Cables for Airport Infrastructure: Technical Requirements Explained

By JianYunCable -

 


Table of Contents

  1. Overview of Airport Cable Requirements
  2. Types of Cables Used in Airport Infrastructure
  3. Key Technical Specifications
  4. Regulatory and Compliance Standards
  5. Practical Considerations for Cable Selection
  6. Challenges and Solutions
  7. Conclusion

1. Overview of Airport Cable Requirements 

Airports require cables for diverse applications, including runway lighting, terminal power supply, ground support equipment, and communication systems. These cables must:

  • Withstand Environmental Stress: Resist UV radiation, extreme temperatures (-40°C to 90°C), moisture, and jet fuel exposure.
  • Ensure Safety: Incorporate flame-retardant and low-smoke zero-halogen (LSZH) properties to minimize fire risks in crowded terminals.
  • Support High Reliability: Deliver consistent power (e.g., 0.6/1 kV to 35 kV) and data transmission for critical systems like air traffic control.
  • Comply with Standards: Meet aviation-specific standards (e.g., FAA AC 150/5345-7F) and international regulations (e.g., IEC 60502-1, EN 50575).
    Cables must also be durable for a lifespan of 20–30 years and flexible for installation in complex airport layouts.

2. Types:both Types of Cables Used in Airport Infrastructure 

Airports utilize several cable types tailored to specific applications:

2.1. Airfield Lighting Cables (AFLCs)

  • Description: Primary and secondary cables for runway, taxiway, and approach lighting systems.
  • Features:
    • Conductors: Copper, Class 2 or 5 per IEC 60228 for flexibility.
    • Insulation: Cross-linked polyethylene (XLPE) or ethylene propylene rubber (EPR) for high dielectric strength.
    • Sheathing: UV-resistant PVC or LSZH for safety.
    • Voltage: 5 kV for primary circuits, 600 V for secondary circuits.
  • Applications: Powering runway edge lights, threshold lights, and guidance signs.
  • Example: Jianyun Cable’s FAA-compliant 5 kV AFLCs with XLPE insulation for reliable airfield performance.

2.2. Power Cables

  • Description: Medium- and low-voltage cables for terminal buildings, ground support, and backup systems.
  • Features:
    • Conductors: Copper or aluminum, stranded for flexibility.
    • Insulation: XLPE or PVC for temperature resistance (up to 90°C).
    • Armoring: Steel wire (SWA) or tape for mechanical protection in underground ducts.
    • Voltage: 0.6/1 kV for low-voltage, 11–35 kV for medium-voltage distribution.
  • Applications: Power supply for terminals, baggage systems, and HVAC.
  • Example: Jianyun Cable’s SWA-armored 11 kV XLPE cables for robust airport power distribution.

2.3. Control and Instrumentation Cables

  • Description: Multi-core cables for control systems, sensors, and automation.
  • Features:
    • Conductors: Fine-stranded copper (Class 5) for flexibility.
    • Shielding: Braided copper or foil to reduce electromagnetic interference (EMI).
    • Sheathing: LSZH or PUR for fire safety and durability.
    • Voltage: 300/500 V or 0.6/1 kV.
  • Applications: Control of lighting, security systems, and baggage handling.
  • Example: Jianyun Cable’s shielded LSZH control cables for reliable signal transmission.

2.4. Communication and Data Cables

  • Description: Cables for high-speed data, voice, and network connectivity.
  • Features:
    • Conductors: Twisted pair or coaxial copper for signal integrity.
    • Insulation: Polyethylene (PE) or fluorinated ethylene propylene (FEP) for low capacitance.
    • Shielding: Foil or braid for EMI protection.
    • Sheathing: LSZH for fire safety in terminal environments.
  • Applications: Airport Wi-Fi, air traffic control, and passenger information systems.
  • Example: Jianyun Cable’s Cat6 LSZH data cables for high-speed airport networks.

3. Key Technical Specifications 

Cables for airport infrastructure must meet specific technical requirements to ensure performance and safety:

  • Electrical Performance:
    • Voltage Ratings: 600 V to 5 kV for AFLCs, 0.6/1 kV to 35 kV for power cables, 300/500 V for control cables.
    • Insulation Resistance: >1000 MÎİ/km at 20°C to prevent leakage.
    • Voltage Drop: <1.5% for power efficiency (e.g., 4 mm² copper for 15 A over 50 m).
  • Environmental Resistance:
    • Temperature Range: -40°C to 90°C, with short-circuit tolerance up to 250°C (5 seconds).
    • UV Resistance: 720-hour exposure per EN 50618 for outdoor cables.
    • Moisture Resistance: Sealed insulation to prevent water ingress.
  • Mechanical Durability:
    • Bending Radius: 4–6 times cable diameter for flexible installation.
    • Tensile Strength: ≥50 N/mm² for copper conductors to withstand pulling.
    • Abrasion Resistance: PUR or LSZH sheathing for high-wear areas.
  • Fire Safety:
    • Flame-Retardant: Complies with IEC 60332-3 for bundled cables.
    • LSZH Properties: Meets IEC 60754-1 and IEC 61034 for low smoke and toxicity.
SpecificationDetails
Voltage Ratings300 V to 35 kV, application-dependent
Insulation Resistance>1000 MÎİ/km at 20°C
Temperature Range-40°C to 90°C
UV Resistance720-hour exposure (EN 50618)
Fire SafetyIEC 60332-3, LSZH per IEC 60754-1

4. Regulatory and Compliance Standards 

Airport cables must comply with international and aviation-specific standards to ensure safety and reliability:

  • IEC 60502-1: Low-voltage power cables (0.6/1 kV) with XLPE or PVC insulation.
  • IEC 60228: Conductor classes (Class 2 or 5) for flexibility and low resistance.
  • IEC 60332-3: Flame-retardant properties for bundled cables.
  • IEC 60754-1/IEC 61034: LSZH requirements for low smoke and toxicity.
  • FAA AC 150/5345-7F: US standard for airfield lighting cables (5 kV primary, 600 V secondary).
  • EN 50575: European standard for power, control, and communication cables in construction.
  • RoHS/REACH: Restriction of hazardous substances, mandatory in EU-influenced markets.
  • ISO 9001: Ensures consistent manufacturing quality, as upheld by Jianyun Cable.

5. Practical Considerations for Cable Selection 

Selecting cables for airport infrastructure requires careful consideration of:

  • Application Requirements:
    • Use 5 kV AFLCs for runway lighting, 11 kV armored cables for power distribution.
    • Select LSZH cables for terminals to ensure passenger safety.
  • Environmental Conditions:
    • Choose UV-resistant XLPE or PUR cables for outdoor areas (e.g., tarmacs).
    • Use moisture-resistant insulation for underground ducts or wet environments.
  • Installation Needs:
    • Opt for flexible Class 5 conductors for complex routing in terminals.
    • Maintain bending radii (4–6D) to prevent insulation damage.
  • Safety and Compliance:
    • Prioritize IEC 60332-3 and LSZH-compliant cables for fire safety.
    • Verify certifications (e.g., TUV, UL) for global market compliance.
  • Supplier Reliability:
    • Partner with manufacturers like Jianyun Cable, offering TUV-certified, FAA-compliant cables with proven performance, as showcased at Elektro 2025 in Moscow.

6. Challenges and Solutions 

ChallengeSolution
Fire Safety in TerminalsUse LSZH cables (IEC 60754-1) to minimize smoke and toxicity.
Harsh Environmental ConditionsSelect XLPE or PUR cables for UV, moisture, and temperature resistance.
Complex InstallationsUse flexible Class 5 conductors and IP67 connectors (e.g., MC4).
Regulatory CompliancePartner with Jianyun Cable for TUV, FAA, and IEC-certified cables.
High Certification CostsUse dual-certified cables (e.g., TUV/IEC) to cover multiple markets.

7. Conclusion 

Cables for airport infrastructure, including airfield lighting, power, control, and communication cables, must meet stringent technical requirements for electrical performance, environmental resistance, mechanical durability, and fire safety. Compliance with standards like IEC 60502-1, FAA AC 150/5345-7F, and IEC 60332-3 ensures reliability and safety in critical applications. Henan Province Jianyun Cable Co., Ltd. offers a range of TUV-certified, LSZH, and XLPE-insulated cables tailored for airports, ensuring durability and compliance. By selecting cables based on application, environment, and regulatory needs, and partnering with reputable suppliers, airport projects can achieve reliable performance and safety for 20–30 years.

Source: JianYunCable.

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