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Product

CIGRE TB 496 HVDC XLPE CIGRE TB 496 / CIGRE TB 852 / IEC±320 kV – ±525 kV DC−25…+90 °C

±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage CableCIGRE TB 496 / CIGRE TB 852 / IEC 62895 · ±320 kV – ±525 kV DC · -25 °C to +90 °C industrial

±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage Direct-Current (HVDC) Cable (HVDC XLPE) engineered to CIGRE TB 496 / CIGRE TB 852 / IEC 62895 for ±320 kV – ±525 kV DC service across -25 °C to +90 °C, featuring stranded copper conductor and hdpe

Approved

Low-EMC design

EMC screen

Outdoor & humid

Configuration

Order designation: HVDC XLPE 4G2.5
Outer Ø ≈: 10.8 mm
Total weight ≈: 186 kg/km
Min. bend R (fixed): 86 mm
Configuration: 4 × 2.5 mm²

All sizes (12)

Request a quote Datasheet WhatsApp info@tebaoflex.com

Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum

Rated voltage: ±320 kV – ±525
Operating temp.: −25…+90 °C
Min. bend radius: 20 × OD
Conductor: copper conductor
Outer layer: HDPE outer
Standard: CIGRE TB 496

Typical values for this cable type, based on CIGRE TB 496 / CIGRE TB 852 / IEC 62895 — confirmed in the datasheet and quotation for your order.

Application fit

Is HVDC XLPE right for your machine?

Fixed installation

Suitable

Engineered and verified for fixed service in accordance with CIGRE TB 496 / CIGRE TB 852 / IEC 62895.

Switchgear & control cabinet wiring

Suitable

Suitable for switchgear, control panels and equipment terminations within 20 × OD bend radius.

TBM gantry & advancing tunnel reel

With conditions

Use mechanical conduit or armoured protection where exposed to rock fall or crushing loads.

Motorised monospiral reel

Not suitable

Not designed for high-speed monospiral crane reeling; select a dedicated reeling cable.

NSHTOU Reeling Cable

Typical machinesRenewable Energy & EV ChargingHigh-Voltage Grid & Substation InterconnectsWind, Solar & Hydro Power EvacuationUtility Overhead & Underground DistributionIndustrial Power Infrastructure

Construction

Layer by layer

Shown: HVDC XLPE (CIGRE TB 496 / CIGRE TB 852 / IEC 62895) with stranded copper conductor, inner water-swellable tape and hdpe outer sheath (8-layer construction).

Schematic, not to scale — generated from the layer data

#	Layer	Material & reference
1	Stranded copper conductor	High-conductivity copper conductor per CIGRE TB 496 / CIGRE TB 852 / IEC 62895CIGRE TB 496 / CIGRE TB 852 / IEC 62895
2	Inner water-swellable tape	Inner water-swellable tape (lapped tape)CIGRE TB 496 / CIGRE TB 852 / IEC 62895
3	Inner semiconducting screen	Extruded Inner semiconducting screen stress-control layerCIGRE TB 496 / CIGRE TB 852 / IEC 62895
4	Low-peroxide XLPE core insulation	Extruded Low-peroxide XLPE dielectric (continuous layer)CIGRE TB 496 / CIGRE TB 852 / IEC 62895
5	Outer semiconducting screen	Extruded Outer semiconducting screen stress-control layerCIGRE TB 496 / CIGRE TB 852 / IEC 62895
6	Water-swellable barrier tapes	Helically applied water-swellable barrier tapesCIGRE TB 496 / CIGRE TB 852 / IEC 62895
7	Longitudinally welded aluminium sheath	Helically applied longitudinally welded aluminium sheathCIGRE TB 496 / CIGRE TB 852 / IEC 62895
8	HDPE outer sheath	Extruded HDPE outer sheath protective layer (continuous layer)CIGRE TB 496 / CIGRE TB 852 / IEC 62895

HVDC XLPE — Standard Execution

Built to CIGRE TB 496 / CIGRE TB 852 / IEC 62895 with stranded copper conductor and hdpe outer sheath

HVDC XLPE — Custom Cross-Sections

Full range of metric mm² and AWG/kcmil conductor sizes per CIGRE TB 496 / CIGRE TB 852 / IEC 62895

HVDC XLPE — Export Drum Supply

Supplied with EN 10204 3.1 routine dielectric & conductor resistance test certificate

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on CIGRE TB 496 / CIGRE TB 852 / IEC 62895. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage / duty: ±320 kV – ±525 kV DC (CIGRE TB 496 / CIGRE TB 852 / IEC 62895)
Conductor construction: Stranded copper conductor — High-conductivity copper conductor per CIGRE TB 496 / CIGRE TB 852 / IEC 62895
Primary insulation / dielectric: Inner water-swellable tape — Inner water-swellable tape (lapped tape)

Thermal

Continuous operating temperature: −25…+90 °C per CIGRE TB 496 / CIGRE TB 852 / IEC 62895
Short-circuit / peak thermal limit: +160 °C to +250 °C (5 s adiabatic limit depending on dielectric class)
Minimum installation temperature: −5 °C (thermoplastic) / −25 °C (cross-linked or elastomer) / −40 °C (metallic)

Mechanical

Outer protection / covering: HDPE outer sheath — Extruded HDPE outer sheath protective layer (continuous layer)
Minimum bending radius: 20 × OD (installed / static routing)
Layer count & geometry: 8 concentric/structural layers verified by cross-section inspection

Resistance

Environmental & chemical durability: Engineered for industrial service in accordance with CIGRE TB 496 / CIGRE TB 852 / IEC 62895
RoHS & REACH compliance: RoHS 2 (2011/65/EU + 2015/863) & REACH SVHC compliant

Reference standards

Governing product standard: CIGRE TB 496 / CIGRE TB 852 / IEC 62895
Quality management & inspection: ISO 9001:2015 & EN 10204 3.1 factory routine inspection

Identification

Model designation: HVDC XLPE
Customs tariff (HS): 8544.49 / 8544.60 / 7614.10

Sizes

12 standard HVDC XLPE cable sizes

Manufactured to CIGRE TB 496 / CIGRE TB 852 / IEC 62895 across standard single-core and multi-core cross-sections.

Dimensions, construction & weights
Order designation	Configuration	Outer Ø ≈ mm	Weight ≈ kg/km	Min. bend R fixed mm
HVDC XLPE Standard Production Schedule (±320 kV – ±525 kV DC · −25…+90 °C)
HVDC XLPE 3G1.5	3 × 1.5 mm²	8.4	105	68
HVDC XLPE 4G1.5	4 × 1.5 mm²	9.2	128	74
HVDC XLPE 5G1.5	5 × 1.5 mm²	10.1	156	81
HVDC XLPE 3G2.5	3 × 2.5 mm²	9.8	148	78
HVDC XLPE 4G2.5	4 × 2.5 mm²	10.8	186	86
HVDC XLPE 5G2.5	5 × 2.5 mm²	11.9	228	95
HVDC XLPE 4G4	4 × 4.0 mm²	12.6	268	101
HVDC XLPE 4G6	4 × 6.0 mm²	14.2	365	114
HVDC XLPE 4G10	4 × 10 mm²	17.5	580	140
HVDC XLPE 4G16	4 × 16 mm²	20.4	845	163
HVDC XLPE 4G25	4 × 25 mm²	24.8	1,290	198
HVDC XLPE 4G35	4 × 35 mm²	27.9	1,710	223

Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
Single-core and multi-core sizes from 0.5 mm² up to 630 mm² (or AWG/kcmil) available per CIGRE TB 496 / CIGRE TB 852 / IEC 62895.

Conductor resistance & current-carrying capacity
Cross-section	Max. DC R₂₀ Ω/km	Current in air A (30 °C) ≈	Voltage drop mV/A·m
1.5 mm² (AWG 16)	13.30	18	29.0
2.5 mm² (AWG 14)	7.98	26	17.5
4.0 mm² (AWG 12)	4.95	34	10.9
6.0 mm² (AWG 10)	3.30	44	7.3
10 mm² (AWG 8)	1.91	61	4.2
16 mm² (AWG 6)	1.21	82	2.7
25 mm² (AWG 4)	0.78	108	1.7
35 mm² (AWG 2)	0.55	135	1.2

Current ratings are for 3 loaded conductors at 30 °C ambient in free air/tray per IEC 60364-5-52 / NEC.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

ConductorClass 5 stranding
Spark test100 % in-line
Lay-upCores, earth, fillers
SheathingInner, braid / screen, outer
Electrical testsAC voltage, resistance
DimensionsOD, wall thickness
Inspection documents & dispatchDrum & dispatch

Testing & inspection	Test value / reference	Frequency
Routine tests
Conductor DC resistance & dimensional verification (CIGRE TB 496 / CIGRE TB 852 / IEC 62895)	DC resistance at 20 °C and geometry within CIGRE TB 496 / CIGRE TB 852 / IEC 62895 class limits	Every manufactured drum / spool
Routine dielectric / spark / structural integrity test (CIGRE TB 496 / CIGRE TB 852 / IEC 62895)	Zero breakdown or structural defect over full production length	Every manufactured drum / spool
Sample tests
Thermal aging, mechanical & material qualification (CIGRE TB 496 / CIGRE TB 852 / IEC 62895)	Full compliance with CIGRE TB 496 / CIGRE TB 852 / IEC 62895 across −25…+90 °C	Type qualification & periodic sample audit

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

CIGRE TB 496 CompliantEN 10204 3.1 Routine Test CertificateCE, RoHS 2 (2011/65/EU) & REACH

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HVDC XLPE <size> CIGRE TB 496 ±320 kV – ±525 kV DC CE

Delivery form: Non-returnable fumigated wooden drums or precision DIN spools
Standard lengths: 500 m · 1000 m · 2000 m drums (custom cut lengths on request)
MOQ: 500 m (stock sizes) · 1000 m (custom production)
Lead time: 2–4 weeks ex-works
Incoterms: EXW, FCA, FOB, CIF, DAP

Technical documents

Downloads

PDF±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage – technical datasheet12 sizes · construction, technical data, approvals XLSXHVDC XLPE spec data (Excel)All 12 sizes with dimensions and data, for your BOM or quotation

Revision: 2026-10-21
Updated: 2026-10-21

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

What governing standard and construction define HVDC XLPE (±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage Direct-Current (HVDC) Cable)?

HVDC XLPE (±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage Direct-Current (HVDC) Cable) is manufactured in accordance with CIGRE TB 496 / CIGRE TB 852 / IEC 62895 for ±320 kV – ±525 kV DC service over -25 °C to +90 °C. Its 8-layer construction comprises stranded copper conductor, inner water-swellable tape, inner semiconducting screen, low-peroxide xlpe core insulation, outer semiconducting screen, water-swellable barrier tapes, longitudinally welded aluminium sheath, hdpe outer sheath.

What is the minimum bending radius and installation temperature for HVDC XLPE?

The minimum installed bending radius for HVDC XLPE is 20 × OD across its continuous operating temperature range of -25 °C to +90 °C, ensuring mechanical and dielectric stability without conductor or insulation strain.

How are the concentric layers of HVDC XLPE arranged from inside to outside?

From inside to outside, the construction sequence is: (01) Stranded copper conductor (High-conductivity copper conductor per CIGRE TB 496 / CIGRE TB 852 / IEC 62895); (02) Inner water-swellable tape (Inner water-swellable tape (lapped tape)); (03) Inner semiconducting screen (Extruded Inner semiconducting screen stress-control layer); (04) Low-peroxide XLPE core insulation (Extruded Low-peroxide XLPE dielectric (continuous layer)); (05) Outer semiconducting screen (Extruded Outer semiconducting screen stress-control layer); (06) Water-swellable barrier tapes (Helically applied water-swellable barrier tapes); (07) Longitudinally welded aluminium sheath (Helically applied longitudinally welded aluminium sheath); (08) HDPE outer sheath (Extruded HDPE outer sheath protective layer (continuous layer)).

What factory test certificates are supplied with HVDC XLPE?

Every production drum or spool of HVDC XLPE undergoes routine conductor DC resistance, dimensional and dielectric/integrity testing per CIGRE TB 496 / CIGRE TB 852 / IEC 62895, and is delivered with an EN 10204 3.1 factory test certificate.

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Your selection and application details are copied into the enquiry form below.

01Selected sizes

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02Reel & motion

Add your operating conditions here to include them in your enquiry.

Reel typeDrum core diameter (mm)Cable length on drum (m)Travel speed (m/min)Max. accelerationCycles per hourLength and quantityAmbient temperatureExposure (outdoor, water, oil, abrasion)Destination countryEquipment and operating conditions

03Message for our engineers

HVDC XLPE ±525 kV Extruded DC-XLPE Insulated Copper Land High-Voltage Cable

Selected sizes:


Reel & motion:
- Reel type: 
- Drum core diameter (mm): 
- Cable length on drum (m): 
- Travel speed (m/min): 
- Max. acceleration: 
- Cycles per hour: 
- Length and quantity: 
- Ambient temperature: 
- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
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