With electrification accelerating at an unprecedented rate, electrical grids built more than thirty years ago are now under tremendous strain. Many are outdated and struggle to handle increasing demand during extended periods while maintaining the expected levels of efficiency and reliability.
In this increasingly strained environment, every component of the grid matters. Yet, some of the most critical (and vulnerable) components often remain unnoticed.
While attention is often focused on cables and transformers, the most overlooked and failure-prone elements of electrical grids are the accessories that silently connect everything.
More than 70% of distribution grid failures occur at junctions; but most utilities still rely on inspections with limited visibility.
These hidden critical links are often buried beneath city streets and deep under the ocean floors, silently carrying power. When they fail, the consequences include costly repairs, extended downtime, and widespread service disruptions. Preventing this costly domino effect is a top priority for grid operators today.
So, why do these critical connection points fail in the first place, and more importantly, how can they be avoided?
It is often mistakenly assumed that electrical grid failures are due to faulty cables and transformers. But in reality, it is the accessories (cable connectors, joints, and terminations) that account for a disproportionate share of failures.
These components degrade over time due to thermal fatigue, mechanical stress, vibrations, moisture ingress, and, in many cases, improper installation practices such as misalignment or over torque. Pinpointing the location of a failure is notoriously difficult. Limited visibility and lack of diagnostic data make troubleshooting time-consuming and costly.
As an example, an MV cable connector failure can cost, on average, between €10,000 and €50,000 to repair.
These failure mechanisms underscore why accessories, despite their compact size, harbor a disproportionate share of the operational risk within medium-voltage grids. Yet their role extends well beyond reliability concerns alone, serving as critical enablers of performance, safety, and future-ready grid modernization.
Accessories are instrumental in powering mega data centers, lighting cities, and supporting transport systems. This strain is especially evident in older accessories, many of which were never designed to support today’s continuous and elevated load demands.
According to the European Network of Transmission System Operators for Electricity (ENTSO-E), over 60% of Europe’s grid components are more than 30 years old. These aging components are expected to deliver uninterrupted power in an environment where downtime is no longer acceptable.
Across Germany, Italy, and the Netherlands, up to 80% of medium-voltage cable faults stem from defective joints and splices, as reported by national utilities (Unareti Grid Fault Analysis, 2022).
Much like the telecommunications industry before it, the energy sector must now evolve toward real-time visibility, predictive fault detection, and continuous diagnostic intelligence to meet the demands of a modernized grid.
To address these vulnerabilities and modernize grid maintenance strategies, accessories are now being elevated into intelligent assets.
Despite their modest size, accessories like joints and connectors are often the weakest links in grid infrastructure. Their vulnerability is compounded by harsh environmental exposure; yet, until recently, they have been treated as passive components.
That’s now changing. As utilities grapple with aging infrastructure and the rising cost of outages, accessories are being redefined as intelligent and predictive assets. Equipped with embedded sensors and connected into digital monitoring platforms, today’s smart accessories enable early fault detection and real-time performance insights, allowing operators to shift from reactive maintenance to proactive grid management.
Utilities adopting these technologies have already reported notable reductions in outage durations, emergency interventions, and overall operational expenditures.
Transforming accessories from passive components into intelligent assets requires a new generation of technologies. These innovations empower operators with real-time visibility capabilities, allowing them to anticipate failures before they occur, rather than respond after the fact.
To meet these evolving expectations, manufacturers are now delivering advanced accessory systems featuring:
Together, these technologies are shifting maintenance strategies from reactive interventions to proactive, data-driven grid optimization, enabling faster diagnostics, more accurate root-cause analysis, and fewer unexpected outages.
But what makes these smart accessories possible? At the heart of this transformation are three enabling technologies, powering the shift from passive parts to intelligent, self-monitoring systems:
Utilities that embed smart accessories within predictive diagnostics and installation traceability frameworks are achieving tangible performance gains:
The evolution of accessories from passive components to intelligent assets is reshaping how utilities manage and future-proof their grids. Smart accessories now play a strategic role in boosting reliability, extending component lifespan, and reducing operation costs.
As utilities confront the twin pressures of aging infrastructure and accelerating electrification, these solutions are becoming essential to predictive maintenance and resilient network operation. This marks a broader transformation, from static systems to intelligent, self-monitoring grids.
Nexans is helping lead this industry shift, providing advanced smart accessory systems and end-to-end lifecycle support that enable grid operators to anticipate, monitor, and optimize their networks with unprecedented precision and confidence.
Samuel Griot joined Nexans in 2021 as head of the electrical engineering department within Nexans Innovation, to lead a team of experts developing new innovative solutions for low, medium and high voltage applications in order to answer the future needs for the electrical grids. He was appointed early 2025 Innovation Solutions Director for the PWR Grid Market Division. He has a strong background in electrical grid architecture and switchgears. He holds a Master degree in electrical engineering from INSA of Lyon, France.
Moussa Kafal leads the Grid Reliability portfolio at Nexans, spearheading the development and global deployment of advanced solutions that enhance the performance, integrity, and resilience of power networks. Holding a PhD in Engineering and executive credentials from HEC Paris, he bridges deep technical expertise with strategic acumen to accelerate energy system transformation. Moussa oversees key initiatives across Europe, North America, LATAM, and APAC, positioning Nexans as a leading smart grid solutions provider in a rapidly evolving digital infrastructure landscape.
From aerospace to manufacturing, today’s leaders are no longer just providers of products. They are long-term partners involved in every phase of the customer journey, from design and deployment to diagnostics, support, and, increasingly, training.
Across industries, the way companies serve their customers is being redefined. Training has become a critical part of how companies reduce risk, ensure operational results, and build trust with those who rely on their technologies.
In many sectors, performance depends as much on human precision as on technological advancement:
These approaches reflect a shared belief that strong customer experience comes not only from great products, but from the ability of people to apply them correctly, consistently, and along the whole value chain, from the start to the end. Up-skilling is even more relevant in the energy sector.
As the global push for decarbonization accelerates, electrification has become the backbone of energy systems. Power networks today must integrate renewable energies and always more decentralized generation, leading to bi-directional flows and intermittent production. In the meantime, electrification and new customer needs are growing (electrical vehicules, heat pumps, AI development and related construction of datacenters, electro intensive industries…).
Grids must therefore be modernized and become Smarter. They also have to become more resilient against extreme weather events. Their vulnerability against human errors during installation has become more critical than ever.
According to ENTSO-E, more than 60 percent of Europe’s grid components are over 40 years old. In this context, the margin for error is shrinking. A single installation mistake can affect reliability, safety, and customer satisfaction, leading to delays, warranty claims, and long-term service costs.
The numbers speak for themselves:
These are not design flaws. They are execution problems. And they are preventable.
One of the root causes is a growing global shortage of qualified professionals in the grid sector. Across the energy industry, there is a bottleneck in the availability of skilled technicians able to install and maintain increasingly complex grid systems. This talent gap affects not only speed of deployment but also safety and long-term performance of states and industries. In many countries, there are not enough certified teams to meet infrastructure goals, particularly in fast-developing electrification markets. The result is clear: without widespread access to certified training, even the most advanced technologies remain vulnerable.
In many countries, certification must also carry formal recognition. In France, for example, certifications are expected to bear official accreditation such as CofracTM, ensuring that certification process is fair for all national stakeholders. QualiopiTM is also a well-recognized quality stamp to ensure training process meets national standards and is recognized by the wider market. These stamps not only validate training quality, they first and foremost bring a license to operate for grid installors while supporting professional mobility and technical accountability on the grid.
Training also closes the gap between system design and field reality. In today’s energy infrastructure, it serves three purposes: it transfers critical technical knowledge and workmanship, strengthens accuracy and speed on the ground, and supports a culture of accountability and excellence.
In recent assessments, teams that completed structured and certifying training programs showed:
These improvements are not theoretical. They directly affect grid resilience, budget predictability, customer satisfaction and trust.
As grids become more complex, training must adapt. This includes at Nexans:
Training today is not a static classroom experience. It is technical, tailored, and aligned with operational goals. In most cases, it also provides certification that is now increasingly necessary to operate and secure installations in compliance with industry standards.
In response to growing demand for skilled installation and maintenance teams and to a lack of certified technicians in most countries, Nexans has structured a comprehensive global training program. Delivered worldwide through eight centers located mainly in Africa, Middle East, Asia-Pacific and Europe including France and DOM-TOM, and supported by a dedicated team of 25 trainers and experts all over the world (including the US and Latin Americas), the program is designed to reflect the diversity and complexity of real-world electrification projects.
In 2024 only, over 2,800 professionals took part in training sessions offered in seven languages and tailored to more than 15 voltage levels and accessory types. The curriculum spans low-, medium-, and high-voltage systems, as well as renewable applications, with flexible, on-demand modules to support different phases of a project.
Each session combines technical theory with hands-on practice. For the most demanding applications, installed samples are tested under real conditions using partial discharge and AC withstand protocols, and certification is awarded based on demonstrated results, not just attendance (in France, the certification process is COFRAC accredited).
In complex projects, reliability can be such a stake that on top of installer training, supervision of operation can be the best way to ensure best in class execution of the installation. In such cases support can be proposed on site by a technical expert or trainer, or if the project is remote, mixed-reality tools.
That is where tools like Microsoft HoloLens 2 come in. This headsets and glasses device allow a remote expert to guide a technician in real time, through visual overlays and live communication.
At Nexans, such mixed reality solutions are directly integrated into training sessions and remote support services, offering installers immediate, hands-free assistance in the field. This approach enhances installation quality and optimizes project execution, especially in isolated locations such as offshore wind farms or rural substations.
The success of electrification worldwide depends not only on smart systems, but on the right-skilled people who install and operate them. Training gives those people the skills and confidence they need to deliver reliability, safety and consistency to the grid networks.
Companies that invest in training are doing more than reducing technical risk. They are building trust, reinforcing performance, and redefining what great customer experience looks like. In the race toward a sustainable energy future, human expertise is what brings every connection to life.
As an innovation-driven leader in the electrification sector, Nexans continues to pioneer advanced training and supervision solutions that help build the grids of tomorrow.
Laurent Keromnes, graduated from ENSCPB Bordeaux in 1997 (Physics and Chemistry), started his career as a chemical engineer in Arkema, the French chemical company. He spent there almost 11 years developing PVC foams and then organic peroxides dedicated to polymer crosslinking.
Since 2011, he moved to Nexans (cable manufacturer) to work on cable development. After 5 years in the Research Center he moved to another position in the company, as a Business development engineer for buried cables in power networks. He is involved in standardization as a TC20 member at AFNOR, and member of several Technical Committees for cables at french SYCABEL.
From early 2024 he is now in charge of Nexans training centers involved in Medium Voltage (MV) accessories installation for Power Grid Business Division.
Imagine a vast network of invisible or suspended arteries – made of copper, aluminum, and innovation. A network so essential it silently powers our cities, our industries, and our lives.
For decades, these infrastructures have kept pace with urbanization, economic growth, and the transformation of our lifestyles.
And yet, built for a more centralized and predictable world, they must now rise to an unprecedented challenge: adapting to a future that is more electric, more renewable, and more resilient.
How can we modernize these networks – the vital veins of a changing society? What if the answer wasn’t to rebuild everything from scratch, but to better harness what we already have?
Our power grids are silent witnesses to urbanization, economic expansion, and major shifts in how we live. But they were designed for a very different world: one that was centralized, less electrified, and far more predictable.
Today, these infrastructures must meet entirely new demands. They need to absorb the surge in renewable energy, support the rise of electric mobility, adapt to growing self-consumption, and respond to increasing needs for energy flexibility. They also need to become more resilient in the face of increasingly frequent extreme weather events.
Did you know?
In this context, should we tear everything down to rebuild it better? Not necessarily. The solution often lies in a leaner, faster, and more sustainable approach: strengthening, optimizing, and adapting what already exists.
This strategy offers many benefits. It shortens implementation times, limits disruptions for local communities, allows better cost control, and reduces the carbon footprint of projects.
Through several technical levers:
Here’s a concrete example: In Europe, several pilot projects have modernized aging sections of the grid without dismantling them:
The result: more efficient, more resilient networks – without rebuilding from scratch.
What if our old networks became a resource for the future? Modernizing also means learning how to repurpose what already exists. Copper and aluminum cables can be recovered and reused after treatment, materials reinjected into new projects, and smart control modules installed to extend infrastructure lifespan.
A circular logic that gives grids a second life and supports more responsible electrification.
By giving grids a second life, we help preserve natural resources and reduce the environmental footprint of new infrastructure.
This approach was at the heart of the discussion at ChangeNOW 2025, during a dedicated conference, “Circular Economy – Today’s Waste is Tomorrow’s Growth”, featuring David Grall, VP Sustainability & Corporate Transformation at Nexans, and Xavier Mathieu, VP Metallurgy at Nexans.
They presented concrete solutions to:
Optimizing without overconsuming. Transforming without rebuilding everything.
That’s the ambition behind a successful energy transition: making our grids more robust, adaptable, and efficient.
In a world where 80% of energy will come from renewable sources by 2050, upgrading our existing infrastructure is a strategic imperative.
This isn’t about giving up on innovation – it’s about applying it where it matters most. It’s about acting now to build a more sustainable future.
Modernizing our grids means strengthening energy resilience,
Reducing our environmental impact,
And accelerating the transition to an electrified world… without starting from scratch.
Sources:
McKinsey, Eurelectric, AIE + Electric Disturbance Events report
IEA report “Electricity Grids and Secure Energy Transitions” (october 2023)
Imagine a bustling metropolis where data circulates as freely as traffic on its busiest avenues. This is the reality of modern data centers: the beating hearts of our digital economy. They are indispensable, powering everything from your favorite streaming platforms to the AI tools transforming industries.
But beneath the surface, a critical component often goes unnoticed: power cables. These cables are the backbone of data centers, ensuring electricity flows reliably and efficiently to fuel our connected world.
Let’s explore why power cables are far more than utility components. In fact, they are strategic assets shaping the future of our digital society.
Let’s dive deeper.
At the core of this intricate system are three key players ensuring uninterrupted power delivery:
Each cable is meticulously designed to withstand the unique demands of this high-pressure environment – reliability, efficiency, and safety are paramount. And while they might seem like a small piece of the puzzle, their impact is enormous.
Indeed, despite accounting for only about 2% to 2.5% of a data center’s total construction costs, the significance of electrical power cables cannot be overstated. Studies have shown that power-related issues are a leading cause of data center outages, with uninterruptible power supply (UPS) failures being a primary contributor.
The financial implications of such outages are substantial:
Impressive enough to understand the critical importance of investing in high-quality electrical power cables. Ensuring the integrity and reliability of these cables can significantly reduce the risk of outages, thereby safeguarding the data center’s operations and financial performance.
Beyond direct financial costs, outages can lead to reputational damage, loss of customer trust, and compliance breaches.
But investing in high-quality cables isn’t just about avoiding costly downtime – it’s about safeguarding the very foundation of digital operations.
With cable technology constantly evolving, the latest advancements are revolutionizing data center infrastructure by addressing key challenges such as fire safety, energy efficiency, and sustainability.
Here are Nexans 4 groundbreaking innovations:
Nexans is committed to reducing greenhouse gas emissions by offering low-carbon cables that integrate recycled materials, including up to 50% recycled plastic and low-carbon aluminum, with the ambition of incorporating 30% recycled copper in the cables by 2030.
Nexans’ low-carbon cables achieve a 35% to 50% reduction in emissions compared to standard cables, supporting data centers in achieving their environmental goals.
Data centers house high-density equipment, making fire risks a major concern. Electrical faults or obsolete installations account for over 25% of building fires in Europe, causing €25 billion in damages annually.
To enhance safety and reliability, Nexans provides a Fire Safety range compliant with the most demanding international safety regulations. Nexans’ Low Fire-Hazard cables incorporate technologies to minimize fire spread and the release of corrosive smoke, whereas our Fire-Resistant cables are designed to maintain circuit integrity, ensuring the critical safety systems remain operational under extreme temperatures.
Nexans’ advanced real-time monitoring technologies detect faults, predict maintenance needs, and optimize performance. By leveraging advanced analytics, these systems enhance reliability and minimize downtime, by two means:
With over 30 years of experience, Nexans’ superconducting solutions provide maximum transmission capacity and efficiency.
Compact yet powerful, these cables are ideal for urban data centers facing space constraints and escalating power demands. They allow grid operators to transfer more power at medium voltage without the need for extensive infrastructure upgrades.
Nexans is at the forefront of these advancements. providing a full spectrum of cables – low, medium, and high voltage – designed to meet the diverse electrical demands of data centers.
Power cables are more than just wires.
The role they play in data centers extends far beyond functionality. They are pivotal to ensuring reliability, improving efficiency, and driving sustainability. As data centers evolve to meet the demands of our increasingly digital world, the innovations in cable technology remain a cornerstone of progress.
From fire-resistant designs to low-carbon materials, superconducting technologies, and smart monitoring systems, the innovations shaping cable infrastructure today are setting the stage for a resilient digital future.
At Nexans, we’re proud to empower data centers with cutting-edge solutions that not only meet today’s challenges but also prepare for tomorrow’s opportunities.
Together, we’re building a more connected, sustainable future – one cable at a time.
In the not-too-distant future, you won’t just be driving a vehicle running on electricity when you get behind the wheel, you will be contributing to national energy production!
Or at least that’s the promise of the carmakers, who are already marketing vehicles with bidirectional charging. When you plug in your car for charging, it also becomes a power source for the grid or your home, potentially halving your electricity bill. This technology is already deployed by Tesla in the USA and could be implemented more widely soon, since Renault is working on around fifteen projects of this type in partnership with grid operator Enedis.
This is just one of the ways in which energy production is becoming more varied and decentralized, with the transformation of power grids. We could say that this is the end of the traditional model of energy production, based on just one or two producers supplying energy from two or three main sources.
If you hear the term Electricity 4.0, it’s not just another marketing ploy, but a way to underline a break with the past. It relates to the need for more abundant, more efficient and – above all – sustainable energy sources to support the fourth industrial revolution, a transformation driven by electric mobility, data centers (cloud computing, data and artificial intelligence) and, first and foremost, the electrification of everything and the digitalization of virtually all areas of activity.
Electricity has all the qualities necessary to address these new challenges. For a clearer understanding, remember that it took 150 years for electricity to meet just one-quarter of our energy requirements, and that we need to reach 60% in just 25 years if we are to meet carbon neutrality targets.
This will involve a 40% increase in electricity demand by 2040, and a six-fold increase in the share of wind and solar power in the energy mix.
This change of scale will require a significant increase in the annual pace of investment in the grid (cables, pylons, transformers, etc.), with figures doubling or tripling compared with the past fifteen years. France, for example, has one of the oldest grids in Europe, with power lines that are 50 years old on average.
Further, renewable electricity is set to dominate the EU electricity sector by 2030. The change is gathering pace, with renewable energies expected to generate 66% of EU electricity by 2030, up from 44% in 2023.
This progress can be achieved only by implementing technological solutions able to fine-tune the balance between production and consumption, and to improve efficiency, security and sustainability.
The electricity revolution is all about the multiplication and decentralization of energy production methods.
We have an increasingly complex energy mix, with some countries using energies that are on the way out, like coal and gas, others opting for nuclear power, and – more generally – a growing proportion of hydro, solar and wind power.
At the same time, everybody is free to set up their own installation. This option is now very much a part of everyday life: an increasing number of individuals, SMEs, shopping malls and business corporations are investing in energy production. It is no longer an option reserved solely for major investors: a modest manufacturing firm in southern France can easily meet a third of its electricity needs by installing solar panels.
Between 2022 and 2023 in France, the number of new installations tripled for private customers and doubled for business users. And this is just the beginning, according to Laetitia Brottier, vice-president of Enerplan, the union of solar energy professionals.
Although the complexity of integrating new producers can lead to bottlenecks in grid access, this movement nevertheless plays an essential role in efforts to decarbonize our economies, and it is made possible by the transition towards smart grids.
These new-generation grids enable more agile energy management and make it easier to integrate new decentralized energy production sources, such as wind and solar power. According to a European Union study, optimizing the use of renewable energies through smart grids could reduce greenhouse gas emissions by between 10 and 15%.
As a result, a completely new approach is taking shape, since energy production can be initiated and adjusted to reflect demand in the field, and in real time.
A multitude of sensors deployed across the chain, from the end user to the power distribution network, will enable live monitoring of power flows and consumption. This will allow for better management of the load, i.e. the maximum power supported by the system, so that switching on different household appliances at the same time will no longer cause a power cut.
In the same way as electrification, energy efficiency has a key role to play in the energy transition, allowing us to turn the heating on before we get home, control the shutters according to light and weather conditions, and so on. Connected objects will turn our homes into ‘energy ecosystems’, adapting appliances to weather conditions, to our activities, and to the price fluctuations announced by electricity suppliers based on their supply costs. This will make it possible to limit soaring household energy bills, while maintaining comfort.
This transformation will be seen not only in households and residential infrastructures but also on plants and industrial sites. It is already increasingly common for production workers and technicians to operate automated, remotely controlled systems (motors, furnaces, assembly lines, etc.), providing the grid with information on current and future energy consumption. Here again, this allows them to take advantage of the lowest possible market prices.
For this reason, manufacturers are innovating continuously to develop systems able to monitor all the components in the electrotechnical chain, such as electrical transformers, cables and connection accessories such as junctions. The purpose of digitalizing power networks is to monitor the activity and load of all these components, to prevent malfunctions and optimize use. Allowing for the measurement of partial discharges also helps to extend the service life of installations. In consequence, the monitoring of electrical infrastructures pursues two main aims: to measure and optimize power consumption, and to increase network reliability and service life.
To address the challenges of electrification 4.0, we must innovate continuously. We need to expand and modernize electrical infrastructures to cope with the constantly increasing load, to improve grid reliability, with a view to avoiding blackouts in the short term and extending service life in the longer term, and to reduce the consumption of electrical equipment through precise real-time metering.
Corporate Vice-President, Innovation, Services and Growth, Nexans
Smart meters, such as Linky in France, promote more informed energy use, since consumers are able to track their consumption, and make changes accordingly. In this way, they become more proactive as consumers, playing an active role in the energy transition.
In its latest study on this subject, Berg Insight set the number of smart meters in Europe at almost 190 million at the end of 2023, an increase of around 4% on 2022. Smart meter penetration in Europe is set to rise from around 60% in 2023 to almost 80% in 2028.
These meters also provide a wealth of valuable data on household energy consumption and trends. They help to identify energy-hungry appliances so that they can be used more effectively and/or repaired to limit energy losses.
It is important to remember that production will inevitably exceed demand from time to time. Electricity consumption remains structurally higher in the daytime, on weekdays and in winter. However, solar production is higher in summer, while high pressure systems bring cold snaps and a lack of wind for wind turbines.
This being so, a large-scale transition to sustainable energies is intrinsically linked to storage technologies. These technologies need to demonstrate their efficiency in coping with variations in the production of renewables, when the sun disappears, or the wind is not strong enough. We are referring here not only to batteries, such as those used in electric vehicles, but also to pumped storage power plants. Note that the three main types of renewable energy – water, solar and wind – are highly complementary.
Sébastien Arbola, Executive Vice-President in charge of Flexible Generation & Retail activities at Engie, said: “For every megawatt of renewable energy installed, we will need between 10 and 15% of equivalent capacity in the form of storage.”
This fast-growing market requires new solutions, such as those developed by Nexans, which is contributing to the design of transmission and distribution networks able to collect renewables at source, and to the integration of storage sites on a larger scale, more widely distributed across a given area.
In Europe, Spain and Germany have the largest number of energy storage systems in terms of capacity, at 20 and 16 Gigawatts respectively. These countries already rely on solar and wind power for over 50% of their energy requirements. In comparison, EDF in France is aiming for 10 Gigawatts by 2035.
As you can see, electricity 4.0 is far more than just a technological adjustment. With the planet on high alert, managing electricity is fundamental in the transition to cleaner energies. Renewable power plants are one way to reduce our carbon footprint, along with more efficient distribution networks, new energy storage solutions, and interconnections with networks in neighboring countries.
This will also help us to take back control of our energy supply sources. With geopolitical tensions on the rise, this is vital for limiting energy dependency, managing price fluctuations and ensuring grid security.
A leader in sustainable electrification, Nexans opened an R&D site called AmpaCity in 2022. Based in Lyon (France), this global innovation center dedicated to low-carbon electrification covers an area of over 6,000 m², including 4,500 m² of laboratories. Some 100 engineers, researchers and technicians of eight different nationalities work together here to develop innovations for the electricity of the future. In this center, the Group is developing a portfolio of almost 1,800 patents, with between 50 and 80 new inventions filed every year, in areas including electrical insulation, materials with reduced environmental impact, fire-retardant cable systems and grid monitoring solutions.
Jérôme Fournier was appointed Corporate Vice-President Innovation, Services & Growth on January 1, 2019.
He joined Alcatel Cables in 1997, working in the metallurgy division. Between 2007 and 2011, he was in charge of R&D at Nexans. From 2011 to 2018, he worked for the Michelin Group where he held a number of positions as Head of R&D. As Vice-President for innovation, he is responsible for the Group’s R&D, Design Labs, innovation partnerships and acceleration units.
As a key driver to move away from fossil fuels, which are a massive source of CO2 emissions, renewables are an essential part of the future of energy. In this context of race against time to combat climate change, a growing emphasis is put on decarbonization of electricity.
The transition to renewable energy on a large scale is reliant on energy storage technologies. Energy storage is an essential part of the transition to clean energy and the foundation upon which the decarbonization of today’s grids must be built. Due to the intermittent nature of renewable energy — mainly wind and solar — grid operators must rely on energy storage systems to balance supply and demand. This interdependence means that storage is integral to grid resilience and reliability.
It is projected that by 2030, global energy storage installations will reach a cumulative 411 gigawatts (GW), according to the latest forecast from research company BloombergNEF — an increase of 15 times the storage online in 2021.
Other significant factors driving energy storage growth are government policies aimed at curbing increasing energy prices, meeting peak demand, and energy independence. In 2022, the Inflation Reduction Act (IRA) bill was signed into law, representing the U.S.’s largest investment to fight climate change.
A major challenge facing the industry today is the need for widespread grid-scale storage technologies. Today, the most viable solution is pumped-storage hydropower, which generates electricity by pumping water into a reservoir and then releasing it to generate electricity at a different time. Unfortunately, this technology can only be applied in specific locations. As such, grid operators must resort to fossil fuel energy sources to meet peak demand periods.
However, in recent years, advancements in storage technologies are now providing new opportunities for the potential to meet energy fluctuations in energy demand without resorting to fossil fuels. Thus giving grid operators the ability to store excess renewable energy and, to some extent, help balance in real-time energy demand to meet peak periods.
Proper energy storage ensures a reliable power supply as the electricity grid becomes more dependent on variable renewable energy (VRE) sources. What often differentiates technologies are their storage capabilities, reactivity, scalability, and application requirements.
Battery storage is increasingly vital in solar and wind applications as it can be easily installed and provides a cost-effective solution. In recent years, newer battery technologies, alternatives to traditional lithium-ion batteries, have made their deployment safer and more cost-effective. For example, zinc batteries provide a viable alternative due to their superior stationary storage capability, non-flammability, and stable supply.
The emergence of newer thermal energy storage (TES) technologies is making it a viable alternative in commercial buildings. TES systems can store heat or cold to be used later and are divided into three types: sensible heat, latent heat, and thermochemical. When installed in a building, a TSE solution allows the building itself to act as a thermal battery — storing renewable energy in tanks or vessels to be used when needed.
Hydrogen energy storage is an ideal carbon-free fuel that can lessen reliance on fossil fuel backup power plants to match supply and demand. Its high-energy storage capacity makes it attractive for grids integrating larger shares of variable energy. Because energy sources like wind and solar are variable, hydrogen storage enables any excess renewable energy to be converted into hydrogen through electrolysis. This surplus hydrogen, stored in fuel cells, ensures stable and reliable carbon-free energy.
Superconducting magnetic energy storage (SMES) stores energy in a magnetic field. Because it can release stored energy instantaneously, it is considered ideal for grid applications requiring fast reaction time. Due to its negligible energy losses, there is increasing interest in finding a way to use it in large-scale energy storage applications. A few prototypes are currently in service, mostly under investigation, and they are beginning to be identified as a possible cost-effective solution.
Mechanical energy storage encompasses a wide range of technologies, including pumped hydro-storage (PHS), flywheels, compressed air energy storage (CAES), and liquid air energy storage (LAES). Today, the technology most widely used in large-scale energy storage is PHS, considered the ideal form of clean energy storage for electricity grids reliant on wind and solar energy.
Absorbing surplus energy, PHS technology releases energy when demand spikes, thus ensuring grid reliability at scale. The International Hydropower Association (IHA) estimates that PHS projects worldwide store up to 9,000 gigawatt hours (GWh) of electricity, accounting for over 94 percent of installed global energy storage capacity.
New materials and the development and supply of storage batteries for surplus renewable energy are quickly evolving to meet maturing requirements. Newer power electronics can convert stored energy into electricity to provide low to zero-impact solutions.
Nexans contributes in several ways to the energy transition, of which electricity storage is a key element, starting with the supply of transmission and distribution grids for the collection of renewable energy—wind and solar—at the source. It is crucial to collect electricity where it is generated (e.g. offshore wind farms) at an acceptable cost. The integration of storage sites is based on the same connection capacity, whether on a high-power scale or more widely distributed over a region.
Integrating variable renewable energies into smart grids will require an ever-increasing ability to monitor real-time usage requirements alongside automated systems in order to balance demand and supply loads. Faced with the need for greater flexibility, Nexans has developed new services accordingly.
For electric mobility applications, which are highly dependent on the technical and economic performance of electricity storage, Nexans supplies proper cable connections and protections, as for charging stations of electric vehicles, through specific safety functionalities to ensure safe energy storage.
Nexans has also acquired worldwide expertise and leadership in electrical and fire safety, that can be extended to the new applications of storage, such as vehicle batteries as they are becoming increasingly crucial.
The Group has been innovating for decades with industrial cryogenic and superconducting systems, such as with the development of a cryogenic transfer system of liquefied natural gas and hydrogen. As liquid hydrogen is very likely to play a key role in storage, Nexans will continue to innovate with breakthrough technologies to design tomorrow’s electricity grid.
Progress in energy storage technologies is vital to the transition to clean energy and the decarbonization of electricity. In the future, large-scale energy storage technologies will evolve and thus provide smart grids with the ability to reach their full potential. Diversifying and strengthening the supply chain of the new equipment for a massive deployment is a major challenge, especially for critical raw materials in a tense geopolitical context. Innovating by recycling materials used in end-of-life products is already a key driver, for which Nexans has prepared and positioned itself particularly well
Frédéric Lesur is senior engineer in high voltage cable systems and power grids at Nexans with 25+ years’ experience, holding several R&D positions at cable manufacturers and utilities.
In 2021 he becomes responsible for the Grid Engineering Design Lab, helping customers optimize the cabling architectures of utility-scale renewable farms projects.
His passion for science popularization made him the host of the YouTube channel WHAT’s WATT by Nexans.
Frédéric has always been an active member in standardization and working groups. Author of 50 publications, he contributes to major conferences and workshops in the field of power grids.
Today, governments from around the globe with bold commitments to reduce greenhouse gas (GHG) emissions are pressuring the construction and building sector to reduce its carbon emissions and consumption of raw materials.
And for good reason. Commercial and residential buildings are responsible for almost 40% of greenhouse gas emissions (GHG) and consume 30% of final energy globally. Decarbonizing the building and construction sector is critical to achieving net zero emissions by 2050. Doing so will need fundamental changes in how buildings are designed, built, and operated worldwide. This shift will require the sector to favor more environmentally friendly building materials and practices, institute better material efficiency strategies, and reduce raw material usage.
The move to innovative low-carbon building materials is essential to reduce the building and construction sector’s environmental impact. Concrete is not only the most commonly used building material but is responsible for 8% of global GHG emissions.
A viable alternative to traditional concrete is low-carbon brick made from recycled materials or traditional clay bricks fired in a low-carbon process using biogas from waste, biomass methanation, or solar and wind power.
Construction materials company Saint-Gobain, for example, is leading the way in the production of sustainable, low-carbon products. Earlier this year, the global company announced the production of zero-carbon plasterboard at its modernized plant in Fredrikstad, Norway. Decarbonizing the manufacturing process was possible by switching from natural gas to hydroelectric power, thus avoiding 23,000 tons of CO2 emissions annually. In addition, the company is the first in the industry to produce zero-carbon flat glass, made possible by using 100% recycled glass (cullet) and 100% green energy produced from biogas and decarbonized electricity.
Eco-friendly materials such as hemp and flax are viable alternatives for reducing the sector’s environmental impact. Cavac Biomatériaux, specializing in the industrial application of plant fibers, manufactures insulation from hemp and flax.
The 2022 Global Status Report for Buildings and Construction foresees global consumption of raw materials to double by 2060. By implementing better material efficiency strategies, there is a massive potential for the building sector to reduce its GHG emissions, according to the report’s panel.
Furthermore, material efficiency strategies, including recycled materials, in G7 countries could reduce emissions in the material cycle of residential buildings by more than 80% in 2050. Globally, the Ellen MacArthur Foundation estimates that the circular economy would reduce CO2 emissions from building materials by 38% in 2050.
A key initiative within the European Union’s Circular Economy Action Plan (CEAP) is the Digital Product Passport (DPP). This initiative aims to make sustainable products the norm in the EU by facilitating transparency throughout the value chain and boosting circular business models. Instituting a circular business model in the building and construction sector is key to reaching important sustainability targets.
Construction materials and products are estimated to consume 50% of all raw materials extracted from the Earth’s crust, and demolition activities represent 50% of all waste generated. To reduce its cables’ environmental impact, Nexans increasingly uses low-impact materials throughout the production value chain.
It is projected that the availability of important raw materials will continue to decrease in the years to come. An example is copper, an essential component of electrical cables and wiring due to its high conductivity and strength. Because copper mining can no longer meet global demand, 40% of copper production comes from recycled copper.
For over 35 years, Nexans has been recycling copper and aluminum scrap as part of its Sustainable Development policy to reduce raw material usage and promote a circular business model. In 2008, Nexans and SUEZ launched RECYCÂBLES, France’s leading recycler of cables and non-ferrous metals. The joint venture processes 36,000 tonnes annually of cables, generating 18,000 tonnes of metal granules and 13,000 tonnes of plastic. The combination of leading-edge technologies enables the generation of 99.9% pure copper granules.
Today, Nexans uses up to 15% of recycled copper in new cable manufactured and is on target to use recycled aluminum by 2024. Employing recycled copper, aluminum, and plastics provides Nexans’ customers a sustainable product without compromising quality.
With the global floor area expected to double by 2060, implementing energy-efficient and environmentally friendly building materials and practices is vital.
Nexans is working to improve the impact of its products by sourcing components that meet reduced energy usage guidelines established by the company’s Corporate Social Responsibility (CSR) directives. In addition, Nexans’ R&D product development aims to protect the environment and human health by managing the chemical substances used in its manufacturing processes and ensuring that all new projects take into account the end product’s environmental footprint. For example, starting in 2025, a large part of cables manufactured at the Nexans facility in Autun, France, will be halogen-free to reduce their toxic gas emissions in the event of a fire.
Energy-efficient, zero-carbon buildings will require looking at how building materials are designed, made, and used. This will mean examining the value chain and changing how we make, use, and reuse all materials—from the actual product to the packaging and transportation—to reduce the industry’s overall environmental impact.
Christophe Demule is the Building Innovation Director at Nexans, working within the Innovation Service and Growth Department. Previously, he held the position of Engineering VP for our Business Group Industry Solutions & Projects, bringing with him extensive experience in manufacturing. In 2021, he designed and launched the implementation of the Building Innovation Strategy with the creation of six Design Labs worldwide. With a focus on User experience by using the Design Thinking Methodology, Innovations are solving pain points of our customers and bringing added value to all stakeholders.
Superconductivity is currently the subject of intense interest and debate, fuelled in particular by research into superconductors at ambient temperature and pressure, the discovery of which would trigger a technological revolution. The many questions raised by this work are reminiscent of the scientific challenges researchers had to overcome when they discovered high-temperature superconductors in 1986. A look back at this crucial technology for the cable industry, exploring recent advances, persistent challenges, but also how Nexans is providing the world’s very first superconducting cable system integrated into a rail network.
As we move towards an all-electric future, the need to increase power supply in cities becomes ever more urgent. Equally important is the need for resilience: as electricity becomes the main source of energy, supply will need to be 100% reliable. Downtime is not an option.
Superconducting cable are electrical connectivity miracles. They have unique qualities that make them perfectly suited to modern, high-capacity electrification projects in cities.
First, superconducting cables can carry extraordinarily high currents – far greater than conventional copper or aluminium cables. This makes it possible to transmit and distribute electricity at relatively low voltages. In practical terms, this means there is less need for substations in city centres – a major cost saving.
Second, superconductors can transmit a huge amount of power relative to their size. For example, a single superconducting cable with a diameter of just 17 cm can transmit 3.2 GW – enough to power a large city. Corridors for superconducting cables can be as narrow as one metre, meaning they can be deployed with minimal disruption.
Third, superconducting cables do not produce heat and can be fully shielded on an electromagnetic standpoint, so there is no interference with power, telecom and pipe networks which typically criss-cross cities. Many of the constraints that govern cable routing do not apply when superconductors are used.
On top of this, superconductors are incredibly efficient. Superconducting cables have extremely low resistance when an AC current is carried and no resistance when the current is DC, so losses are minimal.
Nexans is working with SNCF, France’s national rail company, on a pioneering project to boost power supplies to Montparnasse station in Paris using superconducting cables.
Montparnasse is one of the busiest railway stations in France and handles more than 50 million passengers a year. This figure is expected to exceed 90 million by 2030. Handling new demand will require extra trains – and extra power.
As with any city-centre power upgrade, the big challenge at Montparnasse was finding a way to bring in a new power supply without the need to dig up the surrounding roads – which can be a long, expensive and disruptive process.
Fortunately, the existing cable route between Montparnasse railway station and the substation that serves it had spare conduits available. Unfortunately, there were only four of them. Using conventional copper cables to deliver the required power would require a dozen of cables. What could be done?
Superconducting cables are the answer. Nexans’ solution uses just two cables, each less than 100mm in diameter so they can be easily threaded through the existing conduits. Despite their small dimensions, each cable is capable of handling 5.3 MW, or 3500 A at 1500 VDC – a huge amount of electrical energy.
What makes this project so significant is that it is the first-ever use of superconducting cables in France, and the first time superconductors are integrated in a railway grid anywhere in the world. The new power supply at Montparnasse will be commissioned in 2023.
The Montparnasse project underlines the massive potential superconducting cable systems have for boosting power supplies in cities – particularly where site constraints place limits on the use of conventional copper and aluminium cabling.
Rail transport aside, superconducting cable systems are likely to play a bigger and bigger role in satisfying the rising demand for electricity. This is being driven by new commercial uses – such as data centres – and by new sources of domestic consumption, which include electric vehicle charging, heat pumps and air conditioning.
In addition to meeting increased demand for bulk power, superconducting systems will play a critical role in boosting the resilience of urban electricity networks.
The Resilient Electric Grid (REG) project in Chicago, USA, underlines the direction of travel. Nexans designed, manufactured and installed a superconducting cable for the REG system, which helps to prevent power outages by interconnecting and sharing excess energy capacity from nearby substations, and by preventing high fault currents.
Nexans is the global leader in superconducting cable systems. Our unique capabilities in R&D, innovation, testing, manufacturing and deployment mean that we are perfectly placed to assist our customers, partners and stakeholders as they prepare to electrify the future.
With the global demand for electricity expected to increase 20% by 2030 and the increasing pressure to transition to renewables, the War of the Currents is once again in the spotlight.
Back in the 1880’s, when Westinghouse and Edison were battling for their respective approach to electricity distribution, the infrastructure to transmit direct current (DC) power was at the time inefficient and expensive. And as such, Nikola Tesla’s approach using alternating current (AC) ultimately won. And since that time, our current electrical infrastructure is dominated by AC technology. But times have changed since then.
Today, over 70% of devices in a building need DC to operate. A conversion from AC to DC results in energy wastage of upwards to 20%, according to EMerge Alliance. Reducing the need to convert has profound implications regarding energy savings and environmental impact. And this is why eliminating or reducing AC to DC conversion in buildings is critical.
The International Energy Agency reports that in 2021 the operation of buildings accounted for 30% of global final energy consumption and 27% of total energy sector emissions. As a result, governments are placing increasing pressure on the building sector to move towards ambitious energy performance directives to reduce the carbon footprint of buildings. Directives such as “nearly zero-energy buildings” in the U.S. and in Europe aim for buildings to require a low amount of energy provided by renewables produced on-site or nearby.
Directives like these, along with the growing usage of self-consumption, onsite battery storage and DC-powered devices from LED lighting and heating, ventilation and air-conditioning (HVAC) systems to electric vehicles (EV) and electronic devices, are driving the building industry to switch to DC power distribution.
In terms of electric power distribution, there is a progressive shift towards DC due to the growing interest in low voltage (LV) and medium voltage (MV) microgrids reflecting the fundamental changes in how electricity is generated, stored, and consumed. We are convinced that AC and DC networks will coexist with a significant share.
However, expert knowledge of the behavior of the insulation system is vital to ensuring the reliability of LV cables and accessories in buildings.
The behavior of LVAC cable systems is largely known but not for LVDC.
One of the focuses of Nexans’ R&D center AmpaCity is to optimize our cable design: we perform this optimization, which is achieved by understanding the electrical behavior of insulation systems under DC stress conditions and the impact of DC current on cable breakdown, ageing and corrosion. We’re also committed to investigate on more effective polymers for DC cable insulation with lower environmental impact than AC classical solution.
As mentioned earlier, power generation is moving closer to demand. Rooftop solar photovoltaics are becoming more commonplace. According to the EU Solar Energy Strategy, EU will make compulsory the installation of rooftop solar in new public and commercial and residential buildings. Furthermore, PV panels produce natively DC. In addition to the widespread implementation of on-site battery storage for uninterrupted power supplies (UPSs) used by businesses and data centers to maintain supply security, along with the growing deployment of battery energy storage systems (BESSs) for grid balancing.
Another major change in recent years is the growth of electric vehicles (EVs) and the need for DC charging stations in commercial, residential, and office buildings. With global policies encouraging and mandating the move to EVs, the market for chargers is growing rapidly, at an estimated compound annual growth rate (CAGR) of 29% from 2023 to 2050.
Distributing DC power locally throughout a building provides important benefits in safety, costs, and device reliability.
From a safety point of view, AC power is inherently more dangerous. In fact, the risk of electrocution of the human body by DC is considered to be lower than with AC, as the total impedance of the human body decreases as the frequency increases. And for high growth categories such as EV chargers, the move to DC versus AC chargers means better overall safety.
The data center sector accounts for around 4% of global electricity consumption, and is set to continue growing. Improving energy efficiency in this sector is crucial. For example, cost savings in electricity-intensive buildings such as DC-powered data centers can represent savings of 4-6% compared to conventional AC installations.
In addition to the reduction in electrical losses linked to the transport of electricity in cables, there is also the reduction in AC-DC conversion losses.
Providing DC devices (loads) with DC power eliminates power losses incurred through conversion and thus eliminates an estimated 5 to 20% in energy waste. In addition, the AC to DC conversion process at the device level can shorten its operating life. For example, distributing DC power directly to a LED fixture (thus avoiding the AC to DC conversion) can substantially extend its operating life. Plus, distributing DC power locally reduces the cost and footprint of AC to DC adapters and converters.
In conclusion, DC power distribution in buildings is on the horizon, but change will take time. Even with a move to DC microgrids, there are other significant challenges to be addressed in the coming years, notably the uptake by industry professionals, many of whom need to become more familiar with DC power and its benefits. This is due to the long experience and knowledge of AC power.
Furthermore, advancement in building standards and codes which address specifications for DC-powered devices is required, as with the further analysis of the cost-effectiveness of DC power distribution in retrofit and new construction.
Cables are a fundamental part of a building’s electrical infrastructure and are a critical player in the transition to DC-powered structures. The buildings of tomorrow will be smart, connected, sustainable, and powered by DC. Nexans is committed to this transformation by manufacturing specific cable systems compatible with these new infrastructures. And our strategic partnerships and involvement in key industry groups are helping to make the transition to DC-powered buildings a reality.
Lina Ruiz is responsible for the LVDC, MVDC and new architectures technical platforms for Nexans within the Research and Territories Techno Centre.
She previously worked as a project manager and technical innovation team leader in the field of renewable energies. In 2023, she joined Nexans to accelerate the exploration program on direct current for low and medium voltage. In her current role, she is responsible for providing new and differentiated solutions in the field of direct current.
A wave of change is happening in the building industry. As we’ve witnessed in the last couple of years, the sector once referred to as “brick and mortar” is bracing itself for a digital revolution. Traditionally slow to embrace new technologies, resulting in decades-long productivity stagnation, digitalization of the $7.5 trillion building construction market is long overdue.
In the 2022 McKinsey global survey of over 500 executives in the building products sector, an overwhelming 70% expected to increase their investment in innovation and R&D. So much so that survey respondents ranked digital design tools such as building information modeling (BIM), software solutions and automation ahead of sustainability.
Investing in innovation and R&D is expected to be the key market differentiator in the next three to five years – rippling across the entire value chain and driven in part by climate change and productivity.
Productivity has long been a major issue in the construction sector, with the average capital project running 20 months behind schedule and a staggering 80% over budget. The industry is increasingly applying digital tools across the entire spectrum, from design and construction to operations, but at varying levels depending on the construction phase.
Improving productivity necessitates closing the gap between product and document management systems to simplify and increase technician productivity.
Even as gains have been made, there is vast potential to further improve productivity through increased usage of digital technologies in all phases of the processes—design, construction, and operations.
With increasing government regulation for the industry to decarbonize, digitalization is a crucial enabler in reducing the environmental impact of construction projects globally.
As the electrification of buildings grows and expands in the years to come, ensuring efficient implementation of cabling solutions is essential to safety and productivity gains. Narrowing the gap between productivity management tools and document management systems is one key to easing the work of electricians. As skilled labor shortages continue, further enhancements in information access and traceability are vital.
The digital connection between the physical product and its accompanying documentation is lacking in the industry. This is often the case with electrical products, where installers seldom have easy access to up-to-date documentation. The lack of traceability means details such as who installed the product are often lost once the initial work is completed.
As buildings move from fossil fuels to renewable energy, the demand for skilled electricians will increase, along with the need for tech-related professionals to manage the influx of digital systems and tools required to meet this industry shift.
As the building sector moves forward in its digital transformation, Building Information Modeling (BIM) will increasingly become the standard and foundation of construction projects. This bridging of physical building elements with their accompanying digital format (referred to as BIM content) facilitates the working processes throughout a building project’s value cycle from planning and design to construction and operations.
BIM content provides architects, designers, and builders easy access to essential product information such as installation instructions, energy consumption, eco-labels, operation costs, and product lifecycle. Nexans is working with BIM providers to integrate its offerings so as to facilitate electrical cable installation, maintenance, and safety.
As newer technologies such as drones, robotics, and 3D printing become more commonplace on construction sites, ensuring that BIM is the foundation of the construction industry’s digital strategy is critical. According to McKinsey, the move to 5D BIM, combining 3D physical models of buildings with cost, design, and scheduling data, could result in a 10% savings in contract value by detecting clashes, reducing project life span, and potentially reducing material costs by 20%.
The shift from analog to digital documentation and traceability is key to moving the building products market forward. And thus, reversing the industry’s fragmentation to ensure better productivity, cost efficiency, and safety. This is especially important in the electrification of buildings to provide safe installation and operations.
Thanks to its cloud-based app, Evermark™, Nexans provides its clients easy access to information about the physical product installed, such as follow-up of maintenance, electrical drawings and product data. Thanks to NFC tags, Evemark™ provides a digital connection between the physical product and the necessary documentation, and ensure full traceability of the electrical installation throughout the product’s lifecycle—from implementation phases to maintenance and replacement. It provides immediate access to pertinent information on- and off-site, reducing cost and time while increasing productivity.
With new technologies come new possibilities. The key is ensuring that future digital tools integrate seamlessly for a heightened level of customer satisfaction.
Jenny Nÿstrom is Nordics Design Lab & Innovation within Nexans. She has been working in the cable industry since nearly 20 years, being involved in the domain of product marketing and product management, mainly for Building, Telecom and Utility sectors.
