GENERAL PARTICULARS AND TECHNICAL PARTICULARS FOR ACSR

CONDUCTORS

1. SCOPE: This specification provides for the Manufacture, Testing before despatch
supply and delivery of ISI Marked Aluminum Conductors Galvanised Steel Reinforced
(ACSR) conductors.
2. STANDARD: The conductor shall strictly comply in all respect with the Indian
Standard Specification IS:398 (Part-2)/1996 with the latest amendments unless
otherwise stipulated in this specification, or any other International Standards which
ensure equal or higher quality material and workmanship.
The ACSR Conductor shall also conform to the following standards:-
Sl.No. Indian Title International
Standards
1 IS:209-1979 Specification for Zinc BS-3436-1961
2 IS:398-1996 Specification for aluminium
conductors for overhead
transmission prupose.
Part-II Aluminium Conductors IEC-209-1966
Galvanized steel reinforced BS-215 (Part-II)
3 IS:1521-1972 Method of Tensile Testing of Steel ISO/R89-1959
wire
4 IS:1778-1980 Reels and Drums for Bare BS-1559-1949
conductors
5 IS:1841-1978 E.C. Grade Aluminium rod produced
by rolling
6 IS:2629-1966 Recommended practice for Hot Dip
Galvanizing of iron and steel
7 IS:2633-1986 Method of testing uniformity of
coating of zinc coated articles.
8 IS:4826-1968 Galvanized coatings on round steel ASTM A472-729
wires.
9 IS:5484-1978 E.C. Grade Aluminium rod produced
by continuous casting and rollings.
10 IS:6745-1972 Methods of determination of weight of BS-443-1969
zinc-coating of zinc coated iron and
steel articles
3. MATERIAL:
3.1 The conductors offered shall be of best quality and workmanship. The steel
reinforced aluminium conductors shall be manufactured of hard drawn EC Grade
aluminium wires and high tensile galvanised steel wires of the sizes as specified in
Table-I and with mechanical and electrical properties as specified in Table-II . The
coating on the galvanized steel wires may be applied by hot process or electrolytic
process in accordance with IS:4826-1979(specifications for hot dipped galvanized
coatings on round steel wires). The core wire used for ACSR Conductor shall also be
of ISI Marked.
3.2 The wires shall be smooth and free from all imperfections such as spills and splits
and rolling and wire drawing defects etc., resulting in reduction in cross – sectional
area over the entire length.
4. TOLERANCE: The following tolerance shall be permitted:-
(i) Tolerance on Nominal diameter of Aluminium wires plus/minus 1%.
(ii) Tolerance on Nominal diameter of High Tensile Galvanised Steel Wires plus /
 minus 2%.

5. MODULUS OF ELASTICITY AND CO-EFFICIENT OF LINEAR EXPANSION:

The values of the final modulus of elasticity and co-efficient of linear expansion
of ACSR conductor shall be as given hereunder:-

Item No. of wires Final Coefficient of linear Density at temp. of

modulus of expansion per 0 C 20 0 C
elasticity
GN/mm2
(practical)
ACSR 6/1 79 19.1X10-6 for ACSR 7.8gm/cm3 (Steel )
(Al./Steel) conductor 2.703gm/cm3 (Al.)
ACSR 6/7 75 19.8X10-6 for ACSR 7.8gm/cm3 (Steel)
(Al./Steel) conductor 2.703gm/cm3 (Al.)
ACSR 30/7 80 17.8X10-6 for ACSR 7.8gm/cm3 (Steel )
(Al./Steel) conductor 2.703gm/cm3 (Al.)

6. JOINTS IN WIRES:
(a) During stranding in aluminium wire no welds shall be made for the purpose of
achieving the required conductor length.
Joint in the stranded Aluminium wires of finished conductors are permitted as
per the provisions of IS:398 Part-II & latest amendment thereof.
(b) There shall be no joints in finished steel wires forming the core of the steel
reinforced aluminium conductor.

7. STRANDING:
7.1 The wires used in the manufacturing of a stranded conductor before stranding
satisfy all requirement of IS:398(Part-2)/1996 with its latest amendments. The lay ratio
of the layer shall be within the limit given under clause-8 below.

7.2 In all construction, the successive layers shall have opposite directions of lay.
The outermost layer shall have right hand lay. The wires in each layer shall be evenly
and closely stranded.

8. LAY RATIO: The 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) shall be within the limit given below:-

Item No. of wires Ratio of Lay ratio for Lay ratio for
Aluminu Steel Tota Aluminium Aluminium wire Steel wire
m l Wire dia to Max. Min. Max. Min.
Steel wire
dia
ACSR 6 1 7 1 14 10 - -
Conductor 6 7 13 1 14 10 28 13
30 7 37 1 14 10 28 13
(First layer)
16 10
 (Second
layer)

9. PACKING AND MARKING:

(A) The conductor shall be wound in non-returnable reels or drums conforming to
IS: 1778 (Specifications for reels and drums for bare wire) or the latest version thereof.
The drums shall be marked with the following details:-
(a) Manufacturer’s name
(b) Trade Mark, if any
(c) Drum No. & identification Number
(d) Size of conductor
(e) Number and lengths of pieces of conductor on each drum
(f) Gross mass of the packing
(g) Net mass of conductor
(h) ISI or relevant international standard specification mark, if any
(i) Name and address of the consignees.

10. PACKING CONDITION:

10.1 The conductor shall be supplied in non-returnable strong wooden drums
provided with lagging of adequate strength constructed to protect the conductor
against any damage and displacement during transit, storage and subsequent
handing and stringing operations in the field. The drums shall generally conform to IS-
1778-1980 and latest version except as otherwise specified hereinafter. The conductor
drums shall be adequate to wind one standard length of SQUIRREL /WEASEL/
RABBIT/ RACCOON/ DOG/ PANTHER ACSR Conductor.
10.2 The drums shall be suitable for wheel mounting and for letting off the conductor
under a minimum controlled tension of the order of 5 KN. The Conductor drums shall
be provided with necessary clamping arrangements so as to be suitable for tension
stringing of power conductor.

10.3 The bidders should submit their drawings of the conductor drums along with the
bid. After placement of letter of intent the Manufacturer shall submit four copies of fully
dimensioned drawing of the drum for Employer’s approval.
10.4 All wooden components shall be manufactured out of seasoned wood of good
quality free from defect that may materially weaken the component parts of the drums.
Preservative treatment for anti-termite / anti-fungus shall be applied to the entire drum
with preservatives of a quality which is not harmful to the conductor.
10.5 All flanges shall be 2-ply construction with 64 mm thickness. Each ply shall be
nailed and clenched together at approximately 90 degrees. Nails shall be driven from
the inside face of the flange, punched and then clenched on the outer face. Flange
boards shall not be less than the nominal thickness by more than 2 mm. There shall
not be less than 2 nails per board in each circle.
10.6 The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails.
The battens shall be closely butted and shall provide a round barrel with smooth
external surface. The edges of the battens shall be rounded or chamfered to avoid
damage to the conductor.
10.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and the barrel supports slotted to receive them. The barrel studs shall be
threaded over a length on either end, sufficient to accommodate washers, spindle
plates and nuts for fixing flanges at the required spacing.
10.8 Normally, the nuts on the studs shall stand protruded of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be countersunk. The
ends of the barrel shall generally be flushed with the top of the nuts.
10.9 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen based paint.
10.10 Before reeling, card board or double corrugated or thick bituminized waterproof
bamboo paper shall be secured to the drum barrel and inside of flanges of the drum
by means of a suitable commercial adhesive material. The paper should be dried
before use. Medium grade craft paper shall be used in between the layers of the
conductor for multi strand conductor i.e. above 100 mm2. After reeling the conductor,
the exposed surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from dirt, grit and
damage during transportation and handling and also to prevent ingress of rain water
during storage / transport.
10.11 A minimum space of 75 mm shall be provided between the inner surface of the
external protective lagging and outer layer of the conductor. Outside the protective
lagging, there shall be minimum of two binders consisting of hoop iron / galvanised
steel wire. Each protective lagging shall have two recesses to accommodate the
binders.
10.12 Each batten shall be securely nailed across grains as for as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not be less than
twice the thickness of the batten. The nail shall not protrude above the general surface
and shall not have exposed sharp edges or allow the battens to be released due to
corrosion.
10.13 The conductor ends shall be properly sealed and secured with the help of U-
nails on one side of the flanges.
10.14 As an alternative to wooden drum Bidder may also supply the conductors in
non-returnable painted steel drums. The painting shall conform to IS:9954-1981,
reaffirmed in 1992. Wooden / steel drum will be treated at par for evaluation purpose
and accordingly the Bidder should quote the rate.

11. STANDARD LENGTH:-

“The standard wire length for ACSR shall be 2 kms. for squirrel & weasel
Conductors where for other sizes it shall be 1.5 kms. Longer lengths shall be
acceptable. Short lengths of not less than 50% of the standard lengths, as
indicated above, shall be acceptable to the maximum extent of 10% of the
quantity ordered for each size”.
12. TESTS:
(A) Type Test Certificate:-
The following type test should be performed on ISI Marked ACSR Conductor
as IS:398 (PART-II):-
(i) Measurement of Diameter (Aluminium & Steel Wire)
(ii) Breaking Load Test (Aluminium & Steel Wire)
(iii) Resistance Test (Aluminium Wire)
(iv) Ductility Test (Steel Wire)
 (v) Galvanizing Test (Steel Wire)
(vi) Measurement of lay ratio
(vii) Wrapping Test
Tests to be performed for size more than 100 mm2 :-
(i) Surface condition test,
(ii) Ultimate breaking load test
(iii) Stress strain test
The type test certificate should invariably be submitted alongwith tender. The
test certificate should not be older than ten years from the date of opening of tender
and should be performed at the Govt. Approved Laboratory only.
It may be noted carefully that the type test reports submitted by the bidders will
be sent to the testing laboratory / institution from where the type test are carried out
for verification & genuineness. In case any discrepancy is reported by Testing
Laboratory / Institution the offer will be outrightly rejected and the action against the
bidder for submission of forged / fake type test report will be taken in accordance with
Clause 34 of Annexure-B (GENERAL TERMS & CONDITIONS OF PURCHASE)
12.1 Samples of individual aluminium, aluminium alloy and steel wires for tests shall
be taken before stranding from not less than 10% of the spools/coils. If samples are
taken after stranding, they shall be obtained by cutting 1.2 metres from the outer end
of the finished conductor from not more than 10% of the reels.
12.2 The mechanical tests shall be carried out on single wires only and not on
complete conductor.
12.3 The Rejection and Re-test procedure shall be followed as stipulated in
IS:398(Part-2)/1996 and IS:398(Part-4)/1994.

13. CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS:

The supplier/manufacturer of conductor should arrange for the inspection by
the representative of the purchaser specially authorised for this purpose. At least 5%
of the total number of drums of conductors taken at random should be checked to
ascertain the lengths of conductor adopting either of the following two methods:-
(a) The drum along with the conductor should be weighed and six empty drums
along with protective laggings & studs etc. normally used for winding the conductor
should also be weighed. Net weight of the conductor should be calculated by
subtracting the average weight of the six empty drums from the gross weight of the
conductor and drums. Having known the weight of the conductor, the length of the
conductor can be computed.
In case of empty conductor drums, a check weighment of every one in ten
empty drums shall also be done before the conductors are wound on the drums.

(b) Arrangements should be made available in the works of the manufacturer for
transferring the conductor from one reel to another at the same time measuring the
length of the conductor so transferred by means of a meter. Percentage shortage, if
any, in the length thus obtained and as declared by the supplier in the packing list shall
be applied to all the drums.

14. CHECK MEASUREMENT:- Where length of conductor is verified by weighment

basis, the determining factor will be length/weight ratio of the sample drums verified at
the firm’s premises of the lot of which the drum under measurement at the consignee’s
end forms a part.
(i) Wherever at the end of the consignee, length measurement machines are
available, conductors shall be accepted by verification of lengths only and where the
length measurement machines are not available, conductor shall be accepted on
weighment basis.
(ii) In case, where the recorded weight on the drum tallies with the measured
weight at consignee’s end, then the conductor length shall be accepted as recorded
on the drum. In other cases, the determining factor will be weight / length ratio of the
sample(s) inspected at the firm’s premises of the lot of which the drum under
measurement at the consignee’s end, forms a part. The factors of weight/length ratio
shall however be made available to the consignees in the despatch instructions itself.
If such factors are not available due to some reasons, actual measurement of diameter
shall be made and weight/length ratio shall be obtained for the purpose of computing
length.

TABLE-I

SIZE AND PROPERTIES OF ACSR/ CONDUCTORS (As per IS:398 (Part-

2)/1996)

Code Nom- Stranding and Secti- Total Appr- App- Calcul- Appro-
Word inal wire diameter onal Secti- xim- roxi ated ximate
alum- area of onal ate mate resist- calcu-
inium Alum- area over- mass ance lated
Al. Steel
area inium all 20 0C break-
Diam- ing
eter load
mm2 mm mm mm2 mm2 mm2 Kg/ Ohm/ KN
Km Km
1.Squirrel 20 6/2.11 1/2.11 20.98 24.48 6.33 85 1.3940 7.61
2.Weasel 30 6/2.59 1/2.59 31.61 36.88 7.77 128 0.9289 11.12
3.Rabbit 50 6/3.35 1/3.35 52.88 61.70 10.05 214 0.5524 18.25
4.Raccoon 80 6/4.09 1.4.09 78.83 91.97 12.27 319 0.3712 26.91
5. Dog 100 6/4.72 7/1.57 105.00 118.30 14.15 394 0.2792 32.41
6. Panther 200 30/3 7/3 212.10 261.50 21.00 974 0.1390 89.67
 TABLE-II

(A) PROPERTIES OF ALUMINIUM/STEEL WIRES USED IN THE

CONSTRUCTION OF ACSR CONDUCTOR

(i) For ALUMINIUM WIRES:-

Size DIAMETER Cross Mass Resistance Breaking load Min.

Secti- 20 0 C
Nom- Min Max onal Before After
inal area of stranding stranding
nomi-
nal dia.
wire

1 2 3 4 5 6 7 8 9
2
mm mm mm mm Kg/ Ohm/Km KN KN
Km
Squirrel 2.11 2.09 2.13 3.497 9.45 8.237 0.63 0.60
Weasel 2.59 2.56 2.62 5.269 14.24 5.490 0.89 0.85
Rabbit 3.35 3.32 3.38 8.8140 23.82 3.265 1.43 1.36
Raccoon 4.09 4.05 4.13 13.140 35.51 2.194 2.08 1.98
Dog 4.72 4.67 4.77 17.50 47.30 1.650 2.78 2.64
Panther 3.00 3.03 2.97 7.069 19.11 4.079 1.17 1.11

(ii) For Steel Wires:-

SIZE DIAMETER Gross Mass Breaking load Min.

Nominal Min. Max. sectional Before After
Area of stranding stranding
nominal dia
wire
1 2 3 4 5 6 7
mm mm mm mm2 Kg/Km KN KN
Squirrel 2.11 2.07 2.15 3.497 27.27 4.60 4.37
Weasel 2.59 2.54 2.64 5.269 41.09 6.92 6.57
Rabbit 3.35 3.28 3.42 8.814 68.75 11.58 11.00
Raccoon 4.09 4.01 4.17 13.140 102.48 17.27 16.41
Dog 1.57 1.54 1.60 1.936 15.10 2.70 2.57
Panther 3.00 3.06 2.94 7.069 55.13 9.29 8.83

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