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Lb40 Aluminum Clad Steel Wire In Long Span Transmission Line

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(ACS) Aluminum Clad Steel Wires

Construction

Aluminum-clad steel wire, commonly abbreviated as AW or AS or AC, is an electrical conductor composed of an inner steel core and outer Aluminum cladding. Aluminum clad steel wire is a bimetallic in which aluminum covers on the steel core continuously and evenly.

Advantages

Aluminum-clad steel wire is superior to galvanized or aluminized steel in every way.

● Better corrosion resistance due to thick EC-grade aluminum covering

● Wider range of combinations of tensile strength and conductivity

● Lighter weight

● Excellent thermal stability

● Wider variety of products, with broad range of properties, quality, and size of steel wire and aluminum cladding.

● Compared with ordinary aluminum conductor steel reinforced, the conductor weight is 5% lighter, current-carrying capacity is 2-3% higher and power loss decreases 4-6%. Thus, the service life is long and it adds none erection cost.

Application

The aluminum clad steel wire is widely used in long-span transmission line, coastal areas and island as well as other hot and humid regions, salt fog regions and heavily polluted regions where the high corrosion resistance strand is needed.

It is used as the core of ACSR/AW, overhead ground conductor, extra high voltage overhead conductor, optical fiber composite overhead ground line, self-damping conductor line, bare overhead conductor, OPGW, ground wire, messenger wire, guy wire formed wire for protecting, terminating and splicing transmission and distribution lines, fence, barber wire and hardware, etc.

Standards

IEC 61232, ASTM B415, ASTM B502, AS 3607 and other International Standards.

However, can also supply a range of alternative designs with customized solutions to meet customer requirements.

Abbreviations

AW : Aluminum-clad steel wire as per ASTM B 502 Standard.

AS : Aluminum-clad steel wire as per IEC 61232 Standard.

AC : Aluminum-clad steel wire as per AS 3607 Standard.

Classification of Aluminum Clad Steel wire

Clas

14%

IACS

20.3%

IACS A

20.3%

IACS B

23%

IACS

27%

IACS

30%

IACS

35%

IACS

40%

IACS

Sectional Ratio of Al (%)

 13 25 25 30 37 43 52 62

Sectional Ratio of St (%)

 87 75 75 70 63 57 48 38

Weight Ratio of AL (%)

 5 10.4 10.4 12.9 16.9 20.7 27.3 36.1

Weight Ratio of ST (%)

 95 89.6 89.6 87.1 83.1 79.3 72.7 63.9

Physical Constants

Class

14%

IACS

20.3%

IACS A

20.3%

IACS B

23%

IACS

27%

IACS

30%

IACS

35%

IACS

40%

IACS
Nominal Density at 20°C (g/cm3 ) 7.14

6.59

 6.59

6.27

5.91

5.61

 5.15 4.64
Final Modulus of Elasticity (Gpa) 170

162

 155

149

 63

132

122

 109
Coefficient of Linear Exp. (per °C) 12 x 10-6

13 x 10-6

 12.6 x 10-6 12.9×10-6 13.4 x 10-6

13.8 x10-6

14.5 x 10-6

15.5 x 10-6
Temperature coefficient (per °C)

0.0034

0.0036

0.0036

0.0036

 0.0036

0.0038

0.0039

0.004
% Elongation at Fracture on 250mm

1.5

 1.5 1.5 1.5 1.5 1.5 1.5 1.5
The design of an aluminum-clad steel wire with a specified conductivity is based on 61 % IACS of aluminum and 9 % IACS of steel. For example, the conductivity of 30% IACS is dealt with as follows: Designed conductivity: Aluminum (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 nΩm). When only the aluminum covering is taken into account as the conductive part in the conductor, the electrical resistance of aluminum-clad steel wires can be calculated by the cross-sectional area of aluminum as per above and the conductivity of 61 % IACS.

Specifications for Aluminum Clad Steel Wires (Before Stranding)

Class Type

Nominal Diameter

(mm)

Min Tensile Strength (MPa)

Min stress at 1 % elongation (MPa)

 Max. Resistivity at Over 20°C (nΩ∙m)

14%1ACS

 over

Upto & Including
A 1.24 3.0 1590 1410 123.5
3.0 3.5 1550 1380
3.5 4.75 1520 1380
4.75 5.5 1400 1200
B 2.1 4.0 1770 1550

20%1ACS

 1.24 3.25 1340 1200

84.80
3.25 3.45 1310 1180
3.45 3.65 1270 1140
3.65 3.95 1250 1100
3.95 4.1 1210 1100
4.1 4.4 1180 1070
4.4 4.6 1140 1030
B 4.6 4.75 1100 1000
23%1ACS 2.50 5.00 1220 980 74.96
27%1ACS 2.50 5.00 1080 800 63.86
30%1ACS 2.50 5.00 880 650 57.47

35%1ACS

 A 2.50 5.00 810 590

49.26
B 2.50 5.00 880 650

40%1ACS

 A 2.50 5.00 680 500 43.10
B 2.50 5.00 750 550

SINGLE WIRE AS PER ASTM B 415 STANDARD

Size

AWG

Diameter

Tensile

Strength

Cross

section

D C Resistance

at 20°C

Nominal

Weight

Minimum Thickness of Aluminum Cladding
in. mm

ksi

N/mm²

in²

mm²

Ω/km

lb/1000 ft

Kg/km

in

mm
( CONDUCTIVITY = 20.3 % IACS)
4.0 0.204 5.189 155 1070 0.03278 21.149 4.010 93.67 139.37 0.01022 0.259
0.188 4.775 160 1100 0.02776 17.909 4.735 79.32 118.02 0.00940 0.239
5.0 0.182 4.620 165 1140 0.02599 16.766 5.058 74.25 110.49 0.00910 0.231
0.173 4.392 170 1170 0.02348 15.148 5.598 67.09 99.82 0.00865 0.220

6.0

 0.162 4.115 175 1210 0.02061 13.298 6.377 58.89 87.63 0.00810 0.206
0.155 3.934 180 1240 0.01884 12.158 6.975 53.84 80.12 0.00775 0.197
7.0 0.144 3.665 185 1280 0.01635 10.551 8.037 46.73 69.53 0.00722 0.183
0.137 3.477 190 1310 0.01472 9.497 8.930 42.06 62.58 0.00685 0.174
8.0 0.129 3.264 195 1340 0.01297 8.367 10.135 37.06 55.14 0.00643 0.163
9.0 0.114 2.906 195 1340 0.01028 6.631 12.787 29.37 43.70 0.00572 0.145
10.0 0.102 2.588 195 1340 0.00816 5.261 16.117 23.30 34.67 0.0051 0.129
11.0 0.091 2.304 195 1340 0.00646 4.168 20.343 18.46 27.47 0.00454 0.115
12.0 0.081 2.052 195 1340 0.00513 3.308 25.634 14.65 21.80 0.00404 0.103
CONDUCTIVITY = 27 % IACS)
4.0 0.204 5.189 125 862 0.03278 21.149 3.019 84.00 124.99 0.01430 0.363
0.188 4.775 106 731 0.02776 17.909 3.209 67.52 100.47 0.01410 0.358
5.0 0.182 4.620 110 758 0.02599 16.766 3.428 63.21 94.06 0.01364 0.347
0.173 4.392 114 786 0.02348 15.148 3.794 57.11 84.98 0.01297 0.329
6.0 0.162 4.115 114 786 0.02061 13.298 4.322 50.14 74.60 0.01215 0.309
0.155 3.934 118 814 0.01884 12.158 4.727 45.84 68.21 0.01162 0.295
7.0 0.144 3.665 122 841 0.01635 10.551 5 5.447 39.78 59.19 0.01082 0.275
0.137 3.477 126 869 0.01472 9.497 6.052 35.80 53.28 0.01027 0.261
8.0 0.129 3.264 156 1076 0.01297 8.367 7.632 33.23 49.45 0.00900 0.228
9.0 0.114 2.906 156 1076 0.01028 6.631 9.629 26.34 39.19 0.00801 0.203
10.0 0.102 2.588 156 1076 0.00816 5.261 12.136 20.90 31.10 0.00713 0.181
11.0 0.091 2.304 156 1076 0.00646 4.168 15.319 16.56 24.64 0.00635 0.161
12.0 0.081 2.052 156 1076 0.00513 3.308 19.303 13.14 19.55 0.00566 0.144
( CONDUCTIVITY = 30 % IACS)

4.0

 0.204 5.189 102 703 0.03278 21.149 2.717 79.74 118.65 0.01532 0.389
0.188 4.775 106 731 0.02776 17.909 3.209 67.52 100.47 0.01410 0.358
5.0 0.182 4.620 110 758 0.02599 16.766 3.428 63.21 94.06 0.01364 0.347
0.173 4.392 114 786 0.02348 15.148 3.794 57.11 84.98 0.01297 0.329
6.0 0.162 4.115 114 786 0.02061 13.298 4.322 50.14 74.60 0.01215 0.309
0.155 3.934 118 814 0.01884 12.158 4.727 45.84 68.21 0.01162 0.295
7.0 0.144 3.665 122 841 0.01635 10.551 5.447 39.78 59.19 0.01082 0.275
0.137 3.477 126 869 0.01472 9.497 6.052 35.80 53.28 0.01027 0.261
8.0 0.129 3.264 128 883 0.01297 8.367 6.869 31.54 46.94 0.00964 0.245
9.0 0.114 2.906 128 883 0.01028 6.631 8.666 25.00 37.20 0.00858 0.218
10.0 0.102 2.588 128 883 0.00816 5.261 10.923 19.84 29.52 0.00764 0.194
11.0 0.091 2.304 128 883 0.00646 4.168 13.787 15.72 23.38 0.00680 0.173
12.0 0.081 2.052 128 883 0.00513 3.308 17.372 12.47 18.56 0.00606 0.154
( CONDUCTIVITY = 40 % IACS)

4.0

 0.204 5.189 80 552 0.03278 21.149 2.038 65.95 98.13 0.02554 0.649
0.188 4.775 84 579 0.02776 17.909 2.407 55.85 83.10 0.02350 0.597
5.0 0.182 4.620 88 607 0.02599 16.766 2.571 52.28 77.79 0.02274 0.578
0.173 4.392 92 634 0.02348 15.148 2.845 47.23 70.29 0.02161 0.549
6.0 0.162 4.115 96 662 0.02061 13.298 3.241 41.47 61.70 0.02025 0.514
7.0 0.144 3.665 98 676 0.01635 10.551 4.085 32.90 48.96 0.01804 0.458
0.137 3.477 98 676 0.01472 9.497 4.539 29.61 44.06 0.01711 0.435
8.0 0.129 3.264 99.5 686 0.01297 8.367 5.152 26.09 38.82 0.01606 0.408
9.0 0.114 2.906 99.5 686 0.01028 6.631 6.500 20.68 30.77 0.01430 0.363
10.0 0.102 2.588 99.5 686 0.00816 5.261 8.192 16.41 24.41 0.01274 0.324
11.0 0.091 2.304 99.5 686 0.00646 4.168 10.340 13.00 19.34 0.01134 0.288
12.0 0.081 2.052 99.5 686 0.00513 3.308 13.029 10.32 15.35 0.01010 0.257

SINGLE WIRE AS PER ASTM B 502 STANDARD

Diameter Tensile Strength Stress at 1% Extension Resistity Density
in. mm ksi N/mm2 ksi N/mm2
0.0770 ~ 0.1289 1.956 ~ 3.274 195 1344 175 1206

51.01

84.8

0.2381

6.59
0.1290 ~ 0.1369 3.275 ~ 3.477 190 1310 170 1172
0.1370 ~ 0.1443 3.478 ~ 3.665 185 1275 165 1137
0.1444 ~ 0.1549 3.666 ~ 3.934 180 1241 160 1103
0.1550 ~ 0.1620 3.935 ~ 4.115 175 1206 160 1103
0.1621 ~ 0.1729 4.116 ~ 4.392 170 1172 155 1068
0.1730 ~ 0.1819 4.393 ~ 4.620 165 1137 150 1034
0.1820 ~ 0.1880 4.621 ~ 4.775 160 1103 145 1000
Coefficient of linear expansion Modulus of Elasticity

: 12.6 x 10-6 /°C

: 23500 Ksi (162000 MPa)

Temperature coefficient of Resistance: 0.0036/°C

Minimum Aluminum Thickness : 10% of nominal wire radius

SINGLE WIRE AS PER AS-3607 STANDARD

Diameter(mm) Tensile Strength Cross section

D.C Resistance

at 20℃

 Nomial weight

Min.thickness of

Aluminum cladding
standard max. min. N/mm2 KN mm2

Ω/km

 kg/km in mm
1.600 1.640 1.560 1340 2.69 2.011 42.28 13.25 0.080
1.750 1.790 1.710 1340 3.22 2.405 35.34 15.85 0.088
2.250 2.290 2.210 1340 5.33 3.976 21.38 26.20 0.113
2.500 2.540 2.460 1340 6.58 4.909 17.32 32.35 0.125
2.750 2.791 2.709 1340 7.96 5.940 14.31 39.14 0.138
3.000 3.045 2.955 1340 9.47 7.069 12.03 46.58 0.150
3.250 3.299 3.201 1340 11.12 8.296 10.25 54.67 0.163
3.500 3.553 3.448 1310 12.60 9.621 8.83 63.40 0.175
3.750 3.806 3.694 1270 14.03 11.045 7.70 72.78 0.188
Coefficient of linear expansion Modulus of Elasticity

: 12.9 x 10-6 /°C

: 23500 Ksi (162000 MPa)

Temperature coefficient of Resistance: 0.0036/°C

Minimum Aluminum Thickness : 10% of nominal wire radius

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