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The Kaliwa Dam Project is a flagship infrastructure initiative in the Philippines, designed to address water supply demands and provide flood control. During the tunnel excavation phase, the project relies heavily on Tunnel Boring Machines (TBMs). The harsh underground environment—characterized by high humidity, confined spaces, and continuous heavy machinery movement—places extreme demands on the electrical power supply system.
Zhongdong Cable Manufacture Co., Ltd. was selected as the cable supplier to provide reliable power and lighting solutions for the TBM tunnel secondary power system.
Supplying cables for TBM tunneling is not a standard application. The project faced several critical challenges:
Fire Safety in Confined Spaces: Tunnels are enclosed environments. Any electrical fault or spark poses a severe fire risk. The cables required high-level flame retardancy to ensure worker safety.
Mechanical Stress & Flexibility: TBM equipment moves frequently, meaning the power cables are subjected to constant dragging, bending, and mechanical vibration. The cables needed excellent flexibility and durable outer sheaths.
Corrosive & Humid Atmosphere: The underground environment is highly humid with potential water seepage, requiring cables with superior moisture resistance.
Strict Delivery Schedule: A massive quantity of over 34,000 meters was required to keep the project on track without delays.
To meet the rigorous demands of the Kaliwa Dam project, Zhongdong Cable supplied customized Cu/XLPE/PVC Flame-Retardant cables.
1. Power Supply Cable (5-Core Configuration)
IEC Specification: 0.6/1kV Cu/XLPE/PVC 3×50 mm² + 2×25 mm² (Flame Retardant)
Design: The 5-core configuration (3 phase conductors + 1 neutral + 1 PE ground) provided a compact and highly efficient wiring solution for the heavy-duty TBM equipment, ensuring both power transmission and safety grounding in a single cable run.
2. Tunnel Lighting Cable (2-Core Configuration)
IEC Specification: 0.6/1kV Cu/XLPE/PVC 2×25 mm² (Flame Retardant)
Design: Specifically tailored for the secondary lighting circuits along the tunnel, ensuring stable visibility and safe working conditions for the crew.
Key Technical Advantages:
Flame Retardant Property: Compliant with IEC 60332-3 (equivalent to Class C flame retardant). The specialized PVC outer sheath prevents flame propagation, significantly reducing fire hazards in the enclosed tunnel.
High Conductivity: High-purity annealed copper conductors (Class 2 stranded) ensure minimal voltage drop and stable power for high-load TBM operations.
Excellent Flexibility: The optimized stranding process ensures the cables can withstand the continuous mechanical stress and bending of TBM trailing cables.
| Item No. | Application | IEC Cable Specification | Core Configuration | Quantity |
|---|---|---|---|---|
| 1 | TBM Secondary Power Supply | 0.6/1kV Cu/XLPE/PVC 3×50+2×25 mm² (FR) | 5-Core (with N & PE) | 17,210 meters |
| 2 | TBM Secondary Lighting | 0.6/1kV Cu/XLPE/PVC 2×25 mm² (FR) | 2-Core | 17,210 meters |
(Note: "FR" stands for Flame Retardant. The original Chinese standard specification is ZC-YJV-0.6/1kV. All cables comply with IEC 60502-1 standard.)
Zhongdong Cable successfully manufactured and delivered a total of 34,420 meters of specialized cables for this international project. All products underwent strict factory acceptance tests (FAT), including conductor resistance tests, insulation withstand voltage tests, and flame retardant tests, fully complying with international standards.
From standard electrical installations to highly demanding environments like subways, tunnels, and mining, Zhongdong Cable provides tailored solutions. We combine advanced manufacturing capabilities with strict quality control to support global engineering projects.
Need heavy-duty cables for your next tunneling or infrastructure project?
Contact us today with your specifications for a professional technical proposal and competitive quotation.
“Zhongdong Cable's flame-retardant cables for the Kaliwa Dam Project performed well. Products met IEC standards, suited the TBM tunnel conditions, and the 34,420 meters were delivered on schedule. Professional support and qualified products. Satisfied and willing to continue cooperation.”
CU/XLPE/PVC Single Core Power Cable 0.6/1kVZhongdong Cable combines premium raw materials, large-scale manufacturing capabilities, and strict quality control systems to deliver cable products that fully match your technical requirements and brand identity.
