IS398(Part4):1994

Indiizn Standard

ALUMINIUM CONDUCTORS FOR

OVERHEAD TRANSMISSION PURPOSES
PART 4 ALUMINIUM ALLOY STRANDED CONDUCTORS
(ALUMINIUM-MAGNESIUM-SILICON TYPE) - SPECIFICATION

( Third Revision )
Second Reprint MARCH 1999

UDC 621.315.145:621.315.55 [669.71-4271

@BIS 1994

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH MAR MAR0
NEW DELHI llCKKI2

August 1994 Price Group 3

Conductors and Accessories for Overhead Lines Sectional Committee, ETD 37

FOREWORD

This Indian Standard (Part 4) (Third Revision) was adopted by the Bureau of Indian Standards, after the
draft finalized by the Conductors and Accessories for Overhead Lines Sectional Committee had been
approved by the Electrotechnical Division Council.

This part of the standard was originally published in 1953, the first revision was then, brought out in 1961
and the second revision in 1979. Third revision has been undertaken with a view to effecting the following
modifications:
a) to line up with the International Standards.
b) to further rationalize the sizes of aluminium alloy stranded conductors (aluminium-magnesium-
silicon type) to conform to the requirements of Indian power utilities.

This standard is issued in different parts covering different types of conductors. This part dealing with
aluminium alloy stranded conductors forms Part 4 of the series. The other parts in the series are given
below:
Part 1 Aluminium stranded conductors
Part 2 Aluminium conductors, galvanized steel-reinforced
Part 3 Aluminium conductors, aluminized steel-reinforced
Part 5 Aluminium conductors, galvanized steel-reinforced for extra high voltage

In this revision the conductor and the alloy wire properties have been rationalised to keep in tune and to
ensure compatibility with other Indian Standards for conductors. The minimum breaking load of alloy
wires before and after stranding have been introduced. The standard resistivity figure of 0.032 5 ohm.
mm2/m at 20°C has been adopted for arriving at the calculated resistance of the conductors. However,
individual wires with a maximum resistivity up to 0.032 8 ohm.mm2/m at 20°C will be permitted.

In the preparation of this standard, assistance has been derived from the following:

IEC Pub 208 (1966) Aluminium Alloy Stranded Conductors, International Electroteclinical
Commission

BS 3242 : 1970 Specification for Aluminium Alloy Stranded Conductors for Overhead Power
Transmission. British Standards Institution

ASTM-B 398M-86 Specification for Aluminium Alloy 6201 T81 Wire for Electrical Purposes

ASTM-B 399M-86 Standard Specification for Concentric Layer-Stranded Aluminium Alloy

6201 -TSl Conductors

The values of modulus of elasticity and co-efficient of linear expansion are ‘given in Annex A for
information.

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, shall be rounded off in accordance with
IS 2 : 1960 ‘Rules for rounding off numerical values (rev&d)‘. The number of significant places retained
in the rounded off value should be the same as that of the specified value in this standard.
 IS 398 ( Part 4 ) : 1994

Indian Standard
ALUMINIUM CONDUCTORS FOR
OVERHEAD TRANSMISSION PURPOSES
PART 4 ALUMINIUM ALLOY STRANDED CONDUCTORS
(ALUMINIUM-MAGNESIUM-SILICON TYPE) - SPECIFICATION

( Third Revision )
1 SCOPE 3.1.4 Lay Ratio

1.1 This standard (Part 4) covers the requirements

Ratio of the axial length of one complete turn of
and tests for aluminium alloy stranded conductors
the helix formed by an individual wire in a stranded
of the aluminium-magnesium-silicon type for
conductor to the external diameter of the helix.
overhead power transmission purposes.
2 REFERENCES
3.1.5 Heat-Treatment Botch
2.1 The following Indian Standards are necessary
adjuncts to this standard:
One furnace load of material heat treated at the
IS No. Title same time, at the same temperature and for the
1885(Part 32) : Electrotechnical vocabulary: same length of time.
1971 Part 32 Cables, conductors and 4 PIIYSICAL CONSTANTS FOR ALUMINIUM
accessories for electricity supply ALLOY VVIRRS
9997 : 1981 Aluminium alloy redraw rods for
4.1 Resistivity
electrical purposes Cfirstrevision)
For the purposes of this standard, the standard
3 TERMINOLOGY value of resistivity of aluminium alloy wire which
3.1 For the purpose of this standard, the following shall be used for calculation is to be taken as
definitions in addition to those given in IS 1885 0.032 5 ohm mm2/m at 20°C. The maximum value
(Part 32) : 1971 shall apply. of resistivity of any single wire shall not, however,
exceed 0.032 8 ohm. mm2/m at 20°C.
3.1.1 Stranded Conductor
4.2 Density
Conductor consisting of three or more aluminium At a temperature of 20°C the density of aluminium
wires of the same nominal diameter twisted
alloy wire is to be taken as 2.70 kg/dm3.
together in concentric layers. When the conductor
consists of more than one layer, successive layers 4.3 Co-efficient of Linear Expansion
are twisted in opposite directions.
The co-efficient of linear expansion of aluminium
3.1.2 Diameter alloy wire is to be taken as 23 x 10 -“PC.
4.4 Constant-Mass Temperature Co-efficient (a)
The mean of two measurements at right angles
taken at the same cross-section. At a temperature of 20°C, the constant-mass
temperature co-efficient of resistance of aluminium
3.1.3 Direction of Lay
alloywires, measured between two potential points
The direction of lay is defined as right-hand or rigidly fixed to the wire, is taken as 0.003 60/C.
left-hand. With right-hand lay, the wires conform 5 MATERIAL
to the direction of the central part of the letter Z ,
when the conductor is held vertically. With left- ; 5.1 The wires shall be of heat treated aluminium,
hand lay, the wires conform to the direction of the magnesium silicon alloy having a composition ap-
central part of the letter S when the conductor is propriate to the mechanical and electrical proper-
held vertically. ties specified in Table 1.

1
IS398( Part 4):1994

6 FREEDOM FROM DEFECTS 7.1.2 Tolerances on Nominal Sizes

A tolerance of +- 1 percent shall be permitted on

6.1 The wires shall be smooth and free from all
imperfections not consistent with good commercial the nominal diameter specified in Table 1.
practice, for example, spills, splits and scratches. 7.2 Stranded Conductors
7 STANDARD SIZES 7.2.1 Sizes

7.1 Wires The sizes of stranded aluminium alloy conductors

shall be as given in Table 2.
7.1.1 Nominal Sizes
7.2.2 The resistance of stranded conductors shall
The aluminium alloy wires for standard con- be in accordance with Table 2. The masses (exclud-
structions covered by this standard shall have ing the mass of grease, if applied) are given in Table
the diameters specified in Table 1. 2 for information.

Table 1 Aluminium Alloy Wires Used in the Construction of

Stranded Aluminium Alloy Conductors
(Clauses 5.1,7.1.1,7.1.2, 12.4and B-3.1 )

Cross Sectional Minimum Breaking

Area of Nominal Load
Diameter Wire
-
Stranding Stranding
mm mm mm2 kg/km kN kN ohms/km

(1) (2) (3) (4) (5) (6) (7) (8)

2.00 1.98 2.02 3.142 8.482 0.97 0.92 10.653

2.50 2.47 2.53 4.909 13.25 1.52 1.44 6.845

2.89 2.86 2.92 6.560 17.71 2.03 1.93 5.106

3.15 3.12 3.18 1.193 21.04 2.41 2.29 4.290

3.31 3.28 3.34 8.605 23.23 2.66 2.53 3.882

3.40 3.31 3.43 9.079 24.51 2.80 2.66 3.611

3.45 3.42 3.48 9.348 25.24 2.89 2.75 3.571

3.55 3.51 3.59 9.898 26.72 3.06 2.91 3.390

3.66 3.62 3.70 10.52 26.41 3.25 3.09 3.187

3.71 3.67 3.15 10.81 21.19 3.34 3.17 3.101

3.81 3.77 3.85 11.40 30.78 3.52 3.34 2.938

3.94 3.90 3.98 12.19 32.92 3.11 3.58 2.146

4.00 3.96 4.04 12.57 33.93 3.88 3.69 2.663

4.26 4.22 4.30 14.25 38.48 4.40 4.18 2.345

NOTES
1 Maximum resistance values given in co1 8 have been calculated from the maximum values of the resistivity and the cross
sectional area based on the minimum diameter.
2 The minimum breaking load is calculated on nominal diameter at ultimate tensile strength of 31.5kg/mm2 for a wire before
stranding and 95 percent of that after stranding.

2
 IS 398 ( Part 4 ) : 1994

Table 2 Aluminium Alloy Stranded Conductors

( Clauses 7.2.1 and 7.2.2; and Table 1)

Sl Actual Stranding Approx Approx Calculated Maximum Approx

No. and Wire Overall Ma.?& Resistanceat 20-C Calculated
Dia Dia Breaking Load

mm2 mm mm kg/km ohms/km kN

(1) (2) (3) (4) (5) (6) (7)

1. 15 3t2.50 5.39 40.15 2.304 0 4.33

2. 22 l/2.00 6.00 60.16 1.541 0 6.45

3. 34 l/2.50 7.50 94.00 0.990 0 10.11

4. 55 7f3.15 9.45 149.20 0.621 0 16.03

5. 80 l/3.81 11.43 218.26 0.425 0 23.41

6. 100 714.26 12.78 272.86 0.339 0 29.26

7. 125 19t2.89 14.45 342.51 0.273 5 36.64

8. 148 19t3.15 15.75 406.91 0.229 0 43.50

9. 173 19f3.40 17.00 474.02 0.196 9 50.54

10. 200 19j3.66 18.30 549.40 0.171 0 58.66

11. 232 1913.94 19.70 636.67 0.147 1 68.05

12. 288 37i3.15 22.05 794.05 0.118 2 84.71

13. 346 37t3.45 24.15 952.56 0.098 4 101.58

14. 400 370.71 25.97 1101.63 0.082 9 117.40

15. 465 3714.00 28.00 1 280.50 0.073 4 136.38

16. 525 61i3.31 29.79 1 448.39 0.065 1 146.03

17. 570 61L3.45 31.05 1 573.71 0.059 8 158.66

18. 604 61t3.55 31.95 1 666.00 0.056 8 167.99

19. 642 61j3.66 32.94 1 771.36 0.053 4 178.43

20. 695 61i3.81 34.29 1 919.13 0.049 2 193.25

21. 767 6114.00 36.00 2 115.54 0.044 6 213.01

NOTES
1 For the basis of calculation of this table, see Annex B.
2 The actual area of a stranded conductor has been taken as the sum of the cross-sectional areas of the individual wires of
nominal diameter.
3 Maximum resistance values of stranded conductor have been calculated on the basis of maximum resistivity and the cross
sectional area based on the minimum diameter.

8 JOINTS IN WIRES 15 m apart in the complete stranded conductor.

Such joints shall be made by resistance or cold-
8.1 Conductors Containing Seven Wires pressure butt welding. They are not required to
There shall be no joint in any wire of a stranded
fulfil the mechanical requirements for unjointed
conductor containing seven wires, except those wires. Joints made by resistance butt welding sub-
made in the base rod or wire before final drawing. sequent to welding, be annealed over a distance of
at least 200 mm on each side of the joint.
8.2 Conductors Containing More Than Seven
9 STRANDING
Wires
9.1 The wire used in the construction of a stranded
In stranded conductors containing more than conductor shall, before and after stranding, satisfy
seven wires, joints in individual wires are permitted all the relevant requirements of this standard.
in any layer except the outermost layer (in addition
to those made in the base rod or wire before final 9.2 The lay ratio of the different layers shall be
drawing) but no two such joints shall be less than within the limits given in Table 3.

3
IS 398( Part 4):1994

Table 3 Lay Ratios for Aluminium Alloy Stranded Conductors

( Clauses 9.2 and B-2.3 )

Number of Lay Ratios

f -A
WiresIn 316 12 18 24
Conductor
Wire Layer Wire Layer Wire Layer Wire Layer
A h h A
rMi” MU ’ ‘Min Mar ’ ‘Min Mar ’ ‘Min Max ’

(1) (2) (3) (4) (5) (6) (7) (8) (9)

3 10 14 - - - - - -
7 10 14 - - - - - -
19 10 16 10 14 - - - -
37 10 17 10 16 10 14 - -
61 10 17 10 16 10 15 10 14

NOTE- For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic mean of the relevant minimum and
maximum values given in this table.

9.3 In all constructions, the successive layers shall to the manufacturers or producers may be obtained
have opposite directions of lay, the outermost layer from the Bureau of Indian Standards.
being right-handed. The wires in each layer shall
12 TESTS
be evenly and closely stranded.
12.1 Selection of Test Samples
9.4 In aluminium alloy stranded conductors
having multiple layers of wires, the lay ratio of any 12.1.1 Samples for the tests specified in 12.2, 12.3
layer shall be not greater than the lay ratio of the and 12.4 shall be taken by the manufacturer before
layer immediately beneath it. stranding, from not less than 10 percent of the
individual lengths of aluminium alloy wire included
10 LENGTIIS tiD VARIATIONS IN LENGTHS
in any one final heat-treatment batch and which will
10.1 Unless otherwise agreed between the pur- be included in any one consignment of stranded
chaser and the manufacturer, stranded aluminium conductors.
alloy conductors shall be supplied in the
12.1.2 Alternatively
manufacturer’s usual production lengths and with
a permitted variation of +5 percent in the length of If desired by the purchaser at the time of placing an
any one conductor length. order that the tests be made in the presence of his
representative, samples of wire shall be taken from
10.2 Random Lengths
length of stranded conductors. Samples shall then
Unless otherwise agreed between the purchaser be obtained by cutting 1.2 metres from the outer
and the manufacturer, it shall be permissible to end of the finished conductor from not more than
supply not more than 10 percent of the lengths on 10 percent of the finished reels or drums.
any one order in random lengths; none of them shall
12.1.3 Tests for electrical and mechanical proper-
be shorter than one-third of the nominal length.
ties of aluminium alloy wire shall ordinarily be
11 PACKING AND MARKING made before stranding because wires unlaid from
11.1 The conductor shall be wound on reels or conductors may have different physical properties
drums and marked with the following: from those of the wire prior to stranding because of
the deformation brought about by stranding and by
a) Indication of source of manufacture,
straightening for test.
b) Size of conductor,
12.1.4 Spools offered for inspection shall be
c) Length of conductor, and divided into equal lots, the number of lots being
d) Net and gross mass of conductor. equal to the number of samples to be selected, a hat-
11.1.1 The conductor may also be marked with tion of a lot being counted as a complete lot. One
Standrad Mark. sample spool shall be selected at random from each lot.
12.2 Breaking Loed Test
11.1.1.1 The use of Standard Mark is governed by
the provisions of Bureau of Indian Standards Act, 12.2.1 The breaking load of one specimen, cut
1986 and the Rules and Regulations made there- from each of the sample taken under 12.1.1
under. The details of conditions under where the or 12.1.2 shall be determined by means of suitable
licence for the use of standard mark may be granted tensile testing machine. The load shall be applied

A
 IS398(Part4):1994

gradually and the rate of separation of the jaws of 1

the testing machine shall be not less than 25 Rm =RT 1 + a(T-20)
mmlmin and not greater than 100 mm/min. where
&a = resistance corrected at 20 OC,
12.3 Elongation Test
RT = resistance measured at I%,
The elongation of one specimen cut from each of a = constant-mass temperature co-efficient
the samples taken under 12.1.1 or 12.1.2 shall be of resistance, 0.003 6, and
determined as follows. T = ambient temperature during measure-
12.3.1 The specimen shall be straightened by hand ment.
and an original gauge length of 200 mm shall be The resistance corrected at 20°C shall be not more
marked on the wire. A tensile load shall be applied than the maximum values specified in Table 1.
as described in 11.2 above and the elongation shall be
measured after the fractured ends have been fitted 13 REJECTION AND RETESTS
together. lf the fracture occurs outside the gauge 13.1 Should any one of the test pieces first
marks, or within 25 mm of either mark, and the selected fail to the requirements of the tests, two
required elongation is not obtained, the test shall be further samples from the same batch shall be
disregarded and another test should be made. selected for testing, one of which shall be from
When tested before and after stranding, the elon- the length from which the original test sample
gation shall be not less than 4 percent on a gauge was taken unless that length has been withdrawn
length of 200 mm. by the supplier.

12.4 Resistance Test 13.2 Should the test pieces from both these addi-
tional samples satisfy the requirements of the tests,
The electrical resistance of one specimen cut from
the batch represented by these samples shall be
each of the samples taken under 12.1.1 or 12.1.2
deemed to-comply with the standard. Should the
shall be measured at ambient temperature. The
test pieces from either of the two add.itional
measured resistance shall be corrected to the value
samples fail, the batch represented shall be deemed
at 2O“C by means of the formula:
not to comply with the standard.

ANNEX A
( Foreword )
MODULUS OF ELASTICITY AND COEFFICIENT OF LINEAR EXPANSION

No. of W5-es Final Modulus of Elastic@ CoefJicient of Linear

GNh2 ErpansionPC
3 0.650 0 x IO6kg/cm* 23.0 x 10”
7 0.632 4 x lo6 kg/cm* 23.0 x lo4
19 0.612 x lo6 kg/cm* 23.0 x 1od
37 0.5814 x lo6 kg/cm* 23.0 x lOA
61 0.550 8 x lo6 kg/cm* 23.0 x 10d

NOTE-These values ate given for information only.

IS 398 ( Part 4 ) : 1994

Break Up Details of Revised AMC Conductor

SI For Electra-Mechanical For Uprating &ding For Bridging

No. Equivalence to Ed- ACSR Conductors Gaps
ingACSR Coductors
h_____ 7 A
Existing
Size in Eqt. ACSR Size in ACSR Size in
mm2 mm2 Conductor mm2
1. 20 20 125/150 100 15-Street Lighting/
Telecommunication 700-800
2. 35 30 kV/ Substation bus-bars
3. 55 50 29Ot345 200 765-800 kV/Substation
bus-bars, equivalent to ACSR
4. 100 100 525 420
5. 17.5 150 64OJ695 560
6. 230 200
7. 400 400
8. 465 420
9. 570 520
10. 605 560

ANNEX B
(Table 2 )
NOTES ON TIIE CALCULATION OF TABLE 2

B-l INCREASE IN LENGTH DUE TO B-3 CALCULATED BREAKING LOAD OF

STRANDING CONDUCTOR

B-l.1 When straightened out, each wire in any par- B-3.1 The strength of conductor in terms of in-
ticular layer of a stranded conductor, except the dividual component wires shall be taken as follows:
central wire, is longer than the stranded conductor
by an amount depending on the lay ratio of that a) For a conductor containing not more than
37 wires, 95 percent of the sum of strength
layer.
of the individual wires calculated from the
B-2 RESISTANCE AND MASS OF values of the minimum beraking load given
CONDUCTOR in co1 6 of Table 1.

B-2.1 The resistance of any length of a stranded b) For a conductor containing more than 37
wires, 90 percent of the sum of strengths of
conductor is the resistance of the same length of
the individual wire calculated from the
any one wire multiplied by a constant as set out in
values of the minimum breaking load given
Table 4.
in co1 6 of Table 1.
B-2.2 The mass of each wire in any particular layer
of stranded conductor, except the central wire, will Table 4 Stranding Constants
be greater than that of an equal length of straight ( Clauses B-2.1, B-2.2 and B-2.3; and Table 1 )
wire by an amount depending on the lay ratio of in Conductor
Number of Wires , Stranding~nslants ,
that layer (see B-1.1). The total mass of any length
of an aluminium stranded conductor is, therefore, Mass Electrical
Resistance
obtained by multiplying the mass of an equal
(1) (2) (3)
length of straight wire by an appropriate constant,
as set out in Table 4. 3 3.029 0.336 6
7 7.091 0.144 7
B-2.3 In calculating the stranding constants in 19 19.34 0.053 57
Table 4, the mean lay ratio, that is the arithmetic
37 37.74 0.027 57
mean of the relevant minimum and maximum
61 62.35 0.016 76
values in Table 3, has been assumed for each layer.

6
Bureau of Indian Standards

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harmonious development of the activities of standardization, marking and quality certification of goods and
attending to connected matters in the country.

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Enquiries relating to copyright be addressed to the Director (Publication), BIS.

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needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue
of ‘BIS Handbook’ and ‘Standards Monthly Additions’.
This Indian Standard has been developed from Dot: No. ETD 37 (3534)

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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 AMENDMENT NO. 1 MAY 2000
TO
IS 398 ( PART 4 ) 1994 ALUMINIUM CONDUCTORS
FOR OVERHEAD TRANSMISSION PURPOSES
PART 4 ALUMINIUM ALLOY STRANDED CONDUCTORS
(ALUMINIUM-MAGNESIUM-SILICON TYPE) - SPECIFICATION

( Third Revision )

(Foreword, 1~s~IWOsentences ofparu 4 ) - Substitute the following for the

existing:

‘The maximum resistivity of 0.032 8 ohm.mm2/m at 20°C has been adopted for
arriving at the calculated resistance of conductor.’
(Page 1, clause4.1 )- Substitute the following for the existing:
‘4.1 Resistivity
For the purpose of this standard, the maximum value of resistivity of any sintle
aluminium alloy wire which shall be used for calculation is 0.032 8 ohm.mm /m
at 2OOC.’
( Page 2, Table 1, col 5 ) - Substitute ‘28.41’ and ‘29.19’ for ‘26.41’ and
‘21.19’ respectively.
(Page 3, Table 2, co1 6, Sl No. 8 ) - Substitute ‘0.229 8’ for ‘0.229 0’.
(Page 3, Table 2, col6, Sl No. 14 ) -Substitute ‘0.085 5’ for ‘0.082 9’.

(Page 3, clause 8.1 ) -Substitute the following for the existing:

‘8.1 Conductors Containing Up to Seven Wires
‘There shall be no joints in any wire of a stranded conductor containing up to 7
wires except, those made in the-base rod or wire before final drawing.’

( Page 5, Annex A, co1 2, title) - Substitute ‘kg/cm2 ‘for ‘G N/m2 ‘.

( Pago 6, Annex A ) - Delete the table of ‘Breakup details of revised
AAAC Conductor.’

(ETD37)

feprography Unit, BIS, New DeltdJndia