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Bahra Cables Company was established in 2008 to serve Saudi & GCC Markets.

It is based
in Bahra industrial city located 25km from Jeddah. Bahra Cables Factory occupies over
200,000 square meters of prime manufacturing space together with associated design
offces, laboratories and storage area. It specializes in Manufacturing and Distributing
Electric Cables.
Bahra Cables Company is committed to the production of the best product quality
and service,utilizing cutting edge European Technology in its manufacturing. The core
technologies in production processes, material applications and logistic procedures were
provided by German experts with key functions being managed by German engineers.
The organization has a lean vertical management structure which is designed to integrate
with a highly developed IT-based structure. This partnership allows the rapid fow of
information through the management chain and facilitates timely response in the best
traditions of hands on management. Bahra Cables Company has the fexibility to
provide a versatile product range to serve the construction, electric utilities, distribution,
industrial, oil & gas and petrochemical sectors. The cables produced comply with both
American standards ( UL , ANSI and ICEA ) and European standards ( IEC, BS, NF and
VDE specifcations.)
The scope of this catalogue is to provide an in depth view of the technical information of
the low voltage cables 0.6/1.0KV, with PVC or XLPE insulation to IEC 60502-1 and XLPE
insulation to BS 5467.
Bahra Cables Company Catalogues is about Control & Auxiliary cables, Power and control
Tray Cables to UL 1277, cables having low emission of smoke and corrosive gases (LSF)
to IEC60502-1 or BS 6724 are available upon request.
Area:
Bahra Cables Company has a total land area of about 200,000sqm at disposal.
The built area, including offces and plant, of start up phase is more than 30,000sqm.
The factory extension under construction is more than 20,000sqm already.
The total available stock yard for storage is more than 20,000sqm
Product Scope
Bahra Cables Company is committed to deliver the highest standard wires and power
cables to the local market and for export.
GENERAL
INTRODUCTION
Bahra Cables Company has a versatile product range cover most of our customer needs :
- Flexible wires and cables up to 300 mm2.
- Building wires, THHN/THWN to UL 83, with conductor sizes starting from 16 AWG.
- Building wires to IEC 60227 and BS 6004 , from 1.5 mm2 and above.
- LV Power Cables with PVC and XLPE insulation to IEC 60502-1, BS 5476 and UL 1277.
- MV cables to IEC 60502-2 up to 18/30 (36) kV and to BS 6622 up to19/33 (36) kV.
- Bahra Cables Company will produce cables with low emission of smoke and corrosive
gases when affected by fre, for LV& MV cables to BS 7211, BS 6724 and BS 7835.
- HV cables up to 69 kV to IEC 60840 , and to ANSI / ICEA S-108-720, with conductor
sizes up to 1200 mm2.
The future product scope will be extended to Extra High Voltage cables up to 480 kV and
conductor cross sections bigger than 2000 mm2
Machinery:
All production machines are top of the line of the cables machinery suppliers. From start
up with wire drawing lines to extrusion lines, to assembly machines up to the laboratories
and the fnal test felds, all technical equipment is provided with the highest European
standards of electronic control equipment and measuring devices which insures that the
requirements of different quality standards are met.
All machines/production lines are prepared for data communication and data exchange
bottom up and top down using the most modern decentralized control software at the
lines (PLC) combined with an effcient central steering and a planning system focused on
the demand of cable manufacturers. This way, full traceability will be guaranteed from
production start to end, by being able to follow up the machines involved and the material
used.
Logistics:
All material fow in BCC from incoming raw material up to outgoing cables will be planned
and controlled by a complete software system. Herein a classical ERP system will be
enhanced and completed by the state of art MES (Manufacturing Executive System)
which has a unique focus on the specifc problematic issues of cables manufacturing with
longitudinal products being winded up and winded off.
The MES will cover:
Planning
The planning system is active on several levels. For the proper function, all master data
(material properties, dimensions, etc.) are saved and permanently maintained in the
central database based on
- Cable design
- Planning of Sales Orders
- Planning of Production Orders
Data Communication
The exchange of data is important in several areas.
- Incoming inspection
- Raw Materials - Status of production orders
- Finished goods
- Shipping status
GENERAL
INTRODUCTION
Human Resource
HR Manager
Production
Manager
Sales & Marketing Operations
COO
Engineering
Manager
Procurement
Manager
Logistics
Planning Manager
Technology
Technical Manager
Finance
Financial Manager
IT
Software Manager Hardware Manager
General Manager
Sales & Marketing
Sales & Marketing
Manager
Project Sales
Manager
Marketing Manager
Sales Manager
CEO
BCC
MANAGEMENT
Human Resource
HR Manager
Production
Manager
Sales & Marketing Operations
COO
Engineering
Manager
Procurement
Manager
Logistics
Planning Manager
Technology
Technical Manager
Finance
Financial Manager
IT
Software Manager Hardware Manager
General Manager
Sales & Marketing
Sales & Marketing
Manager
Project Sales
Manager
Marketing Manager
Sales Manager
CEO
COMMITTED
TO QUALITY
BCC Quality Policy
Our aim at Bahra Cables Co. is to delight our customers throughout their business
association with us in the supply of electric cables, by achieving:
Total Quality Excellence of product complying with the relevant local and
international standards.
Effcient service and reliability that meets our customer`s expectations in every
respect.
Continual Improvement of our products and quality system in order to acheive
error free product.
Enhancing the employee`s skills is the main resource of improvements.
Revision of our business management system for complying with ISO 9001:2008.
so that by enhancing the communication and contribution of management, employee`s,
suppliers and customers, we can provide value superior to that which our customers expects.
TALAL K. IDRISS
Chief Executive Offcer
Manufacturing Facilities
BAHRA CABLE MANUFACTURING COMPANY specializes in manufacturing and distribution
of electric cables has a fully equipped manufacturing plant using cutting edge European
Technology with top of the line machineries from leading European suppliers and its core
technology in production processes were provided by German Engineers.
BAHRA CABLE MANUFACTURING COMPANY is among the most advanced cable
manufacturing plant in the region.
1. Drawing Machines
99.99% ETP copper is drawn down to smaller diameter through various drawing
processes, annealed and packed according to cable construction requirements.
Electrically quality aluminum rod is drawn down to smaller diameter using top of the line
dedicated drawing machine to eliminate copper contamination.
2. Stranding Machines
Are used to twist individual wires together in a geometric or non-geometric confguration
to form a fexible electrical conductor and construct conductors in layers up to 61 wires in
a single pass.
3. Drum Twisters
Multiple insulated conductors are assembled and enclosed called armoring to enhance
the physical properties of the cable.
4. Taping Lines
Assembled conductors are further enhanced by applying tapes for armoring and water
proofng.
5. Extrusion Lines
This top of the line machine extrude insulation over the electrical conductors, apply inner
and outer jackets of cables and can process different type of compounds according to
customer requirements with an integrated cable and single core and length marking and
an on-line measuring and testing equipment.
6. CCV Lines
Our lines is an state of the art machines capable of producing medium to high voltage cable
and conforming to the highest quality standards for the usage of super clean materials.
The process is computer monitored and all process information is stored electronically.
7. Screening Machines
This machine is used to apply metallic screening to protect the cables from short circuit.
8. Coiling Lines
To coil fnished product according to customer packaging requirements.
MANUFACTURING
FACILITIES
All machines in the production lines are prepared for data communication and data ex-
change bottom up and top down using the most modern decentralized control software
at the lines (PLC) combined with an effcient central steering and planning system focused
on the demand of cable manufacturers. This way, full traceability will be guaranteed from
production start to end, by being able to follow up the machines involved and the material
used.
Machines Make Country of Origin
Rod Breakdown Machine Niehoff Germany
Intermediate Drawing Machine Niehoff Germany
Multi Wire Drawing Niehoff Germany
Buncher
Niehoff
Setic
Germany
France
Stranding Machine
Pourtier
Setic
Caballe
France
France
Spain
Extruder Line
Rosendahl
Mailifer
Austria
Finland
Assembly Machine
Pourtier
Setice
France
Armouring Machine Pourtier France
Screening Machine Pourtier France
CCV Line Mailifer Finland
Packing Machine Skaltek Sweden
Rewinding Machine Pourtier France
MANUFACTURING
FACILITIES
RANGE OF
PRODUCTION
Building Wires
Wires to American standard UL 83
Copper Conductor cross section area:
From 16 AWG to 8 AWG.
PVC insulation QMTT2 approved material by UL.
Nylon Poly Amid Jacketed wire.
Flame Retardant comply to VW-1 Vertical Flae Test.
Oil and Gasoline Resistant Wire.
Specifcation BS 6004 IEC 60227
Copper conductor class 1 solid, class2 strand or class 5 Flexible Conductor.
PVC insulation ( TI-3 90 C ).
Flame retardabt wire to IEC 60332-1.
Control cable
Specifcation IEC 60227
Copper Conductor cross section area : from 1.5 mm2 to 4.0 mm2 ( multicore
cables 2 cores , 7 cores, 12 cores up to 48 cores ).
Conductor Insulation Material: PVC or XLPE.
Armoured with galvanized steel wire or galvanized steel tape ( or non armoured).
PVC (Inner) / outer jacket.
Low voltage power cables 0.6/1.0 kv
Specifcation IEC 60502-1
Aluminium or Copper conductors.
Single core cables up to 630 mm2 and Multicore cables up to 500 mm2.
XLPE or PVC insulation.
Armoured with galvanized steel wire or galvanized steel tape ( or non armoured)
PVC (Inner) / outer jacket.
Fully complying to IEC 60502 and SEC Specifcation (11-SDMS-01).
Low smoke halogen free cable
XLPE Insulated wire - Low Smoke Halogen free wire to BS 7211.
XLPE Insulated - Low Smoke Halogen free cables (ST8) to IEC 60502-1.
Flame Retardant to IEC 60332-2.24.
Jacketing Acid gas emission test
- ( HCI emission to IEC 60754-1<0.50%)
- PH >4.3.
- Conductivity < 10 Micro Siemens.
Copper conductors for earthing
Bare Copper Stranded conductor / uncoated or coated / comply to SEC specifcation
Standard 10-SDMS-02 and to BS EN 60228 (IEC 60228), for earthing requirements.
Specifcation BS 6004 IEC 60227.
LV Overhead line conductor type quadruplex
Specifcation IEC 60502 & ASTM B549
Quadruplex LV overhead conductor of
- Hard Drawn Aluminum conductor / BLACK weather resistant XLPE insulation
for the Phase Conductor.
- Aluminium conductor steel reinforced ( ACSR/AW )/non isulated netural phase
conductor.
Sizes:
- 3(1x120) + 1x120mm2.
- 3(1x50) + 1x50 mm2.
Complying to IEC 60502 & SEC Specifcation 11-SDMS-02.
Overhead line conductors ACSR /AW type to ASTM B549
Aluminium-Clad Steel Core / Aluminium stranded conductor for overhead lines
for 13.8 & 33KV application.
Sizes codes examples: Quail, Meline & Condor .
Other OHL of AAC, AAAC, ACSR, ACAR.
Complying to ASTM B549 & SEC Specifcation 10-SDMS-01& EN50182.
Medium voltage cables 8,7/15 (17,5) kv & 18/30 (36) kv
Specifcation IEC 60502-2 / BS 6622.
Aluminum or copper conductors.
Single core cables up to 1000mm2 and multicore cables up to 3x300/35 mm2.
XLPE insulation/ CCV technology.
Armoured with galvanized steel tape (or non armoured).
LDPE/HDPE/PVC inner/outer jacket.
Fully complying to IEC 60502-2.
High voltage cables 36/66 (72) kv
Specifcation IEC 60840/ BS 7912 / ICEA S94-S97-682.
Aluminum or copper conductors.
Single core cables up to 1000mm2.
XLPE insulation / CCV Technology.
Armoured aluminum wire (or non armoured).
Specifcation IEC 60502-2 / BS 7912.LDPE/HDPE/PVC inner/outer jacket.
complying to IEC 60840.
RANGE OF
PRODUCTION
Required Tests:
Voltage test (Routine test).
Partial discharge.
Capacitance test.
Heat Cycle test
Impulse test.
Step test.
Power Frequency voltage test.
Applicable test and equipments standards
IEC 60038 - IEC standard voltages.
IEC 60060-1 - High voltage test techniques.
Part1: General defnitions and test requirements.
IEC 60183 (Guide to the selection of high voltage cables).
IEC 60885-3 - Electrical test methods for electric cables.
Part3: Test methods for partial discharge measurements on lengths of extruded
power cables.
RANGE OF
PRODUCTION
List of Monitoring and Measuring Equipment
No# Equipment Type Measured Parameters
Country of
Manufacture
1 pH Meter pH Germany
2 Conductivity Meter Conductivity Germany
3 Analytical Balance Weight Switzerland
4 Weighing Balance Weight Switzerland
5 Weighing Balance Weight Switzerland
6 Milli Ohmeter Resistance Germany
7 Mikro Ohmeter Resistance Germany
8 Mikro Ohmeter Resistance Germany
9 Megger Insulation Tester Insulation Resistance England
10 Megger Insulation Tester Insulation Resistance England
11 Melt Indexer Melting Flow Germany
12 Thermocouple Thermometer Temperature Newzealand
13 H.V Transformer High Vlotage USA
14 Electrometer/High Resistance Meter Resistance USA
15 Mikro Ohmeter Holding Device Length Germany
16 Material Testign Machines Tensil Germany
17 Dial Calipers Thickness Germany
18 Cylindrical Measuring Pins Diameter Germany
20 Precision Caliper W/Adjstmnt Length Germany & Japan
21 Digital Vernier Calipers Thickness Germany & Japan
22 Micrometer Diameter Germany & Japan
23 Digital Laser Head Diameter USA
24 Optical Profle Projectors Thickness England
25 Laboratory Drying Ovens Temperature Germany
26 Water Bath (Heating Element) Temperature Germany
PRODUCTION
MACHINES
Objective
This document was established to demonstrate the compliance of BCC to the local and
international standards that requires the monitoring and measurement of characteristics of
product at appropriate stages of product realization. Furthermore, this document aimed to
satisfy customer on the quality assurance requirements for wire & cable.
Scope
This Test Plan is applicable to all manufactured wire & cable of Bahra Cables Company at
several production stages from incoming to in-process up to fnished product.
Test Plans:
A. Incoming Material Test Plan
All incoming raw materials are tested and the quality is controlled based on our estab-
lished Material Specifcation. Our Material Engineer ensures that all the required material
tests are conducted by the qualifed Material Inspectors based on established Quality
Procedures and only those materials which have passed in the incoming inspection are
released to production.
Below is the list of our raw materials with the corresponding required no. of samples.
Quality Assurance
Raw Material Test Frequency
High Conductivity Continuously Cast And Rolled Copper Rod For
Wire Drawing
2 /10 Coils
Continuously Cast And Rolled Aluminum Rod For Wire Drawing 2 /10 Coils
Annealed Copper Tape For Cable Shielding 3 Samples / Delivery
Galvanized Mild Steel Wire For Electric Cables
Armouring
3 Sample / Delivery
Galvanised Mild Steel Slitted Tape For Armouring Of Electric 3 Sample / Delivery
Pvc Compound For Insulation Of Building Wires To Thw, Thw-2,
Thhn And Thwn
1 Sample / Delivery
Pvc Compounds For Cables Insulation 1 Sample / Delivery
Pvc Compounds For Sheathing Of Cables 1 Sample / Delivery
Cross-Linkable Silane Copolymer With Catalyst
Masterbatch For Xlpe Insulating
3 Sample / Core
Polyester Tapes For Electric Cables Wrapping 3 Sample / Delivery
Polypropylene Rope For Electric Cable Filling 3 Sample / Delivery
Polypropylene Tapes For Cable Binding 3 Sample / Delivery
Colour Masterbatch For Polymeric Compounds 1 Sample / Delivery
LIST OF TESTING
EQUIPMENTS
B. In-process Inspection Test Plan
Below is the list of in-process inspection and test which are carried out during the whole
manufacturing process to ensure conformance of the product.
Process & Inspection/Tests Test Frequency Inspection/Tests Aid
Copper Wire Drawing:
Rod Breakdown
Diameter
Surface fnish
E.A.B
Lubricant state - Fat content
- pH value
Start and 1 in 10
Start and 1 in 10
Every Week
Every Week
Micrometer
Visual
Elongation M/C
Refractometer
pH meter
Copper Wire Drawing:
Intermediate Multi wire
Diameter
Surface fnish
E.A.B
Lubricant state - Fat content
- pH value
Each Bobbin
Start and 1 in 10
Every Week
Every Week
Micrometer
Visual
Elongation M/C
Refractometer
pH meter
Aluminium Wire Drawing:
Diameter
Wrapping test
Surface fnish
Sample Every 10 Bobbins Micrometer
Testers
Visual
Stranding Of Conductor:
No. Of wires ; wire lays & P.S lays
Direction of wire lay & P.S lays
Conductor dimensions
Conductor Resistance
Conductor weight/m
Surface fnish
Each Bobbin
Visual/ change gears
Measuring tape/meter scale
Micrometer
Weighting scale
Visual
PVC or XLPE INSULATING:
Machine settings
Insulation thickness:
Actual Avg. & Min. point
Diameter/eccentricity
Color/Finish/marking
Spark testing
Every Drum
(Start and one sample from
every drum)
Visual
Profle Projector
Profle Projector
Visual
Spark Tester
XLPE CURING
Curing time
Hot set Test (in the lab.)
Shrinkage Test (in the lab.)
Every Drum
Digital Timer
Oven / Vernier
Oven / Vernier
LIST OF TESTING
EQUIPMENTS
Process & Inspection/Tests Test Frequency Inspection/Tests Aid
Laying Up Of Cores :
Core Colour / number sequence
Filler size & Nos.
Coring lay
Tape registration
Laid-up diameter
Cable shape
Every Drum
(Start and one sample from
every drum)
Visual
Visual
Gear setting
Visual
Diameter tape
Visual
Extruded Bedding :
Machine settings
Bedding thickness:
Actual Avg. & Min. point
Diameter/ over bedding
Colour/Finish
Every Drum
(Start and one sample from
every drum)
Visual
Profle Projector
Profle Projector
Visual
Wire Armouring :
Wire material/No. of wires.
Diameter over armour
Armour wire lay
Direction of lay
Cable shape and fnish
One sample from every drum Visual
Dia. tape/Vernier caliper
Gear position
Visual
Visual
Tape Armouring :
Tape width & Thickness / gap
Diameter over armour Every Drum Diameter tape /Vernier caliper
Outer Sheathing :
Machine settings
Sheath thickness: Actual Avg. &
Min. Point.
Eccentricity
Overall diameter
Colour/Finish/ marking
Spark Test
Every Drum
(Start and one sample from
every drum)
Visual
Profle Projector
Profle Projector
Dia. tape/ vernier caliper
Visual
Spark Tester
Rewinding Of Cables :
Cable fnish
Cable marking
Spark Test
Every Drum
Visual
Visual/metre scale
Spark Tester
Insulation / Sheath Repair :
Repair fnish
Spark Test Every Drum Visual
Spark Tester
LIST OF TESTING
EQUIPMENTS
C. Finished Wire & Cable Test Plan
Our Test Field Engineer ensure that fnal inspection is carried out based on local and
international standards and no fnished product will be delivered to customer without
quality clearance.
The following parameters and product information are taken as records during the fnal
inspection.
No#.
For Finished Wire
(Every Produced Drum)
For Finished Cable
(Every Produced Drum)
1. Date Date
2. Metal No. Metal No.
3. Lot No. Lot No.
4. Product Code Product Code
5. Length Length
6. Embossing or Marking Embossing or Marking
7. Thickness ( PVC & Nylon) Construction
8. Color Surface Finish
9. Insulation Resistance per Length (Meg-ohm/
km)
10. AC Dielectric Voltage Test AC Dielectric Voltage Test
11. Conductor Resistance at 20 C (Ohm/km) Conductor Resistance at 20 C (Ohm/km)
12. Armour( Resistance, No./dia, W/Thick)
13. Filler Used
14. Wire Size Diameter (Core Diameter, Over Bedd, Over
Armour, Over all)
15. Wooden Drum No.
16. Specifcation Specifcation
17. Status
LIST OF TESTING
EQUIPMENTS

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