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AACSR/AW – Aluminum Alloy Conductor Aluminum Clad Steel Reinforced

BARE CONDUCTOR

AACSR/AC Conductor AS 3607

AACSR/AC Conductor to AS 3607 is a bare overhead conductor in which aluminium alloy wires are stranded around a core of aluminium-clad steel wires. It is supplied as AACSR/AC/1120 with alloy 1120 wires or as AACSR/AC/6201 with alloy 6201A wires, from Archery (6/1) upwards. Code names follow the ACSR/AC names of Appendix E with the alloy added as a suffix, for example Darts 1120, and the TDS values are the calculated properties of Tables 3.3 and 3.4.

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In an AACSR/AC Conductor both the envelope and the core carry current: the aluminium cladding of the steel wires conducts, so the calculated resistance treats the alloy wires and the aluminium-clad steel as two paths in parallel. Alloy 1120 gives lower resistance, and alloy 6201A higher strength, for the same stranding. Tests under the standard are made on the component wires; the conductor values are calculated and given for information.

Conductor Construction

  • Alloy wires: Aluminium alloy 1120 or 6201A with the compositions of AS 2848.1, meeting Table 2.3 or Table 2.4 before stranding (AS 3607 Clauses 2.2.1 and 2.3.2.1)
  • Core wires: Fully-killed steel to AS 1442 with an aluminium cladding containing not more than 0.05% copper and not more than 0.50% copper, silicon and iron together (AS 3607 Clauses 2.2.2.1 and 2.2.2.4)
  • Steel core: Where there is more than one steel wire, a central wire carries the others equally spaced around it; a king wire 5% larger in diameter may be specified for the centre (AS 3607 Clauses 3.1.1 and 3.1.2)
  • Stranding and lay: Successive layers have opposite lay directions with the outermost layer right-handed, and each layer is stranded evenly and closely within the lay ratios of Table 3.1 (AS 3607 Clauses 3.4.1 and 3.4.2)
  • Joints: Seven-wire conductors: aluminium joints only by cold-pressure butt-welding and no joint in the steel wire; larger conductors: aluminium joints by cold-pressure or annealed resistance butt-welding, steel joints by resistance butt-welding protected against corrosion; any two joints at least 15 m apart (AS 3607 Clauses 3.3.2 and 3.3.3)
  • Grease: Either partly greased, with grease on the steel only, or fully greased, with all wires except the outermost layer greased; the grease has a drop point of at least 120 °C to ASTM D 566 (AS 3607 Clauses 1.4.10, 1.4.11 and 2.2.3)
  • Alloy identification: Where specified, a durable non-hygroscopic coloured thread inside the conductor shows the alloy: blue for 1120 and red for 6201A (AS 3607 Clause 3.2)
  • D.C. resistance: The resistances of the alloy wires and of the aluminium-clad steel are found separately and combined as a parallel equivalent; the equivalent aluminium area also counts the aluminium-clad steel (AS 3607 Clauses A4.4 and A5.5)

Standard Strandings

Stranding (Alloy / Steel Wires) Code Names Listed Sizes
6/1 Archery 1120 to Baseball 6201 4
6/7 Bowls 1120 to Bowls 6201 2
18/1 Boxing 1120 to Boxing 6201 2
30/7 Cricket 1120 to Diving 6201 6
54/7 Golf 1120 to Hurdles 1120 3

The same strandings are listed for both alloys in Tables 3.3 and 3.4, the 6201A list stopping at Diving 6201. The calculated breaking load is 98% of the alloy wire strengths plus 85% of the steel wire strengths (AS 3607 Clause A6). The TDS tab gives the stranding, overall diameter, area, mass, calculated breaking load, equivalent aluminium area and d.c. resistance at 20 °C of each size.

Typical Applications

  • Bare overhead transmission lines
  • Primary and secondary overhead distribution lines
  • Messenger support for overhead lines
  • Line designs that need the strength of a steel core together with the corrosion resistance of an aluminium-clad core

AACSR/AC Conductor to AS 3607 has an alloy 1120 or 6201A envelope on an aluminium-clad steel core. The table below summarises the material and construction values that the standard sets; the calculated properties of every standard size are listed in the TDS tab.

Technical Characteristics

Applicable Standard AS 3607
Standard Scope Composite bare conductors of aluminium or aluminium alloy wires reinforced with steel wires, for overhead power transmission
Conductor Code AACSR/AC/1120 or AACSR/AC/6201
Alloy Wires Aluminium alloy 1120 or 6201A to AS 2848.1
Resistivity at 20 °C Alloy 1120 0.0293 µΩ·m; alloy 6201A 0.0328 µΩ·m; aluminium-clad steel 0.085 µΩ·m (maximum values)
Aluminium-Clad Steel Wires Density 6590 kg/m³; modulus of elasticity 162 GPa; coefficient of linear expansion 12.9 × 10⁻⁶ per °C
Cladding Thickness At least 5% of the standard wire diameter at any point
Standard Sizes 1120: Archery 1120 to Hurdles 1120, 11 sizes; 6201: Archery 6201 to Diving 6201, 6 sizes
Strandings 6/1, 6/7, 18/1, 30/7 and 54/7
Overall Diameter 9 mm to 31.5 mm
Cross-Sectional Area 49.48 mm² to 586.9 mm²
Wire Diameter Tolerance Alloy ±1%, ovality 2%; aluminium-clad steel up to 2.5 mm ±0.04 mm, above 2.5 mm ±1.5%, ovality 3%
Alloy Identification Thread Blue for 1120, red for 6201A, where specified
Calculated Breaking Load 98% of the alloy wire strengths plus 85% of the steel wire strengths

Ordering Information

Please state the quantity; the code name or stranding and conductor type, for example 30/7/3.00 AACSR/AC/1120 (Darts 1120); the length per drum; whether the conductor is to be greased, and if so partly or fully; whether a king wire is required; whether coloured alloy identification threads are required; whether special tests or optional routine tests are required; and any additional drum marking.

Aluminium Alloy 1120 / Aluminium-Clad Steel

Code Stranding and Wire Diameter Nominal Overall Diameter Cross-Sectional Area Approx. Mass Breaking Load Equiv. Aluminium Area D.C. Resistance at 20 °C
Aluminium Alloy 1120 Aluminium-Clad Steel Wire/Strand
mm mm mm mm² kg/km kN mm² Ω/km
Archery 1120 6/3.00 1/3.00 9.0 49.48 163 18.4 42.7 0.662
Baseball 1120 6/3.75 1/3.75 11.3 77.31 254 27.6 66.7 0.424
Bowls 1120 6/4.75 7/1.60 14.3 120.4 385 40.0 106 0.267
Boxing 1120 18/3.50 1/3.50 17.5 182.8 540 51.5 167 0.169
Cricket 1120 30/2.50 7/2.50 17.5 181.6 636 75.2 151 0.188
Darts 1120 30/3.00 7/3.00 21.0 261.5 913 108 217 0.130
Dice 1120 30/3.25 7/3.25 22.8 306.9 1070 127 254 0.111
Diving 1120 30/3.50 7/3.50 24.5 356.0 1240 143 295 0.0961
Golf 1120 54/3.00 7/3.00 27.0 431.2 1380 150 377 0.0750
Gymnastics 1120 54/3.25 7/3.25 29.3 506.0 1620 176 442 0.0639
Hurdles 1120 54/3.50 7/3.50 31.5 586.9 1880 197 513 0.0552

Aluminium Alloy 6201 / Aluminium-Clad Steel

Code Stranding and Wire Diameter Nominal Overall Diameter Cross-Sectional Area Approx. Mass Breaking Load Equiv. Aluminium Area D.C. Resistance at 20 °C
Aluminium Alloy 6201 Aluminium-Clad Steel Wire/Strand
mm mm mm mm² kg/km kN mm² Ω/km
Archery 6201 6/3.00 1/3.00 9.0 49.48 163 20.3 38.4 0.737
Baseball 6201 6/3.75 1/3.75 11.3 77.31 254 31.1 60.0 0.472
Bowls 6201 6/4.75 7/1.60 14.3 120.4 385 46.8 95.0 0.298
Boxing 6201 18/3.50 1/3.50 17.5 182.8 540 60.8 149 0.189
Darts 6201 30/3.00 7/3.00 21.0 261.5 913 118 195 0.145
Diving 6201 30/3.50 7/3.50 24.5 356.0 1240 158 266 0.106

Wire Tests Before Stranding

  • In accordance with AS 3607 Clauses 4.1.1 and 4.1.2, component wires are tested before stranding as routine tests on specimens from every tenth spool prepared for the stranding machine, following Table 4.1; a failure leads to two retests, and a second failure rejects the spool and brings individual tests of the five spools made before and after it.
  • In accordance with AS 3607 Clauses 4.2.1 and 4.2.2, every specimen is checked against the diameter limits of Clause 2.3.1 and tensile tested to AS 1391, reaching the ultimate tensile stress of Tables 2.2 to 2.7.
  • In accordance with AS 3607 Clauses 4.2.3 and 4.2.4 and Tables 4.3 and 4.4, the aluminium-clad steel wires pass either of the alternative tests: an elongation on a 250 mm gauge length of at least 1.0% to 1.5% depending on diameter, or at least 20 twists on a length of 100 times the wire diameter, before and after stranding.
  • In accordance with AS 3607 Clause 4.2.3 and Table 4.3, where the optional P10 routine test is ordered, the alloy wires reach a minimum elongation on 250 mm of 0.8% to 1.4% for alloy 1120 and 3.0% for alloy 6201A, depending on diameter.
  • In accordance with AS 3607 Clause 4.2.5 and Table 4.5, the alloy wires are wrapped eight turns around a wire of their own diameter at no more than 60 turns per minute and meet the acceptance criterion of Table 4.5, which marks the wrapping test as not applicable to aluminium-clad steel wires.
  • In accordance with AS 3607 Clause 4.3.3, the radial thickness of the aluminium cladding, measured to 0.02 mm on an etched cross-section or with a suitable instrument, is at least 5% of the standard wire diameter at every point.
  • In accordance with AS 3607 Clause 4.4, the alloy and aluminium-clad steel wires are measured for resistance to IEC 468 at 10 °C to 30 °C, corrected to 20 °C, and the resistivity does not exceed the values of Clause 2.3.2.3 or 2.3.3.3.

Special Tests and Conductor Checks

  • In accordance with AS 3607 Clauses 3.1.1 and 3.3.1, the wires lie naturally in their correct positions, tend to stay in place when the conductor is cut, and joints made during stranding are free from visible defects.
  • In accordance with AS 3607 Clause 4.1.3 and Table 4.2, where special tests are required, wires are taken from a conductor sample from one drum in every 200 km or from one drum per production run, whichever gives more samples, and reach at least 95% of the specified ultimate tensile stress.
  • In accordance with AS 3607 Clause 4.5, lay ratios are measured on the stranding machine under tension at the start and end of each production run of a size, and lie within Table 3.1.

Testing Location, Packing and Marking

  • In accordance with AS 3607 Clauses 4.6 and 4.7, all tests and inspection are carried out at the production works.
  • In accordance with AS 3607 Clauses 5.1 and 5.2, the conductor is supplied on drums to AS 2857 or AS C365, Part II, marked with the producer’s name, drum serial number, size and type of conductor, grease condition, length, gross mass, handling instructions and a ROLL THIS WAY arrow.

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