Test Procedure

Type Tests on Conductor ACSR Rail

(Offer 019-14V/3015)

Customer: Newage Cables Limited

Lahore, Pakistan

Test Objects: Conductor ACSR Rail

Cross-Sectional Area: 517,38 mm²

Tests to conduct: Tensile test acc. IEC 61089 Cl.6.5.3

Stress-strain test acc. IEC 61089 annex B,
Aluminum wire joint test acc. IEC 61089 Cl. 5.5

Test Engineer: Dipl.-Ing. Jérémy Unterfinger

Test Site: SAG Versuchs- und Technologiezentrum

SAG GmbH
Leitungsbau
Versuchs- und Technologiezentrum, Pittlerstraße 44, 63225 Langen
Telefon: +49 6103/7600-0, Fax: +49 6103/7600-149

This procedure consists of: 4 pages with - tables, 2 figures, - diagrams, - drawings and - enclosures
The results presented in this report refer only to the specified test objects.
Publication of this report - complete or in parts - needs the permission of: SAG GmbH, Versuchs- und Technologiezentrum
In case of additional electronic transmission of the report, only the printed and signed version is valid.
*Tests not within the accreditation scope.
SAG Versuchs- und Technologiezentrum
Test Procedure (Offer 001-14V/2996) Page 1 of 4

1. Ultimate Tensile Strength Test

1.1. Set-Up

The tensile test is carried out according to IEC 61089: 1991-05 + Amendment 1997-05. The
conductor sample is mounted in a horizontal 600 kN, class 1, tensile testing machine. The sample
length is 17 m. The ends of the conductor are cast in special resin clamps in order to avoid
transversal compression loads on the individual layers during the loading procedure.
The load and displacement measurement are continuously saved.
The load is uniformly increased to reach 30 % RTS within 1 to 2 minutes. The same velocity is then
maintained until the breakage of the sample.

The breaking strength of the conductor is determined by the load reached at which one or more
wires of the conductor broke. Figure 1 shows the set-up of tensile strength test.

Figure 1: Set-up of the tensile strength test.

1.2. Requirements:

The sample shall withstand without the fracture of any wire not less than 95% of RTS of the
conductor.
RTS for ACSR Rail: 116,5 kN Required breaking load => 110,6 kN

1.3. Results

Data are given in a graph “elongation/force” and the values for the maximum forces of total
conductor and if possible of steel core.
SAG Versuchs- und Technologiezentrum
Test Procedure (Offer 001-14V/2996) Page 2 of 4

2. Stress-Strain Test

2.1. Set-Up

Tests are performed in a horizontal 600 / 120 kN class1 tensile testing machine according to
IEC 61089: 1991-05 + Amendment 1997-05. The samples are kept at the ends in special epoxy
resin clamps, in order to avoid pressure and deformation of the aluminum wires. The sample length
is around 17 m. The load rate is corresponding to the relevant standard.

Measured signals are recorded continuously by a PC.

For stress strain test two measuring flanges are mounted on the specimen close to the clamps at a
load of 5% RTS, thus marking the initial length. The movement of the flanges is monitored during
the test by length transducers. These signals together with the measured initial length are used for
calculation of strain.

∆l2 t ∆l1 F

AP AC AC Z

AP anchor point F [kN] load measurement

AC resin anchor clamp L [m] measuring lenght
M multi channel amplifier ∆l1, 2 [mm] strain measurement
Z tensile testing machine
t [°C] temperature measurement

Figure 2: Scheme for Stress Strain Test

SAG Versuchs- und Technologiezentrum
Test Procedure (Offer 001-14V/2996) Page 3 of 4

2.2. Test Performance

Load is increased to 30% RTS and maintained for 30 min, then it is released. The next steps are 50,
70 and 85% of RTS are as the holding periods are 1 h each. After the final unloading the load is
increased again for breakage after removal of the length transducers. This part of the test is only for
information and not a substitute for an UTS test, as permanent elongation of the conductor might
change the breaking strength.

For conductors with different core material a test on a second sample is performed afterwards. The
outer layers are removed from the sample, so only the core is loaded in the test. Elongation is
measured in the same manner than the complete conductor. Load steps then are defined according
to the strains measured on the complete conductor at the beginning of the holding periods while the
load then is maintained at the same level for 0.5 h or resp. 1h.

2.3. Requirements

Data of stress-strain is for information and calculation purpose, there are no requirements defined.

2.4. Results

The result of the test is a curve stress vs. strain and a polynomial through the points at the end of the
holding periods in order to derive 4th order polynomial functions. These are used to calculate
stresses in steel and aluminum portions, which are given in a graph. From the releasing curves the
modulus of elasticity at the load steps is calculated.
SAG Versuchs- und Technologiezentrum
Test Procedure (Offer 001-14V/2996) Page 4 of 4

3. Wire Joint Test

3.1. Test Set-up

The tensile test is carried out according to IEC 61089-5.5.5.

5 wires containing a welding are tested. The sample length is around 50 cm.

The samples are mounted in a vertical 50 kN, class 1, tensile testing machine. The load is increased
until breakage.

3.2. Requirements

Stress at breakage shall be > 150 MPa (for hot butt weld joints)

Nominal diameter of wires: 3,70 mm

Required force for nominal Diameter and 150MPa: 1613 N

3.3. Results

Stress at breakage is calculated from the measured values for diameter and force and compared to
the requirements.