(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 | 12.9x10-6 | 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 |