between 2 adjacent quads at 800 Hz for 300 m pF 100 100 100 100
(k9-k12) , max.
V 500 500 500 500
Test Voltage one cond ,against all others V 2000 2000 2000 2000
All conductors against screen

We certify that above mentioned data are guaranteed for the offered cable

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