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( Reaffirmed 1997 )
 IS : 3835 - 1966

Indian Standard
SPECIFICATION FOR
ALUMINIZED STEEL CORE WIRE FOR
ALUMINIUM CONDUCTORS ( ACSR )
Wrought Steel Products Sectional Committee, SMDC 5

Chairman Refiresenting

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SHRI S. VISVANATHA~~ The Tata Iron & Steel Co Ltd, Jamshedpur

Members

SERI N. C. BAQ~EI National Test House, Calcutta

S-1 V. S. BH~ARY National Metallurgical Laboratory ( CSIR ),
Jamshedpur
DR U. N. BHEANY The Indian Iron & Steel Co Ltd, Burnpur
SHRI K. H. SEABMA ( Alternate )
SHRI S. C. BI~~AS’ Mukand Iron & Steel Works Ltd, Bombay
DR V. B. JOSHI ( Alternate )
Da G. P. CEATTEF~JEB Indian Institute of Metals, Calcutta
CHIEF METALLURGIST Hindustan Steel Ltd, Rourkela; and Boilers Sectional
Committee, EDC 40, IS1
SEBI B. P. GHOSE Hindustan Steel Ltd, Durgapur
SHBI B. N. GUPTA SteelCaF;;;lling Mills’ Association of India,

SERI S. BANEWEE ( Alternate )

SHBI HABOEAND SIN~H The Indian Steel and Wire Products Ltd, Indranagar
SHRI R. R. KAFZISH (Alternate*)
JOINT DIBEOTOB, RESEABCH Ministry of Railways
(M&C)
SHRI A. K. BA~ILJEE ( Alternate )
Jorrcr DIRECTOE, STAXDAEDS Ministry of Railways
( WAQON )
JOINT DIRECTOB ( IBON AND
STEEL ) ( Alternate )
SHRI G. S. LITTLEJOHN The Metal Box Co of India Ltd, Calcutta
SERI D. R. MALIE Directorate General of Ordnance Factories
( Ministry of Defence ), Calcutta
SHRI D. SBN ( Alternate )
SHRI P. R. NAJX Iron & Steel Control, Calcutta

/ ( Continuedon page 2 )

INDIAN STANDARDS INSTITUTION

u,UC BHAVAN, 9 BAHADUB SHAH ZAFAB MABG
NEW DELHI I
IS:383501966

( Continuedfrom pugc 1)
Members Rejresenting
SH~I E. K. N. NAMBIU Inspection Wing, Directorate General of Supplies &
Disposals ( Ministry of Supply )
SH~I D. K. RAY ( Altcrnute)
SEBI V. K. RAJA~OPALAN Hindustan Steel Ltd, Bhilai
SHBI M. N. KEANNA ( Alternate)
SH~I D. V. REDDI Ministry of Defence ( DGI )
SHRI M. M. GUPTA (Alternate)
REPRESENTATIVE Guest, Keen, Williams, Ltd, Calcutta
SHBI S. SATYANARAYANA Hindustan Shipyard Ltd, Visakhapatnam

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DB R. V. TAYHANISAR Ministry of Defence ( R & D )
SH~I K. D. A~ARWAL (Alternate)
SHRI D. V. VADEEA Central Boilers Board ( Ministry of Industry )
SERI K. S. VAIDYANATHAN M. N. Dastur & Co Private Ltd, Calcutta
SHRI C. H. WATSON The Tinplate Co of India Ltd, Golmuri ( Tatanagar )
SHBI B. S. KRISHNAMACHAR, Director General, ISI ( Ex-oficio Member)
Deputy Director General ( Secretary)

2
 IS : 3835- 1966

Indian Standard
SPECIFICATION FOR
ALUMINIZED STEEL CORE WIRE FOR
ALUMINIUM CONDUCTORS ( ACSR )

0. FOREWORD

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0.1 This Indian Standard was adopted by the Indian Standards
Institution on 10 November 1966, after the draft finalized by the Wrought
Steel Products Sectional Committee had been approved by the Structural
and Metals Division Council.
0.2 In view of the general policy of attaining self-sufficiency in the country,
the substitution of imported raw materials has at present assumed great
significance. Zinc being one of the raw materials for which we have to
depend mainly on import, the possibility of substituting zinc with aluminium
in various applications is being explored. The investigation conducted
in this country and elsewhere has shown that aluminized core wire can
replace galvanized steel core wire in the production of ACSR and all other
aluminium conductors. With a view to encouraging indigenous production
of aluminized steel core wire to be used for ACSR conductors, this Indian
Standard has been prepared.
0.3 In the preparation of this standard, assistance has been derived from
ASTM B 341-63T ’ Aluminium coated aluminized steel core wire for
aluminium conductors steel reinforced ( ACSR )’ issued by the American
Society for Testing and Materials.
0.4 This standard contains clause 13.1 and a Note under clause 8.2 which
permit the purchaser to use his option for selection to suit his requirements.
0.5 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, expressing
the result of a test or analysis, shall be rounded off in accordance with
IS : Z-1960*. The number of significant places retained in the rounded off
value should be the same as that of the specified value in this standard.
\ ’
1. SCOPE
1.1 This standard covers requirements for round aluminized steel core wire
intended to be used for mechanical reinforcement in the manufacture of
ahnninium conductors ( ACSR ) .
*Rules for rounding off numerical values ( revised ).

3
IS : 3835 - 1966

2. TERMINOLOGY

2.1 For the purpose of this standard, the definitions of various terms given
in IS : 1956-1962* shall apply.

3. SUPPLY OF MATERIAL

3.1 General requirements relating to the supply of aluminized steel wire

shall be as laid down in IS : 1387-1959t.

4. MANUFACTURE

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4.1 Steel shall be manufactured by the open-hearth, electric, basic oxygen
or a combination of these processes. In case any other process is employed
in the manufacture, prior approval of the purchaser should be obtained.
Aluminizing shall be done by hot-dip or by any other approved process.

5. CHEMICAL COMPOSITION

5.1 The chemical composition of the steel when analysed in accordance

with IS : 228-1959$ shall be as follows:
Constituent, Percent
r
Carbon Manganese Silicon Sulphur Phosphorus ’
Max Max
o-50 to 0.95 o-50 to 1.30 0.10 to o-30 o-050 0.040

5.2 The ingot or pig aluminium used for coating the wires shall not contain
more than the following impurities:
Percent
Copper 0.10
Iron 0.50

6. FREEDOM FROM DEFECTS

6.1 All finished wires shall be well and cleanly drawn to the dimensions
specified. The surface of the aluminized wires shall be free from splints,
scale inequalities ( see also Note in Table 4 ), flaws and other harmful
defects. The aluminium coating shall be continuous and of reasonably
uniform thickness.
*Glossary of terms relating to iron and steel.
tGenera1 requirements for the supply of metals and metal products.
IMethods of chemical analysis of pig iron, cast iron and plain carbon and low-alloy
steels ( revised).

4
 IS : 3835- 1966

7. PHYSICAL TESTS

7.1 The tensile strength of wire, when tested in accordance with

IS : 152 I- 1960* shall be as given in Table 1.

TABLE 1 TENSILE STRENGTH

NOMINAL STRESS AT TENSILE ELONGATION,

DIAIVIETEB 1 PERCENT STRENGTH PEBOENT
EXTENSION

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mm Min Min

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Min ( Gauge
( kgf/mm* ) ( kf/mm’ ) length = 250 mm)
1.25 to 2.24 119.5 130.0 3.5
Over 2.24 to 3.15 112.5 126.5 4.0
,) 3-15 ), 3.55 105.5 123-O 4-o
,, 3.55 ,) 3.75 102-o 119.5 5.0
)) 3.75 95.0 116.0 5.0

7.2 Wrapping Test-The aluminized steel wire when subjected to

wrapping test in accordance with IS : 1755-19611_ shall withstand without
fracture being wrapped eight times round a mandrel of diameter equal to
twice the diameter of the wire.

8. TEST FOR ALUMINIUM COATING

8.1 Adherence of Coating - The aluminized wire shall withstand being

wrapped in a close helix round a mandrel having diameter as specified in
Table 2, without cracking or flaking the aluminium coating to such an
extent that any aluminium may be removed by rubbing with bare fingers.

TABLE 2 DIAMETER OF MANDREL FOR ADHERENCE TEST

NOMINAL DIABIETEB RATIO OF MANDREL

OB WIXE DIAMETEB TO
mm WIRE DIAMETEE

1.25 to 2.24 3
Over 2.24 to 3.55 4
,> 3.55 5

*Tensile testing of steel wire.

(-Wrapping test of wire.

T--
-
IS:3835-1966

8.1.1 Loosening or detachment of superficial small particles of alumi-

nium formed by mechanical polishing of the surface of the aluminized
wire shall not be considered for the test.
8.2 Weight of Coating - The weight of aluminium coating of steel wires
when determined in accordance with IS : 382 I* shafl conform to the require-
ments as specified in Table 3.
NOTE -Until this standard is published, tests for both weight and continuity of
coating shall be carried out in accordance with the methods mutually agreed to between
the manufacturer and the purchaser.

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TABLE 3 WEIGHT OF ALUMINIUM COATING

NOYINALDIAMETEB WEIQETOECOATING
OB WII&E Min

mm g/m’
1.25 to 1.50 70
Over 1.50 to I.80 76
,, 1.80 ,, 2.24 79
,, 2.24 ,, 2.50 85
), 2.50 ,, 3.00 92
,, 3.00 ), 3.55 98
,, 3.55 ), 4.50 104
,, 4.50 116

8.3 Continuity of Coating - The aluminized wires shall conform to the

test for continuity of coating, carried out in accordanqe with IS : 3821*.

9. TOLERANCE

9.1 The tolerance permitted on the diameter of aluminized wire shall be as

given in Table 4.

10. JOINTS

10.1 The finished wire shall be free from any kind of joints made after
aluminizing.
10.2 Joints may be made in the hot rolled wire-rods or semi-finished wires
before or after patenting and prior to cold drawing, either by electric resist-
ance butt weldings or by flash butt welding process.
*Method for determination of weight and uniformity of aluminium coating on iron or
steel articles ( under preparation ) .

6
 IS:3835-1966

TABLE 4 TOLERANCE ON DIAMETER

I
( Clause 9.1 )

NOMINAL DIAFAETEB 01 PEIU~ISSIBLE TOLEBANOES

COATED WISE _h- ---7
51”s Minus

mm mm mm

Below 2.00 o-05 0.03

z-00 to 3.00 0.08 0.05

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Over 3.00 to 3.55 O-08 o-05
,, 3.55 0.10 0.08
NOTE -The surface of aluminium coatings, particularlythose produced by hot-dip
process are not perfectly smooth and devoid of irregularities. It is, therefore, recom-
mended that for determining the tolerances, uniform portions of the aluminized wire
shall only be taken.

10.3 In case of welded joint, the tensile strength of finished wire containing
the welded section shall be not less than 90 percent of the tensile strength
specified in 7.
10.3.1 The test for proof stress at one percent extension shall not be
applicable to welded joints.

11. SAMPLING
11.1 Unless otherwise agreed, one test specimen shall be taken from each
lot of ten coils in the condition as aluminized and prior to splitting it into
individual coils.

12. RE-TEST
12.1 Should any one of the test pieces selected fail to pass any of the tests
specified in the standard, two further samples shall be selected for testing in
respect of each failure. Should the test pieces from these additional samples
pass, the lot represented by the test samples shall be deemed to comply with
the requirements of that particular test. Should the test pieces from either
of these additional samples fail, the lot represented by the test samples shall
be considered as having not complied with the standard. The lot may,
however, be resubmitted for testing every coil with a view to sorting out
the defective coils.

13. PACKING AND MARKING

13.1 The finished wire shall be packed in compact coils, symmetrical in
shape. The inside diameter of coils shall be as agreed to between the
manufacturer and the purchaser.

7
IS : 3835 - 1966

13.2 Each coil of wire shall bear a durable tag showing the nominal size
of wire, length and weight of coil, date of manufacture and trade-mark or
the name of the manufacturer.
13.3 The material may also be marked with the IS1 Certification Mark.
NOTE- The use of the IS1 Certification Mark is governed by the provisions of the
Indian Standards Institution ( Certification Marks ) Act, and the Rules and Regulations
made thereunder. Presence of this mark on products covered by an Indian Standard
conveys the assurance that they have been produced to comply with the requirements
of that standard, under a well-defined system of inspection, testing and quality control
during production. This system, which is devised and supervised by IS1 and operated
by the producer, has the further safeguard that the products as actually marketed are

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continuously checked by IS1 for conformity to the standard. Details of conditions, under
which a licence for the use of the IS1 Certification Mark may be granted to manufacturers
or processors, may be obtained from the Indian Standards Institution.

8
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