Manufacturing stage of second Malta-Sicily Interconnector cable completed

Manufacturing of the high-voltage second Malta-Sicily interconnector cable has been completed at the Nexans’ facility in Charleston, USA, Malta’s Energy Ministry has said.

“This achievement marks a major step forward in the delivery of the Interconnector 2 (IC2). The successful manufacturing and testing of the subsea cable, together with the completion of preparatory offshore works, is another important step that helps us advance to the installation phase,” Energy Minister Miriam Dalli said.

“The IC2 project is a strategic investment aimed at enhancing Malta’s electricity interconnection with mainland Europe, increasing resilience, supporting the integration of renewable energy, and contributing to the country’s long-term energy transition goals,” Dr Dalli said.

The manufacturing process included several specialised stages, beginning with the production of the fibre optic cables in Norway and the drawing of the copper conductors to the required shape and size.

After the insulation and sheath extrusion processes, the three cable phases were then assembled together with the fibre optic cables and fillers to form the complete subsea cable. This was followed by the armouring process, which provides the cable with the structural integrity and mechanical protection required for subsea installation and long-term operation. 

The cable was produced in sections of approximately 10km each, which were subsequently jointed within the factory to form two main cable lengths. One of these lengths also includes the spare cable, which will be stored in Malta for future contingency and repair purposes.

The ministry said that the cable underwent rigorous testing.

The project has now entered its next critical phase, with the cable awaiting load-out onto the newly launched cable-laying vessel Nexans Electra.

Interconnect Malta Divisional Manager (Design and Automation), Joseph Vassallo said: “We are proud to collaborate with leading international partners to deliver infrastructure that strengthens Malta’s energy security. The completion of manufacturing and successful comprehensive testing of the 103km subsea cable at Nexans’ Charleston facility, represent a major technical and logistical achievement for the IC2 project.” 

This €300 million investment has been approved for ERDF funding under the priority “promoting a clean and just energy transition” and contributes directly to smart and stable energy systems. The project has been recognised as an “Operation of Strategic Importance” in the 2021–2027 Programme, with €261 million allocated in European funding.