Proven Technology Foundations thumbnail

Proven Technology Foundations

TS Conductor's innovation builds upon three proven industrial technologies with extensive track records: pultrusion-based composite core manufacturing (refined since the 1950s), carbon fiber composites (validated through military and commercial aerospace applications since the 1970s), and annealed aluminum (proven reliable in ACSS conductors since the 1970s). Rather than introducing entirely new materials or processes, TS Conductor combines these mature technologies in a novel way, allowing utilities to benefit from innovation while relying on thoroughly validated manufacturing processes and material platforms that have demonstrated their reliability across multiple industries.

While TS Conductor represents the next generation of advanced conductor technology, our innovation builds upon proven industrial processes and materials that have demonstrated their reliability over many decades. Since our commercial deployment in 2016, utilities around the world have embraced our technology, recognizing its performance advantages and familiar installation characteristics.

Historical Development of Core Technologies

Our conductor technology integrates three mature industrial processes, each with decades of proven performance:

The composite core manufacturing process dates back to the 1950s. This pultrusion technology has been continuously refined over 75 years, creating a robust and well-understood manufacturing method.

Carbon fiber composites entered military aerospace applications in the early 1970s before expanding into commercial aviation. This half-century of demanding aerospace applications has thoroughly validated the material’s performance characteristics and long-term reliability.

The annealed aluminum we use has been serving the utility industry since the 1970s in ACSS conductors. This extensive field experience provides confidence in the material’s long-term performance under real-world conditions.

Technology Maturity

TS Conductor’s innovation lies in how we combine proven technologies in a novel way. Each component of our solution rests on established manufacturing processes and material platforms that have been validated through decades of industrial use.

This foundation of proven technologies allows us to deliver innovation without the uncertainties typically associated with new materials or processes. Our customers can be confident that the core elements of our technology have been thoroughly validated through decades of real-world application across multiple industries.

Rather than asking utilities to take a leap of faith on unproven technology, we offer a solution that builds upon their existing knowledge and experience. The result is a conductor that delivers superior performance while maintaining the reliability and familiarity that utilities require.

More articles.

See All Articles
Thermal Sag thumbnail
Technical Characteristics

Thermal Sag Behavior: Knee Points and Material Properties

Bi-component conductors, made with two different materials, exhibit a thermal "knee point" - a temperature at which the aluminum strands reach zero tension due to thermal expansion as the conductor heats up. Traditional ACSR exhibits a knee point around 125°C but can't operate there due to aluminum strand damage, while ACSS shows a lower knee point but experiences high sag above it due to steel's thermal expansion. TS AECC exhibits virtually no thermal sag above its knee point due to its carbon fiber core's extremely low thermal expansion coefficient.

Standard Installation thumbnail
Performance & Operation

Standard Installation and Maintenance

TS Conductor’s AECC is the only advanced conductor that is fully compatible with traditional ACSR/ACCC installation and maintenance practices, requiring no specialized training or equipment. The aluminum encapsulation layer acts as a protective cushion during compression fitting installation, achieving 100% compaction around the core and preventing moisture ingress. The pre-tensioned design allows for standard bending radius requirements (25 times the conductor's outer diameter), while the sealed nature eliminates special storage requirements, maintaining full mechanical and electrical properties even after extended storage.

Longevity by Design thumbnail
Performance & Operation

Longevity by Design

TS Conductor ensures long-term reliability through multiple design features addressing potential degradation mechanisms. The aluminum encapsulation prevents galvanic corrosion by eliminating moisture and oxygen contact with the core, while also protecting against matrix degradation from environmental factors. The design's system-level performance benefits from annealed aluminum strands that redistribute stress through controlled creep, and trapezoidal strand configuration enabling optimal energy dissipation without fatigue, while compression fittings create a solid metal surround achieving 100% compaction around the composite core.

Award-Winning Design thumbnail
Fundamental Technology

Award-Winning Design: Aluminum Encapsulated Carbon Core (AECC)

TS Conductor's award-winning AECC technology represents the next generation of advanced conductors. The design optimizes three critical components: a pre-tensioned carbon core (without glass fibers) that delivers maximum strength and stiffness with near zero thermal expansion, a seamless aluminum encapsulation layer that preserves core pre-tensioning and provides multiple protective functions, and trapezoidal strands made from annealed aluminum that maximize conductivity. This integration achieves superior performance across all key metrics while maintaining the built-in safety and reliability of traditional options, earning recognition from organizations like the U.S. Department of Energy, Public Utilities Fortnightly, S&P Global Platts, and Bloomberg NEF.