ROLL FORM STRANDER PROCESS

1600-2240MM

300 mm2 (600 kcm) compact strand at 240 m/min (800 ft/
min) line speed up to 1200 tpm
The Roll Form Stranding process combines the advantages of two
highly productive processes, namely: Roll Forming and Double
Twist Stranding. These two systems are forged together to create
One High Speed Continuous Manufacturing Cell.

We Enable Innovation
 ROLL FORM STRANDER PROCESS
1600-2240MM

Model Reel Size Reel Capacity Finished Product Size Ranges Twist Rate
(Dia*OAW) Copper
ACSR Aluminum
Copper Aluminum Cabling Max. Speed
Max.
Max. Max.
Stranding Max. Stranding Max. Max. (Note #1)
mm mm in Kg lb Kg lb mm2 AWG mm2 AWG mm2 AWG mm/in tpm
1600 1600 63 7800 17200 2400 5200 100 4/0 120 250kcm 240 500kcm 27/1.06 1200
1800 1800 71 10200 22500 3100 6800 100 4/0 185 350kcm 240 500kcm 27/1.06 1200
2000 2000 79 14000 31000 4200 9300 100 4/0 240 500kcm 300 600kcm 33/1.30 1000
2240 2240 88 16000 35000 6000 13200 100 4/0 240 500kcm 300 600kcm 33/1.30 1000

Fig 1 Note #1 Max. Speeds listed are machine limits. Product performance speeds subject to product limitations.

The Ceeco Bartell Roll Form Strander with its patented roll Fig 2 shows clearly the ability of the process to operate at
forming system produces compact conductors with full speed whilst producing 150 mm2 (300 kcm)
maximum productivity, when compared to conventional
methods.

$
Capital Cost/

$
Twist

$ $ $
Double Twist Tubular Central Rigid Planetary
Strander Strander Strander Strander Strander
Double Twist Rigid Planetary
Factors Strander Tubular Strander Central Strander Strander Strander
Capital Cost/Twist 1 3–5 7–9 9–12 16–24
“Working Significant Almost none Significant Significant Almost none
factor” (Rigid) (Planetary) (Rigid) (Rigid) (Planetary)
Lay limitations Unilay only n/a None None None
Layer limitations Up to 4 layers 2 layer None None None
Typical payoff Stem Bobbin Stem Bobbin Bobbin
package
Required Required Required
Payoff mode Continuous Semi-Continuous
loading cycle loading cycle loading cycle

GRAPHICAL COMPARISON OF CONVENTIONAL DOUBLE TWIST METHODS

Fig 2
General
The Roll Form Strander program covers
machines designed to accommodate
reels up to 2240mm (84in). The scope
of the products that can be
manufactured includes:
• Copper and aluminum stranded
conductors between #8 AWG and
600 kcm or 10 mm2 and 300 mm2
• The process is capable of
manufacturing bunched conductors to
compact strand with Fill Factors
between 76% and 97%
• Aluminum Conductors Steel
Reinforced (ACSR) using a single steel
wire core
• All Aluminum and Aluminum alloy
Conductors (AAC & AAAC) 1800mm Roll Form Strander
• Cabling of insulated conductors
Typical performance is high lighted in with stranding of wires using the same By incorporating a Single Input Wire diameter
Fig 1 and Fig 2 wire diameter for a wide range of program into the strand design, significant
cross sections. savings can be achieved:
The machine is an “outside/in” Single Input Wire (SIW) diameter meets
• Higher productivity at stranding machine
configuration with bow, capstan, take- the acceptance of the world’s major
up, traverse and loading platform. conductor standards such as IEC • Higher productivity in wire drawing
60228, HD 383 and the ASTM • Lower drawn wire scrap
Depending on the strand design, up to standards. Ceeco Bartell’s Roll Form • Lower insulating Costs
4 layers of roll forming strand are Strander is the worlds only process
• Improved return on investment
needed. Each roll stand is driven which fully utilizes the advantages of
individually allowing slight changes in Single Input Wire diameter. • Quicker set-up
speed to be made at each position to • Reduced work in process
compensate for the variances in the • Shorter cycle times
spiral length. It further allows more
precise distributions of wire tension in • Smaller input wire storage area
each layer optimizing the straightness
of the resulting conductor.

The machine is a side loading unit and

is equipped with a standard floor
loader designed to load and unload the
take-up reel with minimum operator
effort.

Single Input
Wire (SIW)
Single Input Wire (SIW) diameter
represents a strand design mentality
and manufacturing methodology that
effectively reduces the conversion cost
from rod to strand without
compromising conductor performance.

This concept can be achieved by

replacing the traditional stranding of
wires using different wire diameters 1800mm Roll Form Strander front view
 ROLL FORM STRANDER PROCESS
1600-2240MM

Roll Form System

The Roll Form Strander is equipped
with an external roll form system. The
objective of this system is to present
to the strander the material in the
optimum format depending on the
desired strand construction.

This roll form system can be as simple

as a two layer ( ie: 1+6 ) construction
or as intricate as a five layer
( ie: 1+6+12+18+24 ) construction.
The scope of the strand design
determines the application Profile grooves of the top and bottom rollers.
configuration.

PROCESS STEPS
MANY DESIGNS ARE AVAILABLE
Double Twist Roll Forming Coil Payoff
FOR EACH LAYER:
(a) Roll forming of the input wires.
This is achieved with a driven roll
stand shaping each wire in a layer.

(b) Round wire layers where a

number of round wires are closed
without any change in section. The
“S” roll metering system is used in
this instance.

Assembly into
compact conductor Roll Formed Profiles Round Wire

Payoffs
The stem payoff or the large static
spooler packages are the packages of
choice allowing up to 1000 kg
(2000lb) of aluminum or 3000 kg
(6000 lb) of copper conductor material
to be staged behind the Roll Form
Strander. The stem package allows
continuous operation and is the pre-
ferred solution especially when the
SIW philosophy is an integral part of
the manufacturing process.
Compressed SIW Schedule Compact SIW Schedule
( Copper and Aluminum ) ( Copper and Aluminum )

IMPERIAL SCHEDULE METRIC SCHEDULE IMPERIAL SCHEDULE METRIC SCHEDULE

WE ENABLE INNOVATION
Bartell Machinery Systems is a global leader in providing highly-engineered industrial manufacturing equipment for the
Tire & Rubber, Oil & Gas, and Wire & Cable industries. An ISO 9001:2008 certified company, Bartell has delivered innovative
solutions to leading manufacturers since our founding in 1940, with over 8,500 machines now installed worldwide. We
offer the industry’s most advanced and proven tire bead machinery, systems for producing subsea oil & gas flexible pipe,
and innovative wire & cable machines. Our products are fully designed and rigorously tested to optimize safety, production
efficiency, operational reliability, and maximized asset life cycle. We pride ourselves upon setting new standards for
quality, performance and value in every machine we build. With generations of industry knowledge and engineering design
experience coupled with our world-class sales and technical service network, Bartell’s employees are dedicated to providing
you with state-of-the-art technologies capable of meeting your most advanced production needs.

Tire & Rubber Wire & Cable Oil & Gas

For over 70 years Bartell has
been the preeminent supplier of
machines to the world’s leading
tire manufacturers that optimize
tire quality, safety, productivity
and cost efficiency. Our machine
systems continue to drive the
technological changes and
breakthroughs in component
preparation and assembly
that have shaped the modern
tire industry. With particular
expertise on the core tire-wheel
interface or bead area, Bartell
has led the way generation after
generation developing features
and characteristics that allow
tire designers to expand their
technologies. Through research,
development and an intimate
process understanding, Bartell
enables the industry to deliver
the highest performance and
quality demanded by today’s tire
consumers.
From advanced fibre optic
and LAN cable production to
high speed manufacture of
energy cables, Bartell range
of Ceeco branded wire &
cable products have been at
the forefront of technologies
that cut costs, expand data
signal rates and allow higher
transmission frequencies to
speed communications and
power to all corners of the
globe. Advances in power cable
manufacturing via Bartell’s
Roll Form Stranding machines,
increase cable production rates
up to five times over traditional
methods, while reducing costs
in both drawing operations
and insulating materials. Our
design expertise, in-depth
process understanding and
product development allow
Bartell’s customers to optimize
their product quality, reduce
manufacturing costs and
improve competitiveness.
Bartell’s Ceeco products are
found at the heart of factories
worldwide producing flexible
risers and umbilicals for the
offshore oil and gas industry,
including some of the world’s
largest systems for Tensile
Armouring, Flexlock and Carcass
production. Our commitment
to research and development
pushes the envelope for subsea
flexibles capable of withstanding
water depths beyond 3,000
meters. Bartell has additionally
developed successful
technology for making onshore
flexible pipelines on-location
reducing time, labor and
shipping costs. We are focused
on delivering leading-edge
technologies that allow our
customers to succeed in the
newest frontiers of oil and
gas production.
WE ENABLE INNOVATION
Ceeco Bartell provides manufacturing solutions to the wire,
cable, & pipe industries with a comprehensive range of products
and services worldwide.

Ceeco Bartell Products

400 Applewood Crescent • Suite 100
Vaughan, Ontario, Canada, L4K 0C3
We Enable Innovation Tel 1.905.761.2993
Fax 1.315.336.0947
www.ceecobartell.com

Bartell Machinery Systems Limited

1 Pearson Road, Central Park • Telford TF2 9TX – England
44-1-952-201 291 Fax 44-1-952-201 083
Email: sales@bartellmachinery.co.uk • www.bartellmachinery.com
Corporate Headquarters
6321 Elmer Hill Road Tel 315.336.7600 Website www.bartellmachinery.com
Rome, New York 13440-9325, USA Fax 315.336.0947 Email sales@bartellmachinery.com