Bermuda Electric Bus Fleet Electrification Project

1. Project Background: Bermuda’s Urban Transport Electrification Challenge

In 2024, Bermuda officially launched its urban public transportation electrification program, aiming to replace a large portion of its diesel bus fleet with eco-friendly electric buses to reduce carbon emissions and improve service stability. As an island nation with high humidity, strong salt fog, and strict North American electrical safety standards, the project placed extremely high requirements on wiring materials.

The client, a local public transport infrastructure provider, faced several urgent challenges during the early design stage. First, the project required full UL certification to pass local safety inspections, and many generic cables could not meet regulatory compliance. Second, the coastal environment caused rapid corrosion and aging of ordinary wires, leading to potential failures and increased long-term maintenance costs. Third, the internal wiring of electric buses includes both fixed control circuits and flexible mobile wiring areas, requiring two different types of wires with distinct performance characteristics. Fourth, the project schedule was tight, and the client needed a supplier with proven experience in electric vehicle projects to avoid delays in design, production, and delivery.

Without a professional and targeted wire solution, the client risked inspection failure, operational breakdowns, and project postponement, which would directly affect the official launch of Bermuda’s electric bus fleet.

2. Our Customized Solution: ST Wires & MTW Wires for Different Scenarios

Based on the client’s actual needs, we developed a complete dual-wire system using ST wire and MTW wire, two specialized UL-certified products designed for separate functions inside the electric buses. This dual-product structure solved the one-size-fits-all problem of conventional wiring solutions and significantly improved safety and durability.

MTW Wires (UL 1063) – For Fixed Control & Power Distribution

MTW (Machine Tool Wire) under UL 1063 was selected for fixed internal circuits, including power distribution boxes, control modules, air conditioning systems, lighting circuits, and sensor lines. We provided sizes ranging from 18 AWG up to 4/0 AWG to match different current-carrying demands.

MTW wire features thermoset insulation, stable electrical performance, and excellent oil resistance and heat resistance, with an operating temperature up to 105°C. It performs best in fixed, non-moving routing paths, ensuring long-term stability without deformation or cracking. Compared with general-purpose wires, MTW has stronger resistance to chemical substances and is more suitable for long-term use in enclosed bus electrical cabins.

ST Wires (UL 62) – For Flexible & Mobile Wiring Sections

ST wire under UL 62 was applied to flexible and semi-mobile areas such as door control systems, steering auxiliary circuits, wiring harnesses near rotating components, and connections subject to frequent vibration. We supplied sizes from 16 AWG to 2 AWG to support reliable power transmission under bending and vibration.

ST wire features excellent flexibility, cold resistance, and abrasion resistance. Its specially formulated jacket allows repeated bending without cracking, making it far more durable than standard rigid wires in dynamic environments. For Bermuda’s coastal climate, ST wire also provides better resistance to humidity and salt fog, reducing aging and failure risks.

By using MTW for fixed circuits and ST for flexible sections, we created a highly optimized, purpose-built wiring system that perfectly matched the electric bus structure.

3. Product Advantages & Why the Client Chose Our Solution

The client chose our ST and MTW wires not only because of complete certification but also because our products solved pain points that other suppliers could not address.

First, full UL certification coverage. Our MTW wire complies with UL 1063, and ST wire meets UL 62 standards. Both have passed VW-1 flame testing, ensuring full compliance with Bermuda’s electrical safety regulations. This eliminated the client’s worries about inspection failures.

Second, environmental adaptability. Ordinary wires deteriorate rapidly in high-salt, high-humidity environments. Our ST and MTW wires use weather-resistant insulation materials that maintain stable performance in coastal conditions, greatly extending service life and lowering maintenance costs.

Third, scenario-based design. Other suppliers offered only single-type wires, which either lacked flexibility or were unsuitable for fixed distribution panels. Our dual-wire solution improved overall safety and reliability.

Fourth, mature project experience. We have previously participated in multiple electric vehicle and transportation electrification projects, allowing us to quickly provide accurate size matching and installation suggestions without repeated testing or modification.

4. Strict Quality & Safety Assurance

Quality and safety were the top priorities throughout the project. All ST and MTW wires were produced under a complete ISO 9001 quality management system. Each batch underwent conductor resistance testing, voltage withstand testing, insulation thickness testing, and bending durability testing before shipment.

All products carry authentic UL certification, with traceable certification numbers. The wires also meet RoHS environmental requirements, fully aligning with Bermuda’s green transportation policies. Strict quality control ensured zero defects and zero safety hazards during on-site installation and operation.

5. Efficient Production & Fast, Stable Delivery

Understanding the client’s tight schedule, we activated our rapid response mechanism. Using our mature production lines and sufficient raw material inventory, we quickly arranged mass production for ST and MTW wires without compromising quality.

Our logistics team planned an efficient shipping route suitable for Bermuda, ensuring on-time arrival. Although we do not disclose specific delivery days, we maintained an efficient and responsive pace that met the client’s construction timeline and supported the smooth progress of bus assembly.

Our technical team also provided remote wiring guidance, helping the installation team correctly distinguish between ST and MTW applications, optimize routing, and avoid improper use.

6. Project Results & Client Feedback

The entire wiring system was successfully put into use with the electric bus fleet. After continuous operation, the wires maintained stable performance with no aging, cracking, or functional abnormalities. The system fully passed local safety inspections, and the project was completed as scheduled.

The client expressed high recognition of our solution. They commented that our ST and MTW wires effectively solved their certification, durability, and environmental adaptation challenges. The dual-wire design improved overall system stability and reduced potential failure risks. They also praised our fast response and professional technical support, which made the entire project run efficiently.

7. Long-Term Value for Future Transportation Electrification

This Bermuda project further proves our ability to provide professional wire solutions for global transportation electrification. Whether for electric buses, charging stations, commercial EVs, or marine electrical systems, we can provide customized UL-certified ST, MTW, and other automotive-grade wires based on actual working conditions.

We combine certification completeness, product reliability, scenario-based design, and efficient delivery to help international customers reduce costs, lower risks, and ensure project success.

8. Contact Us for Your Custom Wire Solutions

If you are engaged in electric vehicle, transportation electrification, or infrastructure projects and need reliable UL-certified ST, MTW, or other specialized wires, welcome to contact us for customized solutions.

Dongguan GERITEL Electrical Co., Ltd.Tel/WhatsApp/WeChat: +86 135 1078 4550 / +86 136 6257 9592

Email: manager01@greaterwire.com