1S; 398 (Part IM) - 1976
(Reaffirmed 2004 )
‘Edition 3.3
(1985-04)
Indian Standard
SPECIFICATION FOR
ALUMINIUM CONDUCTORS FOR
OVERHEAD TRANSMISSION PURPOSES
PART III ALUMINIUM CONDUCTORS,
ALUMINIZED-STEEL REINFORCED
(Second Revision )
(Incorporating Amendment Nos. 1, 2 & 3)
UDC 621.315.55 : 659.71 : 621.315.1
© BIS 2002
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARC
NEW DELHI 110002
Price Group 4IS : 398 (Part IN) - 1976
Indian Standard
SPECIFICATION FOR
ALUMINIUM CONDUCTORS FOR
OVERHEAD TRANSMISSION PURPOSES
PART II ALUMINIUM CONDUCTORS,
ALUMINIZED-STEEL REINFORCED
(Second Revision )
‘Conductors and Power Cables Sectional Committee, BTDC 32
Charman Representing
‘SHRIM.R. BHAT Bombay Suburban Blectrle Supply Ltd,
Bombay
Members
‘SHREN. D. CHAWLA (Alternate to
Shei M. Re Bhat)
‘SHREK. K. AGRAWAL. Directorate General of Posts & Telegraphs,
‘SHR: V.R. SUNDARARAN (Alternate). “New Delhi
Suu S. K. Biswas (GuPTs) Directorate General of Mines Safety
‘SHREN, KCSEN (Alternate) (Minlstry of Labour, Employment &
RehubttZaton). Bh
We Cons, Brann Dicsetarate General of Teehneal
‘Shr HE ©: Bat Aternate) ‘Bevelopment & Production (A),
ain tienen, New Deh
SHRI K, V. CHAUBAL Federation af Blectricy Undertakings of
Tala, Bombay
Situ C. Dascurts, Calg Etre Supply Corporation Le,
ca
Derury Dinector Buzcrnica. ‘Naval Headquarters
NOCMEERING (MATERIA
‘STAFF Orrioee BuEcTRICN,
TENGINESAING (DESIG) {Akernate)
SuuM, Dey ‘Indien Cable Co Ltd, Calcutta
SHR V, Ravaan (Alera)
Sung: L. Dosion Bombay Elecite Supply & Transport
‘SHRI AVTAR SING: ( Alternate) "Undertaking Betay: oa
MALR.S, Duanota,
'SHREC, M. BHAT ( Alternate)
DIRECTOR (TRANSWISSION)
Directorate of Standardization, Ministry of
Defence
Central Electricity Authority, New Delhi
‘DePury Dmacton (Teewsiassion) ( Aliemate)
{Continued on page2)
‘© IS 2002
BUREAU OF INDIAN STANDARDS
‘This publication is protected under the Zndlan Copyright Act (KIV of 1957) and
‘reproduction in whole or in part by any means except with written permission of the
‘publisher shail be doemed co be an Infringement of copyright under the sald Act.IS : 398 (Part IM) - 1976
(Conuinued from page 1)
Members Roprosonting
‘Sum V. A. KRISHNAMURTHY Cnn Public Works Departments,
‘SURVEYOR oF WoRKS II (ELEcTrucat) { Alternate)
SHRED. R. MANOHAR
‘SHRI JS. BHAN ( Alternate)
SRI M. N. MUKERDES
National Insulated Cable Co of tndia Lid,
‘Caleurta
allway Board (Ministry of Ratlways)
SHRI C. A. SANKARAKARAYANAN ( Alternate}
‘Sum S, K MUKHEREE.
‘Saar S. N. Navan
‘SHRI P. K, KRISHNAN NAIR ( Alternate]
‘SHRI V. G.G. NavaR.
‘Stet V. K, CHATURVEDY (Alternate)
SHRI J, S, Passi
‘Sia P-L. KAPUR ( Alternaze)
SHRI A.S. Preto.
SHEL A. K, RAMAN
‘National Test House, Calewtta
‘Aluminium Industries Ltd, Kundara
)
Oriental Power Cubles Led, Kata
Dirertrate Genera of Suppies& Disposals
‘faspecton Wingy New Dae
Delp Elertele Supply Undertaking,
‘New Delhi
‘Asian Cables Corporation Ltd, Bombay
SHE BIC MUNDHRA (Alternate
‘Suma KCN RaMaswasey Directorate General of Technical
Seat. P Clrna(Aurote) Bevigomane New oe
SH M. J. “Tota Fiyro-Elecrie Power Ltd,
‘Suni, V. GonDHALEKAR (Alemate) 'Boiay nd
‘Sen S. SABAPATHY
“Tamil Nadu Electricity Board, Madras
‘SHRIP. S. THIRUNAVUNKARASU (Alternate)
‘Suri L. KC SaNCHE
‘SHRI A, S. BHATTACHARJEE ( ARernate
‘Sura PS, SHadt
‘SHRIS. R. PADMANABHAN ( Alternate)
Stow. P. SACHOEY,,
Fort Gloster Industries Ltd, Calcutta
(Cable Corporation of India Ltd, Bombay
Director General, ISI ( Ex-ofcto Member)
Director (Elec tech)
Seereraries
Sher T. RASKRAMAN
Deputy Director (Elec tech), BIS.
SHRI Hanceianan SINGH
Deputy Director (Elec teh), BIS
Panel for Revision of IS ; 398-1961, ETDC 32 : P11
Convener
‘SHRIM. DRY Indian Cable Co Ld, Calcutta
Members
DIRECTOR (TRANSMISSION) ‘Central Blecriety Authority, New Delhi
‘SHRI B. S,
Kocusr,
‘SHRI. RAO (Akernate)
SHRI O. P. MamauR
‘SHRI. IC MUKHERIT( Aliernace)
SHRI. K, KRISHNARNAM
Sur. SaBaPaTHy
Rural Blectrifention Corporation Ltd,
New Deihi
Electrical Manufacturing Ca Ltd, Galeutta
‘Aluminium Industelos Ltd, Kundara
‘Tamil Nadu Blectclelty Board, Madras
2IS: 398 (Part ID) - 1976
Indian Standard
SPECIFICATION FOR,
ALUMINIUM CONDUCTORS FOR,
OVERHEAD TRANSMISSION PURPOSES,
PART DI ALUMINIUM CONDUCTORS,
ALUMINIZED-STEEL REINFORCED
(Second Revision )
®. FOREWORD
4 This Indian Standard (Pare I) Second Revision) was edupted by
the Indian Standards Institution on 3 June 1976, after the dr
finalized by the Conductors and Power Cables Sectional Committee had
been approved by the Electrotechnical Division Council.
(0.2 This standard was originally published in 1953 and the first reviston
was brought out in 1961, The second revision has been undertaken with
‘a view to effecting the following modifications:
2) To line up with the international standards;
1) To further rationalize the sizes of stranded aluminium conductors.
steel relnforced aluminium conductors and to Introduce a few sizes.
which will have a higher aluminium/steel ratio:
©) To introduce aluminized-stee! reinforced aluminium conductors:
a
)To Introduce aluminium alloy stranded conductors
{aluminium-magnesium-silicon type).
0.2.1 While revising this standard, it was decided to issue it in different
Barts covering diferent types of conductors. This part dealing with
aluminized-steel reinforced aluminium conductors form Part [lof the
series. Other parts in the series are given below:
Part I Aluminium stranded conductor
Part If Aluminium conductor, galvanized-steel reinforced
Part IV Aluminium alloy stranded conductors (under preparation)
0.3 The important deviation from the standards published by the IEC is
with respect fo the value adopted for resistivity. Owing to dificuties in
petting EC grade aluminium of 2 higher conductivity locally, tho
standard has prescribed a resistivity of 0.028 45 ohm.mmé/m at 20°C,
whereas, the ‘value prescribed in the IEC standard Is 0.028 264
‘ohm mmé/m at 20°C.1S: 388 (Part ITD) - 1976
0.4 In the preparation of this standard, considerable assistance has been
derived from AS 1220, Part. . ‘Draft Australian Standard Specification
for aluminium conductors for overhead transmission purposes: Part...
Aluminized-steel reinforced (ACSR/AZ), Doc: 1898" issued by the
Standards Association of Australia.
0.5 The values of modulus of elasticity and coefficient of linear
expansion are given in Appendix B for information.
0.6 This edition 3.3 incorporates Amendment No. 2 (May 1983) ond
Amendment No. 3 (April 1985). Side bar indicates modification of the
text as the result of incorporation of the amendments.
0.7 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final values, observed or calculated,
essing the result of a test, shall be rounded off in accordance with
IS: 2-1980*, The number of significant places retained in the rounded
off values should be the same as that of the specified values in this
standard.
SECTIONI GENERAL
1. SCOPE
11 This standard (Part IM) covers the requirements and tests for
aluminium conductors, aluminized steel reinforced used for overhead
power transmission purposes.
2, TERMINOLOGY
2.0 For the purpose of this standard, the following definitions in addition
to those given in IS : 1885 (Part XXXIN)-1871t shall apply.
21 Aluminium Conductor, Aluminized-Steel_ Reinforced —
Conductar consisting of seven or more aluminium and aluminized steel
wires built up in concentric layers. The centre wire or wires are of
aluminized steel and the outer layer or layers of aluminium.
2.2 Diameter — The mean of two measurements at right angles taken
at the seme cross section
2.3 Direction of Lay — The direction of lay is defined as righthand or
left-hand. With right-hand lay, the wires conform to the direction of the
central part of the letter Z when the conductor is held vertically. With
left-hand lay, the wires conform to the direction of the central part of the
letter $ when the conductor is held vertically.
2.4 Lay Ratio ~ Ratio of the axial length of a complete turn of the helix
formed by an individual wire in a stranded conductor to the external
diameter of the helix.
"Rules for rounding off numerleal values {s0vlsed).
{$Blectrotechnical vocabulary: Part XXIL Cables, conductors and accessories for
tectrieity supply.
41S: 398 (Part IM) - 1976
3. PHYSICAL CONSTANTS FOR HARD-DRAWN ALUMINIUM.
3.1 Resistivity — The resistivity of aluminium depends spon its purity
and its physical condition, For the purpose of this standard, the
maximum value permitted i 0.028 45 ohm.mm?/m at 20°C, and this
‘value has been used for calculation of the maximum permissible values
of resistance.
Noms — Is not intended to chock the reisvty frm che measured values of
resistance,
3.2 Density — At a temperature of 20°C, the density of hard-drawn
aluminium has been taker ac 708 gems a
3.3 Constant Mass Temperature Coefficient of Resistance — Ata
temperature of 20°C the constantmass temperature coeficient of
resistance of hard-drawn aluminium, measured between two potential
points rigidly fed tothe wire, the metal belng allowed to expand freely,
been taken as 0.004 per degree Celsius.
3.4 CocMicient of Linear Expansion—The coefficient of linear
expansion, of hard-drawn aluminium at O°C has been taken as
23.0 x 10° per degree Celsius. This value holds good for all practical
Purposes over the range of temperature from 0°C to the highest safe
‘operating temperature.
4, PHYSICAL CONSTANTS FOR ALUMINIZED STEEL WIRES
4.1 Density — Ata temperature of 20°C, the density of aluminized steel
‘wire has been taken as 7.80 glem’.
4.2 Coefficient of Linear Expansion — In order to obtain uniformity
{in calculations, 2 value of 11.8 x 10-8PC has been taken as the value for
the coefficient of linear expansion of aluminized steel wires used for the
cores of steel reinforced aluminium conductors.
SECTION Il MATERIALS
5. MATERIAL
5.1 The conductor shall be constructed of hard-drawn aluminium and
aluminized steel wires which have the mechanical and electrical
properties specified in Tables 1 and 2.
The coating on the aluminized steel wires may be applied by the hot
process of the electrolytic process. ”
‘When specified by the purchaser, neutral grease may be applied between
the layers of wires.
Nore— Lithium soap grease corresponding to Grade TI of 1S:7628-1974* is
| Sitsictorsuch apie
| ~ *Specification for thtum soap greases
51S : 398 (Part IM) - 1976
6. FREEDOM FROM DEFECTS
1.1 The wires shall be smooth and free from all imperfections, such as
spills and splits,
SECTION III DIMENSIONS AND CONSTRUCTION
7. STANDARD SIZES
7.1 Wives
7.1.1 Nominal Sizes — The aluminium and aluminized steel wires for
the standard constructions covered by this standard shall have the
diameters specified in Tables 1 and 2. The diameters of the steel wires
shall be measured over the aluminium coating
7.12 Tolerances on Nominal Sizes
1.1.2.1 Aluminium wires — A tolerance of + 1 percent shall be permitted
on the nominal diameter specified in Table 1
‘TABLE 1 ALUMINIUM WIRES USED IN THE CONSTRUCTION OF
ALUMINIUM
CONDUCTORS, ALUMINIZED-STEEL
REINFORCED
{ Clauses 5.1, 7.1.1, 7.1.2.1, 12.2.1, 12.5 and A-3.2)
DiaweTeR CROSS-SECTIONAL MASS RESISTANCE BREAKING LaKD,
aah oF ATZO'C, Min
Nom Min Max NOMINAL Max”
DIAMETER Wine, Before Alter
‘Stranding Stranding
o @ ® , Oo @ a @
me mmm mm? kgm fm kN aN
160 148152 1767 478 1654 © 032030
198 ed 138 sor Ble 9625 O84
Zi 208 213 3497 845 8283 «oss eo
259 256 262 $20 1424 $527 sons
300 237 305 Toss eal stor, AL
318 3158321 raw = tar S81 128128
335 332 338 Bad 2382 3288.38
350 34s 353 Sel 2501 3028 ss La
353 349337 s7er 2645 Zend BTA.
380 378 sae 34 goes 2821800
409 405 41301343631 2208 20R 98
413 400 4173403812185 213 Be
4m 487 477 1750 4730186127824
Nove 1—The resistance has been caleulated from the maximum value of
resistivity and the cross-sectional area based on the minimum diameter,
Note 2 —The resistance of individual wires shall be such that the completed
stranded conductor meets the requirements of the maximum resistance specified In
‘Table 3 calculated by epplying the relevant stranding constants given in Table 5.
6IS: 398 (Part IM) - 1976
7.1.2.2 Aluminkzed steel wires — A tolerance of +2 percent shall be
permitted on the nominal diameter specified in Table 2.
‘TABLE 2 STEEL WIRES USED IN THE CONSTRUCTION OF
ALUMINIUM CONDUCTORS, ALUMINIZED-STEEL
‘REINFO)
(Clauses §.1, 7.1.1, 7.1.2.2, 12.2.1, and A-3.2)
DueTeR, CROSS-SECTIONAL — Mass BREAKING LOAD.
Area oF Mia
Nom Min Max’ Nowat [oe
DuwseTeR WIRE fore After
Stranding Stranding
o 8 @ @, @ @ a
mm mam mm me? gem RN iy
150147188 1767 13.78 234 2u3
sr 1s¢ 180 1936 15.10 248 234
198 182 200 3017 23.53 333, 384
Zul 207245 3.497 ma 444 4.22
230 225235 4185 324} 515, 430
259 284284 5750 4103 633 5.20
300 294 306 7.069 55.13 833
318 31z 324 7942 e135, 913
335 328 342 aad 6875 10.14
353 346360 9787 Test 11.25
40940147 134 10248 1428
7.2 Aluminium Conductors, Aluminized-Steel Reinforced
7.2.1 The sizes of standard aluminium conductors, aluminized-steel
reinforced shall be as given in Table 3.
7.2.2 The resistances shall be in accordance with Table 3. The masses
(excluding the mass of grease, if applied) are given in Table 3 for
information.
8. JOINTS IN WIRES
8.1 Aluminium Wires —In aluminized-steel reinforced, aluminium
conductors containing any number of aluminium wires, joints. in
individual aluminium wires are itted, in addition to those made in
the base rod or wire before final drawing, but no two such joints shall be
Jess than 15 m apart in the cor ete et ‘Stranded conductor. Such joints:
shall be made by resistance or cokt pressure butt-welding. They are not
required to fulfil the mechanical requirements for unjointed wires,
Joints made by resistance butt-welding shall, subsequent to welding, be
annealed over a distance of at least 200 mm on each side of the jaint.1S : 398 (Part IM) - 1976
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GHOUOANITA TISLS-GAZINTNATY ‘SHOLONGNOD WAININNTY £ TTAVL1S : 398 (Part IM) - 1976
8.2 Aluminized Steel Wires — There shall be no joints, except those
‘made in the base rod or wire before final drawing, in steel wires forming,
the core of a steel reinforced aluminium conductor, unless the core
consists of seven or more aluminized steel wires. In the latter case joints
in individual wires are permitted in addition to those made in the base
od or wire before final drawing, but no two such joints shall be less than
15 m apart in the complete stéel core. Joints in aluminized steel wires
shall be made by resistance butt-welding or brazing and shall be
protected against corrosion.
9, STRANDING
9.1 The wires used In the construction of aluminium conductors
aluminized-steel reinforced shall, before stranding, satisfy all the
relevant requirements of this standard.
92 The lay ratio ofthe diferent layers shall be within the limits given in
le 4.
9.3 The ratio of the nominal diameter of the aluminium wires to the
nominal diameter of the aluminized steol wires in any particular
construction of aluminized-steel reinforced aluminfum conductor, shall
conform to the appropriate value given in Table 4.
9.4In all constructions, the successive layers shall have opposite
directions of lay, the outermost layer belng right-handed. The wires in
each layer shall be evenly and closely stranded.
8.5 In conductors having multiple layers of aluminium wires, the lay
fatio of any alumintum layer shall be not greater than the lay ratio of
the aluminium layer immediately beneath it.
10, LENGTHS AND VARIATIONS IN LENGTHS
10.1 Unless otherwise agreed between the purchaser and_ the
manufacturer, aluminized-steel reinforced aluminium conductors shall
bbe supplied in the manufacturer’s usual production tengths and with a
permitted variation of § percent in the length of any one conductor
length.
10.2 Random Lengths — Unless otherwise agroed between the
purchaser and the manufacturer, it shall be permissible to supply not
‘more than 10 percent of the lengths on any one order in random lengths:
none of them will be shorter than one-third of the nominal length.
SECTION IV PACKING AND MARKING
11. PACKING AND MARKING.
11.1 The conductor shall be wound on reels or drums* and marked with
the following:
a) Manufacturer's name or trade-name;
“it is recommended that resls and drums conforming to 1S:.1778-1961
"Specification for reals and drums for bare wire" be used.
9IS : 398 (Part If) - 1976
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) Size of conductor;
Net and gross mass of conductor; and
@) Length of conductor,
11.1.2 The conductor may also be marked with the Standard Mark.
Nore — The use ofthe Standard Mark Is governad by the provisions ofthe Bureau
of Indian Standards Act, 1886 and the Rules and Regulations made thereunder.
‘The Standard: Mark on products covered by an Indian Standard conveys the
assurance that they have been produced £9 comply with the requirements of tat
standard under a well defined system of Inspecdon, testing and quellty contral
le is devised and supervised ly BIS and sperm by the proder. Standard
marked products are also continously chucked by BIS for confarmily to that
standard a3 a further safoguard, Detall of conditions under which a liante forthe
use ofthe Standard Mark may bo granted te manufacturers or producers may be
dbtained from the Bureau of indian Standards.
SECTION V_ TESTS
12, TESTS
12.1 Selection of Test Samples
12.1.1 Samples of individual wires for tests specified in 12.2, 12.3, 12.4,
12.5 and 12.6 shall normally be taken by the manufacturer before
stranding, from the outer ends of not less than 10 percent of wire coils.
12.1.2 Alternatively, if desired by the purchaser at the time of placing an
order that the tests be made in the of his representative,
samples of wire shall be taken from lengths of stranded conductors,
Samples shall then be obtained by cutting 1.2 metres from the outer end
of the finished conductor from not more than 10 percent of the finished
reels or drums. If there is more than one length on any reel or drum, the
sample shall be taken from the outer length.
12.13 Coils offered for inspection shall be divided* Into equal lots, the
number of lots being equal to the number of samples to be selected, a
fraction of a lot being counted as a complete lot. One sample coil shall be
selected at random from each lot.
12.2 Breaking Load Test—This test shall be made on both
aluminium and aluminized steol wires.
12.2.1 The breaking load of one specimen cut from each of the sample
taken under 12.2.1 or 12.1.2 shall be determined by means of a suitable
tensile testing machine. The load shall be applied gradually and the rate
of separation of the jaws of the testing machine shal] be not less
than 25 mmvmin and not greater than 100 mm/min.
‘The ultimate breaking load of the specimens shall be not less than the
appropriate value specified in Tables I end 2.
“This pay be done physeally or on the bass of dentition numbers ofthe cols
offered fa suppiy.
aL1S: 398 (Part IID) - 1976
12.3 Ductility Test — This test shall be made on aluminized steel
‘wires only, by elther of the two tests given in 12.3.1 and 12.3.2.
12.3.1 Torsion Test — One specimen cut from each of the samples taken
under 12.4. or 12.1.2 shall be gripped at its ends in two viees, one of
which shall be free to move longitudinally during the test. A small
tensile load not exceeding 2 percent of the breaking load of the wire,
shall be applied to the sample during testing. The specimen shall be
Gwisted by causing one of the vices to revolve until fracture occurs and
the number of shall be indicated by a counter or other suitable
device. The rate of twisting shall not exceed 60 rev/min.
When tested before stranding, the number of complete twists before
fracture occurs shall be not less than 18 on a length equal to 100 times the
Slameter of the wire. The primary fracture shall show a smooth surface at
Fight angles to the axis of the wire. Any secondary fracture shall be ignored.
When tested after stranding, the number of complete twists before
fracture occurs shall be not Jess than 16 on a length equal to 100 times
the diameter of the wire. The fracture shall show a smooth surface at
right angles to the axis of the wire,
12.3.2 Elongation Test — The elongation of one specimen cut from each
of the samples taken under 12.L1 or 12.1.2 shall be determined. The
specimen shall be straightened by hand and an original gauge length
of 200 mm shall be marked on the wire. A ¢ensile load shall plied as
described in 122 and the elongation shall be measured after the
fractured ends have been fitted together. If the fracture occurs outside
the gauge marks, or within 26 mm of either mark and the required
elongation is not obtained, the test shall be disregarded and another test
made, When tested before stranding, the elongation shall be not less
than 4 percent, When tested after stranding, the elongation shall be not
less than 3.5 percent.
| Note — The choice between the torsion test ang the elongation test shall be atthe
discretion of the purchaser, In the absence of any ceffice Ineation frem the
Purchaser torsion test shall be carried out in preferenes to elangation test.
12.4 Weapping Test — This test shall be made on both aluminium and
aluminized steel wires.
12.4.1 Aluminium Wires —One specimen cut from each of the samples
of aluminium wire taken under 12.1.1 or 12.1.2 shall be wrapped round
wire of its own diameter to form a close helix of eight turns. Six turns
shail then be unwrapped and again closely wrapped in the same
direction as before. The wire shall not break or show any crack.
[Nore — Slight surface cracks shall not constitute cause for rejection.
12.4.2 Alumintzed Steel Wires—One specimen cut from each of the
samples of aluminized steel wire taken under 12.1.1 or 12.1.2 shall be
‘wrapped round a mandrel of diameter equal to 4 times the wire diameter to
forma close hl of @ turns, Sc turns shal then be unwrapped and again