How Are Aluminium Conductors Made? A Detailed Guide

Aluminum is an element, which means it’s not made – even though it isn’t the shiny metal we consider it to be. It must be processed in its purest form.

While aluminum is a widespread element on Earth and makes up 8.23 percent of the crust of earth mass, it’s quite rare to find pure aluminum on Earth. Aluminium has a very strong affinity to oxygen, usually in the form of an oxide or silicate.

In addition, Aluminium conductors are widely employed in power distribution and transmission systems because of their lightweight, high conductivity, and corrosion resistance. What is the process by which these conductors are constructed? Here, we’ll thoroughly explain how to make conductors from aluminum.

What are Aluminium Conductors?

Mining Aluminium

The most commonly used aluminum source is the sedimentary rock Bauxite. It’s mined from the ground and composed mostly of aluminum oxide and other minerals. Bauxite is currently the most significant aluminum source, and several of the largest reserves are located in countries such as Australia, Brazil, China, Guinea, and India. 

Bauxite has many shades and consistency, such as white, yellow, green, tan, and white. However, it’s most often known as reddish, ranging from dull scarlet to burning red due to higher ferrous oxides (goethite and haematite). Visit for more information about Aluminium conductors.

Extraction – The Bayer Process

After the bauxite is mined, it must be refined to produce pure aluminum. This is done by making the raw material to create aluminum oxide (alumina). This can be achieved using the Bayer procedure by pressuring and heating the bauxite and adding sodium hydroxide. This process separates the aluminum oxide from the larger bauxite.

The aluminum oxide is melted, then heated using a reducing agent, usually fossil fuels or any other carbon source, to eliminate any oxygen in the mine, leaving only pure aluminum. Pure aluminum (which generally is about 99.8 percent pure) is formed into ingots and then sold to companies for use in manufacturing.

Raw Materials

The primary ingredients used to make conductors made of aluminum include high-purity aluminum and aluminum alloy wires and steel rods. High-purity aluminum is used for the central core, while aluminum alloy wires create that outer layer. Steel rods serve to support the core for the stranding process.

Rod Production

The initial step in manufacturing is the manufacturing of aluminum rods. They are made by melting high-purity aluminum or alloy of aluminum in a furnace and then making it into long, circular forms. The rods then cool and cut into shorter lengths, generally 9-12 meters.

Drawing Process

Following that comes the process in which aluminum rods are removed through an array of dies that reduce their diameter and extend their length. This process is repeated a few instances until the required size and diameter are reached. The resultant aluminum wire is then wound on spools.

Stranding Process

The final production stage is the stranding procedure, where the aluminum wire is strung together to create the conductor. Core support made of steel is put in the center of the machine that is twisted, and the wires made of aluminum are wrapped around it. The number of layers and wires utilized will depend on the desired conductivity and the strength of the material used for the conducting.


Conductors made of aluminum are an essential element of distribution and power transmission systems. Their fabrication process demands careful consideration of their raw materials and precise production methods. The process involves various steps, including producing rods, drawing, and stranding. All of these have a high-quality, robust, durable, and reliable conductor.