Aluminium-Copolymer
Hermetic moisture barrier and mechanical protection for power and telecom cables
Aluminium-Copolymer
The aluminium-copolymer tape (AL/PE) combines an aluminium foil with a heat-activated copolymer coating on one or both sides. This structure delivers a hermetic barrier against moisture and chemical agents, while the copolymer bonds directly to the cable jacket during the extrusion process, forming a composite protection layer that integrates shield and jacket in a single sealed system.
In power and fibre-optic cables, aluminium-copolymer acts simultaneously as a moisture barrier, an electromagnetic shield and — depending on aluminium thickness — as a return path for short-circuit currents. The copolymer forms a chemical bond with the most common jacket resins — LDPE, LLDPE, MDPE, HDPE and halogen-free polyolefins (HFPO) — providing a permanent bond that eliminates moisture migration between layers.
Aluminium thicknesses range from 0.08 to 0.30 mm with a 50 µm copolymer coating per side. Aluminium thickness is selected based on mechanical-protection requirements and short-circuit capacity, while the copolymer keeps a constant thickness optimised for bonding without unnecessarily increasing cable diameter.
In submarine cables, aluminium-copolymer also contributes impact and compression resistance during laying and operation, protecting inner layers against the mechanical stresses of the marine environment. The hermetic barrier is especially critical in these applications, where any water ingress would irreversibly compromise the insulation.
Applying the copolymer through hot vulcanisation guarantees a perfect bond to both the aluminium substrate and the cable jacket, eliminating any risk of delamination throughout the cable's service life, even under continuous moisture exposure or thermal cycling.
How to choose the right one?
The aluminium thickness depends on the balance between barrier requirements, short-circuit protection capacity and finished-cable flexibility. The copolymer thickness (50 µm) is common to all references and optimised for bonding with the most common jacket materials.
| Reference | Al thickness | Copolymer thickness | Total thickness | Typical application | When to choose |
|---|---|---|---|---|---|
| AL/PE 80/50 | 0.08 mm ±6% | 0.050 ±0.005 mm | 0.13 mm | Fibre-optic cables, telecoms | Maximum flexibility, basic barrier |
| AL/PE 150/50 | 0.15 mm ±6% | 0.050 ±0.005 mm | 0.20 mm | Communication cables, LV power | Barrier/flexibility balance |
| AL/PE 200/50 | 0.20 mm ±6% | 0.050 ±0.005 mm | 0.25 mm | MV power cables | Reinforced mechanical protection |
| AL/PE 300/50 | 0.30 mm ±6% | 0.050 ±0.005 mm | 0.35 mm | Submarine cables, HV power | Maximum protection, short-circuit capacity |
Technical specifications
The values shown below come from tests run to international standards and characterise the material's behaviour both during processing and in service.
Mechanical properties
| Property | Test method | Value |
|---|---|---|
| Tensile strength | YD/T 723-2007 | ≥75 MPa |
| Elongation at break | YD/T 723-2007 | ≥25% |
| Peel strength (copolymer-aluminium) | YD/T 723-2007 | ≥0.45 N/mm |
| Shear strength | YD/T 723-2007 | The tape fails in tension before the copolymer-aluminium bond |
| Kinetic friction coefficient | YD/T 723-2007 | ≤0.65 |
Copolymer properties
| Property | Test method | Value |
|---|---|---|
| Melt flow index | ASTM D1238 (190/2.16) | 10 g/10 min |
| Melting point | ASTM D3418 (DSC) | 100°C |
The copolymer forms a chemical bond with: LDPE (low-density polyethylene), LLDPE (linear low-density polyethylene), MDPE (medium-density polyethylene), HDPE (high-density polyethylene) and HFPO (halogen-free polyolefins). Values shown are typical and do not constitute binding specifications.
Available variants
Coating configuration
- One side — copolymer on the inner side (in contact with the jacket)
- Two sides — copolymer on both sides, for double-bond applications
Alternative aluminium thicknesses
- Other thicknesses available on request, per specific protection requirements
Delivery formats
Aluminium-copolymer is supplied in jumbo reels optimised for continuous feed in cable manufacturing lines. The formats are designed to minimise splices and maximise productivity.
Jumbo reel
Reel for continuous feed in manufacturing lines
Other formats and dimensions available on request. Custom slitting service available.
Application sectors
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We process material from our stock or material supplied by the customer.
Need technical advice?
Our technical team is available to help you select the optimal material for your application.
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