J

NORME CEI
INTERNATIONALE IEC
INTERNATIONAL 1232
Premiere edition
STANDARD First edition
1993-06

Fils d'acier revetus d'aluminium

pour usages electriques

Aluminium-clad steel wires

for electrical purposes I
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 -2- 1232 © CEl:1993

SOMMAIRE .

Pages

AVANT-PROPOS .................................................................................................................... 4
INTRODUCTION...................................................... ................................................................. 6

Articles

1 Domaine d'application .................................................................................................... 8

2 References normatives .................................................................................................. 8

3 Definitions........................................................................................................................ 8

4 Prescriptions .................................................... ............................................................... 10

5 Echantillonnage ..........................•................................................................................... 12

6 Methodes d'essai ............................................................................................................ 12

7 Emballage ....................................•................................................................................... 18

8 Acceptation et refus ....................................................................................................... 18

Tableaux ......................... ......................................................................................................... 20

Annexes

A Rapport de section de !'aluminium et de l'acier ............... ................... ............................. 24

B Allongement .. .... ... .. ........ ..... ............ ....... .. ........ ..... .. .......... ..... ......... .. ... .. ..... ............. .. .. .... 32

,.
1232 © IEC:1993 -3-

CONTENTS

Page

FOREWORD............................................................................................................................ 5
INTRODUCTION....................................................................................................................... 7

Clause

1 Scope............................................................................................................................... 9·

2 Normative references ............. .. ........ ........................................... .. ......... .... .................... 9

3 Definitions ............................................................................................................,........... 9

4 Requirements .................................................................................................................. 11

5 Sampling.......................................................................................................................... 13

6 Test methods .................................................................................................................. 13

7 Packaging........................................................................................................................ 19

8 Acceptance and rejection .......................................................................................... :... 19

Tables 21

Annexes
A Ratio of aluminium and steel cross-sectional areas............................... ....................... 25
B Elongation ... .. ....... ... ..... .......... .. .. .. ..... ...... .. .. ..... ... .... ... ..... .......... ....... ....... .. ..... ........ .. .. ... 33
1232 © IEC :1993 -5-

INTERNATIONAL ELECTROTECHNICAL COMMISSION

ALUMINIUM-CLAD STEEL WIRES

FOR ELECTRICAL PURPOSES

FOREWORD

1) The IEC (International Electrotechnical Commission) is a worldwide organization for standardization

. comprising all national electrotechnical committees (IEC National Committees) . The object of the IEC is to
promote international cooperation on all questions concerning standardization in the electrical and
electronic fields. To this end and in addition to other activities, the IEC publishes International .Standards.
Their preparation is entrusted to technical committees; any IEC National Committee interested In
the subject dealt with may participate in this preparatory work. International, governmental and
non-governmental organizations liaising with the IEC also participate in this preparation. The IEC
collaborates closely with the International Organization for Standardization (ISO) in accordance with
conditions determined by agreement between the two organizations.
2) The formal decisions or agreements of the IEC on technical matters, prepared by technical committees on
which all the National Committees having a special interest therein are represented, express, as nearly as
possible , an international consensus of opinion on the subjects dealt with.
3) They have the form of recommendations for international use published in the form of standards, technical
reports or guides and they are accepted by the National Committees in that sense.
4) In order to promote international unification, IEC National Committees undertake to apply IEC International
Standards transparently to the maximum extent possible in their national and regional standards. Any
divergence between the IEC Standard and the corresponding national or regional standard shall be cloarly
indicated in the latter.

This International Standard I EC 1232 has been prepared by IEC technical committee 7:
Bare aluminium conductors.

The text of this standard is based on th e following documents:

DIS Report on Voting

7(C0)434 7(C0)436

Full information on the voting for the appro val of this standard can be found in the report
on voting indicated in the above table .

Annexes A and B are f or information only.

 1232 © IEC:1993 -7-

INTRODUCTION

Aluminium-clad steel wires have been used as all aluminium-clad steer stranded wires for
overhead ground wire purposes and as reinforcement of aluminium conductors for over-
head line conductor purposes. In some cases, they are also used as phase conductors.
Since vctrious national standards exist in each country for the aluminium-clad steer wires.
this International Standard establishes the requirements for properties.

It should be noted that this standard has been prepared after consideration of the existing
IEC BBB.

j
1232 © IEC :1993 -9--

ALUMINIUM-CLAD STEEL WIRES

FOR ELECTRICAL PURPOSES

1 Scope

This International Standard applies to bare, hard-drawn, round, aluminium-clad steel wires
of different electrical and mechanical properties, in the diameter ranges 'shown in table 5,
for electrical purposes, before stranding.

It is intended to cover applications, for reinforcement in aluminium conductors and for all
aluminium-clad steel stranded conductors.

It does not cover the wires for redrawing purposes.

2 Normative references

The following normative document contains provisions which, through reference in this
text. constitute provisions of this International Standard. At the time of publication, the
edition indicated was valid. All normative documents are subject to revision, and parties to
agreements based on this International Standard are encouraged to investigate the possi-
bility of applying the most recent edition of the normative document indicated below.
Members of IEC and ISO maintain registers of currently valid International Standards.

IEC 468 : 1974, Met.h od of measurement of resistivity of metallic materials.

3 Definitions

For the purpose of this International Standard, the following definitions apply:

3.1 aluminium-clad steel wire: Round wire consisting of a round steel core with a
uniform and continuous aluminium covering.

3.2 diameter: Mean of two measurements at right angles taken at the same cross-
section.

3.3 class: Aluminium-clad steel wires defined as "20SA", "27SA", "30SA" and "40SA",
corresponding to their conductivity grades of 20,3 %, 27 %, 30 % and 40 % !ACS* .

3.4 type: Aluminium-clad st eel wires of class 20SA are divided into two types, A and 8,
according to their tens ile strength characteristics.

• IACS: Intern ation al An nealed Coppe r Standard.

 1232 © IEC:1993 - 11 -

4 Requirements

4.1 Materials

4.1.1 The base metal shall be steel produced by the open-hearth, electric-furnace, or
basic-oxygen process and shall be of such composition that the finished clad wire shall
have the properties and characteristics given in this standard.

4.1.2 The aluminium used for covering shall have a minimum purity of 99,5 % and
quality sufficient to meet thickness and electrical resistance requirements of this standard.

4.2 Freedom from defects

The wires shall be smooth and free from all imperfections such as fissures, roughness,
grooves, inclusions or other defects which may endanger the performance of the product.

4.3 Density

For the purpose of calculating the nominal mass of the wires. the density of the aluminium-
clad steel wire shall be taken as shown in table 1.

4.4 Tolerances on nominal diameter of wires

Aluminium-clad steel wires shall not depart from the nominal diameter by more than the
amounts given in table 2.

4.5 Minimum thickness of aluminium

I'
The minimum aluminium thickness of wires at any point shall comply with the requirements
i given in table 3. ·

4.6 Tensile stress

The wire shall comply with the requirements given in table 5. In computing breaking load
of a single wire from tensile stress . the actual diameter of the finished wire shall be used.

4.7 Elongation

The wire shall comply with either the re_quirement ot 1 % minimum e!cngatlor. atter
fracture, or 1,5 % minimum total elongation at fracture. for. in both cases , a gauge length
of 250 mm. Measurement shall be made either under no load after fracture or at the time
of fracture by the use of a suitable extensometer.

Unless otherwise agreed upon between the manufacturer and purchaser at the time of
purchase, it is at the option of the manufacturer to select the measurement method.

The test shall be made by only one of th e two methods prescribed in 6:3. 2.

4.8 Resistivity

The maximum resistivit y of wires shall conform to th e requirements prescribed in table 5 at

the tempe rature of 20 °c.

• •
1232© IEC:1993 -13-

4.9 Torsion test

The wire shall withstand, without fracture, not less than 20 twists in a length equivalent to
100 times the nominal diameter of the wire.

The specimen, after twisting to destruction, shall show no separation of the aluminium
from the steel when examined with the naked eye or with normal corrective glasses.

4.1 o Stress at 1 % extension

The wire shall conform to the requirement of stress at 1 % extension given in table 5. The
test shall be made on straight undeformed wires.

4.11 Joints

4.11 .1 There shall be no joints of any kind made in the finished wire . Joints may be
made in the wire rods prior to drawing to the finished wire.

The finished wire at such joints shall meet the requirements of 4.5.

4.11.2 Jointing equipment and procedure shall be such that it can be demonstrated that
the tensile stress of a finished wire specimen containing the jointed section shall be not
less than 80 % of normal part, and also greater than 90 % of minimum specified value in
table 5.

4. 11.3 Elongation, torsion and stress at 1 % extension tests are not required for jointed
sections in a finished wire .

5 Sampling

Samples for tests shall be taken by the manufacturer from 10 % of the individual lengths
of finished wire .

In case of wire supply in large quantities and where the manufacturer has demonstrated
capability of meeting or exceeding the requirements, the number of samples may be
reduced, by agreement between the purchaser and the manufacturer, to a level which
ensures that each production lot of wire is given an adequate monitoring.

6 Test methods

6 .1 Place of testing

All tests shall be made at the manufacturer's plant unless mutually agreed betwee n the
manufacturer and purchaser.

s.2 Tests

The following tests numbers 1 to 9 shall be made on each of the samples before strand-
ing. Wh en the wires are to be used for products consisting of
only aluminium-clad steel
wires, it may be agreed between the manufacturer and t he purchaser not to carry out
test 9.
1232 © IEC:1993 - 15 -

1) Appearance;
2) finish;
3) diameter;
4) tensile stress;
5} elongation;
6} torsion;
7) resistivity; iI
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8) minimum aluminium thickness; I

9) stress at 1· % extension.

6.3 Test method

6.3 .1 Tensile test

The breaking load of the specimen shall be determined by means of a suitable tensile test-
ing machine. The load shall be applied gradually and the rate of separation of the jaws of
the testing machine shall be not less than 25 mm per minute and not greater than 100 mm
per minute.

In calculating the tensile stress from the measured breaking load, the diameter of the \.:,
finished wire before stressing shall be used.

6.3.2 Elongation tests ·

The elongation tests may be made on the same samples in the same operation as the
tensile test described in f?.3.1 .

a) Percentage elongation after fracture

The ultimate elongation measured under no load shall be determined on the specimen.
The specimen shall be straightened by hand and an original gauge length of 250 mm
marked on the wire and loaded as described in the tensile test. After the wire is broken
the specimen ends shall be carefully placed together and the distance between the
gauge marks measured . ,,1;1'
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The elongation is the increase in gauge length expressed as a percentage of the !
original gauge length. l'
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If the fracture occurs outsid e the gauge marks, or within 25 mm of either mark, and the
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required elongation is not obtained, another test shall be made .

b) Percentage total elongation at fracture

The specimen shall be gripped in the jaws of a tensile testi ng machine. A load
corresponding to the appropriate tensile stress given in table 4 shall be applied and an
extensometer applied on a 250 mm gauge length and adjust ed to the appropriate initial
setting given in t able 4.
A tensile load shall be applied as describe d in the tensile test an d t he reading at the
time of fracture shall be taken as th e elongation of specimen.
If the fract ure occurs out side the gauge marks, or within 25 mm of either mark, and the
required elongation is not obt ained, another test shall be made .
1232 © IEC:1993 -17 - -

6.3.3 Torsion test

One specimen shall be gripped at its ends in two vices with the distance between vices
equivalent to 100 times the nominal wire diameter, one of which shall be free to move
longitudinally during the test. A small tensile load, not exceeding 2 % of the breaking
strength of the wire, shall be applied to the sample during testing.

The specimen shall be twisted by causing one of the vices to revolve until fracture occurs
and the number of twists shall be indicated by a counter or other suitable device.

The rate of twisting shall not exceed 60 rev/min.

6.3.4 Thickness of aluminium

The thickness of aluminium of the specimen shall be determined by using suitable electrical
indicating instruments operating on the permeameter principle. or direct measurement.

Measurements shall be read to three decimal places, and number rounded to two decimal
places is considered as measured thickness. For reference purposes, direct measurement
shall be used to determine aluminium thickness on specimens taken from the end of the
coils.

6.3.5 Resistivity test

The electrical resistance of the specimen shall be measured by the method specified in
IEC 468 at a temperature which shall be not less than 10 °c or more than 30 °c. The
measured resistance shall be corrected to the value at 20 °C by means of the formula:

R 20 - R 1 )
- T ( 1 + a ( T - 20)

where
T is the temperature of measurement in °C;
fir is the resistance at T °C ;
~ is the resistance at 20 °C ;
"lit
1·1
et is the constant-mass temperature coefficient of resistance at 20 °C. I I
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The resistivity at 20 °C shall then be calculated from the reslstafice at 20 "C, total cross- "'
section of the wire calculated from the measured wire diameter and the length of wire over
which the resistance is measured.

6.3 .6 Stress at 1 % extension

The specimen shall be gripped in the jaws of a tensile testing machine. A load corre-
sponding to the appropriate tensile stress given in table 4 shall be applied and an extenso-
meter applied on a 250 mm gauge length and adjusted to the appropriate initial setting
given in table 4. ·

Th e lo ad shall then be increased uniformly until the extensomei er indicates an extension

of 2,50 mm in 250 mm.
1232 © IEC:1993 ~ - 19 -

At this point, the load shall be read, from which the value of the stress at 1 % extension
shall be calculated using the diameter of finished wire before stressing. The value
obtained for the specimen shall be not less than the appropriate value given in column 5
of table 5. The specimen may subsequently be used for the tensile test specified.

7 Packaging

7.1 Lengths and tolerance on length

Aluminium-clad steel wires shall be supplied with a length specified by the purchaser with
+6
a permitted vai'iation of %.

Random lengths shorter or longer than this requirement are only acceptable if prior
agreement between the purchaser and manufacturer is made.

7.2 Packing method

Aluminium-clad steel wires shall be suitably packed on reel or in coil in order to protect
against damage in ordinary handling and transporting.

8 Acceptance and rejection

8.1 Failure of a test specimen to comply with any one of the requirements of this
standard shall constitute grounds for rejection of the lot represented by the specimen.

8.2 If any lot is so rejected, the manufacturer shall have the right to test only once all
individual reels or coils of aluminium-clad st eel wires in t he lot and submit those which
meet the requirements of acceptance .
1232 © IEC:1993 - -21 -

Table 1 - Nominal density of wires

Class Type Nominal density at 20 •c

g/cm 3

A 6,59
20SA
B 6,53
27SA - 5,91
30SA - 5,61
40SA - 4,64

Table 2 - Tolerances on diameter of wires

Nominal diameter Tolerance

2,67 mm and greater ±1,5%

Less than 2,67 mm ±0,04mm

Table 3 - Minimum thickness of aluminium covering

Class Minimum thickness of aluminium covering

20SA 8 % of nominal wire radius for nominal diameter less than 1,80 mm
10 % of nominal wire radius for nominal diameter including and over 1,80 mm
27SA 14 % of nominal wire radius
30SA . 15 % of nominal wire radius
40SA 25 % of nominal wire rad ius

Table 4 - Initial settings for determining stress at 1 % extension

and total elongation at fracture

1 2 3

Nominal diameter
iniiiai stress Initial setting of extensometer
Over Up to and
including

mm mm MPa cm/cm

1,24 2,50 81 ,4 0,000 5

(0 ,05 % extension )
2, 50 3,30 162 0,00 1 0
(0 , 1O % exten sion)
3,30 5,50 244 0,001 5
(0, 15 % extension)

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1232 © IEC:1993 -23-

Table 5 - Tensile and resistivity requirements of wires (before stranding)

1 2 3 4 5 6

Nominal diameter Tensile Stress

stress at 1 o/o Resistivity at 20 °c
Class Type Over Up to and extension
including Min. Min. Max.

mm mm MP a MPa nn-m

1,24 3,25 1 340 1 200

3,25 3,45 1 310 1 180

3,45 3,65 1 270 1 140

3,65 3,95 1 250 1 100

3,95 4,10 , 210 1 100 84,80

(corresponding to
20SA A
. 4,10 4,40 1180 1 070
20 ,3 o/o IACS
conductivity)

4,40 4,60 1 140 1 030

4,60 4.75 1 100 1 000

4,75 5,50 1 070 1000

B 1,24 5,50 1 320 1100

63,86
(corresponding to
27SA - 2,50 5,00 1 080 800 27 % !ACS
conductivity )

57,47
(corresponding to
30SA - 2,50 5,00 880 650
30% IACS
conductivity)

43,10
(corresponding to
40SA - 2,50 5,00 680 500
40 % !ACS
conductivity)

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1232 © IEC:1993 -25-

Annex A
(informative)

Ratio of aluminium and steel cross-sectional areas

A.1 Classification of aluminium-clad steel wires

Aluminium-clad steel wires are divided into four classes by their conductivity grade,
corresponding to standard aluminium covering, medium aluminium covering and thick alu-
minium covering respectively.

Table A.1 - Classification of aluminium-clad steel wires

Class Aluminium covering Conductivity

20SA Standard 20,3% IACS

27SA Medium 27% IACS

30SA Medium 30% IACS

40SA Thick 40% IACS

A.2 Standard ratio in cross-section

The standard ratio in cross-section of each aluminium-clad steel wire is as follows and is
based on the total cross-section of wires.

Table A.2 - Standard ratio of aluminium and steel

Class Aluminium ratio Steel ratio

20SA 25% 75%

27SA 37% 63%

30SA 43% 57%

40SA 62% 38%

.r

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1232© IEC:1993 - -27-

A.3 Conductivity

The design of an aluminium-clad steel wire with a specified conductivity is based on 61 %

IACS of aluminium and 9 % IACS of steel.

For example, the conductivity of 30SA is dealt with as follows :

Designed conductivity: Aluminium (61 % IACS x 0,43) +

Steel (9 % IACS x 0,57) = 31,36 % IACS.

Then, taking into consideration allowances, minimum conductivity is specified as 30 %

IACS (57,47 nn·m).

When only the aluminium covering is taken into account as the conductive part in the
conductor, the electrical resistance of aluminium-clad steel wires can be calculated by
the cross-sectional area of aluminium as per above clause A.2 and the conductivity of
61 % IACS.

For this reference, the relationship of SA wire conductivity between "with steel conduc-
tivity" and "without steel conductivity" is given in table A.3 .

Table A.3 - Conductivity

Conductivity (% IACS )

SA wire
Class
Aluminium Steel Minimum specified value Calculated value
including both alum inium e xclud ing conductivity
and steel of steel

20SA 20,3 15,3

27SA 27 22,6
61 9
30SA 30 26,2

40SA 40 37,6
I I
1232 © IEC:1993 -29-

A.4 Aluminium thickness

The relationship between standard aluminium ratio in the cross-sectional area and
minimum aluminium thickness is as follows :

Table A.4 - Aluminium thickness

Standard Average aluminium Minimum aluminium

Classe aluminium ratio thickness: AAT thickness: MAT
in the (concentric thickness) (concentricity error)
cross-section

Aluminiu=@Steel Aluminiu=@Steel

AAT MAT

20SA 25% 13.4 % of nominal wire radius 8 % of nominal wire radius

for nominal diameter
less than 1,80 mm
10 % of nominal wire radius
for nominal diameter
including and over 1,80 mm

27SA 37% Ditto, but 20,5 % 14 % of nominal wire radius

30SA 43 % Ditto, but 24,5 % Ditto , but 15 %

40 SA 62% Ditto , but 38.4 % Ditto , but 25 %

A.5 Nominal density at 20 "C

The nominal density at 20 °C of 20SA-type B, 27SA, 30SA and 40SA is calculated from
3 3
the density at 20 °c of aluminium 2,70 g/cm , steel 7,80 g/cm and their ratio in cross-
section, while that of 20SA-type A is as specified by ASTM 8415/8502, etc.
 1232 © IEC :1993 - 31 -

A.6 Physical constants

Physical constants for aluminium-clad steel wires are given in table A.5.

Table A.5 - Physical constants

Class 20SA 27SA 30SA 40SA

Type A B - - -
Final modulus
of elasticity GPa 162 155 140 132 109
(practical)

Coefficient
of linear K-1 13,0 x 10-6 12,6 x 10-6 13,4 x 10-6 13,8 x 10- 6 15,5 x 10-6
expansion

Constant-mass
temperature
coefficient 1(""1 0 ,003 6 0,003 6 0 ,003 6 0 ,003 8 0 ,004 0
of resistance
(a)

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1232 © IEC:1 993 -33-

Annex B
(informative)

Elongation

8 .1 Terms

The . terms "percentage elongation after fracture" and "percentage total elongation at
fracture" refer to clause 4 of ISO 6892* .

8.2 Elongation test

Although the percentage elongation after fracture is quite common for wires such as
hard-drawn aluminium wires and zinc-coated steel wires, it is particularly noticed that
percentage total elongation at fracture has been practically used for aluminium-clad steel
wires, which is specified by ASTM 8415/8502 and other national standards .

In consideration of uniformity with IEC 888 .. and convenience in practical use, both test
methods are included as alternative methods.

• ISO 6892 : 1984, M e tallic ma terials - Tensile resting

•• IEC 888: 1987, Z inc-coa te d steel wires fo r stranded conductors

• •