Reconductoring programmes (HTLS and advanced conductors)
BOTTLENECKNexans holds concentrated HTLS conductor supply and manufacturing bottlenecks prevent second sources from meeting FERC Order 1920 demand.
Replacement of conventional conductors with high-temperature low-sag conductors on existing structures, doubling capacity within existing right-of-way. HTLS conductor OEMs benefit from supply constraints. FERC Order 1920 mandate drives utility evaluation and procurement.
Why the concentration exists
HTLS conductors replace conventional steel-core conductors with advanced materials that operate at higher temperatures while maintaining structural integrity. These conductors use composite cores made from carbon fiber, glass fiber, or metal-matrix ceramic fibers instead of traditional steel. The composite materials are twice as strong as steel and less susceptible to thermal expansion, which enables higher operating temperatures without excessive sagging.[8][18]
The primary advantage of reconductoring is speed and cost compared to building new transmission corridors. Reconductoring projects take less than half the time and cost less than half of new-build lines. This approach bypasses permitting delays and difficulties in securing new rights-of-way, which are major obstacles in densely populated areas.[3]
What the evidence shows
Two largest suppliers control 42-45% combined market share, with significant barriers for new entrants.
dataintelo.comWho supplies it
Nexans has established itself as a major supplier with over 5,000 km of ACSS conductors installed across Europe and over 2,700 km of HTLS conductors manufactured since 2011. The company offers a comprehensive range including HVCRC Lite and ACSS designs that increase ampacity by 10% to 100%. Nexans received €250 million in financing from the European Investment Bank in September 2025 to support R&D and industrial investments.[1][15][17]
Multiple manufacturers serve the Indian market including APAR, Prem Cables, and Lumino Industries, which offer HTLS conductor manufacturing and installation services. TS Conductor Inc. partnered with Laser Power Infrastructure for AECC technology manufacturing in India. De Angeli Prodotti partnered with Exel Composites to supply advanced conductors.[2][4][5][7][10]
Who controls it
What it depends on, and what depends on it
These conductors enable transmission capacity upgrades on existing infrastructure without requiring new tower construction or right-of-way acquisition. Large-scale reconductoring can double transmission capacity within existing corridors. This capacity expansion supports renewable energy integration, as over 1,500 GW of solar and wind projects await grid connection globally.[6][16]
Reconductoring provides the majority of new transmission capacity needed for clean energy goals. Modeling shows reconductoring could provide over 80% of new interzonal transmission needed to reach over 90% clean electricity by 2035. In some scenarios, reconductoring accounts for 66% of transmission capacity additions through 2035.[12][13]
Where it sits in the stack
Takes in: Existing transmission structures; HTLS conductor supply (L2.4.2)
Sends on: Doubled line capacity without new right-of-way
What would break it
Regional adoption patterns vary significantly. Southeast Asia and parts of the Middle East adopt HTLS conductors during refurbishment cycles when aging lines require maintenance. Europe and North America are expanding reconductoring as transmission systems built decades ago require upgrades. India has some of the fastest ACCC deployment rates globally.[9][12]
Government funding programs are accelerating market development. The U.S. DOE's GRIP Program is authorized to provide up to $10.5 billion over five years for grid resilience and innovation including reconductoring. The European Investment Bank's financing to Nexans supports industrial capacity expansion.[11][17]
What to watch
The U.S. Department of Energy announced approximately $1.9 billion for the SPARK program on March 12, 2026, to accelerate reconductoring and advanced transmission technology upgrades. Applicants must submit concept papers by April 2, 2026, and full applications by May 20, 2026. Project selections are anticipated in August 2026.[11][14]
Nexans plans to open a new factory in Lens by 2026 that will increase copper wire production by more than 50% and recycle up to 80,000 tonnes of copper annually. This facility is part of the company's expansion supported by European Investment Bank financing.[17]
Related nodes
Sources
- powertranstech.com
- laserpowerinfra.com · 2026-01-29T03:55:34
- haas.berkeley.edu
- apar.com · 2025-09-17T16:14:03
- exelcomposites.com · 2025-06-13T06:15:34
- pnas.org · 2024-09-23T00:00:00
- premcables.com
- hnzdcable.com · 2026-05-15T01:39:26
- cleantechnica.com · 2026-03-11T16:36:21
- luminoindustries.com
- energy.gov · March 12, 2026
- spectrum.ieee.org
- haas.berkeley.edu
- utilitydive.com · 2026-03-12
- nexans.co.uk
- nexans.co.uk
- eib.org · 22 September 2025
- eesi.org
Full scorecard, owner shares, supply edges and the full tracked roster are in the desk letter.
GET THE BRIEFING