Aluminum Rods Bare Conductors And Cables Universal Cable (M) Berhad, incorporated in 1967 has grown steadily to become the country’s single largest cable manufacturer today since its 1990 merger with Through its far sighted planning and unceasing product and service innovation, cable and wire products. domestic and export markets to aluminium rods and high voltage cable, UCMB has achieved a distinguished reputation as a leading supplier of power and telecommunication cables to major corporations both local and foreign. most advanced facilities for manufacturing aluminium and aluminium alloy rods The aluminium and aluminium alloy rods manufactured today for the wire and standards. This catalogue serves as a guide to UCMB’s manufacturing processes and standards in the manufacture of aluminium rod, conductor and cables.
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Aluminum Rods Bare Conductors And CablesUniversal Cable (M) Berhad, incorporated in 1967 has grown steadily to become the country’s single largest cable manufacturer today since its 1990 merger with
Through its far sighted planning and unceasing product and service innovation,
cable and wire products.
domestic and export markets to aluminium rods and high voltage cable, UCMB has achieved a distinguished reputation as a leading supplier of power and telecommunication cables to major corporations both local and foreign.
most advanced facilities for manufacturing aluminium and aluminium alloy rods
The aluminium and aluminium alloy rods manufactured today for the wire and
standards.
This catalogue serves as a guide to UCMB’s manufacturing processes and standards in the manufacture of aluminium rod, conductor and cables.
ALL ALUMINIUM CONDUCTORS ( AAC )BS 215, Part 1 .......................................................................................................................................................10
Common conversion factor ..............................................................................................................................
Publications referred to......................................................................................................................................36
This trend is due to their excellent overall properties. Principally these are listed as:
1. Conductivity
2. Strength
3. Workability
4. Light Weight
5. Corrosion resistanceMost industrial, marine and chemical atmospheres cause corrosion.
6. Compatibility with insulation
clean stripping.
and distribution. The major areas dominated by aluminium and aluminium alloy conductors are non-insulated overhead power transmission, insulated overhead power transmission and non overhead power distribution.
alloy conductors offer good conductivity, light weight, excellent resistance to corrosion, good bending properties, greater tensile strength than copper and excellent compatibility with most common insulation used by the wire and cable industry.
heavy current installations) where weight and ease of handling are important factors.
ALUMINIUM CONDUCTORS
9
wire) to wire stranding from a large diameter of redraw aluminium and aluminium alloy rods.
annealing and heat-treating.
distribution cables where the characteristics of aluminium are of importance.
10
ALL ALUMINIUM CONDUCTORS ( AAC )( BS 215, Part 1 )
Code name area
Construction,
diameter
Calculatedarea
overalldiameter
weight
Calculatedbreaking
load
CalculatedDC resistance
at 20°C
Hard-drawn copper
mm² mm² mm mm²
Midge 22 23.3 3.99 1.227
50 9.30 33.2
60 63.6 10.2 9.90
Wasp 100 106 13.2 290 16.00 0.2702 66.6
Hornet 150 16.3 99.3
Chafer 200 213
Cockroach 250 266 21.1 731 167
300 323 23.3 203
Centipede 26.5 63.10 261
ALL ALUMINIUM CONDUCTORS ( AAC )
show some typical stranding patterns.
19(1+6+12)7(1+6)
11
ALL ALUMINIUM CONDUCTORS ( AAC / 1350 ) ( AS 1531 )
ALUMINIUM CONDUCTORS STEEL REINFORCED / HIGH STRENGTH (ACSR/HS) ( ASTM B 232 )
Codename
Hard-drawncopper
area
Construction,Calculated area
overalldiameter
Standardweight
Calculatedbreaking
load
CalculatedDC
resistance at 20°CSteel Steel
mm² mm² mm kgf
GrousePetrelMinorca
GuineaDotterel
DorkingBrahmaCochin
159.0176.9
203.2211.3
50.3
69.7
100.0111.2
120.0
51.6156.11
96.51
107.0
30.1032.73
52.15
56.30
9.3211.712.2
13.5
16.0
16.9
222379
500590656
1,005
2,5915,096
9,233
0.7112
0.5163
0.3605
0.3002
0.2707
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( JIS C 3110 )
sectionalarea
diameterCalculated
cross-sectional area overalldiameter
weight
Minimumtensileload
CalculatedDC resistance
at 20°CSteel Steel
mm² mm² mm² mm Kgf
2532
95120160
200
330
520*610
31.957.7
159.3
519.5
5.39.6
15.929.137.2
59.3
67.367.3
56.3
6.9
10.5
13.516.1
20.3
25.3
31.2
101129233
733
9121,1101,320
1,6731,9692,3202,700
907
10,21010,950
13,91015,600
1.15
0.3010.233
0.120
0.07020.0559
0.0356
23
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( DIN 48204 )
sectionalarea
Steel Totalsectional
area
Overalldiameter weight
Calculatedbreaking
load
CalculatedDC resistance
at 20°CConstruction Construction
mm² mm² mm² mm² mm Kg
15.323.9
51.2
69.9
96.5
105.7121.6122.1
127.9
209.1212.1
230.9
263.7
339.3
510.5
561.7
571.2653.5
2.5
5.7
31.7
15.356.3
75.5
71.3
39.5
39.5
56.3
39.563.6
71.3
39.5
27.9
75.756.3
109.7
157.7173.1211.9
213.6
261.6
260.7
369.1
553.9
621.0611.2
610.7
1,090.9
11.29.611.7
11.713.616.0
17.515.5
16.117.1
19.020.321.0
21.021.9
25.0
27.026.7
30.629.9
30.7
32.2
32.2
36.0
6297
372196
712
901
591605
1,002
1,2361,160
1,653
1,561
1,636
1,7702,092
2,1632,570
593920
1,295
1,752
10,012
5,902
6,761
10,71910,129
12,333
13,900
12,25915,59112,272
13,70217,077
22,223
0.6573
0.2992
0.2736
0.22590.1939
0.1571
0.1363
0.0757
0.0666
0.0590
0.05660.0526
0.0506
0.0277
PVC - COVERED ALUMINIUM CONDUCTORS( BS 6485 and BS 215, Part 1 )
aluminiumwire
Construction,
diameterdiameter ofconductor
CalculatedDC resistance
at 20°Cbreaking
load
diameter of covered conductor
mass of coveredconductor
mm² mm mm
225060*100150*200250*
9.3010.2013.1716.25
21.10
1.227
0.2702
3.99
9.9016.0025.70
11.713.016.019.721.7
100220270
610760970
PVC - COVERED ALUMINIUM CONDUCTORS
The PVC - covered conductors have been developed primarily to give protection to telecommunication lines which are crossed by power lines and to give protection to the public from low voltage lines in case of accidental contact for short periods.
The PVC - covered power lines have also been found useful in corrosive atmospheres and for
exceed 650 V r.m.s. between any two conductors or 250 V r.m.s. between any conductor and earth.
25
CHEMICAL COMPOSITION
1350 6201 6101 1120
Silicon Max.
Copper Max.Manganese Max.Magnesium Max.Chromium Max.Zinc Max.Boron Max.Gallium Max.Vanadium & Titanium, total Max.Other elements, each Max.Other elements, total Max.
PROPERTIES OF ALUMINIUM, ALUMINIUM ALLOY AND COPPER
Characteristics UnitCopper
Hard-drawn 6201 6101 1120 Hard-drawn
2.703 2.703 2.703 2.703 2.703
Tensile strength Min. 16 Max. 9.2 16 ~ 19 16 ~ 19
m Ohm.cm 3.31 2.93 1.777
Conductivity at 20°C 61 61.5 51 52 97 100
Temperature per °C 0.00390 0.00393
expansion23 23 23 23 23 17 17
Melting Point °C 660
Mechanical properties of aluminium alloy wires as per ASTM B 398
Tensile strength ( MPa )
Over Up to and including
1.5 3.25 330 315 3.0
3.25 315 305 3.0
Mechanical properties of aluminium alloy wires as per IEC 60104
Tensile strength ( MPa )
Over Up to and including Minimum Minimum
--- 3.5 325 3.0
3.5 --- 315 3.0
APPENDIX : TECHNICAL DATA
27
Electrical properties of aluminium alloy wires as per ASTM B 398 and IEC 60104
Tolerance Conductivity
Over Up to and including ( mm )
--- 3.00 ± 0.03 52.5
3.00 --- 52.5
Mechanical and electrical properties of aluminium 1120 wires as per AS 1531
Tensile strength Conductivity
Over Up to and including ( MPa )
1.5 2.5 250 0.0293
2.5 3.25 250 1.0 0.0293
3.25 3.75 1.2 0.0293
3.75 230 1.2 0.0293
230 0.0293
COMPARISON OF ALUMINIUM AND COPPER CONDUCTORS
ParticularCopper (annealed) Take hard-drawn
Weight 30 329
61
329 30
Diameter 55
50 200
137 73
61
Diameter
Weight 50 200
Weight 237
Diameter 119
CURRENT RATING CALCULATION FOR BARE CONDUCTOR ( IEC 61597 )
The symbols used in this section :
D = conductor diameter (m)
Si = intensity of solar radiation (W/m2)Ke
RT
Nu = Nusselt number : Nu = 0.65 Re0.2 + 0.23 Re0.61s = the Stefan-Boltzmann constant (5.67 x 10-8 W.m-2.K-4)Re = the Reynolds number : Re=1.644 x 109 v D [( T1 + 0.5 ( T2 - T1 )]
-1.78
with the conductor, 0.02585 W.m-1.K-1
v = wind speed (m/s)T1 = ambient temperature (K)T2
Imax= current rating (A)
Imax = [( Prad + Pconv - Psol )/RT]1/2
(a) Prad - the heat loss by radiation of the conductor ( W/m ) Prad = s D Ke ( T2
4 - T14 )
(b) Pconv - the convection heat loss ( W/m ) Pconv 2 - T1 )
(c) Psol - the solar heat gain by the conductor surface ( W/m )Psol = D Si