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For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?

2025-09-12

1. Nylon (Polyamide) Wheel Pulleys

Pros
- Lightweight → easy to transport & install.
- Smooth surface → less risk of conductor/OPGW sheath damage.
- Good electrical insulation (no induction heating risk).
- Often used with rubber or polyurethane lining for extra protection.
Cons
- Lower load capacity than aluminum/steel.
- Wears faster in rough, rocky, or dusty environments.
Best For
- OPGW / ADSS / fiber optic cables.
- AAC / AAAC / small ACSR conductors.
- Distribution and sub-transmission lines (≤220 kV).

2. Aluminum Wheel Pulleys

Pros
- Stronger than nylon, but still lightweight.
- Good wear resistance.
- Can handle higher loads and longer spans.
- Can be lined with rubber/nylon for conductor protection.
Cons
- Conductive → can cause eddy current heating if energized accidentally.
- Slightly higher cost than nylon.
Best For
- ACSR/AAAC conductors in transmission lines.
- Long-span pulls where higher tension is expected.
- EHV/UHV projects (220–500 kV) with bundle conductors.

3. Steel Wheel Pulleys

Pros
- Very strong → suitable for heavy conductors and long spans.
- High resistance to mechanical wear and impact.
- Can be rubber-lined to protect conductor sheath.
Cons
- Heavy → harder to transport & install.
- If not lined, can damage conductor or OPGW.
- Needs corrosion protection (galvanized or painted).
Best For
- Large ACSR/ACSS/EHV conductors.
- River crossings, long-span mountain projects.
- Bundle conductor stringing (with multiple sheaves).

4. How to Choose (Step by Step)

Check conductor type
- Optical (OPGW/ADSS) → Nylon with smooth/rubber lining.
- Standard ACSR/AAAC → Nylon (light duty) or Aluminum (heavy duty).
- Heavy EHV/UHV conductors → Aluminum or Steel (rubber-lined).
Check conductor size & weight
- Small/medium (<30 mm OD) → Nylon.
- Medium/large (30–40 mm OD) → Aluminum.
- Extra large (>40 mm OD) → Steel or Aluminum heavy-duty.
Check span length & pulling tension
- Short spans (≤500 m) → Nylon is fine.
- Long spans (500–1500 m) → Aluminum preferred.
- Extra-long spans (river crossings, >1500 m) → Steel required.
Check environment
- Dusty/rocky → Aluminum or steel (nylon wears quickly).
- Marine/coastal → Aluminum (corrosion-resistant) or stainless-lined pulleys.

5. Practical Guidelines

Always match pulley groove radius ≥ 1.5 * conductor diameter (to reduce sidewall pressure).
For bundle conductors → use bundle pulleys with 2/3/4 wheels.
For OPGW/ADSS → never use steel directly; always nylon or lined aluminum.
Always use pulleys with sealed bearings for smooth rotation.

Rule of Thumb

Nylon wheel → Light conductors, OPGW, ADSS, short span projects.
Aluminum wheel → Standard conductors, long spans, EHV/UHV.
Steel wheel → Heavy conductors, river/mountain crossings, extreme loads.

Blog Details

Home Blog

For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?

1. Nylon (Polyamide) Wheel Pulleys

Pros
- Lightweight → easy to transport & install.
- Smooth surface → less risk of conductor/OPGW sheath damage.
- Good electrical insulation (no induction heating risk).
- Often used with rubber or polyurethane lining for extra protection.
Cons
- Lower load capacity than aluminum/steel.
- Wears faster in rough, rocky, or dusty environments.
Best For
- OPGW / ADSS / fiber optic cables.
- AAC / AAAC / small ACSR conductors.
- Distribution and sub-transmission lines (≤220 kV).

2. Aluminum Wheel Pulleys

Pros
- Stronger than nylon, but still lightweight.
- Good wear resistance.
- Can handle higher loads and longer spans.
- Can be lined with rubber/nylon for conductor protection.
Cons
- Conductive → can cause eddy current heating if energized accidentally.
- Slightly higher cost than nylon.
Best For
- ACSR/AAAC conductors in transmission lines.
- Long-span pulls where higher tension is expected.
- EHV/UHV projects (220–500 kV) with bundle conductors.

3. Steel Wheel Pulleys

Pros
- Very strong → suitable for heavy conductors and long spans.
- High resistance to mechanical wear and impact.
- Can be rubber-lined to protect conductor sheath.
Cons
- Heavy → harder to transport & install.
- If not lined, can damage conductor or OPGW.
- Needs corrosion protection (galvanized or painted).
Best For
- Large ACSR/ACSS/EHV conductors.
- River crossings, long-span mountain projects.
- Bundle conductor stringing (with multiple sheaves).

4. How to Choose (Step by Step)

Check conductor type
- Optical (OPGW/ADSS) → Nylon with smooth/rubber lining.
- Standard ACSR/AAAC → Nylon (light duty) or Aluminum (heavy duty).
- Heavy EHV/UHV conductors → Aluminum or Steel (rubber-lined).
Check conductor size & weight
- Small/medium (<30 mm OD) → Nylon.
- Medium/large (30–40 mm OD) → Aluminum.
- Extra large (>40 mm OD) → Steel or Aluminum heavy-duty.
Check span length & pulling tension
- Short spans (≤500 m) → Nylon is fine.
- Long spans (500–1500 m) → Aluminum preferred.
- Extra-long spans (river crossings, >1500 m) → Steel required.
Check environment
- Dusty/rocky → Aluminum or steel (nylon wears quickly).
- Marine/coastal → Aluminum (corrosion-resistant) or stainless-lined pulleys.

5. Practical Guidelines

Always match pulley groove radius ≥ 1.5 * conductor diameter (to reduce sidewall pressure).
For bundle conductors → use bundle pulleys with 2/3/4 wheels.
For OPGW/ADSS → never use steel directly; always nylon or lined aluminum.
Always use pulleys with sealed bearings for smooth rotation.

Rule of Thumb

Nylon wheel → Light conductors, OPGW, ADSS, short span projects.
Aluminum wheel → Standard conductors, long spans, EHV/UHV.
Steel wheel → Heavy conductors, river/mountain crossings, extreme loads.

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Blog Details

For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?

For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?

For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?

For stringing cable pulley,we have nylon wheel and aluminum wheel,steel wheel,how to choose?