AS1049-2003 Telecommunication Cables-Insulation

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AS 1049
sheath and jacket

Australian Standard™
Telecommunication cables—Insulation,
AS 1049—2003
This Australian Standard was prepared by Committee CT-001, Communications
Cabling. It was approved on behalf of the Council of Standards Australia on
14 November 2002 and published on 16 May 2003.
The following are represented on Committee CT-001:

Australian Chamber of Commerce and Industry
Australian Communications Authority
Australian Communications Industry Forum
Australian Electrical and Electronic Manufacturers Association
Australian Information Industry Association
Australian Telecommunications Users Group
BICSI Australia
Electrical Compliance Testing Association
Electrical Regulatory Authorities Council
Electrical Supply Association of Australia
Institute of Engineers Australia
National Electrical and Communications Association
New Zealand Consulting Interests

New Zealand Defence Force
Plastics and Chemicals Industry Association
SingTel Optus
Telecom New Zealand
Telstra Corporation Limited
Vendor Interests New Zealand
Additional interests participating in the preparation of this Standard:
Elf Atochem (Australia) Pty Limited
Corning Cables Australia
Qenos Pty Ltd
General Cables Aust Ltd
Pirelli Power Cables and Systems
Ponga Donga Pty Ltd
Compco Pty Ltd
Belden Australia Pty Ltd
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This Standard was issued in draft form for comment as DR 01094.

AS 1049—2003
Australian Standard™
Telecommunication cables—Insulation,
sheath and jacket
Originated as AS 1049—1971.
Previous edition 2000.
Fifth edition 2003.
COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 4942 9
AS 1049—2003 2
PREFACE
This Standard was prepared by the Standards Australia Committee CT-001,
Communications Cabling, to supersede AS 1049—2000. In the course of preparation, this
Standard has incorporated relevant material from UL 444, Standard for Safety for
Communications Cables.
The objective of this Standard is to provide polymer manufacturers, telecommunication
cable manufacturers and end users with requirements and test methods for plastics used in
telecommunication cables insulation, sheathing and jackets in order to maintain quality
control and acceptance levels at the various stages of manufacture.
The objective of this revision is to incorporate requirements for additional materials used
for insulation, sheaths and jackets.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

Thirty six test methods are set out in normative appendices.
Statements expressed in mandatory terms in footnotes and notes to tables are deemed to be
requirements of this Standard.
3 AS 1049—2003
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL..................................................................................... 6

1.1 SCOPE.................................................................................................................... 6
1.2 APPLICATION ...................................................................................................... 6
1.3 MATERIAL SELECTION.................................................................................... 10
1.4 REFERENCED DOCUMENTS............................................................................ 12
1.5 DEFINITIONS...................................................................................................... 13
1.6 ACRONYMS........................................................................................................ 16
SECTION 2 PE INSULATION .............................................................................................. 18

2.1 SCOPE OF SECTION .......................................................................................... 18
2.2 COMPOUND........................................................................................................ 19
2.3 INSULATION ...................................................................................................... 20
SECTION 3 PA 12 SOLID INSULATION............................................................................. 27

3.1 SCOPE OF SECTION .......................................................................................... 27
3.2 INSULATION TESTS .......................................................................................... 27
SECTION 4 NON-HALOGENATED PPO-BASED MATERIAL (CONTAINING A

FIRE/FLAME RETARDANT) FOR SOLID INSULATION.................................................... 28
4.1 SCOPE OF SECTION .......................................................................................... 28
SECTION 5 PVC SOLID INSULATION............................................................................... 30

5.1 SCOPE OF SECTION .......................................................................................... 30
SECTION 6 PP SOLID INSULATION .................................................................................. 32

6.1 SCOPE OF SECTION .......................................................................................... 32
SECTION 7 PE SHEATH OR PE JACKET ........................................................................... 33

7.1 SCOPE OF SECTION .......................................................................................... 33
7.2 COMPOUND........................................................................................................ 33
7.3 SHEATH OR JACKET......................................................................................... 35
SECTION 8 POLYAMIDE JACKET ..................................................................................... 38

8.1 SCOPE OF SECTION .......................................................................................... 38
8.2 COMPOUND........................................................................................................ 38
8.3 JACKET ............................................................................................................... 39
SECTION 9 INTEGRALLY BONDED PE SHEATH AND POLYAMIDE JACKET ........... 41

9.1 GENERAL............................................................................................................ 41
9.2 COMPOUND........................................................................................................ 41
9.3 INTEGRALLY-BONDED SHEATH AND JACKET........................................... 41
AS 1049—2003 4
SECTION 10 PVC SHEATH OR JACKET............................................................................ 43

10.1 SCOPE OF SECTION .......................................................................................... 43
10.2 SHEATH OR JACKET TESTS ............................................................................ 43
10.3 CABLES EXPOSED TO UV RADIATION ......................................................... 43
SECTION 11 NHMH FOR SHEATH OR JACKET............................................................... 46

11.1 SCOPE OF SECTION .......................................................................................... 46
11.2 SHEATH OR JACKET TESTS ............................................................................ 46
SECTION 12 FLUOROPOLYMER INSULATION, SHEATH OR JACKET........................ 49

12.1 SCOPE OF SECTION .......................................................................................... 49
12.2 INSULATION, SHEATH OR JACKET TESTS................................................... 49
SECTION 13 PEFR INSULATION, SHEATH OR JACKET ................................................ 51

13.1 SCOPE OF SECTION .......................................................................................... 51
13.2 INSULATION, SHEATH OR JACKET TESTS................................................... 51
SECTION 14 SRPVC INSULATION, SHEATH OR JACKET ............................................. 52

14.1 SCOPE OF SECTION ...............................................................................................52
14.2 INSULATION, SHEATH OR JACKET TESTS.......................................................52
SECTION 15 CROSSLINKED POLYMER INSULATION, SHEATH OR JACKET............ 53

15.1 SCOPE OF SECTION ...............................................................................................53
15.2 INSULATION, SHEATH OR JACKET TESTS.......................................................53
APPENDICES
A TEST METHOD 1: DETERMINATION OF VISUAL APPEARANCE ................55
B TEST METHOD 2: DETERMINATION OF DENSITY .........................................56
C TEST METHOD 3: DETERMINATION OF MELT FLOW INDEX .....................58
D TEST METHOD 4: DETERMINATION OF SOFTNESS NUMBER ....................62
E TEST METHODS 5 AND 6: DETERMINATION OF TENSILE
STRENGTH AT BREAK/YIELD AND ELONGATION AT BREAK—
BEFORE AND AFTER AGEING .............................................................................64
F TEST METHOD 7: FLEXIBILITY AFTER AGEING............................................71
G TEST METHOD 8: PRESSURE TEST AT HIGH TEMPERATURE.....................72
H TEST METHOD 9: DETERMINATION OF SHRINKBACK ................................73
I TEST METHOD 10: DETERMINATION OF STRIPPING....................................76
J TEST METHOD 11: COLD BEND PERFORMANCE ...........................................78
K TEST METHOD 12: DETERMINATION OF HEAT SHOCK...............................80
L TEST METHOD 13: DETERMINATION OF ENVIRONMENTAL
STRESS-CRACKING ...............................................................................................81
M TEST METHOD 14: DETERMINATION OF BOND STRENGTH.......................87
N TEST METHOD 15: DETERMINATION OF BENDING
PERFORMANCE ......................................................................................................91
O TEST METHOD 16 AND 17: CONFIRMATION OF STABILIZER
TYPE AND DETERMINATION OF STABILIZER CONCENTRATION .............92
P TEST METHOD 18: DETERMINATION OF COMPATIBILITY OF
PE INSULATION WITH FILLING COMPOUND ................................................101
Q TEST METHOD 19: DETERMINATION OF CORROSION ...............................107
R TEST METHOD 20: DETERMINATION OF VOLATILE LOSS........................108
S TEST METHOD 21: DETERMINATION OF CARBON BLACK
CONCENTRATION................................................................................................110
5 AS 1049—2003
T TEST METHOD 22: DETERMINATION OF CARBON

BLACK DISPERSION ............................................................................................112
U TEST METHOD 23: DETERMINATION OF COLOUR DIFFERENCE
BY VISUAL ASSESSMENT ..................................................................................116
V TEST METHOD 24: DETERMINATION OF COLOUR DIFFERENCE
BY INSTRUMENTAL ASSESSMENT..................................................................119
W TEST METHOD 25: QUALITATIVE EVALUATION OF BLEEDING OF
COLORANTS..........................................................................................................120
X TEST METHOD 26: DETERMINATION OF COLOURFASTNESS TO
DAYLIGHT .............................................................................................................122
Y TEST METHOD 27: DETERMINATION OF COLOURFASTNESS
TO WATER .............................................................................................................127
Z TEST METHOD 28: PLASTICIZER COMPATIBILITY .....................................129
AA TEST METHOD 29: VOLUME RESISTIVITY....................................................130
BB TEST METHOD 30: DIELECTRIC STRENGTH .................................................132
CC TEST METHOD 31: SPARK TEST.......................................................................133
DD TEST METHOD 32 AND 33: DETERMINATION OF DIELECTRIC
DISSIPATION FACTOR AND RELATIVE PERMITTIVITY .............................134
EE TEST METHOD 34: DETERMINATION OF COMBUSTION............................139

FF TEST METHOD 35: SIMULTANEOUS DETERMINATION OF IGNITABILITY,
FLAME PROPAGATION, HEAT RELEASE AND
SMOKE RELEASE .................................................................................................141
GG TEST METHOD 36: DETERMINATION OF DRIP .............................................143
HH PREPARATION OF COMPRESSION MOULDED PE PLAQUE ........................146
II PREPARATION OF COMPRESSION MOULDED PVC PLAQUE.....................151
JJ PURCHASING GUIDELINES................................................................................153
AS 1049—2003 6
STANDARDS AUSTRALIA
Australian Standard
Telecommunication cables—Insulation, sheath and jacket
SECT ION 1 SCOPE AND GENERA L
1.1 SCOPE
This Standard specifies the material requirements of the finished products and some of the
compounds used to manufacture telecommunication cables and provides test methods to
evaluate the properties specified.
The Standard specifies the requirement for the composition, physical and electrical
performance and test methods of various materials, insulation, sheath and jacket as follows:
(a) Sections 2 to 15 Sections 2 to 15 specify the requirements of the compounds and
finished products.
(b) Appendices A to II Appendices A to II provide a set of reference test methods for
determination of compliance with the requirements of this Standard.
NOTE: Appendix JJ provides recommendations for purchasing guidelines to be supplied at the
time of enquiry or order of the cable.
This Standard does not cover cables using materials that are semi-conductive.
This Standard does not include such aspects of telecommunication cables as spacers or
cores in co-axial cables.
This Standard does not include dimensions or electrical requirements of completed cables.
1.2 APPLICATION
This Standard is intended for use by the following:
(a) Polymer manufacturers, to form the basis of the raw material quality control
procedures for the manufacture of PE and PA compounds.
(b) Cable manufacturers, to form the basis of the cable material quality control
procedures for the manufacture of a range of insulation, sheath and jackets of
different materials.
(c) Cable end-users, to form the basis of the cable acceptance procedures for the
completed cable.
For different cable materials, tests are performed on—
(i) compounds;
(ii) insulation, sheath and jacket materials taken during manufacture; and
(iii) insulation, sheath and jacket materials taken from completed cable.
These requirements are summarized in Table 1.1.
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TABLE 1.1
SUMMARY OF MATERIAL TESTS
Section and material
2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fluoro- Crosslinked
PEFR SRPVC
Test Appendix PE Integrally- PVC NHMH polymer polymer
PE PA 12 PPO PVC PP PA insulation, insulation,
sheath, bonded sheath, sheath, insulation, insulation,
insulation insulation insulation insulation insulation jacket sheath, sheath,
jacket PE/PA jacket jacket sheath, sheath,
jacket jacket
jacket jacket
Visual
1 Visual appearance A i sj
Physical
2 Density B c c
3 Melt flow index C c c
4 Softness D
Mechanical
7
5 Tensile strength at E
break/yield
After ageing test
6 Elongation at break i sj
After ageing test i
7 Flexibility after F *
ageing
8 Pressure test at G
high temperature
9 Shrinkback H i i i i i
10 Stripping I
11 Cold bend J
performance
12 Heat shock K
 Standards Australia
13 ESCR L
14 Bond strength M
AS 1049—2003
After ageing test
15 Bending N
performance
(continued)
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AS 1049—2003
TABLE 1.1 (continued)
2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fluoro- Crosslinked
PEFR SRPVC
jacket jacket
jacket jacket
Chemical
16 Antioxidants O ci
17 Metal deactivator ci
18 Filling compound P i
compatibility
19 Corrosion Q
20 Volatile loss R
21 Carbon black S
concentration
22 Carbon black T
dispersion
8
23 Visual colour U i
difference
24 Instrumental V
colour difference
25 Colour bleeding W i i i i i
26 Colourfastness to X i sj
daylight
27 Colourfastness to Y i sj
water
28 Plasticizer Z
compatibility
(continued)
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2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fluoro- Crosslinked
PEFR SRPVC
jacket jacket
jacket jacket
Electrical
29 Volume resistivity AA
30 Dielectric strength BB
31 Spark test CC i i i i i
32 Dielectric DD c
dissipation factor
33 Relative c
permittivity
Fire
34 Combustion EE
9
35 Simultaneous test FF
36 Drip GG
Other tests
37 Acid & corrosive
–
gas emissions
38 Wrapping –
39 Long term stability –
40 Thermal ageing –
41 OIT –
* for PVDF only
LEGEND: c = compound, i = insulation, s = sheath, j = jacket, = insulation, sheath or jacket as indicated in column heading
AS 1049—2003
AS 1049—2003 10
1.3 MATERIAL SELECTION

1.3.1 General
This Standard covers the specification of materials for both indoor and outdoor
applications. The materials themselves are not restricted to indoor or outdoor use; it is the
combination of the materials, cable design and installation practices that determines the
suitability of a material for its application, e.g. if the cable is directly exposed to UV, if the
insulation is jointed in an outdoor enclosure and therefore subject to high thermal loads or
if the material is for telecommunication switch cable, restrictions apply. Choices within a
materials type have therefore been added which are based on known application
requirements. However, methods other than the choice of material may be used to overcome
environmental restrictions, e.g. if a cable is subject to UV exposure, a black PE sheath
could be used or another material used if the cable is installed under eaves or within
conduit. Material choices are summarized in Table 1.2.
1.3.2 Temperature ratings
Some materials involve additional choice because of their temperature rating, an important
parameter for use in service. For the purposes of this Standard, the temperature rating of a
material is used when selecting the temperature for heat ageing prior to testing for some
properties.
1.3.3 Fire and flame tests
Fire and flame tests have not been included in this material standard because the end
performance in a fire is influenced by material choice, cable design and installation
practice.
1.3.4 Multiple layer insulation
Where multiple layer insulation construction is used, the final properties of the composite
insulation will be a combination of the properties of the individual layers and the test
specification shall be as used between the supplier and purchaser.

11 AS 1049—2003
TABLE 1.2
SUMMARY OF MATERIAL CHOICES WITHIN THIS STANDARD
Section Material Choice 1 Choice 2 Choice 3 Choice 4

2 PE insulation Cables jointed Cables jointed Other cables
outdoors/less severe outdoors/more
condition severe condition
3 PA 12 One choice only — — —
insulation
4 PPO based One choice only — — —
insulation
5 PVC Telecommunication Other cable/with a — —
insulation switch cable choice of
temperature rating
of 75, 90 or 105°C
6 PP insulation One choice only — — —

7 PE sheath/ Cable exposed to UV Cable exposed to Other cable/ —
jacket radiation/Black UV radiation/ Coloured
Coloured
8 PA jacket Black jacket Coloured jacket — —
9 Integrally Black PA jacketed Coloured PA — —
bonded PE composite jacketed composite
sheath and PA
jacket
10 PVC sheath/ Telecommunication Other cable not Cable exposed Cable exposed
jacket switch cable exposed to UV to UV to UV radiation/
radiation/with a radiation/Black/ Coloured/
choice of temperature temperature
temperature rating rating of 75, 90 rating of 75, 90
of 75, 90 or 105°C or 105°C or 105°C
11 NHMH Telecommunication Other cable not — —
sheath/jacket switch cable exposed to UV
radiation
12 Fluoropolymer Insulation: Sheath/jacket: — —
insulation, ECTFE, ETFE: ECTFE, ETFE:
sheath/jacket 150°C rating 150°C rating
FEP: 200°C rating FEP: 200°C rating
PFA: 200°C rating PFA: 200°C rating
PTFE: 250°C rating PTFE: 250°C rating
PVDF: 125 and PVDF: 125 and
150°C ratings 150°C ratings
13 PEFR Solid insulation Cellular insulation Sheath
insulation,
sheath/jacket
14 SRPVC Insulation/with a Sheath/jacket/
insulation, choice of temperature rating
sheath/jacket temperature rating of of 75, 90 or 105°C
75, 90 or 105°C
15 XL insulation, Insulation: Sheath/jacket:
sheath/jacket XLPE, XLPVC, XLPE, XLPVC,
XLEVA: 90°C rating XLEVA: 90°C
XLPO: 105°C rating rating
XLPO: 105°C
rating
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AS 1049—2003 12
1.4 REFERENCED DOCUMENTS

The following documents are referred to in this Standard:
AS
1152 Specification for test sieves
1193 Plastics—Methods for determining the density and relative density of
non-cellular plastics
1886 Glossary of terms relating to plastics
2001 Methods of test for textiles
2001.4.1 Part 4.1: Colourfastness tests—Definitions and general requirements
2164 Laboratory glassware—One-mark volumetric flasks
2165 Laboratory glassware—Burettes
2166 One-mark pipettes
2193 Calibration and classification of force-measuring systems
2700 Colour Standards for general purposes

4004 Lighting booths for visual assessment of colour and colour matching
AS/NZS
1530 Methods for fire tests on building materials, components and structures
1530.3 Part 3: Simultaneous determination of ignitability, flame propagation,
heat release and smoke release
1580 Paints and related materials—Methods of test
1580.601.3 Method 601.3: Colour—Methods of colour measurement
1660 Test methods for electric cables, cords and conductors
1660.2.1 Part 2.1: Insulation, extruded semi-conductive screens and non-metallic
sheaths—Methods for general application
1660.2.3 Part 2.3: Insulation, extruded semi-conductive screens and non-metallic
sheaths—Methods specific to PVC and halogen free
thermoplastic materials
1660.3 Part 3: Electrical tests
1660.5.4 Part 5.4: Fire tests—Determination of degree of acidity of gases
evolved during the combustion of materials taken from electric
cables by measuring pH and conductivity
2122 Methods of test for determining combustion propagation characteristics of
plastics
2122.2 Part 2: Determination of minimum oxygen concentration for flame
propagation following top surface ignition of vertically
oriented specimens
IEC
60304 Standard colours for insulation for low-frequency cables and wires
Ed 3.0b
60811 Common test methods for insulating and sheathing materials of electric
cables and optical cables
60811-1-2 Part 1: Methods for general application, Section 2: Thermal ageing
Ed 1.0b methods
60811-4-2 Part 4: Methods specific to polyethylene and polypropylene
Ed 1.0b compounds, Section 2: Elongation at break after
pre-conditioning—Wrapping test after pre-conditioning—
Wrapping test after thermal aging in air

13 AS 1049—2003
ISO
291 Plastics—Standard atmospheres for conditioning and testing
18553 Method for the assessment of the degree of pigment or carbon black
dispersion in polyolefin pipes, fittings and compounds
ASTM
D 638 Test Method for Tensile Properties of Plastics
D 1248 Specification for Polyethylene Plastics Extrusion Materials for Wire and
Cable
D 3849 Test Method for Carbon Black-Primary Aggregate Dimensions from
Electron Microscope Image Analysis
D 4565 Standard Test Methods for Physical and Environmental Performance
Properties of Insulations and Jackets for Telecommunications Wire and
Cable
E1 Specification for ASTM Thermometers

G 152 Practice for Operating Open Flame Carbon Arc Light Apparatus for
Exposure of Nonmetallic Materials
G 153 Practice for Operating Enclosed Carbon Arc Light Apparatus for Exposure
of Nonmetallic Materials
G 155 Practice for Operating Xenon Arc Light Apparatus for Exposure of
Nonmetallic Materials
BELLCORE
GR-421-CORE Generic Requirements for Metallic Telecommunications Cables
EIA
359-A EIA Standard colours for colour identification and coding (includes
supplement EIA 359-A-1-1-1988)
ETSI
EN 50290 Communication cables
EN 50290-2-23 Part 2-23: Common design rules and construction—PE insulation
UNDERWRITERS LABORATORIES
UL 444 UL Standard for Safety for Communications Cables
HAZEN, THOMAS
Recent Improvements in Methods of Measuring the Dielectric Constant
and Loss Characteristics of Polyethylene for Primary Insulation of
Communication Cables, Proceedings of the 13th International Wire and
Cable Symposium. December 2–4, 1964.
1.5 DEFINITIONS
For purpose of this Standard, the definitions in AS 1886 and those below apply.
1.5.1 Layers of cables
The definitions below are listed according to position of layers in the cables as shown in
Figure 1.

AS 1049—2003 14
1.5.1.1 Insulation
A single or multiple layer of the same or different dielectric material(s) over the
conductors. An example of multiple layer insulation is termed ‘foam-skin’ which comprises
of a cellular layer covered with a solid layer.
NOTE: The material(s) may be solid or cellular or a combination of these. Cellular insulation is
manufactured by using a blowing agent compounded in the granules or by using air- or gas-
blowing at the extrusion process.
1.5.1.2 Core
An assembly of insulated conductors, coaxial elements, optical fibre elements, or any
combination of the three.
1.5.1.3 Sheath
A protective layer, e.g. an inner sheath over the core of a cable or an outer sheath over the
armouring.
1.5.1.4 Armouring
A layer over the sheath of a cable to protect the installed cable against, for example, rodents
or mechanical equipment. The armouring may be bonded to the sheath and is typically
manufactured from steel tape, wire or corrugated sheet. An example is rodent resistant
armouring over a PE sheath with an outer sheath of PE and PA jacket.
1.5.1.5 Jacket
The protective layer over the sheath of a cable. Examples are a PE jacket over a metallic
sheath and a PA jacket over a PE sheath.
1.5.1.6 Sacrificial jacket
An additional layer over an existing jacket that is designed to protect the cable, in particular
the PA jacket, against mechanical damage during installation. An example is a sacrificial
jacket over a PA jacket and PE sheath.
1.5.1.7 Finished product
A general term used to describe insulation, sheath or jacket.
1.5.2 Materials and material properties of cables
1.5.2.1 Colour bleeding
The migration of a colorant from the plastic it is added to, into any material in contact with
this plastic. Factors which affect colour bleeding are—
(a) an increase in temperature which usually accelerates colour bleeding;
(b) compatibility with the plastic; and
(c) compatibility with the contact material.
1.5.2.2 Fire retardant
A substance added or a treatment applied to a material in order to suppress, reduce or delay
the combustion of the material.
1.5.2.3 Flame retardant
A substance added, or a treatment applied to a material in order to suppress or delay the
appearance of a flame, reduce its propagation rate, or both.
1.5.2.4 Insect-resistance
The principal property of either PA 11 or PA 12 jacket which provides resistance to insect
attack, particularly ants and termites.

15 AS 1049—2003
1.5.2.5 Non-halogenated
A term used to describe a material that does not contain fluorine, chlorine, bromine or
iodine and which is used in the form of an additive in a compound or in the main backbone
of a polymer.
NOTE: Halogens are used in various compounds to act as fire or flame retardants, or both.
Non-halogenated materials are used where the halogenated material properties of evolution of
corrosive and toxic gases in a fire are not desired.
FIGURE 1 EXAMPLES OF CABLE CONSTRUCTION
1.5.2.6 Polyethylene plastics

Thermoplastic materials, based on homopolymers or copolymers of ethylene, containing not
less than 85% ethylene and not less than 95% olefins.
NOTES:
1 This definition is based on AS 1886, with additional specific limits.
2 Within the limits of this definition all possible structures and densities of polyethylene are
included, e.g. long-chain branched, short-chain branched, linear, alpha-olefin copolymers and
melt homogenized blends of any of these.
1.5.2.7 Semi-rigid plastic
A plastic that has a modulus of elasticity in flexure or, if that is not applicable, then in
tension, between 70 and 700 MPa under stated conditions.
NOTE: Materials are usually classified at standard temperature and relative humidity in
accordance with ISO 291.
1.5.2.8 Temperature rating
The maximum continuous service temperature of the cable.
1.5.3 Cable constructions
1.5.3.1 Air-core cable
A cable construction where the interstices of the cable are not filled.

AS 1049—2003 16
1.5.3.2 Integrally bonded sheath and jacket

A cable construction where the polyethylene sheath is integrally bonded to the PA jacket by
chemical modification or by multiple processing techniques, or by both.
NOTE: One such method is to use a specifically formulated PE which meets the requirements of
Sections 7 and 9.
1.5.3.3 Jelly-filled cable
A cable construction that has a cable core that is filled with a jelly-like substance which
prevents water from seeping or flowing along the length of the cable in the event of a
rupture through the protective sheath layer.
1.5.3.4 Moisture-barriered cable
A cable construction that has a metallic tape which is bonded to the inner surface of the
sheath to prevent moisture permeation into the cable core. The metallic tape may also serve
as an electrical screen.
1.5.3.5 Telecommunication switch cable
Cable used in telecommunication network switch equipment.

1.5.4 Transition period
To allow for the introduction of the new performance requirements for PE insulation for the
more severe condition, a transition period shall exist where the currently approved materials
shall be allowed to be used.
The transition period shall extend to 30-4-2003.
1.6 ACRONYMS
For the purpose of this Standard, the acronyms below apply.
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
BSI British Standards Institution
CIE International Committee on Illumination
ECTFE Copolymer of ethylene and chlorotrifluoroethylene
EIA Electronic Industries Association
ESCR Environmental stress cracking resistance
ETFE Copolymer of ethylene and tetrafluoroethylene
FEP Copolymer of tetrafluoroethylene and hexafluoropropylene
HALS Hindered amine light stabilizers
HDPE High density polyethylene
HPLC High performance liquid chromatography
ISO International Organisation for Standardization
LDPE Low density polyethylene
LLDPE Linear low density polyethylene
MDPE Medium density polyethylene
MFI Melt flow index
NA Not applicable
NHMH Non-halogenated metal-hydroxide-filled thermoplastic
OIT Oxidation induction time

17 AS 1049—2003
PA Polyamide
PE Polyethylene
PEFR Polyethylene containing a flame/fire retardant
PFA Poly(perfluoro alkoxy alkane)
PP Polypropylene
PPO Poly(phenylene oxide)
PTFE Polytetrafluoroethylene
PVC Poly(vinyl chloride)
PVDF Poly(vinylidene fluoride)
RH Relative humidity
SRPVC Semi-rigid poly(vinyl chloride)
UV Ultraviolet
XLEVA Cross-linked poly(ethylene-vinyl acetate)

XLPE Cross-linked polyethylene
XLPO Cross-linked polyolefin
XLPVC Cross-linked poly(vinyl chloride)

AS 1049—2003 18
SECT ION 2 PE INSU L AT I ON
2.1 SCOPE OF SECTION

This Section specifies the material requirements for polyethylene (PE) compound intended
for insulation and for PE insulation taken from the completed cable or where specified,
during manufacture. It also facilitates the transition from a prescriptive approach to a
performance based specification and therefore allows new combinations of insulation and
filling compounds.
Regarding material selection, the highest performance required of insulation is from
installed cable in long service life (>20 years) applications, jointed in outdoor above-ground
enclosures that are subject to severe thermal environment (‘more severe condition’). In such
circumstances the entire cable may be designed to survive conditions which only the
terminated ends will experience. Due to the need for ease of re-entry, and standardized
work practices, there are applications that cannot avoid such conditions, and therefore
require the performance of materials and rigour of testing to prove suitability of purpose.
However, with lesser service requirements and/or more protective methods of termination,
alternative materials and tests for suitability are presented (‘less severe condition’ and
‘other cables’).
For the ‘more severe condition’ of ‘cables jointed outdoors’, PE insulation was previously
specified with proven stabilizer systems and supported by laboratory migration studies,
compatibility testing with filling compounds and long term field performance. Accordingly
specific combinations of PE compound, stabilizer systems and filling compound that have
such proven performance, have been identified. However, this Section facilitates the
migration from this prescriptive approach that has such proven performance, to a
performance based specification for these cables.
There are two applications for ‘cables jointed outdoors’ in Tables 2.1 and 2.2; ‘less severe
condition’ and ‘more severe condition’. The minimum performance specifications to be
adopted are as follows:
(a) ‘less severe condition’ – based on European Harmonization Standard
ETSI EN 50290-2-23, ‘Communication cables, Part 2-23: Common design rules and
construction—PE insulation’,
(b) ‘more severe condition’ – based on the Bellcore Pedestal and OIT tests from GR-421-
CORE ‘Generic Requirements for Metallic Telecommunications Cables’
By default, cables meeting the requirements of the ‘more severe condition’ shall be deemed
suitable for use in the ‘less severe condition’.
For the period of transition (until 30 April 2003) three options are provided for the ‘more
severe condition’ —
(i) all materials shall pass the pedestal and OIT tests as specified in the Bellcore
specification; or
(ii) the existing requirement which is only for the transition period, i.e. prescribed
stabilizers, and pass the compatibility test; or
(iii) a requirement for the transition period only, i.e. new materials shall have the
equivalent performance to the existing materials in the pedestal and OIT tests and
also pass the compatibility test.

19 AS 1049—2003
2.2 COMPOUND
2.2.1 General
The requirement of the compounds in this Clause 2.2 forms the basis of the quality control
program for the unprocessed PE.
All testing specified refers to PE in pellet form appropriately selected from material as
supplied to the cable manufacturer.
2.2.2 Compound characteristics
Compounds intended for solid or cellular insulation on metal conductors shall be
manufactured from PE plastics of density and MFI within the ranges defined in this
Standard.
The PE compound shall contain only virgin plastics.
2.2.3 Manufacturer’s nominated values for density and melt flow index (MFI)
The nominal value (polymer manufacturer’s disclosed value) of density and MFI for the
grade of PE compound used by the cable manufacturer for a particular insulating

application shall be classified according to type and category as defined in ASTM D 1248,
as follows:
Type Range of densities Description

kg/m3
I 910 to 925 Low density
II 926 to 940 Medium density
III 941 to 959 High density
Category Range of melt flow rates g/600 s at

190°C with 2.160 kg load
3 >1.0 to 10
4 >0.4 to 1.0
5 0.4 max
2.2.4 Stabilizers
In the transition period, if the option of prescriptive specification of stabilizers is chosen for
compounds intended for the ‘more severe condition, the compound shall contain a single
antioxidant and a single metal deactivator listed in Table 2.1. These stabilizers are effective
in field service (refer to Tables 2.1 and 2.2 for details of applicable polyethylene grades).
Stabilizers additional to those specified in Table 2.1 may be present, e.g. to assist
processing either at the polymer manufacturing or extruding stage.
NOTE: FOR ALL SPECIFICATION OPTIONS For the stabilizers to function effectively it is
important that they are homogeneously dispersed throughout the polymer matrix and this is best
achieved by the cable manufacturer using a fully compounded PE material supplied by the
polymer compounder. Stabilizer masterbatches do not provide sufficient dispersion when added to
the PE base material by the cable manufacturer when extruding insulation on conductor.

AS 1049—2003 20
2.2.5 Material tests

Where tested in accordance with the appropriate appendices, PE compound intended for
insulation shall comply with the requirements of Table 2.1.
In transition period, until 30 April 2003, compounds intended for insulation of cables
installed in ‘more severe condition’, cables jointed outdoors’ shall either —
(a) meet the requirements of antioxidant identification (test 16), metal deactivator
identification (test 17); or
(b) disregard these tests and meet specified tests on the insulation in Table 2.2.
The requirements for the antioxidant and metal deactivator identification are set out in
Table 2.1.
2.3 INSULATION
2.3.1 General
Insulation shall be made from compound meeting the requirements of Clause 2.2. The
requirements of the insulation in this Clause form the basis of the cable manufacturer’s
quality control and end-user acceptance procedures for the completed cable. The
requirements for cellular insulation shall also apply to foam skin insulation.
2.3.2 Additions to the compound
The insulation shall not contain any reprocessed, reworked or recycled plastics.
2.3.3 Colour masterbatch
The insulation is coloured by using colour masterbatches during the extrusion process.
Solid or cellular insulation may be coloured with the same colour masterbatches. Generally
the cellular insulation is a paler colour than the solid insulation but both are within the
specification limits.
NOTE: Generally, PE insulation for cables jointed outdoors is required to last a number of
decades within a variety of covered outdoor environments, most of which are thermally severe.
This demands that the polyethylene base is well stabilized, that reprocessed, reworked or recycled
material is not used and the only addition to the polyethylene, the colour masterbatch, does not
inadvertently cause degradation throughout the life of the insulation. In particular the grade of
polyethylene carrier, type of colorant, type of coating on the colorant and amount of opacifier are
all important and should be considered when choosing colour masterbatches.
A suitable specification for the colour masterbatch for the ‘more severe condition’, in addition to
meeting the requirements of this Standard when incorporated into insulation, is as follows:
The colorants used in the concentrates shall be finely dispersed, shall not contain lead, cadmium,
mercury or hexavalent chromium, and should have excellent heat stability up to 250°C. The
opacifier shall be a high level rutile (approaching 100%) titanium dioxide with low catalytic
reactivity for high durability in plastics. The carrier shall be a Type I, Category 3 and should
contain a suitable amount of a suitable long term antioxidant. No dispersants, waxes, or low
molecular weight polyolefins shall be used unless the Thermal ageing test (40) requirements can
be achieved. The final concentrates should be easy flowing granules, easily dispersed in all
polyethylenes, and used in both solid and cellular insulation. The concentrates should not cause
agglomerations or imperfections on the conductor insulation such as to cause faults during the
spark test.

21 AS 1049—2003
2.3.4 Insulation tests

Where tested in accordance with the appropriate appendices, PE insulation taken from
completed cables shall comply with the requirements of Table 2.2.
For filled cable, the combination of filling compound and PE determine the compliance
with this Standard and they do not pass or fail independently of one another. Some PE
plastics may pass with one filling compound and not with another. Experience has shown
that the worst case scenario is with the small conductor size, jelly filled and cellular PE
insulation.
In the transition period, until 30 April 2003, cables in the ‘more severe condition’, ‘cables
jointed outdoors’ shall either —
(a) meet the pedestal and OIT tests (thermal ageing test 40); or
(b) meet the antioxidant content (test 16), metal deactivator content (test 17) and filling
compound compatibility test (test 18); or
(c) meet the equivalent performance to the existing materials in the pedestal and OIT
tests (thermal ageing test 40) and pass the filling compound compatibility test
(test 18).
The requirements for the antioxidant and metal deactivator content are set out in Table 2.2.

AS 1049—2003
TABLE 2.1
TEST REQUIREMENTS FOR PE COMPOUNDS INTENDED FOR INSULATION
Criteria
Cables jointed outdoors Other cables
Method or
Test Parameters and conditions Units Less severe condition More severe condition
Appendix Solid Cellular
Solid Cellular Solid Cellular
insulation insulation
insulation insulation insulation insulation
Physical
2 Density B 23°C kg/m 3 Within Type I, II or III 1) & ±2 nominated value 2)
190°C, 2.160 kg load (including base Within Within Within Within Within Within
resins for compounds intended to Category 3,4 Category 3, Category 3,4 Category 3,4 Category 3,4 Category
contain blowing agents) or 53) & 4 or 53) or 53) & or 53) or 53) & 3,4 or 5 3)
±30% ±30% ±30%
nominated nominated nominated
value2) value2) value2)
22
3 Melt flow index C 160°C, 2.160 kg load g/600s NA ±30% NA ±30% NA ±30%
For materials containing a blowing nominated nominated nominated
agent4) value2) value2) value2)
140°C, 5.000 kg load
For materials containing a blowing
agent4)
Electrical
32 Dielectric DD 1 MHz, 23°C Natural – 0.000 4 (max.) 0.000 8 (max.) 0.000 4 (max.) 0.000 8 (max.) NA
dissipation factor5)
Coloured 0.000 6 (max.) 0.001 (max.) 0.000 6 (max.) 0.001 (max.) NA
33 Relative DD 1 MHz, 23°C (natural or coloured) – 2.35 (max.) NA
permittivity
(continued)

Criteria
Method or
insulation insulation insulation insulation
Chemical
16 Antioxidant6) O 2,2’-dihydroxy-3,3’ –bis (1- – NA Either identified NA
methylcyclohexyl) -5,5’ –
bisphenylmethane (e.g. Lowinox WSP)
Ethylene bis(3,3 -bis (3-tertbutyl-4-
hydroxyphenol) butyrate) (e.g.
Hostanox 03)
Pentaerythrityl-tetrakis (3-(3,5-di-tert-
butyl-4-hydroxyphenyl)-propionate)
(e.g. Irganox 1010) 7)
17 Metal O Oxalic acid-bis (benzylidene – NA Either identified NA
23
deactivator6) hydrazide) (e.g. OABH)
N, N’-bis (β-3, 5-di-tert-butyl-4-
hydroxy-phenylpropiono) hydrazide
(e.g. Irganox MD 1024) 7)
NOTES:
1) The density of the compound shall fall within the ranges of Type I, II or III of ASTM D 1248.
2) The nominated value is the polymer manufacturer’s disclosed value.
3) The MFI of the compound shall fall within the ranges of Category 3, 4 or 5 of ASTM D 1248.
4) Compounds containing blowing agent may be tested by either regime.
5) The dielectric dissipation factor for coloured material is determined on plaques made from pellets of PE compound plus colour masterbatch at the concentration used in the
production process.
6) For the duration of the transition period, only applicable to those materials not qualified to test 40.
7) Migration studies have shown that some stabilizers have low and/or varying solubilities in PE of differing density. For the stabilizers in Table 2.1 required at the stated
concentrations in Table 2.2, Pentaerythrityl-tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate) (e.g. Irganox 1010) and N, N’-Bis (β-3, 5-di-tert-butyl-4-hydroxy-
AS 1049—2003
phenylpropiono) hydrazide (e.g. Irganox MD 1024) shall only be used in Type III PE.
AS 1049—2003
TABLE 2.2
TEST REQUIREMENTS FOR PE INSULATION FROM COMPLETED CABLE
Criteria
Method or
insulation insulation 1)
insulation insulation 1) insulation insulation 1)
Visual
1 Visual appearance A – – No defects
Mechanical
6 Elongation at E Unaged 300 (min.)
break IEC 60811-1-2 After ageing in air oven : air core cables 300 (min.) 200 (min.) NA
IEC 60811-4-2 After ageing in air oven : filled cables % 200 (min.) NA
E After ageing in air oven (percentage of NA 75 (min.)
initial value)
38 Wrapping IEC 60811-4-2 Unaged 2) – No cracks NA
24
After ageing in air oven – No cracks NA
39 Long term stability IEC 60811-4-2 – – No cracks NA
9 Shrinkback3) H – % 6 (max.) 2 (max.) 6 (max.)
for Type I
6 (max.)
for Types
II and III
Chemical
40 Thermal ageing Bellcore GR- Insulation oxidation induction time – NA Meet the requirements in NA
421-CORE (OIT) Bellcore GR-421-CORE
Pedestal test NA Meet the requirements in NA
Bellcore GR-421-CORE
23 Visual colour U – – Within the limits of Table U1 or IEC 60304 (see Appendix JJ)
difference
25 Blooming and W – – None observed
migration of colour
26 Colourfastness to X – – Colour change less than four
daylight
27 Colourfastness to Y – _ No transfer to water
water
(continued)
Criteria
Method or
Electrical
31 Spark test CC – – Not more than one breakdown per kilometre
Chemical
16 Antioxidant4) O 2,2’-dihydroxy-3,3’-bis (1- % NA Either, Either, NA
methylcyclohexyl) 0.20 (min.) 0.24 (min.)
-5,5’-bisphenylmethane (e.g. Lowinox
WSP)
Ethylene bis (3,3 -bis (3-tertbutyl-4-
hydroxyphenol) butyrate)
25
(e.g. Hostanox 03)
Pentaerythrityl-tetrakis (3-(3,5-di-tert-
butyl-4-hydroxyphenyl)-propionate (e.g.
Irganox 1010) 5)
(continued)
AS 1049—2003
AS 1049—2003
Criteria
Method or
4)
17 Metal deactivator O Oxalic acid-bis (benzylidene hydrazide) % NA Either, 0.09 (min.) NA
(e.g. OABH)
N, N’-bis (β-3, 5-di-tert-butyl-4-
hydroxy-phenylpropiono) hydrazide
(e.g. Irganox MD 1024) 5)
18 Filling compound P F 207) days NA 100 (min.) NA
compatibility 6) 4 )
26
NOTES:
1) Applicable also to foam-skin insulation.
2) Only to be carried out if elongation at break cannot be done (i.e. if the insulation cannot be removed from the conductor without damage and/or the insulation thickness is
less than 0.8 mm).
3) The requirements of shrinkback are based on an allowance for conductor stretch caused by cable processing.
4) For the duration of the transition period, only applicable to those insulations not qualified to test 40.
5) Migration studies have shown that some stabilizers have low and/or varying solubilities in PE of differing density. For the stabilizers in Table 2.2 required at the stated
concentrations, Pentaerythrityl-tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate) (e.g. Irganox 1010) and N, N’-Bis (β-3, 5-di-tert-butyl-4-hydroxy-
phenylpropiono) hydrazide (e.g. Irganox MD 1024) shall only be used in Type III PE.
6) The compatibility test only applies to insulation intended for cable that is filled.
7) The compatibility test may be terminated if the time to initial failure (F i ) exceeds 85 days. If failures do occur before this time, then the insulation shall have a minimum
F 20 value as specified.
27 AS 1049—2003
SECT ION 3 PA 12 SO L I D I NSU L AT I O N

This Section specifies the material requirements for polyamide 12 (PA 12) solid insulation
taken from the completed cable or, where specified, during manufacture.
NOTE: PA 12 solid insulation is typically used for telecommunication switch cable.
3.2 INSULATION TESTS

Where tested in accordance with the appropriate appendices, all insulation manufactured
from PA 12 shall comply with the test requirements of Table 3.1.
TABLE 3.1
TEST REQUIREMENTS FOR PA 12 SOLID INSULATION FROM
COMPLETED CABLE
Test Appendix Parameters and conditions Units Criteria

Visual
1 Visual appearance A — — No defects
Mechanical
5 Tensile strength at break E Unaged MPa 30.0 (min.)
After ageing in air oven MPa 30.0 (min.)
6 Elongation at break E Unaged % 150 (min.)
After ageing in air oven % 150 (min.)
10 Stripping I — N 1 to 6
11 Cold bend performance J −15°C — No cracking
12 Heat shock K — — No cracking
Chemical
23 Visual colour difference U — — Within the
limits of
Table U1 or
IEC 60304 (see
Appendix JJ)
25 Colour bleeding and W — — None observed
migration
26 Colourfastness to daylight X — — Colour change
less than four
27 Colourfastness to water Y — — No transfer to
water
Electrical
31 Spark test CC — — Not more than
one breakdown
per kilometre

AS 1049—2003 28
SECT ION 4 NON-HA L OGENATED PPO-

BASED MAT E R IA L (CON TA I N I N G A
F I RE/F L AME RETARDAN T) FOR SO L I D
I NSU L A T I O N

This Section specifies the material requirements for solid insulation manufactured from
poly(phenylene oxide) based materials that are non-halogenated and contain a fire/flame
retardant, taken from the completed cable or, where specified, during manufacture.
NOTE: PPO-based insulation is typically used for telecommunication switch cable.

from PPO based materials shall comply with the requirements of Table 4.1.

29 AS 1049—2003
TABLE 4.1
TEST REQUIREMENTS FOR NON-HALOGENATED PPO-BASED
MATERIAL (CONTAINING A FIRE/FLAME RETARDANT)
FOR SOLID INSULATION FROM COMPLETED CABLE
Test Method or Parameters and conditions Units Criteria

appendix
Visual
Mechanical
5 Tensile strength at E — MPa 30.0 (min.)
break
(percentage of initial value)

9 Shrinkback H — % 2 (max.)
Chemical
20 Volatile loss R — g/m 2 10 (max.)
23 Visual colour U — — Within the
difference limits of
Table U1 or
IEC 60304
(see
Appendix
JJ)
25 Colour bleeding and W — — None
migration observed
26 Colourfastness to X — — Colour
daylight change less
than four
27 Colourfastness to Y — — No transfer
water to water
Electrical
31 Spark test CC — — Not more
than one
breakdown
per
kilometre
Fire
34 Combustion EE Oxygen Burn mm 50 (max.)
concentration length
30%
Burn time s 180 (max.)
37 Acid and corrosive AS 1660.5.4 Ph — 3.5 (min.)
gas emission
Conductivity µs/mm 10 (max.)

AS 1049—2003 30
SECT ION 5 PVC SO L I D I NSU L AT I ON

This Section specifies the material requirements for poly(vinyl chloride) solid insulation
NOTE: PVC solid insulation is typically used for telecommunication switch cable and for other
indoor uses, for example in communications, control and data applications.

from PVC, coloured and ink-marked, shall comply with the test requirements of Table 5.1.

TABLE 5.1
TEST REQUIREMENTS FOR PVC SOLID INSULATION FROM COMPLETED CABLE
Criteria 1)
Test Appendix Parameters and conditions Units
Telecommunication switch cable Other cable
Visual
Mechanical
5 Tensile strength at break E Unaged MPa 18 (min.) 13 (min.)
After ageing in an air oven (percentage of initial % NA 85 (min.)
value)
6 Elongation at break E Unaged % 150 (min.) 100 (min.)
After ageing in an air oven (percentage of initial % 75 (min.) 50 (min.)
value)
Chemical
31
19 Corrosion Q — — No visible evidence of the formation of corrosion or salts on
the surface of the copper wire
23 Visual colour difference U Does not apply to ink markings — Within the limits of Table U1 or IEC 60304 (see Appendix JJ)
migration
26 Colourfastness to daylight X — — Colour change less than four
27 Colourfastness to water Y — — No transfer to water
28 Plasticizer compatibility Z — — No formation of drops of liquid or signs of greasiness
Electricity
29 Volume resistivity AA 23 ±1°C GΩm 400 (min.)
60 ±1°C GΩm 0.4 (min.)
30 Dielectric strength BB 2.8 kV d.c., 60 s, 23 ±1°C — No breakdown
31 Spark test CC — — Not more than one breakdown per kilometre

Fire
34 Combustion EE Oxygen concentration 28% Burn length mm 50 (max.) NA
AS 1049—2003
Burn time s 180 (max.) NA
NOTE:
1) Material temperature ratings are differentiated by the ageing times and temperatures as specified in the appendices.
AS 1049—2003 32
SECT ION 6 PP SOL I D I NSU L A T I O N

This Section specifies the material requirements for polypropylene insulation taken from
the completed cable or, where specified, during manufacture.
NOTE: PP insulation is typically used for data cables.

from PP shall comply with the test requirements of Table 6.1.
TABLE 6.1
TEST REQUIREMENTS FOR PP INSULATION FROM
COMPLETED CABLE
Test Appendix Parameters and conditions Units Criteria

Visual
Mechanical
5 Tensile strength at yield E Unaged MPa 20 (min.)
Chemical
23 Visual colour difference U — — Within the
limits of
Table U1 or
IEC 60304 (see
Appendix JJ)
migration
26 Colourfastness to X — — Colour change
daylight less than four
27 Colourfastness to water Y — — No transfer to
water
Electrical
31 Spark test CC — — Not more than
one breakdown
per kilometre

33 AS 1049—2003
SECT ION 7 PE SHEATH OR PE JACKET

This Section specifies the material requirements of PE compound intended for sheath and
jacket and of PE sheath and PE jacket taken from the completed cable or, where specified,
during manufacture.
This Section applies to all PE compounds, PE jacket and to the PE sheath from the
unbonded cable construction. Section 9 covers the composite properties where the PE
sheath is integrally bonded to the PA 11 or PA 12 insect-resistant jacket.
7.2 COMPOUND
7.2.1 General
The requirements of the compounds in this Clause (7.2) form the basis of the quality control
program for the unprocessed PE.

Compounds intended for sheath or jacket shall be manufactured from PE plastics of density
and MFI within the ranges defined in this Standard.
The PE compound shall contain only virgin plastics.
7.2.3 Types of PE compounds
The compound shall be one of the following types:
End use Formulation Description of the sheath or jacket

Black PE containing thermal stabilizer(s) plus
Black
carbon black as the light stabilizer.
Colourable PE containing thermal stabilizer(s) plus
Cable exposed light stabilizers that may include both UV
to UV radiation stabilizer(s), preferably hindered amine light
Coloured
stabilizer(s) (HALS), and titanium dioxide (TiO2).
The light stabilizers may be added during
compounding or extrusion.
Other cables Coloured Colourable PE containing thermal stabilizer(s).
7.2.4 Manufacturer’s nominated values for density and MFI

The density and MFI for the grade of PE compound used by the cable manufacturer for a
particular sheathing or jacket application shall be classified according to type and category
as defined in ASTM D 1248, as follows:
(a) For black compound, the density used for classification purposes refers to the
calculated value which corrects for the concentration of carbon black according to the
relevant appendix.
(b) For testing of consistency of density between batches or blends, the nominal density
(polymer manufacturer’s disclosed value) of the fully compounded material shall be
used.
(c) All Type III Category 5 PE shall use the 21.60 kg load when testing for consistency
of MFI between batches or blends against the nominal MFI (polymer manufacturer’s
disclosed value).

AS 1049—2003 34
Type Range of densities* Description

kg/m3
I 910 to 925 Low density
II 926 to 940 Medium density
III 941 to 959 High density
*Calculated value after correcting for carbon black concentration.
Category Range of melt flow rates

g/600 s at 190°C with 2.160 kg load
3 >1.0 to 10
4 >0.4 to 1.0
5 0.4 max.
7.2.5 Light and heat stabilizers

Carbon black for UV stability is required to be a grade suitable for use in plastics
(‘P’ type). The average particle size shall be 10 to 25 nm when determined in accordance
with ASTM D 3849 or equivalent.
NOTE: Choice of carbon black is critical to ensure that the UV protective ability is suitable. This
means that the primary particle size must conform to the above specification and that effective
dispersion of the carbon black in the compound or final sheath is confirmed by a dispersion test
(test 22).
For colourable PE compound intended for exposure to UV radiation the titanium dioxide, if
used, shall be a coated rutile type, added at the minimum level of 10 g/kg.
NOTE: Coloured PE compounds are not as UV resistant as those incorporating carbon black, and
if used in an application, directly exposed to sunlight, will have a shorter service life.
Compounds should contain suitable long term antioxidants at suitable concentrations with
acceptable non-migratory properties and which do not behave antagonistically with any
other additive. Other types of stabilizers may be present e.g. to assist processing either at
the polymer manufacturing or extruding stage.
NOTE: For the stabilizers to function effectively, it is important that they are homogeneously
dispersed throughout the polymer matrix and this is best achieved by the cable manufacturer
using a fully compounded PE material supplied by the polymer compounder. Masterbatches do
not provide sufficient dispersion when added to the PE base material by the cable manufacturer
when extruding sheath or jacket.
7.2.6 Environmental stress cracking resistance (ESCR) component
The sheath or jacket may contain a suitable ESCR component.
NOTE: If butyl rubber is used as the ESCR component it should be added at a nominal 5% by
mass, be uniformly dispersed, be a copolymer of isobutylene and isoprene containing not more
than 4% of isoprene and having an average molecular mass of not less than 80 000 g/mol.
Where tested in accordance with the appropriate appendices, PE compound intended for
sheath or jacket shall comply with the requirements of Table 7.1.

35 AS 1049—2003
7.3 SHEATH OR JACKET

7.3.1 General
Sheaths shall be made from compound meeting the requirements of Clause 7.2. The
requirements of the sheath or jacket in this Clause 7.3 form the basis of the cable
manufacturer’s quality control and end-user acceptance procedures for the completed
cables.
The sheath or jacket shall not contain any reprocessed, reworked or recycled plastics.
7.3.3 Sheath or jacket tests
Where tested in accordance with the appropriate appendices, PE sheath or jacket taken from
completed cables of the unbonded cable construction shall comply with the requirements of
Table 7.2.

AS 1049—2003
TABLE 7.1
TEST REQUIREMENTS FOR PE COMPOUNDS INTENDED FOR SHEATH OR JACKET
Criteria
Method Compound intended for cable exposed Other cable
Test or Parameters and conditions Units to UV radiation
appendix Black compound Coloured Coloured
compound compound
Physical
2 Density B 23°C kg/m 3 Within Type I, II, or Within Type I, II, or III & ±2
III & ±3 nominated nominated value 1)
1) 2)
value
3 Melt flow index C 190°C, 2.160 kg load g/600s Within Category 3, 4 or 5 & within ±30% nominated
value1)
3)
190°C, 21.60 kg load g/600s Within ±30% nominated value1)
Mechanical
6 Elongation at break E After ageing in weatherometer (percentage of % NA 90(min) NA
36
initial value)
13 Environmental stress-cracking L 200 h — No failures
resistance
Chemical
21 Carbon black concentration S — g/kg 25 ±5 NA
22 Carbon black dispersion4) T Numerical rating — Less than 5 NA
Uniformity of appearance — Better than NA
photomicrograph A,
Figure T2
24 Instrumental colour difference V ∆E* ab — NA 5 (max.)
NOTES:
1) The nominated value is the polymer manufacturer’s disclosed value.
2) The consistency of density on black compound is checked on the fully compounded material.
3) All Type III Category 5 PE are tested for compliance with the nominated value using a 21.60 kg load instead of the normal 2.160 kg load.
4) An alternative (reference) test method noted in Appendix T, ISO 18553 with Numerical Rating of: max 3.0 and no individual button >5.0; rating of appearance
≤photomicrograph in Figure T1 (or T2).
TABLE 7.2
TEST REQUIREMENTS FOR PE SHEATH OR JACKET FROM THE UNBONDED CABLE CONSTRUCTION
Criteria
Method or
Test Parameters and conditions Units Cable exposed to UV radiation Other cable
appendix
Black Coloured Coloured
Visual
1 Visual A — — No defects
Mechanical
6 Elongation at break1) E Unaged % 400 (min.)
After ageing in weatherometer (percentage of NA 90 (min.) NA
initial value)
13 Environmental stress- L 96 h h No failures
cracking resistance
37
Chemical
21 Carbon black S — g/kg 25 ±5 NA
concentration2)
22 Carbon black dispersion2) T 4) Numerical rating — Less than 5 NA
Uniformity of appearance — Better than NA
photomicrograph A,
Figure T2
24 Instrumental colour V ∆E* ab — NA 5 (max.)
difference3)
41 Oxidation induction time ASTM Aluminium pan, no mesh screen, 200 ±0.3°C, minute 20 (min.) 40 (min.) NA
D 4565 standard tangent method to determine onset
NOTES:
1) Test for elongation at break after ageing in weatherometer shall not be required where tested and met on the PE compound.
2) Test for carbon black concentration and test for carbon black dispersion shall not be required where these tests have been performed on the PE compound.
AS 1049—2003
3) Test for instrumental colour difference shall not be required where this test has been performed on the compound.
4) An alternative (reference) test method noted in Appendix T, ISO 18553 with Numerical Rating of: max 3.0 and no individual button >5.0; rating of appearance
≤photomicrograph in Figure T1 (or T2).
AS 1049—2003 38
SECT ION 8 PO LYAM I DE JACKET

This Section specifies the material requirements of PA 11 or PA 12 compound intended for
insect-resistant jacket and of PA 11 or PA 12 jacket taken from the completed cable.
This Section applies to all PA 11 or PA 12 compounds and to the PA 11 or PA 12 jacket
that is from the unbonded cable construction. Section 9 covers the composite properties
where the PA 11 or PA 12 jacket is integrally bonded to the underlying PE sheath.
8.2 COMPOUND
8.2.1 General
The requirements of the compounds in this Clause form the basis of the quality control
program for the unprocessed PA 11 or PA 12.

The PA 11 or PA 12 compound shall contain no recycled, reclaimed or reprocessed
material.
8.2.3 Types of PA 11 or PA 12
The compound shall be one of the following types:
Formulation Description of the jacket

Black Black PA 11 or PA 12 containing
thermal stabilizer(s) plus carbon black
as the light stabilizer.
Coloured Colourable PA 11 or PA 12 containing
thermal stabilizer(s) plus light
stabilizers that preferably include both
UV stabilizer(s), hindered amine light
stabilizer(s) (HALS), and titanium
dioxide (TiO 2).
8.2.4 Light and heat stabilizers

For black PA 11 or PA 12 compound, the carbon black for UV stability is required to be a
grade suitable for use in plastics, with an average particle size of 10 to 25 nm when
determined in accordance with ASTM D 3849 or equivalent.
For colourable PA 11 or PA 12 compound the titanium dioxide shall be a coated rutile type,
added at the minimum level of 10 g/kg.
NOTE: For the stabilizers in both types of PA 11 or PA 12 compound to function effectively, it is
important that they are homogeneously dispersed throughout the polymer matrix and this is best
achieved by the cable manufacturer using a fully compounded PA 11 or PA 12 material supplied
by the polymer compounder. Masterbatches do not provide sufficient dispersion when added to
the base material by the cable manufacturer during jacket extrusion.

39 AS 1049—2003
8.3 JACKET
8.3.1 General
The requirements of the jacket in this Clause 8.3 form the basis of the cable manufacturer’s
quality control and end-user acceptance procedures for the completed cables.
Except for colour masterbatch added to colourable PA 11 or PA 12, no other material shall
be added to the jacket. The jacket shall not contain any reprocessed, reworked or recycled
material.
8.3.3 Jacket tests
Where tested in accordance with the appropriate appendices, PA 11 or PA 12 jacket taken
from completed cables shall comply with the requirements of Table 8.1.

AS 1049—2003
TABLE 8.1
TEST REQUIREMENTS FOR PA JACKET FROM THE UNBONDED CABLE CONSTRUCTION
Criteria
Test Appendix Parameters and conditions Units
Black jacket Coloured jacket
Visual
Mechanical
5 Tensile strength at yield E — MPa 30.0 (min.)
6 Unaged % 280 (min.)
After ageing in air oven
% 80 (min.)
Elongation at break E (percentage of initial value)
After ageing in weatherometer
% 85 (min.)
40
15 Bending performance N — — No cracks or ripples
Chemical
21 Carbon black concentration1) S — g/kg 20 ±3 NA
22 Numerical rating — Less than 5 NA
Carbon black dispersion1) T Better than photomicrograph A,
Uniformity of appearance — NA
Figure T2
Instrumental colour
24 V ∆E* ab — NA 5 (max.)
difference2)
Colour change less
26 Colourfastness to daylight X — — NA
than four
27 Colourfastness to water Y — — NA No transfer to water

NOTES:
1) Carbon black concentration and dispersion may be measured on the compound prior to extrusion.
2) Instrumental colour difference may be measured on the compound prior to extrusion.
41 AS 1049—2003
SECT ION 9 I NTEGRA L L Y BON DED PE

SHEATH AN D PO LY AM I DE JACKET
9.1 GENERAL
This Section specifies the requirements of the composite integrally-bonded PE sheath and
PA 11 or PA 12 insect resistant jacket taken from the completed cable.
NOTE: Integrally-bonded PE sheath and PA 11 or PA 12 jackets are typically used for kink
resistance during cable installation.
The material requirements for the PE and PA 11 or PA 12 are specified in Sections 7 and 8
respectively. This Section covers the requirements of the composite itself which, by the
nature of the integral bonding, can not be specified by the earlier Sections.
9.2 COMPOUND
PE compound intended for sheath shall meet the compound requirements in Section 7
except that the use of carbon black or any colorant is optional and the tests for carbon black
content, carbon black dispersion and instrumental colour difference are not required.
PA 11 or PA 12 compound intended for jacket shall meet the compound requirements of
Section 8.
9.3 INTEGRALLY-BONDED SHEATH AND JACKET

9.3.1 General
The requirements of the integrally-bonded sheath and jacket in this Clause 9.3 form the
basis of the cable manufacturer’s quality control and end-user acceptance procedures for the
completed cables.
Where tested in accordance with the appropriate appendices, composite sheath/jacket taken
from completed cables shall comply with the requirements of Table 9.1.

AS 1049—2003
TABLE 9.1
TEST REQUIREMENTS FOR THE COMPOSITE INTEGRALLY-BONDED PE SHEATH AND PA JACKET
Criteria
Sheath/jacket composite
Test Appendix Parameters and conditions Units Polyethylene
Black jacketed Coloured jacketed
sheath
composite composite
Visual
1 Visual appearance A — — NA No defects
Mechanical
6 Elongation at break E — % NA 280 (min.)
14 Unaged N/mm NA 2.5 (min.)
After ageing for 30 d (percentage of initial
Bond strength M value)
In water at 60°C % NA 70 (min.)
In petrol at 23°C
In air at 80°C
42
15 Bending performance N — — NA No cracks or ripples
Chemical
Carbon black
21 S — g/kg — 20 ±3 NA
concentration1)
22 Numerical rating — — Less than 5 NA
Carbon black Better than
T
dispersion 1) Uniformity of appearance — — photomicrograph A, NA
Figure T2
Instrumental colour
24 V ∆E* ab — NA NA 5 (max.)
difference2)
Colourfastness to Colour change less
26 X — — NA NA
daylight than four
No transfer to
27 Colourfastness to water Y — — NA NA
water
NOTES:
1) Carbon black concentration and dispersion are measured on the jacket of the composite and are not required where these tests have been performed on the compound
prior to extrusion.
2) Instrumental colour difference may be measured on the compound prior to extrusion.
43 AS 1049—2003
SECT ION 10 PVC SHEATH OR JACKET

This Section specifies the material requirements for poly(vinyl chloride) sheath or jacket
NOTE: PVC sheath or jacket is typically used for telecommunication switch cable and for other
indoor uses, for example, in communications, control and data applications.
10.2 SHEATH OR JACKET TESTS

Where tested in accordance with the appropriate appendices, all sheath or jacket
manufactured from PVC shall comply with the test requirements of Table 10.1.
10.3 CABLES EXPOSED TO UV RADIATION

For cables exposed to direct sunlight at any time of the year, the sheath shall have either a
minimum of 10 g/kg carbon black or an appropriate amount of another light stabilizer(s)
added during compounding or extrusion.

AS 1049—2003
TABLE 10.1
TEST REQUIREMENTS FOR PVC SHEATH OR JACKET FROM COMPLETED CABLE
Criteria 1)
Cable exposed to UV
Test Appendix Parameters and conditions Units Telecommunication
Other cable radiation
switch cable
Coloured Black
Visual
Physical
4 Softness D — — 28 to 40 NA
Mechanical
Unaged MPa 12 (min.) 13 (min.)
5 Tensile strength at break E
44
% NA 85 (min.)
Unaged % 200 (min.) 100 (min.)
6 Elongation at break E After ageing in air oven
% 75 (min.) 50 (min.)
9 Shrinkback H — % 15 (max.) NA
Chemical
Within the limits of
Within the limits of Table U1 or
Table U1 or
23 Visual colour difference U — — IEC 60304 NA
IEC 60304 (see
(see Appendix JJ)
Appendix JJ)
26 X — — Colour change less than four NA
daylight than four
(continued)
Criteria 1)
Cable exposed to UV
Test Appendix Parameters and conditions Units Telecommunication
Other cable radiation
switch cable
Coloured Black
27 Colourfastness to water Y — — No transfer to water No transfer to water NA
28 Plasticizer compatibility Z — — No formation of drops of liquid or signs of greasiness
Fire
Burn
mm 50 (max.) NA
Oxygen length
34 Combustion EE
concentration 28% Burn
s 180 (max.) NA
time
45
Material temperature ratings are differentiated by the ageing times and temperatures as specified in the appendices.
AS 1049—2003
AS 1049—2003 46
SECT ION 11 NHMH FO R SHEATH OR

JACKET

This Section specifies the material requirements for non-halogenated metal-hydroxide-filled
thermoplastic material for sheath and jacket taken from completed cable or, where
specified, during manufacture.
NOTE: NHMH is typically used to provide fire or flame retardance for indoor cables where low
evolution of corrosive and toxic gases is desired.
11.2 SHEATH OR JACKET TESTS

Where tested in accordance with the appropriate appendices, all sheath or jacket
manufactured from NHMH shall comply with the test requirements of Table 11.1.

TABLE 11.1
TEST REQUIREMENTS FOR NHMH FOR SHEATH OR JACKET FROM COMPLETED CABLE
Units Criteria
Test Method or appendix Parameters and conditions Telecommunication Other cables not exposed to
switch cable UV radiation
Visual
Mechanical
5 Tensile strength at break Unaged MPa 8 (min.)
E After ageing in air oven
% 90 (min.)
6 Elongation at break Unaged % 125 (min.)
E After ageing in air oven
% 75 (min.)
Pressure test at high
8 G Indentation for k = 0.6, 75 ±2°C % 50 (max.)
temperature
47
12 Heat shock K 100 ±2°C — No cracking
Chemical
Within the limits of Table U1 or IEC 60304 Ed.3.0b
23 Visual colour difference U — —
(see Appendix JJ)
(continued)
AS 1049—2003
AS 1049—2003
Fire
Oxygen Burn length mm 50 (max.) 50 (max.)
34 Combustion EE
concentration 30% Burn time s 180 (max.) 180 (max.)
Ignition time min 9.0 (min.)
Simultaneous determination of
Flame spread time min 2.0 (min.)
35 ignitability, flame propagation, FF NA
heat release & smoke release Heat evolved kJ/m 2 100 (max.)
Optical density m −1 0.3 (max.)
No flaming droplets
36 Drip GG — — for 7/10 test NA
specimens (min.)
PH — 3.5 (min.)
37 Acid & corrosive gas emission AS/NZS 1660.5.4:1998
Conductivity µS/mm 10 (max.)
48
49 AS 1049—2003
SECT ION 12 F L UOROP O L YMER

I NSU L A T I O N , SHEATH O R JACKET

This Section specifies the material requirements for fluoropolymer insulation, sheath or
jacket taken from completed cable or, where specified, during manufacture.
NOTE: Fluoropolymer is typically used for high temperature data cable.
12.2 INSULATION, SHEATH OR JACKET TESTS

Where tested in accordance with the appropriate appendices, all insulation, sheath or jacket
manufactured from fluoropolymer material shall comply with the test requirements of
Table 12.1.

AS 1049—2003
TABLE 12.1
TEST REQUIREMENTS FOR FLUOROPOLYMER INSULATION, SHEATH OR JACKET FROM COMPLETED CABLE
Criteria1)
Parameters and
Test Appendix Units ECTFE and ETFE FEP PFA PTFE PVDF
conditions
Insulation Sheath Insulation Sheath Insulation Sheath Insulation Sheath Insulation Sheath
Visual
Mechanical
Unaged MPa 34 (min.) 17 (min.) 17 (min.) 27 (min.) 24 (min.)
5 Tensile strength at break E
(percentage of initial % 85 (min.) 2) 75 (min.) 85 (min.) 85 (min.) 50 (min.) 3)
value)
Unaged % 100 (min.) 200 (min.) 200 (min.) 175 (min.) 100 (min.)
6 Elongation at break E
(percentage of initial % 75 (min.) 75 (min.) 85 (min.) 85 (min.) 50 (min.) 3)
value)
7 Flexibility after ageing F — — NA No cracking4)
50
9 Shrinkback H — % 6 (max.) NA 6 (max.) NA 6 (max.) NA 6 (max.) NA 6 (max.) NA
Chemical
23 Visual colour difference U — — Within the limits of Table U1 or IEC 60304.3.0b (see Appendix JJ)
Colour bleeding and None None None None None
25 W — — NA NA NA NA NA
migration observed observed observed observed observed
Electrical
Not more Not more Not more Not more Not more
than one than one than one than one than one
31 Spark test CC — — NA NA NA NA NA
breakdown breakdown breakdown breakdown breakdown
per km per km per km per km per km
NOTES:
2) Alternatively 34 MPa (min.).
3) Test is only applicable to materials with a temperature rating of 150°C.
4) Test is only applicable to materials with a temperature rating of 125°C.
51 AS 1049—2003
SECT ION 13 PEFR I NSU L AT I ON, S HEATH

OR JACKET

This Section specifies the material requirements for insulation, sheath and jacket
manufactured from PE that contains fire/flame retardant, taken from completed cable or,
where specified, during manufacture.

manufactured from PEFR shall comply with the test requirements of Table 13.1.
TABLE 13.1
TEST REQUIREMENTS FOR PEFR INSULATION, SHEATH OR JACKET FROM
COMPLETED CABLE
Criteria
Parameters and
Test Appendix Units Solid Cellular
conditions Sheath
Visual
Visual
1 A — — No defects
appearance
Mechanical
Unaged MPa 8 (min.)
Tensile
5 strength at E After ageing in air oven
break (percentage of initial % 75 (min.)
value)
Unaged % 100 (min.)
Elongation at After ageing in air oven
6 E
break (percentage of initial % 75 (min.)
value)
Cold bend
11 J −15°C — No cracking
performance
Chemical
Within the limits of Table U1 or
Visual colour
23 U — — IEC 60304 Ed.3.0b (see
difference
Appendix JJ)
Colour
25 bleeding and W — — None observed NA
migration
Colourfastness
26 X — — Colour change less than four
to daylight
Colourfastness
27 Y — — No transfer to water
to water
Electrical
Not more than one
31 Spark test CC — — breakdown per NA
kilometre

AS 1049—2003 52
SECT ION 14 SRPVC IN SU LAT I ON, SHEATH

OR JACKET

This Section specifies the material requirements for semi-rigid poly(vinyl chloride)
insulation, sheath and jacket taken from completed cable or, where specified, during
manufacture.
NOTES:
1 Refer to Clause 1.5 for the definition of semi-rigid plastic.
2 SRPVC is typically used for data cables.

manufactured from SRPVC shall comply with the test requirements of Table 14.1.
TABLE 14.1
TEST REQUIREMENTS FOR SRPVC INSULATION, SHEATH OR JACKET FROM
FINISHED CABLE
Parameters and Criteria 1)
Test Appendix Units
conditions Insulation Sheath
Visual
Mechanical
Unaged MPa 20 (min.)
Tensile strength at
5 E After ageing in air oven
break % 70 (min.)
Unaged % 100 (min.)
6 Elongation at break E
Cold bend
11 J −15°C — No cracking
performance
Chemical
Within the limits of
Visual colour Table U1 or
23 U — —
difference IEC 60304 Ed.3.0b
(see Appendix JJ)
Colour bleeding and None
25 W — — NA
migration observed
26 X — —
daylight than four
Colourfastness to
27 Y — — No transfer to water
water
Electrical
Not more
than one
31 Spark test CC — — breakdown NA
per
kilometre
NOTE:
1) Material temperature ratings are differentiated by the ageing times and temperatures as specified in the
appendices.

53 AS 1049—2003
SECT ION 15 CROSSL I N KED PO L YM ER

I NSU L A T I O N , SHEATH O R JACKET

This Section specifies the material requirements for crosslinked polymer insulation, sheath
and jacket taken from completed cable or, where specified, during manufacture.
NOTE: Crosslinked polymer is typically used for high temperature data cables.

manufactured from crosslinked polymer materials shall comply with the test requirements
of Table 15.1.

AS 1049—2003
TABLE 15.1
TEST REQUIREMENTS FOR CROSSLINKED POLYMER INSULATION,
SHEATH OR JACKET FROM COMPLETED CABLE
Criteria 1)
Test Appendix Parameters and conditions Units XLPE, XLPVC, XLEVA XLPO
Insulation Sheath Insulation Sheath
Visual
Mechanical
5 Tensile strength at break E Unaged MPa 10 (min.) 13 (min.)
After ageing in air oven % 70 (min.) 85 (min.)
54
After ageing in air oven % 70 (min.) 70 (min.)
9 Shrinkback H — % 6 (max.) NA 6 (max.) NA
Chemical
23 Visual colour difference U — — Within the limits of Table U1 or IEC 60304
(see Appendix JJ)
25 Colour bleeding and migration W — — None observed NA None observed NA
Electrical
31 Spark test CC — — Not more than NA Not more than NA

one breakdown one breakdown
per kilometre per kilometre
NOTE:
55 AS 1049—2003
APPENDIX A
TEST METHOD 1: DETERMINATION OF VISUAL APPEARANCE
(Normative)
A1 SCOPE
This Appendix sets out the method of determining the visual appearance for insulation,
sheath or jacket.
A2 PRINCIPLE
A sample of insulation, sheath or jacket is visually inspected for defined defects.
A3 APPARATUS
The apparatus shall comprise an inspection area meeting the requirements of —

(a) a colour matching booth meeting the minimum specification of AS 4004:1992 for
daylight illuminant; or
(b) a colour assessment area illuminated by either natural daylight from north-facing
windows or fluorescent tubes of correlated colour temperature 6500 K, colour
rendering index greater than 92 and minimum illuminance of 1000 lx.
A4 TEST SPECIMEN
The test specimen shall be a suitable length of the insulation, sheath or jacket.
A5 CONDITIONING
The material shall be conditioned at 23 ±2°C for a minimum of 16 h.
A6 PROCEDURE
Directly after conditioning, the test shall be conducted at 23 ±2°C. The test specimen shall
be visually inspected with normal or corrected vision without magnification in the
inspection area. The following material characteristics shall be inspected:
(a) Smoothness The test specimen shall be smooth and free of regular roughness such as
‘orange peel’ and any other defects such as bubbles, open spots, rips, tears, cuts,
abrasion or foreign material.
(b) Tackiness The test specimen shall be free of tackiness from internal means such as
surface exudation or by externally applied means such as inks, markings or
accidentally applied material.
A7 REPORT
The condition of insulation, sheath or jacket shall be reported as exhibiting defects or not
exhibiting defects.

AS 1049—2003 56
APPENDIX B
TEST METHOD 2: DETERMINATION OF DENSITY
(Normative)
B1 SCOPE
This Appendix sets out the method for determining the density of PE compound.
B2 PRINCIPLE
Samples of PE compound are tested by one of the four test methods in AS 1193, being the
immersion, pycnometer, titration or density gradient column methods.
B3 TEST SPECIMENS
Suitable test specimens shall be prepared according to AS 1193 or as follows:

(a) A test piece shall be prepared by taking test specimens and extruding a melt flow
index ‘cut-off’ in accordance with Appendix C. The extrudate shall be dropped onto a
cool metal plate after being cut off.
(b) Within one day of extruding the test piece, the test piece shall be suspended in about
the centre of a 5 L beaker containing 4.5 L to 4.7 L of briskly boiling water and
covered with a watch glass. The test piece may be suspended by wrapping one end of
a copper wire around the test piece. Condition in the boiling water for 1 h.
(c) At the end of the boiling time, the beaker shall be removed from the hotplate,
provided the water level remains between 4.5 L and 4.7 L, and allowed to stand on
the bench at 23 ±2°C for between 20 h and 24 h. This permits an equilibrium time at
23°C of at least 5 h.
(d) The test piece shall be removed from the water and a 5 mm length shall be cut off
from the thicker end. This portion shall be discarded and from the next 10 mm at least
three small pieces of recognizable shapes and dimensions that permit the most
accurate measurement of the position of the centre of volume of the suspended
specimen shall be cut. The surfaces should be smooth and free from cavities to
preclude entrapment of air upon immersion. If the sample whitens when being cut, a
very sharp razor blade should be used, and the cut made very slowly. This whitening
appears to affect the sample density and should be avoided.
B4 TEST METHOD
The density of PE compound shall be determined in accordance with AS 1193 and
Paragraph B5.

57 AS 1049—2003
B5 CORRECTION OF PE CONTAINING CARBON BLACK

If the PE contains carbon black, then the following correction factor shall be applied to
obtain the density of the base polymer using the following equation:
d = d c – 0.45 C B . . . B(1)
where
d = corrected density value, kilograms per cubic metre
dc = measured density value, kilograms per cubic metre
CB = carbon black concentration, in grams per kilogram, when determined in
accordance with Appendix S
B6 REPORT
The density of PE compound shall be reported in accordance with AS 1193.

AS 1049—2003 58
APPENDIX C
TEST METHOD 3: DETERMINATION OF MELT FLOW INDEX
(Normative)
C1 SCOPE
This Appendix sets out the method for determining the melt flow index of PE compound.
C2 PRINCIPLE
The apparatus used is basically an extrusion plastometer. The material is loaded in the
vertical metal cylinder and under prescribed conditions of load and temperature the molten
material is extruded through a die of specified length and diameter. The rate of extrusion is
measured by weighing the mass of material during specified time intervals.
C3 APPARATUS
The general design of the apparatus is shown in Figures C1 and C2. The essential parts shall
be as follows:
(a) Cylinder A cylinder of hardened steel, fixed in a vertical position suitably lagged for
operation between 140°C and 190°C. The cylinder shall be at least 115 mm long and
the internal diameter shall be 9.550 ±0.025 mm. The base of the cylinder shall be
thermally insulated if the area of exposed metal exceeds 4 cm2 .
(b) Piston A piston of mild steel, whose length shall be at least as great as that of the
cylinder. The piston shall have a head of length 6.35 ±0.23 mm. The diameter of the
head shall be 9.475 ±0.015 mm. The lower edge of the head shall have a radius of
0.4 mm and the upper edge shall have its sharpness removed. Above the head the
piston shall be relieved to about 9.0 mm diameter. A stud may be added at the top of
the piston to support the removable load, but the piston shall be thermally insulated
from this load. Two marks shall be scribed on the piston 30 mm apart in such a
position that they are level with the top of the cylinder when the piston is inserted in
the cylinder and the marks on its head are 20 mm and 50 mm respectively from the
upper end of the die.
(c) Weight A removable load A or B or C that can be placed on top of the piston. The
combined mass of load A and the piston shall be 2.160 ±0.010 kg, the combined mass
of load B and the piston shall be 21.60 ±0.10 kg, and the combined mass of load C
and the piston shall be 5.000 ±0.010 kg.
(d) Heater A heater to maintain the polyethylene in the cylinder at a temperature of
either 140 ±0.5°C or 160 ±0.5°C or 190 ±0.5°C (automatic temperature control is
strongly recommended).
(e) Temperature measuring device A temperature measuring device located as close as
possible to the jet, but situated within the body of the cylinder and calibrated to
permit temperature measurement to ±0.1°C.
NOTE: It is recommended that the temperature measuring device be a platinum resistance
thermometer or a mercury-in-glass thermometer located permanently within the mass of the
cylinder. If any other temperature measuring device is used, then it must be calibrated at the
test temperature with reference to a platinum resistance thermometer or a mercury-in-glass
thermometer which has the required accuracy.
(f) Jet A jet of length 8.000 ±0.025 mm and internal diameter 2.095 ±0.005 mm made
of hardened steel. The jet shall not project beyond the base of the cylinder.

59 AS 1049—2003
C4 TEST SPECIMENS
The test specimens shall be PE compound in the form of pellets.
C5 PROCEDURE
The procedure shall be as follows:
(a) The apparatus shall be cleaned. Abrasives or materials likely to damage the surface of
the piston, cylinder or jet shall not be used in removing superficial PE, or in
manipulating any part of the apparatus.
Suitable solvents for cleaning the apparatus are xylene and tetrahydronaphthalene.
Due regard should be given to the toxic and flammable natures of these solvents. The
piston should be cleaned while still hot with a cloth dipped in the solvent. The
cylinder, while still hot, should be cleaned with a swab dipped in the solvent. The jet
should be cleaned by means of a closely fitting brass reamer or wooden peg, followed
by immersion in boiling solvent. It is recommended that, at frequent intervals, say
once a week for instruments in constant use, the insulating plate and the jet retaining
plate, if fitted (see Figure C1), be removed and the cylinder cleaned throughout.
(b) The temperature of the cylinder, jet and piston shall be set at 190 ±0.5°C unless the
material to be tested contains blowing agent and is intended for cellular insulation in
which case the temperature shall be set at 140 ±0.5°C under 5.000 kg load or
160 ±0.5°C under 2.160 kg load. This temperature shall be maintained for 15 min
prior to the beginning of a series of tests and during the extrusion of the PE.
(c) The cylinder shall be charged with 4 to 5 g of test specimen and the unloaded piston
then re-inserted into the top of the cylinder.
(d) Six to eight minutes after introducing the material, during which time the temperature
of the cylinder shall have returned to the specified temperature, the load A or B or C
shall be placed on the piston to extrude the PE through the jet. The rate of extrusion
shall be measured by cutting the extrudate at the jet at the intervals of time specified
in Table C1 with a suitable sharp-edged instrument to give short lengths referred to as
cut-offs.
TABLE C1
TEST FOR MELT FLOW INDEX
Interval of time
Temperature
PE category between cut-offs
°C
s
For 2.160 kg load
Category 3 190 60
Category 4 190 120
Category 5 190 180
Cellular PE 160 240
For 21.60 kg load
Category 5 190 10
For 5.000 kg load
Cellular PE 140 240, 120 or 601)
NOTE:
1) The time interval is chosen to provide a length of a single cut-off
preferably between 10 mm and 20 mm.

AS 1049—2003 60
(e) Several cut-offs shall be taken within 20 min of the introduction of the specimen into
the cylinder and when the piston head is between 50 mm and 20 mm from the upper
end of the die, i.e. between the times when the first and second marks scribed on it
disappear into the cylinder. The first cut-off and any other that contains air-bubbles
shall be ignored.
(f) Successive cut-offs shall be individually weighed (at least three) to an accuracy of
1 mg and the average mass determined. If the difference between the maximum and
minimum values of the individual masses exceeds 10 percent of the average, the test
results shall be discarded and the test shall be repeated on a fresh portion of the
specimen.
NOTE: The MFI of PE may be affected by previous thermal and mechanical treatment, and in
particular, oxidation will tend to reduce it. Oxidation occurring during the test will usually
cause a systematic reduction in the mass of successive cut-offs. This phenomenon is known as
setting-up; it is not exhibited by PE compounds containing an antioxidant.
C6 CALCULATION
The melt flow index (MFI) shall be calculated, in grams per 600 seconds, as follows:
MFI = 600 × m . . . C(1)

t
where
m = average mass of cut-offs, in grams
t = interval between cut-offs, in seconds.

61 AS 1049—2003
C7 REPORT
The MFI, in grams per 600 seconds, shall be reported as the mean of at least three
successive cut-offs to two significant figures. The load and temperature used to determine
the MFI shall be reported.
FIGURE C1 APPARATUS FOR DETERMINING MELT FLOW INDEX SHOWING LARGE

EXTERNAL DIAMETER CYLINDER, JET RETAINING PLATE AND INSULATING PLATE
DIMENSIONS IN MILLIMETRES
FIGURE C2 PART OF APPARATUS SHOWING SMALL EXTERNAL DIAMETER

CYLINDER WITH AN ALTERNATIVE METHOD OF RETAINING THE JET

AS 1049—2003 62
APPENDIX D
TEST METHOD 4: DETERMINATION OF SOFTNESS NUMBER
(Normative)
D1 SCOPE
This Appendix sets out the method of determining the softness number for sheath or jacket.
D2 PRINCIPLE
Sheath or jacket taken from the completed cable is moulded into a sufficiently thick
specimen to eliminate the effects of the anvil during the measurements. The softness
number is determined from the vertical movement in millimetres, reading to the nearest
0.01 mm, of a 2.5 mm diameter rigid ball which is under an applied load of 500 g.
D3 APPARATUS
The following apparatus is required:
(a) Apparatus for moulding the specimen according to Appendix II.
(b) An indentor, comprising a vertical plunger terminating at its lower end in a steel ball
and capable of substantially frictionless movement. The part of the plunger
immediately above the ball shall be reduced in cross-section so as to avoid its coming
into contact with the specimen under test. The diameter of the steel ball shall be
2.50 ±0.01 mm.
(c) A rigid foot, in the form of an annulus of rectangular cross-section, concentric with
the indentor, having a lower surface (the datum surface) that is flat and normal to the
indentor axis. The foot and its attachments shall allow free passage of the indentor
and shall be capable of substantially frictionless vertical movement. The outside
diameter of the foot shall be 20 ±1 mm and the diameter of the central hole shall be
6 ±1 mm.
(d) Means for lowering the foot, so that it pressed vertically on the test piece with a force
of 8.3 ±1.5 N. The force shall remain constant to within ±0.1 N during the test.
(e) Means for supporting the indentor, so that except when an indentor measurement is
actually being made, the lowest extremity of the indentor is always at least 0.5 mm
above the datum surface of the foot.
(f) Means for lowering the indentor so that it presses vertically in the test piece with an
initial contact force of 0.30 ±0.02 N and means for increasing this force to the total
force of 5.70 ±0.03 N. The initial contact force and the total force (comprising the
initial contact force plus the indenting force increment) shall each remain constant to
within ±0.005 N during the test.
(g) Means which may be mechanical, optical or electrical, for measuring the vertical
movement of the indentor relative to the foot units of 0.01 mm.
(h) Means, e.g. an electrically operated buzzer, for gently vibrating the apparatus to
overcome any slight residual friction. This may be omitted in instruments where
friction is negligible.

63 AS 1049—2003
D4 TEST SPECIMEN
The test specimens shall be compression moulded in a chase of 50 mm diameter cavity and
thickness of at least 10 mm in accordance with Appendix II with the following additional
requirements:
(a) The test specimen shall be moulded by loading the chase with sufficient sheath or
jacket to provide 2% to 10% flash.
(b) The backing plates, parting sheets, chase and material shall be pre-heated at 140°C
under light pressure for 10 min.
(c) The pressure shall then be increased to approximately 4.0 MPa for 2 min.
(d) The test specimen shall then be rapidly cooled to room temperature whilst
maintaining full pressure.
D5 CONDITIONING
D6 PROCEDURE
Directly after conditioning, the test shall be conducted at 23 ±1°C, as follows:
(a) The test specimen shall be laid on a rigid, flat, horizontal anvil and the vibrator
started.
(b) The rigid foot shall be lowered and pressed on to the test specimen with the requisite
force. The indentor shall be immediately lowered and pressed on to the test specimen
with the initial contact force for 5 s at a distance of not less than 7 mm from the
nearest edge.
(c) The vertical movement of the plunger shall be recorded relative to the lower surface
of the foot to the nearest 0.01 mm.
(d) The force on the indentor shall be immediately increased to the total indenting force
for a further 30 s.
(e) The vertical movement of the plunger shall be recorded relative to the lower surface
of the foot to the nearest 0.01 mm.
(f) The measurement shall be repeated to obtain two sets of readings on each side of the
test specimen with points on the same side not less than 7 mm apart.
D7 CALCULATIONS
The softness number is the difference between the vertical height of the indentor under the
contact force and the vertical height under the total indenting force, expressed in units of
0.01 mm, calculated from the measurements of Clause D6(f).
The softness number shall be calculated as the mean of the four calculations.
D8 REPORT
The softness number shall be reported.

AS 1049—2003 64
APPENDIX E
TEST METHODS 5 AND 6: DETERMINATION OF TENSILE
STRENGTH AT BREAK/YIELD AND ELONGATION AT BREAK—
BEFORE AND AFTER AGEING
(Normative)
E1 SCOPE
This Appendix sets out the method for determining the following:
(a) The initial tensile strength at break/yield and elongation at break, for specimens
prepared from insulation, sheath or jacket removed from cable.
(b) The tensile strength at break/yield and elongation at break after ageing, for specimens
prepared from insulation, sheath or jacket removed from cable.
E2 PRINCIPLE
Specimens are tested unaged or after being aged in an air oven or weatherometer.
Measurements are made under tension by uniaxially stretching the specimen of known
dimensions at a uniform continuous rate. The test is continued to the point where the
specimen breaks. The data so obtained is in the form of a load-extension curve which can
be converted to stress and elongation at any desired point on the curve. Elongation of the
specimen is usually followed independently of the curve.
E3 APPARATUS
(a) Testing machine of the constant-rate-of-crosshead-movement type complying with the
requirements of a Grade A machine of AS 2193.
(b) Grips which are self-aligning and of the pneumatic or self-tightening type which exert
a uniform pressure across the gripping surface. When testing insulation, rubber coated
grips or a length of a rubber hose may be inserted between the grips to cover the
length of the grips and to just protrude from the gripping surface such that when
insulation is held in the hose, the corners of the grips are not pressing against the
insulation.
(c) An air oven in accordance with the following:
A forced air circulation oven with 3 to 10 air changes per hour, capable of operating
at the temperature specified in Table E2 for the specified material being tested, shall
be used. The working volume and number of air changes per hour of the oven, tubular
or dumbbell test specimen types, and number of test specimens in the oven shall be
stated with the results.
(d) Weatherometer complying with the requirements of either of the following:
(i) ASTM G 155, Test Method C, using apparatus Type AH, BH, C, D or E and
under the following test conditions:
(A) Radiance level of 0.5 W/m2 . 1 nm bandpass at 340 nm (requiring optical
filter Type A in preference to specified Types C or D).
(B) Black panel temperature of 63 ±5°C.
(C) Relative humidity of 50 ±5%.
(D) No water spray to be used.

65 AS 1049—2003
(ii) ASTM G 152 and ASTM G 153, Test Method 3, using apparatus Type DH or
HH and under the following test conditions:
(A) Relative humidity of 50 ±5%.
(B) No water spray to be used.
(e) Air oven capable of operating at 70 ±2°C.
(f) Dies with the dimensions shown in Figure E1.
E4 TEST SPECIMEN
E4.1 Selection of test specimen
The test specimen shall be in the form of tubes when testing insulation and either dumbbells
or tubes when testing sheath or jacket.
Dumbbell test specimens shall be in the form of dumbbell type A, B, or C as shown in
Figure E1, if the cable outside diameter is equal to or greater than 10 mm, otherwise a
tubular specimen shall be used. The largest dumbbell shall be used, dependent on the cable
diameter from which the test specimen is taken.

AS 1049—2003 66
Specimen dimensions 1) Dumbbell type 2)

A B C
W Width of narrow section 6 4 4
L Length of narrow section 33 25 17

Wo Width overall, minimum 19 12.5 8.5
Lo Length overall, minimum 115 75 50
R Radius of fillet 14 8 7.5
Ro Outer radius 25 12.5 10
D Distance between jaws See Table E1
G Gauge length See Table E1
NOTES:
1) Refer to relevant Standards for tolerance dimensions.
2) Dumbbell A is Type IV of ASTM D 638, Dumbbell B is the large dumbbell of
AS/NZS 1660.2.1 and Dumbbell C is the small dumbbell of AS/NZS 1660.2.1.
FIGURE E1 DUMBBELL TEST SPECIMEN DIMENSIONS
E4.2 Dumbbell specimens

Dumbbell specimens shall be prepared as follows:
(a) For filled PE cables, irrespective of their date of manufacture, the cable sample shall
be pre-aged for 14 d at 70 ±2°C in an air oven to ensure maximum uptake of the
filling compound by the PE. All other cables shall be tested as received.
(b) Any outer coverings shall be removed from the material being tested and the sheath
or jacket shall be cut from the cable in the direction of the axis of the core.
(c) All inner cable components shall be mechanically removed from the sheath or jacket,
i.e. not chemically removed.
(d) If the sheath or jacket contains any ridges, the specimen shall be cut to obtain parallel
surfaces.
(e) A minimum of five dumbbell pieces shall be cut parallel to the axis of the core.
(f) The specimen shall be symmetrically marked about the centre with two ink lines at
the gauge length designated in Table E1.

67 AS 1049—2003
TABLE E1
GAUGE LENGTH AND JAW SEPARATION FOR DUMBBELL
AND TUBULAR SPECIMENS
Gauge length Jaw separation
Specimen form
mm mm
Dumbbell A 25 ±0.25 64 ±5
Dumbbell B 20 ±0.5 50 ±1
Dumbbell C 10 ±0.25 34 ±1
Tubular 20 ±0.5 50 ±1
The minimum thickness shall be measured with the micrometer within the gauge length area
at a minimum of three positions.
The minimum cross-sectional area shall be calculated using the following equation:
Q = TW . . .E(1)
where
Q = is the minimum cross-sectional area, in square millimetres
T = is the minimum thickness, in millimetres
W = is the gauge width as shown in Figure E1, in millimetres.
E4.3 Tubular specimens

Tubular specimens shall be prepared as follows:
(a) For filled PE cables, irrespective of their date of manufacture, the cable sample shall
be pre-aged for 14 d at 70 ±2°C in an air oven to ensure maximum uptake of the
filling compound by the PE. All other cables shall be tested as received.
(b) Five pieces of cable shall be cut, each approximately 150 mm in length.
(c) The cable components shall be removed without damaging the insulation, sheath or
jacket. For test specimens of insulation, the conductor may be removed by removing a
small piece of insulation, sheath or jacket from each end of the specimen, elongating
the conductor approximately 10% and then removing the conductor.
(d) The specimen shall be symmetrically marked about the centre with ink lines at the
designated gauge length as shown in Table E1.
(e) The mean cross-sectional area of each specimen of insulation, sheath or jacket when
required for the calculation of tensile strength shall be determined from the density,
the mass and the length, according to the following equation:
Q = M . . .E(2)
× 10 6
D×L
where
Q = is the cross-sectional area of the test piece, in square millimetres
M = is the mass of the test piece, in grams
L = is the length of the test piece, in millimetres
D = is the density of the plastic, obtained on an additional piece of the plastic using any
suitable method, in kilograms per cubic metre.

AS 1049—2003 68
E5 AGEING
E5.1 In an air oven
Test specimens required to be aged in an air oven shall be aged as follows:
(a) Test specimens shall be aged for the time specified and at the temperature specified in
Table E2.
(b) The tubular or dumbbell test specimens shall not be loaded beyond 0.5% of the
working volume of the oven and shall only contain test specimens of the same
material type.
(c) The test specimens shall be suspended. The temperature sensing device shall be
located centrally within the sample group.
E5.2 In a weatherometer
Test specimens required to be aged in a weatherometer shall be aged as follows:
(a) Test specimens shall be aged by exposure to ultraviolet radiation in the range 275 to
440 nm for the time specified in Table E2.

(b) The weatherometer shall not be loaded beyond normal capacity and shall only contain
test specimens of the same material type.
E6 CONDITIONING
The test specimens shall be conditioned at 23 ±2°C for a minimum of 16 h. PA, PE and any
composites of the two shall be concurrently conditioned at 50 ±5% RH.
E7 PROCEDURE
(a) A minimum of five test pieces shall be tested.
(b) The jaw separation shall be set as shown in Table E1.
(c) The crosshead speed shall be set as shown in Table E2.
(d) The force at break/yield, in newtons, and the increase in length of the specimen at
break in millimetres, as illustrated in Figure E2, shall be recorded as required.
(e) Any results from test pieces breaking in the grips shall be discarded. The testing shall
be continued until a minimum of five test specimens are obtained which break outside
the grip area.
FIGURE E2 AN EXAMPLE OF A LOAD-EXTENSION CURVE IN TENSION SHOWING

LOAD AT YIELD AND EXTENSION AT BREAK

69 AS 1049—2003
TABLE E2
TEST SPECIMEN AGEING CONDITIONS AND CROSSHEAD SPEED
Section Material Application Ageing Ageing time Crosshead
temperature h speed
± 2)
°C(± mm/min
Cable jointed outdoors—
NA NA 500 ±50
Type I
Cable jointed outdoors—
2 PE insulation NA NA 50 ±5
Type II, III
Other cable— Type I 100 48 500 ±50
Other cable— Type II, III 100 48 50 ±5
3 PA 12 insulation — 100 120 50 ±5
4 PPO based insulation — 100 120 50 ±5
Telecommunication switch
100 120 250 ±50
cable
Other cable
5 PVC insulation
75°C rating 100 240 250 ±50
90°C rating 120 168 250 ±50
105°C rating 135 168 250 ±50
6 PP insulation — 100 240 25 ±5
All applications— Type I NA NA 500 ±50
Coloured, intended for

UV exposure
Aged in weatherometer NA 5000 500 ±50
7 PE sheath/jacket
All applications— Type II, III NA NA 50 ±5
Coloured, intended for

UV exposure
Unbonded cable
construction— black and
8 PA jacket coloured
Aged in air oven 100 120 50 ±5
Integrally bonded PE Black and coloured PA
9 NA NA 50 ±5
sheath and PA jacket jacketed composite
100 120 250 ±50
cable
Other cable
10 PVC sheath/jacket 75°C rating 100 240 250 ±50

90°C rating 120 168 250 ±50
105°C rating 135 168 250 ±50
Cable exposed to UV 100 240 250 ±50
radiation—coloured and black
(continued)

AS 1049—2003 70
TABLE E2 (continued)
Section Material Application Ageing Ageing time Crosshead

temperature h speed
± 2)
°C(± mm/min
11 NHMH sheath/jacket All applications 100 168 50 ±5
ECTFE and ETFE, 150°C
180 168 50 ±5
rating
FEP, 200°C rating 230 168 500 ±50
Fluoropolymer PFA, 200°C rating 260 96 500 ±50
12 insulation and
sheath/jacket PTFE, 250°C rating 260 1440 500 ±50
160 168 50 ±5
PVDF, 125°C rating, either
135 720 50 ±5
PVDF, 150°C rating 160 1440 50 ±5
PEFR insulation and
13 All applications 100 48 50 ±5
sheath/jacket
75°C rating 100 240 50 ±5

SRPVC insulation
14 90°C rating 120 168 50 ±5
and sheath/jacket
105°C rating 135 168 50 ±5
XLPO 105°C rating 135 168 500 ±50
XL insulation and XLPE, XLPVC, XLEVA
15
sheath/jacket
75°C rating 115 168 500 ±50
90°C rating 120 168 500 ±50
NOTE: NA = Not Applicable.
E8 CALCULATIONS
The following calculations shall be made as required:
increase in gauge length at break
× 100
Elongation at break (%) = original gauge length . . .E(3)
force at break (N)

Tensile strength at break (MPa) = . . .E(4)
Q (mm 2 )
force at yield (N)
Tensile strength at yield (MPa) = . . .E(5)
Q (mm 2 )
where
Q = is the cross-sectional area of the test specimen
E9 REPORT
The following results shall be reported as required:
(a) Initial The median of five test results for tensile strength at break/yield and
percentage elongation at break.
(b) Heat and weatherometer aged The median of five results for tensile strength at
break/yield and percentage elongation at break as a percentage of the initial median
five results. Any unsatisfactory results owing to the test pieces breaking due to
damage in the grips shall be ignored. If less than four satisfactory results are obtained
the test shall be repeated.

71 AS 1049—2003
APPENDIX F
TEST METHOD 7: FLEXIBILITY AFTER AGEING
(Normative)
F1 SCOPE
This Appendix sets out the method for determining the flexibility after ageing of PVDF
insulation, sheath or jacket.
F2 PRINCIPLE
A sample of the insulated conductor or completed cable is aged in an air oven and then bent
around a mandrel and the behaviour observed.
F3 APPARATUS

(a) Air oven of the closed type, with forced air circulation and preferably with no air
changes or, alternatively, with 3 to 10 air changes per hour, capable of operating at
the temperature specified in Paragraph F5 for the specific material being tested.
(b) Suitable mandrels of the sizes specified in Paragraph F5.
F4 TEST SPECIMEN
The test specimen shall be a sample of insulated conductor or completed cable.
F5 PROCEDURE
F5.1 Insulation
The testing procedure for insulation shall be as follows:
(a) A suitable length of insulated conductor shall be suspended in an air-circulating oven
for 168 h at 158 ±1°C or, alternatively, for 30 d at 136 ±1°C at the manufacturer’s
option.
(b) At the end of this ageing period, the sample shall be removed from the oven and
allowed to cool to room temperature. The sample shall then be wound tightly for six
close turns, around a mandrel whose diameter shall be not greater than the nominal
diameter for the insulated conductor under test. The insulation shall then be examined
for cracks using a magnification of 5×.
F5.2 Sheath
The testing procedure for sheath shall be as follows:
(a) A suitable length of completed cable shall be suspended in an air-circulating oven for
168 h at 158 ±1°C or, alternatively, for 30 d at 136 ±1°C at the manufacturer’s option.
(b) At the end of this ageing period, the sample shall be removed from the oven, allowed
to cool to room temperature for not less than 16 h or more than 96 h, then wound onto
a circular mandrel whose diameter is twice the nominal diameter of the sample. Six
contiguous turns shall be wound onto the mandrel, then unwound, and examined for
cracks using normal or corrected vision without magnification.
F6 REPORT
Any cracks shall be reported.

AS 1049—2003 72
APPENDIX G
TEST METHOD 8: PRESSURE TEST AT HIGH TEMPERATURE
(Normative)
G1 SCOPE
This Appendix sets out the method to determine the resistance of sheathing materials to
pressure at elevated temperature.
G2 PRINCIPLE
A sample of complete cable, or a sample of the sheath removed from the cable is subjected
to a compression force exerted by an indentation device at elevated temperature. The
sample is cooled under the compression load and the indentation measured.
G3 APPARATUS
An indentation device as specified in AS/NZS 1660.2.3 is required.
G4 TEST SPECIMEN
The test specimen shall be 50 to 100 mm of the completed cable or sheath, as described in
the procedure.
G5 TEST METHOD
As specified in AS/NZS 1660.2.3:1998 (Test for sheaths).
NOTE: k = 0.6, temperature 75 ±2°C and the time is—
4h for test pieces having an outer diameter ≤15 mm, or
6h for test pieces having an outer diameter >15 mm.
G6 TEST REPORT
The median value of indentation shall be reported.

73 AS 1049—2003
APPENDIX H
TEST METHOD 9: DETERMINATION OF SHRINKBACK
(Normative)
H1 SCOPE
This Appendix sets out the method of determining shrinkback for insulation, sheath or
jacket.
H2 PRINCIPLE
The shrinkback is determined from the length of the insulation, sheath or jacket as
measured prior to and after heating at the specified temperature.
H3 APPARATUS

(a) Air oven capable of operating at the temperatures listed in Table H1, of the closed
type, with forced air circulation and preferably with no air changes or, alternatively
with 3 to 10 air changes per hour.
(b) Glycerine held at 150 ±2°C.
TABLE H1
AGEING TIME AND TEMPERATURES FOR VARIOUS TYPES
OF INSULATION, SHEATH AND JACKET
Ageing criteria
Section Material Application Temperature
Time
°C
Cables jointed outdoors 4h 100 ±1
2 PE insulation
Other cables 1h 121 ±21)
4 PPO insulation — 4h 100 ±1
Telecommunication switch 10 min in
150 ±2
5 PVC insulation cable glycerine
Other cable 1h 121 ±21)
6 PP insulation — 1h 121 ±2
10 min in
10 PVC sheath and jacket glycerine or 4 h 150 ±2
cable
in oven
11 NHMH sheath and jacket All 4h 100 ±1
60 to 105°C rating 1h 121 ±2
12 Fluoropolymer insulation
125 to 250°C rating 1h 150 ±2
13 PEFR insulation — 1h 121 ±21)
14 SRPVC insulation — 1h 121 ±2
Crosslinked polymer
15 — 1h 121 ±2
insulation
NOTE:
1) For material that melts or deforms at 121°C the lower temperature of 115 ±2°C is used.

AS 1049—2003 74
H4 TEST SPECIMEN
H4.1 Insulation
The test specimens taken from insulation shall be prepared as follows:
(a) Three lengths shall be cut from a long straight piece of insulated conductor, each
200 mm long.
(b) The length of each cut piece shall be reduced to 150 mm by trimming each end.
(c) The length of the insulation shall be measured to the nearest 0.5 mm.
H4.2 Sheath or jacket
The test specimens taken from sheath or jacket shall be prepared as follows:
(a) Three lengths shall be cut, each 150 mm long, from the centre of a piece of sheath or
jacket slipped from a completed cable without longitudinal cuts.
(b) The length of each cut piece shall be reduced to 75 mm by trimming each end.
(c) A line shall be drawn along the full length of each specimen parallel to its
longitudinal axis and the shortest distance between the ends of the line measured to
the nearest 0.5 mm.
H5 CONDITIONING
H6 PROCEDURE
H6.1 Insulation, sheath or jacket
Directly after conditioning, the test shall be conducted as follows:
(a) The test specimen shall be placed on a layer of talc powder in an air oven and held at
the temperature and times listed in Table H1.
(b) The container holding the specimens on the talc shall then be removed from the oven
and allowed to cool naturally to room temperature.
(c) For sheath or jacket test specimens, a suitable sized mandrel shall be inserted through
the tubular specimen to straighten the specimen.
(d) The length of the test specimens shall then be re-measured.
H6.2 Telecommunication switch cable: PVC insulation and an alternative method for
PVC sheath
(a) The straight test specimen shall be immersed vertically into the container of
glycerine, held at the temperature and times listed in Table H1.
(b) The specimens shall then be removed from the glycerine and allowed to cool
naturally to room temperature.
(c) For sheath and jacket test specimens, a suitable sized mandrel shall be inserted
through the tubular specimen to straighten the specimen.
(d) The length of the test specimens shall then be re-measured.

75 AS 1049—2003
H7 CALCULATIONS
The percentage shrinkback of each test specimen shall be calculated as follows:
Shrinkback (%) = original specimen length - final specimen length × 100 . . . H(1)
original length specimen
H8 REPORT
The median percentage shrinkback of the three test specimens shall be reported.

AS 1049—2003 76
APPENDIX I
TEST METHOD 10: DETERMINATION OF STRIPPING
(Normative)
I1 SCOPE
This Appendix sets out the method of determining the stripping force of insulation from an
insulated conductor as manufactured or taken from completed cables.
The test is only applicable to insulated solid conductors of the nominal diameters listed in
Table I1.
TABLE I1
INSULATED CONDUCTOR SPECIFICATIONS
Length of insulation Nominal conductor

Section Material
mm diameter mm
3 PA insulation 25 0.4
4 PPO insulation 25 0.4
5 PVC insulation 50 0.4 and 0.5
I2 PRINCIPLE
A conductor with a set length of insulation is pulled through a die to assess the adhesion of
the insulation to the wire.
I3 APPARATUS
A metal fixture or die block is required, to strip the insulation as the wire is pulled through,
with the following critical dimensions:
(a) The thickness shall be comparable to the diameter of the wire being threaded through,
to assist in preventing the insulation catching.
(b) The hole shall have a diameter approximately 10% greater than the nominal diameter
of the conductor.
I4 TEST SPECIMEN
The test specimens shall be prepared as follows:
(a) From each insulated conductor to be tested, three samples shall be prepared, each of
approximately 125 mm in length.
(b) Approximately 25 mm of insulation shall be removed from one end, and enough from
the other end, to leave the length of insulation required by Table I1 undisturbed.
I5 CONDITIONING

77 AS 1049—2003
I6 PROCEDURE
(a) The longer end of bare wire shall then be threaded through the hole in the metal plate
in one jaw of the tensile testing machine.
(b) The shorter end shall be inserted into the other jaw of the tensile testing machine.
(c) The insulation shall be stripped from the conductor by moving the jaws of the tensile
testing machine apart at a rate between 250 and 350 mm/min.
(d) The maximum recorded stripping force for each sample shall be recorded.
NOTE: Care should be taken to ensure that the specimen remains parallel to the direction of
travel of the jaws. If the conductor breaks, this fact should be recorded and the test repeated.
An excessive number of breaks may indicate either an excessive stripping force or a poor
testing technique.
I7 REPORT
The median of the recorded maximum stripping forces shall be reported.

AS 1049—2003 78
APPENDIX J
TEST METHOD 11: COLD BEND PERFORMANCE
(Normative)
J1 SCOPE
This Appendix sets out the method for determining the cold bend performance of samples
of insulation or sheath from the finished cable.
J2 PRINCIPLE
A sample of the insulated conductor, completed cable or the sheath material is bent around
a mandrel after conditioning the samples for 4 h at −15 ±2°C and any cracking is observed.
J3 APPARATUS

(a) A refrigerator capable of maintaining temperature at −15 ±2°C.
(b) Suitable mandrels of the sizes defined in Paragraph J5.
J4 TEST SPECIMEN
For insulation, samples of insulated conductor shall be used. When testing sheath for cables
less than 12.5 mm overall diameter, the completed cable shall be tested. For cables greater
than 12.5 mm overall diameter, a strip of sheath 4 ±0.5 mm wide shall be tested.
J5 PROCEDURE
J5.1 Insulation
The testing procedure for insulation shall be as follows:
(a) Two samples of insulated conductor shall be taken from the one length.
(b) The test mandrel, its diameter being four times the nominal insulated conductor
overall diameter, and the two samples of insulated conductor shall be conditioned in a
refrigerator at −15 ±2°C for a minimum of 4 h.
(c) While the temperature is maintained at −15 ±2°C, each test specimen shall be wound
around the mandrel for five close turns at a rate of approximately 12 turns per min.
(d) While the test specimens are wound on the mandrel, each test specimen shall be
examined for signs of cracking using normal or corrected vision without
magnification.
J5.2 Sheath
J5.2.1 Cables up to 12.5 mm
The testing procedure for sheath from cables up to 12.5 mm overall diameter shall be as
follows:
(a) Two pieces of completed cable and a mandrel of the size specified in Table J1 shall
be conditioned in a refrigerator at −15 ±2°C for a minimum of 4 h.
(b) While the temperature is maintained at −15 ±2°C, each test specimen shall be wound
around the mandrel for three close turns at a rate of approximately 12 turns per min.

79 AS 1049—2003
(c) While the test specimens are wound on the mandrel, each test specimen shall be
magnification.
TABLE J1
COLD BEND MANDREL DIAMETER
Cable construction Mandrel diameter 1)
No metallic shields or layers 8x
Metallic layers (including braid) directly over core 12x
Metallic layers other than those directly over core 15x
NOTE:
1) The mandrel diameter is a multiple of the nominal cable outside diameter.
J5.2.2 Cables over 12.5 mm

The testing procedure for sheath from cables greater than 12.5 mm overall diameter shall be
as follows:
(a) Two 4 ±0.5 mm wide samples of sheath of sufficient length to wind around the test
mandrel shall be taken.
(b) The sheath samples and a 4 mm diameter test mandrel shall be conditioned in a
refrigerator at −15°C for a minimum of 4 h.
(c) While the temperature is maintained at −15°C, each test specimen shall be wound
around the mandrel for three close turns at a rate of approximately 12 turns per min.
(d) While the test specimens are wound on the mandrel, each test specimen shall be
magnification.
J6 REPORT
Any cracking of the insulation, sheath or sheath material shall be reported.

AS 1049—2003 80
APPENDIX K
TEST METHOD 12: DETERMINATION OF HEAT SHOCK
(Normative)
K1 SCOPE
This Appendix sets out the method of determining the heat shock for insulation, sheath or
jacket.
K2 PRINCIPLE
A sample of the sheath or jacket is wrapped around a mandrel after conditioning and heated
for a set time and temperature. After cooling, the specimen is observed for cracks.
K3 APPARATUS
Mandrels and air oven as specified for the heat shock test (for resistance to cracking) in
AS/NZS 1660.2.3 are required.
K4 TEST SPECIMEN
The test specimen shall be prepared as specified for the heat shock test (for resistance to
cracking) in AS/NZS 1660.2.3.
K5 CONDITIONING
K6 PROCEDURE
(a) Insulation Tested in accordance with the heat shock test (for resistance to cracking)
in AS/NZS 1660.2.3 except for the following:
(i) The term ‘core’ shall mean a single insulated conductor.
(ii) The diameter of the mandrel shall be equal to the diameter of the insulated
conductor.
(b) Sheath Tested in accordance with the heat shock test (for resistance to cracking) in
AS/NZS 1660.2.3 except for the following:
(i) The test shall also apply to NHMH sheath.
(ii) The temperature for heating for NHMH sheath shall be 100 ±2°C.
K7 REPORT
The condition of the insulation, sheath or jacket shall be reported, i.e. whether or not the
specimens cracked.

81 AS 1049—2003
APPENDIX L
TEST METHOD 13: DETERMINATION OF ENVIRONMENTAL
STRESS-CRACKING
(Normative)
L1 SCOPE
This Appendix sets out the method for the determination of the susceptibility of PE to
environmental stress cracking when subjected to certain conditions of stress and the
presence of such environments as wetting agents, soaps, oils or detergents. The test is
applicable to PE taken from compound or sheath.
L2 PRINCIPLE
Conditioned specimens of PE are given a controlled imperfection, stressed and immersed in
a specified reagent. Any stress cracks are then observed and reported.
L3 DEFINITIONS
For the purpose of this Appendix, the definitions below apply.
L3.1 Stress crack
An internal or external rupture in a sample caused by tensile stresses exceeding its short
time mechanical strength.
NOTE: The development of such cracks is frequently accelerated by the environment to which the
polyethylene is exposed. The stresses which cause cracking may be present internally or
externally, or may be a combination of these stresses.
L3.2 Stress crack failure
Any crack visible to an observer using normal or corrected vision is interpreted as a failure
of the specimen. Extension of the controlled imperfection is not to be construed as a failure.
NOTE: Cracks generally develop at the controlled imperfection and run to the outer edge of the
specimen approximately at right angles to it. The cracks need not extend completely through the
specimen to constitute failure. Cracks sometimes develop under the polymer surface, manifesting
themselves as depressions of the surface. If these are observed at the specified minimum, the
observation time should be extended by 25%. If, at the end of the extended time, any of these
depressions have developed into a crack, they are considered a failure.
L4 APPARATUS
(a) A rectangular die to cut specimens of dimensions in accordance with Figure L8, with
square edges. Bevelled edges shall be avoided.
(b) A suitable (e.g. PE) cutting board on which to die-cut the specimens. The board shall
be renewed when the surface is damaged to the extent of affecting the test specimen,
i.e. causing the surface of the specimen to be scratched.
(c) A 5 L glass beaker of nominal dimensions 170 mm diameter and 270 mm high, with
watchglass to cover the beaker.
(d) Suitable containers for annealing the specimens. The container and rack shown in
Figures L1, L2 and L3 are suitable and aid in obtaining reproducible conditions for
the specimens and in identification and separation of batches. The tubes are screw top
aluminium, of nominal diameter 40 mm, and of nominal length 110 mm. The tubes
are perforated with smooth edged holes of not greater than 10 mm diameter.

AS 1049—2003 82
(e) An oven or airconditioned room maintained at a temperature of 23 ±2°C.

(f) A jig for making a controlled imperfection, of dimensions as shown in Figure L8, in
specimens, parallel to the long edge of the specimen and centred on one of the broad
faces. A typical jig is shown in Figure L4.
(g) Modified single-edged blades for use in the cutting jig. The dimensions are shown in
Figure L4. After modification, each blade shall be checked for length and
imperfections in the cutting edge.
(h) Bending clamp as shown in Figure L5.
(i) Transfer tool as shown in Figure L6.
(j) Specimen holders having the internal dimensions shown in Figure L7. The sides of
the channel shall be parallel and the inside corners sharp and square. Any burrs
present on the inside of the channel shall be removed. The inside width is critical.
The external shape and dimensions are not critical.
NOTE: A suitable material for the specimen holder is brass.
(k) Hard glass test tubes nominally 200 mm long, with a nominal outside diameter of
32 mm and wall thickness of about 2 mm.

(l) Tape or film-covered cork or rubber stoppers to seal the tubes.
(m) Constant temperature bath with stirrer, maintained at 50 ±0.5°C.
(n) Rack to hold test tubes in the temperature-controlled bath such that the test
environment in the tubes is below the water level in the bath.
(o) Light source to inspect the specimens during the test.
L5 REAGENT
The reagent for the test is a 100 g/kg solution of poly(ethylene glycol) mono(nonylphenyl)
ether.
NOTE: Crodox CO630 and Teric N9 have been found to be suitable.
The reagent shall be prepared the day before it is required. Weigh the required amount of
distilled or deionized water into a beaker, and slowly add the weighed amount of reagent to
the water. Stir the mixture gently, using a magnetic stirrer or similar agitation until solution
is complete. Do not heat the mixture to assist solution.
L6 PROCEDURE
L6.1 Test specimens
Test specimens shall be prepared as follows:
(a) A plaque shall be moulded in accordance with Appendix HH.
(b) Ten specimens shall be die-punched with the standard die so that they are cleancut,
square and with unbevelled edges. Specimens shall not be cut within 25 mm of the
edge of the plaque. A cutting board shall be used to prevent damage to either the
cutting edge of the die or the surface of the test plaque. The specimen shall be
removed from the die in such a way that the specimen is not marked or stressed.

83 AS 1049—2003
L6.2 Annealing of test specimens

Specimens shall be annealed as follows:
(a) Annealing shall be commenced not later than 24 h after moulding the plaque.
(b) The specimens shall be placed in a container capable of keeping them totally
immersed in 4.5 L to 4.7 L of boiling water in a covered 5 L beaker. The specimens
shall be kept in the boiling water for 60 ±5 min. The volume of the water at the end of
the boiling shall be not less than 4.5 L.
(c) The beaker containing the immersed specimens shall be placed in a controlled
atmosphere of 23 ±2°C, e.g. oven or airconditioned room for between 20 h and 24 h.
This allows an equilibration period at 23°C of at least 5 h.
L6.3 Making the controlled imperfections
Controlled imperfections shall be made in the test specimens as follows:
(a) The specimen shall be removed from the annealing bath and the controlled
imperfection made within 1 h.
(b) Prior to making the first notch, the cutting edge of the blade shall be inspected for
notches and burrs using a microscope with a magnification of at least x100.
(c) The blade shall be inserted into the cutting jig base as shown in Figure L4 and the
specimen shall be centrally placed on top of the blade. Using uniform pressure on the
handle a cut shall be made in one surface of the specimen. The procedure shall be
repeated for the other nine specimens.
(d) The cutting edge of the blade shall be inspected after 30 successive cuts and
discarded whenever there is any question of it having become dull or damaged. In no
case shall a blade be used for more than 100 cuts.
(e) The depth of the cut shall be checked with every renewed or reset blade by making a
controlled imperfection in an additional specimen and measuring the depth of cut at
both ends of the cross-section sample using a microscope with a calibrated graticule.
If one or both depths are outside the value for D given in Figure L8, the blade shall be
reset and the depth of cut thus obtained retested.
NOTE: The depth of notch can be controlled by the use of brass shim fitting over the blade in
the jig of Figure L4. The shim should be wide enough to fit snugly inside the jig channel and
long enough to extend over the blade around the end of the jig and under the jig. The weight
of the jig resting on the shim prevents deformation of the shim during the notching operation.
L6.4 Bending test specimens
The specimens shall be bent as follows:
(a) The ten specimens shall be placed with the controlled imperfection uppermost in the
slots provided in the bending clamp as shown in Figure L5. The clamp shall be closed
by means of a vice or other suitable equipment, taking between 30 s and 35 s for the
complete closing operation.
(b) The transfer tool, shown in Figure L6, shall be placed on top of the closed clamp,
closed over the specimens and then the specimens shall be lifted from the clamp and
placed in the channel of the specimen holder. Each specimen shall be pushed down by
finger pressure to ensure that it is seated on the base of the specimen holder.
(c) Not more than 10 min after the specimens have been bent into the holder, the holder
shall be inserted into a test tube. The test tube shall be filled with reagent to
approximately 13 mm above the top specimen. The tube shall be stopped with a tape
or film covered stopper.
(d) The test tube shall be placed in the temperature controlled water bath at 50 ±0.5°C.

AS 1049—2003 84
L6.5 Inspection of specimens

Specimens shall be inspected without removing them from the bath or test tubes.
L7 REPORT
Result of the assessment shall be reported.
FIGURE L1 SPECIMEN RACK SHOWING ONE TUBE IN POSITION
FIGURE L2 HOW MOVABLE BOTTOM PLATE IS ATTACHED TO ASSEMBLY AND

HOLDS TUBES IN POSITION
FIGURE L3 THE FIXED PLATE AND MOVABLE PLATE IN DETAIL

85 AS 1049—2003
FIGURE L4 NICKING JIG AND MODIFIED BLADE

FIGURE L5 BENDING CLAMP ASSEMBLY
FIGURE L6 TRANSFER TOOL

AS 1049—2003 86
FIGURE L7 SPECIMEN HOLDERS
FIGURE L8 SPECIMEN DETAILS

87 AS 1049—2003
APPENDIX M
TEST METHOD 14: DETERMINATION OF BOND STRENGTH
(Normative)
M1 SCOPE
This Appendix sets out the method for determining the degree of adhesion between the
integrally-bonded PE sheath and PA jacket.
M2 PRINCIPLE
Rectangular strips of the composite cable are prepared, and the PA jacket is stripped back at
180° from the PE sheath using a tensile machine. The bond strength is then calculated and
reported.
M3 APPARATUS
(a) Testing machine of the constant-rate-of-crosshead-movement type complying with the
requirements of a grade A machine of AS 2193.
(b) Grips which are self-aligning and of the pneumatic or self-tightening type which exert
a uniform pressure across the gripping surface.
(c) A double blade knife with the nominated blade separation in Paragraph M6.
(d) Single-edge knife.
(e) Needle-nosed pliers.
(f) Sheath-cutting tool.
(g) Water bath held at 60 ±2°C.
(h) Environment to safely store petrol at 23 ±2°C.
(i) Oven held at 80 ±2°C.
M4 AGEING
Sufficient cable sample, with core intact, to make at least 5 test specimens shall be aged in
each of the following ageing media prior to conditioning and testing of the bond strength;
each cable length to be aged in water and petrol, shall have the ends sealed by some suitable
means to prevent fluid from entering the cable:
(a) Water at 60 ±2°C for 30 days.
(b) Petrol at 23 ±2°C for 30 days.
(c) Air at 80 ±2°C for 30 days.
M5 CONDITIONING
The cable sample(s) shall be removed from each of the ageing media and conditioned at
23 ±2°C and 50 ±5% RH for a minimum of 16 h. Unaged samples shall be maintained in the
test laboratory at 23 ±2°C and 50 ±10% RH for a minimum of 48 h.

AS 1049—2003 88
M6 TEST SPECIMENS
Test specimens shall be prepared from the unaged and aged cable samples as follows:
(a) Five sections, approximately 250 mm long, shall be cut from each cable sample. All
of the core shall be removed, leaving only the PE sheath, PA jacket and the
aluminium moisture barrier if present. It shall be ensured that each section is straight.
(b) For cable samples with an overall diameter of less than 15 mm, the double blade knife
set shall have a blade separation of 3 ±0.25 mm. For other cables, the double blade
knife shall have a blade separation of 5 ±0.25 mm.
(c) While resting the cable sample on the bench, the double blade knife shall be used to
score the jacket starting at a point approximately 100 mm from one end of the sample.
The two cuts should be straight and the PA should be completely cut without
excessive penetration of the PE sheath.
(d) With the single-edge knife, the jacket shall be sliced into at a shallow angle, raising a
thin flap of sheath, as shown in Figure M1. The cut for this flap should start at the
point where the two parallel knife cuts begin.
FIGURE M1 COMMENCEMENT OF PA STRIP
(e) With the needle-nosed pliers, the flap of the jacket shall be gripped and pulled back
along itself, starting the separation of the PA jacket from the PE sheath as shown in
Figure M2. A free length of approximately 50 mm of PA jacket shall be peeled from
the sample.

89 AS 1049—2003
FIGURE M2 SEPARATION OF THE PA STRIP FROM THE PE

(f) A sheath-cutting tool shall be used to cut away some of the sheath and jacket, and a
tab of PE sheath shall be made to hold the test specimen in the tensile test machine.
This tab should be immediately opposite the separated strip of PA, approximately
25 mm long and no wider than the test section. Any aluminium laminate shall be
broken away from the back of the tab of PE sheath at the junction with the rest of the
test specimen by repeated flexing. The test specimen, ready for testing, is shown in
Figure M3.
NOTE: Breaking the metallic tape by flexing reduces the stiffness at the tab-cable intersection
and therefore allows for self-alignment of the test specimen in the tensile testing machine
during the test.
FIGURE M3 THE PREPARED TEST SPECIMEN
M7 PROCEDURE
(a) It shall be ensured that the test specimen is straight.
(b) The test specimen shall be centrally mounted in the jaws of the tensile testing
machine so that the PA jacket is stripped back upon itself at 180 +0, −5°. The tab of
the PE sheath should be gripped so that the test specimen is not obstructed by the
jaws of the tensile testing machine and free to pivot in either of two directions,
i.e. the plane containing the tab and the plane perpendicular to the tab.
(c) The test specimen shall be tested with a crosshead speed of 100 ±10 mm/min. An
average separation force shall be obtained over a separation length of at least 50 mm
as measured on the exposed PE sheath.

AS 1049—2003 90
In addition, the following procedures are also recommended:

(i) Test specimens should be excluded if the PA is pulled away from the sample at an
angle of less than 175° in either of the two directions described in M7(b).
Outside this limit the peel strength is artificially high.
(ii) Test specimens where the PA jacket fails to separate and a breakage occurs, may be
re-started by careful use of the single-edge knife and pliers, provided sufficient length
of the test specimen remains to complete the test.
(iii) The bond strength between the PE sheath and PA jacket can be high enough for the
test specimen to fail by either the PE sheath or PA jacket failing by elongating to
break. In this case, this result should be included in the report and the bond strength
for this sample considered satisfactory.
M8 CALCULATION
The bond strength for each of the test specimens shall be calculated using the following
equation:
Average force (N)

Bond strength (N/mm) = . . . M(1)
Width of strip (mm)
where
Width of strip = the measured blade separation of the double blade knife.
M9 REPORT
The median bond strength, in newtons per millimetre, shall be reported from a minimum of
five test specimens.

91 AS 1049—2003
APPENDIX N
TEST METHOD 15: DETERMINATION OF BENDING PERFORMANCE
(Normative)
N1 SCOPE
This Appendix sets out the method for determining the bending performance of the PA
jacket extruded over a cable. Both the unbonded and bonded cable construction is tested.
N2 PRINCIPLE
The completed cable with a PA jacket is bent around a mandrel and the behaviour observed.
N3 APPARATUS
The following mandrels for the specified cable types are required:
(a) Coaxial cables and cables with a copper screen between the sheath and jacket A
mandrel of 0.90 m or a maximum of 30 times the cable diameter, whichever is the
greatest.
(b) Other cables A mandrel whose diameter is a maximum of 30 times the cable
diameter.
N4 TEST SPECIMEN
The test specimen shall be a sample of completed cable with a PA jacket.
N5 CONDITIONING
The test specimen shall be conditioned by standing for 48 h after extrusion in the normal
factory atmosphere without any other treatment prior to testing.
N6 PROCEDURE
Directly after conditioning, the test shall be conducted, as follows:
(a) The cable shall be bent 360° around the mandrel.
(b) The cable shall be straightened and then bent 360° in the reverse direction around the
mandrel and again straightened.
(c) Steps (a) and (b) shall be repeated.
(d) The cable shall be inspected for any cracks or ripples.
N7 REPORT
Any cracks or ripples in the jacket shall be reported.

AS 1049—2003 92
APPENDIX O
TEST METHOD 16 AND 17: CONFIRMATION OF STABILIZER TYPE AND
DETERMINATION OF STABILIZER CONCENTRATION
(Normative)
O1 SCOPE
This Appendix sets out the method of confirming stabilizer type and determining
concentration in a PE compound, insulation and sheath. Other methods of determining
stabilizer type and concentration may be used provided that they have been demonstrated to
give an accuracy and precision of the same or higher degree than that of the method in this
Appendix. In the event of a dispute, the method of this Appendix should be the referee
method.
O2 PRINCIPLE
The stabilizer is extracted from the polymer and separated from other co-extracted materials
by high performance liquid chromatography (HPLC). The separated stabilizer is detected
photometrically and the response compared with known stabilizer standards,
chromatographed under identical conditions. The presence of stabilizers is identified by
comparison with known stabilizer standards, analysed under the same conditions. In this
method, mixtures of antioxidants or metal deactivators, or both, can be determined
individually by altering the chromatographic conditions.
O3 APPARATUS
(a) A high-performance liquid chromatograph comprising:
(i) Solvent delivery system with gradient elution capability and capable of
delivering solvent (eluent) to within ±1 percent of the specified flow rate.
(ii) Sample injector, 20 µL fixed-loop type.
(iii) Ultraviolet photometric detector, 8 µL to 20 µL by 10 mm long flow-through
cell and having a wavelength selector to enable measurements to be made at
280 nm and 305 nm to 313 nm.
(iv) 10 mV potentiometric chart recorder with 1 s time constant, or other equivalent
recording or data handling device.
(v) Chromatography column conforming to the type set out in Table O1.
(b) 1 × 250 mL Erlenmeyer flask, B24 neck.
(c) 1 × 250 mL Buchner flask, B24 neck.
(d) 1 × 250 mL and 1 × 400 mL squat form measuring beakers.
(e) 1 × 10 mL and 1 × 100 mL measuring cylinders.
(f) 100 mL measuring cylinder with stopper.
(g) 5 × 25 mL, 5 × 50 mL, 1 × 100 mL and 1 × 500 mL volumetric flasks complying with
B-grade requirements of AS 2164.
(h) 10 mL × 0.02 mL cup-top stopcock burette, complying with B-grade requirements of
AS 2165.

93 AS 1049—2003
(i) 1 × 1 mL and 1 × 5 mL graduated pipettes, complying with B-grade requirements of

AS 2166.
(j) 100 mm diameter Petri dish.
(k) Sintered disc Buchner funnel, 80 mm funnel diameter, 65 mm disc diameter and
porosity 3.
(l) Filter aid. (Whatman ‘ashless floc’ is suitable.)
(m) Sieve, 710 micrometres (µm) aperture complying with the requirements of AS 1152,
or equivalent.
(n) Liebig reflux condenser, B24 cone.
(o) Sample clarification kit, comprising—
(i) 10 mL Luer-Lok syringe;
(ii) 13 mm stainless steel swinny filter holder or equivalent; and
(iii) 13 mm diameter 0.5 µm teflon filters.
NOTE: Millipore sample clarification kit is suitable.

(p) Desiccator charged with silica gel.
(q) Spinbar, teflon coated.
(r) Hotplate-stirrer.
(s) Hot water bath.
(t) Rotary evaporator.
(u) Grinding apparatus, being either—
(i) Freezer Mill apparatus; or
(ii) Wiley Mill.
NOTE: Freezer Mill apparatus is available from Spex Industries, Metuchen, N.J., USA.
(v) Flexible teflon tube, 500 mm long, 3.2 mm inner diameter.
(w) Non-sterile 25 mm diameter nylon 0.45 µm PP housing filter.
O4 REAGENTS
O4.1 General
The following reagents shall be available:
(a) n-Hexane, low in aromatic hydrocarbons, HPLC grade.
(b) iso-Propanol, HPLC grade.
(c) Toluene, AR grade.
(d) Ethanol, AR grade.
(e) Ethyl acetate, HPLC grade.
(f) Diethyl ether, HPLC grade.
(g) Dimethyl formamide, HPLC grade.
(h) Liquid nitrogen for Freezer Mill.
(i) Compressed nitrogen gas, high purity.
(j) Antioxidants and metal deactivators as required. See Tables 2.1, 2.2, 7.1 and 7.2.

AS 1049—2003 94
O4.2 Eluents
All solvents used in the preparation of eluents for the HPLC analysis of stabilizers shall be
filtered through a 0.5 µm filter, deaerated and allowed to reach ambient temperature
(23 ±2°C) before mixing.
Using a volumetric flask, 500 mL of the appropriate eluent from Table O1 shall be
prepared.
TABLE O1
ELUENTS FOR USE IN THE HPLC ANALYSIS OF STABILIZERS
Stabilizer being determined Column type Eluent
Irganox 1010 Cyano Nitrile Mixture of iso-propanol: 1 volume
(CN) n-hexane: 99 volumes
Cyano Nitrile Mixture of iso-propanol: 15 volumes

Hostanox 03
Cyano Nitrile Mixture of diethyl ether: 2 volumes

Lowinox WSP (PQ)
Mixture of dimethyl formamide: 10 volumes
Cyano Nitrile
OABH ethyl acetate: 27 volumes
(CN)
n-hexane: 63 volumes
Cyano Nitrile Mixture of iso-propanol: 5 volumes
Irganox MD 1024
NOTE: Other chromatographic column and solvent combinations may be used to determine the type and
concentration of stabilizer, provided it can be demonstrated to give an accuracy and precision of the same
or higher degree than that obtained using the conditions stated in Table O1.
O5 TEST SPECIMEN
The test specimen shall be prepared as follows:
(a) The test specimen shall be samples of pellets, solid and cellular insulation, and sheath
which have been milled. Samples may require cutting or microtoming to a suitable
size to allow milling.
(b) For filled cables, insulation shall be sampled prior to contact with filling compound.
For unbarriered filled cables, sheath shall be sampled as extrudate from the extruder
head. Sheath from barriered filled cable and sheath and insulation from air-core
cables shall be sampled from the cable.
(c) Approximately 5 g of representative sample shall be ground cryogenically under
liquid nitrogen or in a Wiley Mill, such that it passes through a sieve with an aperture
of 710µm. The milled sample shall be spread in a Petri dish and dried over silica gel
in a desiccator for at least 30 min. Milling the sample too fine shall be avoided as
problems may be encountered in subsequent weighing operations due to static charge
build-up.

95 AS 1049—2003
O6 PROCEDURE
O6.1 Extraction of stabilizers
O6.1.1 Antioxidants
The procedure for the extraction of antioxidants shall be as follows:
(a) Approximately 1.5 g to 2 g of prepared test specimen shall be accurately weighed to
the nearest milligram into a 250 mL Erlenmeyer flask and 50 mL of toluene, using a
measuring cylinder and a spin bar stirrer shall be carefully added without splashing.
A reflux condenser shall be connected and placed on a hot plate stirrer. Stirring shall
be commenced slowly, to prevent sample particles from being splashed onto the sides
of the container. A steady stream of nitrogen gas shall be directed into the flask via a
teflon tube from the top of the condenser. The nitrogen purge shall be continued until
all the sample dissolves (10 min to 15 min). The teflon tube shall be removed and the
assembly raised 20 mm to 30 mm above the hotplate with the stirring continued. The
solution shall be allowed to cool slightly and 50 mL of a mixture (1:1) of ethanol and
ethyl acetate, using a measuring cylinder, shall be added from the top of the
condenser at a rate of 15 mL to 20 mL per min. Stirring shall continue for a further

10 min. The condenser and sides of the flask shall be washed with 5 mL ethanol/ethyl
acetate mixture (EEA). The stoppered flask shall then be placed in a
refrigerator (<10°C) for 30 min.
(b) A uniform bed of filter aid from a slurry (1.5 g to 2 g per 150 mL to 200 mL ethanol)
shall be deposited in a Buchner funnel and washed with 10 mL ethanol.
(c) The precipitated PE shall be filtered. The Erlenmeyer flask shall be rinsed with
10 x 7 mL EEA, at ambient temperature unless otherwise stated and the washings
shall be poured over the PE in the Buchner funnel. The PE shall be washed with
4 x 7 mL hot EEA and finally with 5 x 7 mL EEA. The filtrate shall be transferred to
a 400 mL squat beaker. The Erlenmeyer flask shall be rinsed with 4 x 7 mL EEA and
the combined washings added to the beaker. A few boiling chips shall be added and
the EEA-toluene mixture shall be evaporated to dryness on a hot water bath. A gentle
stream of nitrogen gas shall be directed at the liquid surface via a teflon tube for 1 h
to 1.5 h to assist in the evaporation. The residue shall be taken up with 15 mL
n-hexane and evaporated to dryness. Finally, the residue shall be taken up with 15 mL
of the appropriate eluent (see Paragraph O4.2) to be used in the HPLC analysis.
NOTE: A rotary evaporator may be used to remove the excess solvent.
(d) The beaker shall be heated on a hot water bath to almost boiling with occasional
swirling. The sides of the beaker shall be rinsed with 5 mL eluent and shall be
quantitatively transferred to a 50 mL volumetric flask. Filtration (Whatman no. 40
filter paper is suitable) may be necessary where there are appreciable amounts of
suspended material. The rinse and transfer procedure shall be repeated until the
volumetric flask is almost filled to the mark. The volume shall then be made up to the
mark with eluent.
O6.1.2 Metal deactivators
The procedure for the extraction of metal deactivators shall be as follows:
(a) The metal deactivator Irganox MD 1024 is extracted in accordance with
Clause O6.1.1.
(b) Approximately 0.5 g to 1.0 g of prepared test specimen shall be accurately weighed,
to the nearest milligram, into a 250 mL Erlenmeyer flask and then the procedure as
specified in Paragraph O6.1.1 shall be followed with the final solution being made up
to 100 mL rather than 50 mL.

AS 1049—2003 96
(c) OABH in solution is light sensitive, therefore all OABH solutions shall be kept in the
dark after preparation, e.g. by wrapping the standard flasks in aluminium foil.
O6.2 Preparation of standards
O6.2.1 General
Standard solutions shall be prepared as stated in Table O2. OABH solution shall be dealt
with in accordance with Paragraph O6.1.2(b) and (c).
O6.2.2 Stock solution
The appropriate stabilizer shall be weighed to the nearest 0.1 mg, into a 100 mL volumetric
flask to make the requisite concentration of stock solution shown in Table O2. The weighed
solid shall be dissolved in the solvent eluent in Table O1 and diluted to the mark. For
Irganox MD 1024, the weighed solid is dissolved in a minor solvent of the eluent of
Table O1. For all stabilizers except OABH, the ratio of solvent in the stock solution is that
for the eluent given in Table O1. For OABH, it shall be firstly dissolved in 50.0 mL
dimethyl formamide followed by dilution to the mark with ethyl acetate.
O6.2.3 Standard solution

The requisite number of standards of the concentration shown in Table O2 shall be prepared
by dispensing the stock solution into volumetric flasks with a 10 mL x 0.02 mL burette. The
volume shall be made up to such that the ratio of solvents in the standard solution is the
same as the eluent.
NOTE: It is understood that standard dilutions are made at the calibration temperature of the
volumetric container being used.
TABLE O2
PREPARATION OF STANDARD SOLUTIONS
Stabilizer being Stock solution Standard concentration
determined concentration, ppm and quantity
10, 25, 50, 75, 125 ppm
Lowinox WSP (PQ) 500
50 mL each
10, 25, 50, 75, 125 ppm
Hostanox 03 500
50 mL each
2, 5, 10, 15, 20 ppm
OABH 100
50 mL each
10, 25, 75, 125 ppm
Irganox 1010 500
50 mL each
10, 25, 50, 75, 125 ppm
Irganox 1024 250
25 mL each
NOTE: 1 ppm = 1 x 10 −3 grams solute per litre solvent.
O6.3 Chromatography conditions and analysis

O6.3.1 Chromatographic conditions
The chromatographic conditions shall be the following:
(a) Operation of column shall be at ambient laboratory temperature of 23 ±2°C in the
isocratic mode. All stabilizers except for Irganox 1010 shall be analysed in isocratic
mode.
(b) Eluents shall be as specified in Paragraph O4.2.

97 AS 1049—2003
(c) Eluent flow rates may be varied to give analysis times of 5 min to 10 min per
injection, provided there is no detriment to the resolution of the column to a degree
where overlap of adjacent peaks with the analyte peak results in more than 2 percent
error when based on peak height measurements. A 1.5 mL/min eluent flow rate is
suitable for all the stabilizers when employing a 150 mm x 4.6 mm inner diameter
stainless steel column packed with 5 µm Spherisorb CN and joined to a 50 mm guard
column of the same packing material.
(d) Sample injection volume shall be 20 µm for all stabilizers.
(e) Photometric detector wavelength setting shall be as follows:
(i) 280 nm for antioxidants and Irganox MD 1024 metal deactivator.
(ii) 305 nm to 313 nm inclusive for OABH.
(f) Recorder chart speed shall be 10 mm/min.
O6.3.2 Chromatographic analysis
Chromagraphic analysis shall be conducted as follows:
(a) The equipment shall be turned on and allowed appropriate warm-up time. The
photometric detector shall be set on an absorbance range between 0.02 and 0.05. Ten
column volumes of the appropriate eluent shall be pumped through the column at a
rate of 1.5 mL/min, by which time equilibrium and a steady baseline should be
achieved. A gentle stirring of the eluent shall be maintained throughout the analysis.
(b) Ten mL of the polymer extract solution, prepared in accordance with Paragraph O6.1,
shall be filtered through a 0.5 µm filter. The injector loop shall be flushed with a few
millilitres of eluent, then filled with the filtered polymer extract solution and injected
onto the column. Auto samplers may also be used in this procedure. The detector
attenuation shall be adjusted, if necessary, to give a peak height 20% to 60% of full
scale. The injection shall be repeated onto the column. The standard solutions shall be
run, starting with the lowest concentration, at the appropriate attenuation settings.
The loop shall be flushed with a few millilitres of eluent before each injection.
O7 CALCULATION
The following calculations shall be made:
(a) Plot a graph of standard solution concentration (ppm) against peak height (cm) or
peak area, after making due allowance for signal attenuation. Determine from the
calibration graph, the concentration of stabilizer in the final extract solution and
calculate the stabilizer content of the polyethylene using the expression given below.
(b) The concentration of stabilizer in the original polymer test sample is given by:
c× D
C=
m × 10 − 4
where
C = concentration of stabilizer in original polymer sample, percent, mass/mass
c = concentration of stabilizer in final solution-from calibration graph, ppm,
mass/volume
D = sample dilution, in mL
m = mass of polymer test sample taken, in g.
(c) Electronic integrators may also be used to calculate the stabilizer concentration.

AS 1049—2003 98
O8 CONFIRMATION
Confirmation of the stabilizer type shall be made by any one of the following procedures. If
there is any doubt about the identity of the stabilizer, then all three procedures shall be
followed:
(a) Comparison of the stabilizer retention time with the retention time of the stabilizer
Standard.
NOTES:
1 Peak shapes should closely resemble each other.
2 Spiking aliquot portions of the extract solution with stabilizers believed present is also
helpful as variations of retentions values, due to a number of factors, are eliminated.
(b) Correspondence of two retention values that are under comparison, under different
chromatographic conditions which change the chemistry of the separation process,
increases the probability of identification.
(c) Absorbency ratioing, using multiple wavelength photometric detection, to compare
absorption characteristics with known compounds run under the same conditions.
O9 ACCURACY
This method should give results, at the 0.1% level of stabilizer, accurate to ±2% of the
mean value.
O10 CHROMATOGRAPHIC COLUMN SPECIFICATION

O10.1 General
The chromatographic columns shall comply with the following requirements:
(a) The column tube shall be straight, have an inert inner wall and be packed in
accordance with Table O1.
(b) Effective column length shall be 150 mm to 300 mm inclusive.
(c) Inside diameter shall be 3.9 mm to 5.0 mm inclusive.
(d) Column packing average particle diameter shall be 5 µm to 10 µm inclusive.
NOTE: It is suggested that all connecting tubing to and from the column be kept as short as
possible to minimize extra column band broadening effects. Unions, where incorporated, are
also suggested to be of the 'zero dead volume (ZDV)' type.
(e) When tested under the conditions of Paragraph O10.2 and calculated according to
Paragraph O10.3 the Cyano-Nitrile column shall —
(i) exhibit an effective height equivalent to a theoretical plate of not greater than
0.085 mm ±0.005 mm; and
(ii) exhibit a peak asymmetry factor of not less than 0.60 ±0.05 (peak fronting) or
greater than 1.9 ±0.1 (peak tailing) at 10% of the peak height.

99 AS 1049—2003
O10.2 Test conditions

The system shall be equilibrated before making sample injections under the following
conditions:
Sample............................................................. 10 mg/L reference compound* in
50 mL/L iso-Propanol in n-Hexane.
Injection volume .............................................. 20 µL, via 20 µL fixed volume loop.
Eluent .............................................................. 50 mL/L iso-Propanol in n-Hexane.
Average linear eluent velocity .......................... 5.0 mm/s.
Detector wavelength......................................... 280 nm.
Detector cell..................................................... 8 µL to 20 µL inclusive by 10 mm
long.
Recorder chart speed ........................................ 50 mm/min.
* A suitable reference compound is 4,4'-Thiobis (2-tert-butyl-5-methylphenol) (e.g. Santonox R).
O10.3 Calculations
(a) Effective height equivalent to a theoretical plate (Heff ) The effective height
equivalent shall be calculated in terms of the following equations and Figure O1:
L
H eff = . . . O(5)
N eff
t'R 2
N eff = 16 . . . O(6)
Wb
t'R = tR − to . . . O(7)
where
Neff = effective number of theoretical plates
L = column length, in millimetres
Wb = projected tangent base width of the sample peak
tR = retention time of the sample
to = retention time of an unretained solute
t´R = nett retention time of the sample.
NOTE: Retention times and peak width are measured in the same units.
FIGURE O1 MEASUREMENT OF COLUMN EFFICIENCY

AS 1049—2003 100
(b) Asymmetry factor (S) The asymmetry factor shall be calculated from the following
equation and Figure O2:
B − tR . . . O(8)
S=
tR − A
FIGURE O2 MEASUREMENT OF SYMMETRY FACTOR
O11 REPORT
The stabilizer analysed and the stabilizer concentration (%) as calculated in accordance
with Paragraph O7 shall be reported. The positive confirmation of stabilizer type, achieved
in accordance with Paragraph O8, shall be reported.

101 AS 1049—2003
APPENDIX P
TEST METHOD 18: DETERMINATION OF COMPATIBILITY OF PE
INSULATION WITH FILLING COMPOUND
(Normative)
P1 SCOPE
This Appendix sets out the method for determining the compatibility of the PE insulated
conductors with the filling compound used, by testing the thermal stress cracking of test
specimens of insulated conductors cut from selected cables after contact with the filling
compound in the cable.
P2 PRINCIPLE
Insulated conductors taken from filled cables are twisted into a pigtail configuration to
induce uniform stresses and strain, aged in air at 100°C to 104°C and observed daily. The
time to initial failure (F i ), and the F 20 failure point, defined in Paragraph P6, are
determined.
P3 APPARATUS
(a) Squat-form beakers, 2 L.
(b) Identification tag.
(c) Micrometer, producing a contact pressure of 25 ±5 kPa and capable of reading to
0.01 mm.
(d) Forced air-circulating oven. Temperature controlled at 70 ±2°C.
(e) Forced air-circulating oven. No facility for air-change and temperature controlled at
100 +4, −0°C.
(f) Insulated wire twisting device as shown in Figure P1, consisting of the following:
(i) Electric motor and gear box to turn a spindle at a nominal 12 r.p.m.
(ii) Drill chuck connected to spindle of gear-box for holding a mandrel.
(iii) Mandrels of nominal size 0.8 to 2.1 mm diameter in increments of 0.1 mm.
Mandrel diameter tolerance is ±0.01 mm. (The shanks of metric sized drills
have been found satisfactory.)
(iv) Masses, which exert a stress of 15.0 ±0.1 MPa on the metal conductor.
P4 TEST SPECIMEN
(a) The appropriate length of cable shall be cut as specified in Table P1.
(b) Irrespective of the date of manufacture, the cable sample shall be conditioned for 14 d
at 70 ±2°C in order to ensure maximum uptake of the filling compound by the
insulation.
(c) All external coverings shall be removed and the appropriate number of insulated
conductors shall be selected as indicated in Table P1. Excess filling compound shall
be removed by carefully wiping with a paper towel. The first 100 mm of insulated
conductor shall be discarded from both ends and 150 mm long sections shall be cut
from the remainder.

AS 1049—2003 102
TABLE P1
NUMBER OF SPECIMEN LENGTHS FROM EACH INSULATED CONDUCTOR
FOR EACH CABLE SIZE
Cable size Minimum Number of
Number of 150 mm lengths cut from each
(pairs of length of insulated
insulated conductor
insulated cable conductors tested
(a total of 25 lengths)
conductors) m per cable
2 1.25 4 6 lengths from each conductor, plus 1 extra length
from any conductor
6 0.65 12 2 lengths from each conductor, plus 1 extra length
10 0.5 20 1 length from each conductor, plus 5 extra lengths
>10 0.35 25 1 length from 25 different conductors
(include all colours)
FIGURE P1 INSULATED WIRE TWISTING DEVICE

103 AS 1049—2003
P5 PROCEDURE
The procedure for determining compatibility by thermal stress cracking shall be as follows:
(a) The overall diameter of the insulated conductor and the diameter of the copper
conductor shall be measured and recorded to the nearest 0.01 mm.
(b) The smallest mandrel shall be secured in the drill chuck whose nominal diameter is
larger than the overall diameter of the insulated conductor.
(c) A mass shall be selected which will exert a stress of 15.0 ±0.1 MPa on the metal
conductor.
(d) The twisting device shall be set in motion. The chosen mass shall be attached to one
end of a 150 mm long section of insulated conductor, the other end shall be anchored
to the rotating drill chuck and the insulated conductor allowed to twist around the
mandrel.
(e) At least ten, 360-degree contiguous turns of insulated conductor shall be allowed to
be twisted around the mandrel. This twisted specimen is known as a 'pigtail', as
shown in Figure P2.
FIGURE P2 PIGTAIL WITH EYELET
(f) The pigtail shall be carefully slid from the mandrel. The straight portion of insulated
conductor shall be cut off from one end of the pigtail and an eyelet shall be formed
with the straight portion of the other end.
(g) All pigtails of one test shall be assembled together by threading a 200 mm length of
the same insulated conductor through the eyelets of all the pigtails. The ends of the
200 mm length shall be twisted together by hand, an end threaded through the
aluminium identification tag and the end twisted together again. This ensures the tag
does not touch the pigtails. This is known as an assembly of pigtails.
(h) Each assembly shall be hung in a 2 L beaker and placed in a forced air-circulating
oven without air change maintained at 100 + 4, −0°C. The time and date shall be
recorded. The twisting of pigtails and commencement of ageing shall be completed on
the same day.
NOTE: The assemblies are conveniently installed in the beakers by hanging them from a
heavy gauge insulated conductor which has been tied around the outside top rim and then
across the open end of the beaker. The assemblies should not touch the sides of the beaker.
Beakers are used to reduce cross-contamination of stabilizing systems therefore only
assemblies with the same stabilizer system may be hung together in the same beaker.
(i) The pigtails shall be examined for failures at intervals of 24 h. The test may be
terminated if the time to initial failure (F i ) exceeds 85 days. Refer to Table 2.2. If
failures do occur before this time, the pigtails shall be observed until at least 70% of
the pigtails have failed or until 150% of the time given as the minimum F 20 value in
Table 2.2 is reached.

AS 1049—2003 104
(j) Two types of failure have been observed but both failure modes shall be combined for
the purpose of the calculations. The two types are as follows:
(i) One, or more usually, a number of small circumferential cracks along the
pigtail.
NOTE: A crack is defined as any circumferential break in the insulation which is
visible to normal or corrected vision. Cracks appearing on the turn at either end of the
pigtail should be ignored.
(ii) Unzipping effect where part or whole of the exposed insulation unzips along the
metal conductor from a single insulation break.
P6 CALCULATIONS
(a) The failure data shall be arranged in a cumulative frequency table with intervals of
one day. Observation times when no specimens have cracked shall be ignored.
(b) The probability for each cumulative failure point shall be calculated using the
following equation:
100( j − 0.5) . . . P(1)
Ρj =
n
where
j = the cumulative number of failed specimens at a given observation time
n = the total number of specimens.
NOTE: For n = 25, Pj = 4j − 2.
(c) The time to fail against probability shall be plotted on linear-probability graph paper
and the line of best fit drawn (either a straight line or curve, depending on the data).
(d) The time indicated at the intersection of the data line and the 20 percent probability
line shall be defined as the F 20 failure point.
NOTE: It is sometimes observed that a small number of pigtails fail (notably by unzipping) in
a comparatively short time and the remaining pigtails pass the requirement. In these cases
where two failure distributions occur, the early failure data is plotted to ascertain if the F 20
failure point for this data meets the requirement. If the data cannot be plotted because of
insufficient points, then the time the fifth pigtail failed is taken as the F 20 failure point.
An example of the calculation is shown in Table P2 and the data plotted in Figure P3. From
the data and the graph, F i = 55 d and F 20 = 59 d. The total number of specimens in this
example is 25.

105 AS 1049—2003
TABLE P2
EXAMPLE OF CALCULATION
Time to crack No. of specimens Cumulative no. Probability
d cracked cracked (j) 100( j − 0.5)
n
54 0 0 —
55 3 3 10
57 1 4 14
58 1 5 18
59 1 6 22
62 2 8 30
69 5 13 50
70 1 14 54
72 1 15 58
76 6 21 82
78 1 22 86
80 1 23 90
83 1 24 94
86 1 25 98

AS 1049—2003 106
P7 REPORT
The F i or F 20 time, as appropriate, shall be reported as calculated in Paragraph P6.
FIGURE P3 EXAMPLE OF CALCULATION

107 AS 1049—2003
APPENDIX Q
TEST METHOD 19: DETERMINATION OF CORROSION
(Normative)
Q1 SCOPE
This Appendix sets out the method of determining the corrosive properties of insulation on
copper wire.
Q2 PRINCIPLE
The presence of corrosion on the copper conductor is noted after a specimen of PVC
insulated copper conductor is heated at 80°C for 500 h and then held at 95% RH at 40°C for
168 h.
Q3 APPARATUS
(a) Air oven capable of operating at 80 ±1°C, of the closed type, with forced air
circulation and preferably with no air changes or, alternatively, with 3 to 10 air
changes per hour.
(b) Enclosure capable of operating at 40 ±2°C and 95% to 100% RH.
Q4 TEST SPECIMEN
The test specimens shall be five 200 mm lengths of insulated copper conductor cut from the
completed cable.
Q5 CONDITIONING
Q6 PROCEDURE
(a) The specimens of insulated conductor shall be maintained at a temperature of
80 ±2°C for 500 h in an air oven.
(b) The test specimens shall be transferred to a suitable test chamber and exposed for a
further 168 h in an atmosphere held at 95% to 100% RH at a temperature of 40 ±2°C.
(c) The specimens shall be allowed to cool to room temperature and then the insulation
shall be carefully removed.
(d) The conductor surface shall be visually examined and compared with untreated
samples for corrosion, including salts, which have been formed as a result of the test.
Q7 REPORT
The condition of the copper conductor compared to untreated samples shall be reported.

AS 1049—2003 108
APPENDIX R
TEST METHOD 20: DETERMINATION OF VOLATILE LOSS
(Normative)
R1 SCOPE
This Appendix sets out the method of determining the volatile loss for insulation, sheath or
jacket.
R2 PRINCIPLE
The volatile loss is determined from the loss of weight per square metre of insulation,
sheath or jacket after heating the specimen for 120 h.
R3 APPARATUS
A forced air circulation oven with 3 to 10 air changes per hour, capable of operating at the
specified temperature in Table R1, is required. The test specimens shall not occupy more
than 0.5% of the working volume of the oven.
TABLE R1
AGEING TEMPERATURES FOR PPO AND PVC
Section Material Application Ageing temperature
°C
4 PPO insulation Telecommunication switch cable 80 ±1
5 and 10 PVC insulation Telecommunication switch cable 80 ±1
and sheath/jacket
All other cable:
75°C rating 100 ±2
90°C rating 115 ±2
105°C rating 120 ±2
R4 TEST SPECIMEN
R4.1 Insulation
The test specimen taken from insulation shall be prepared as follows:
(a) Five test specimens, each 150 ±1 mm in length, shall be prepared from each sample
of insulated conductor.
(b) The outside diameter of each test specimen shall be accurately measured in several
places and the mean diameter calculated.
(c) Each test specimen shall be weighed.
(d) Each test specimen shall be loosely twisted for one turn over a mandrel approximately
4 mm in diameter.

109 AS 1049—2003
R4.2 Sheath or jacket

The test specimen taken from sheath or jacket shall be prepared as follows:
(a) Two test specimens, each 150 ±1 mm in length and without any longitudinal cuts,
shall be prepared. The specimens are to be prepared from either sheath or jacket that
has been carefully slipped off a completed cable sample.
(b) The outside diameter on each test specimen shall be accurately measured in several
places and the mean diameter calculated.
(c) Each test specimen shall be weighed.
(d) The two open ends of each test specimen shall be plugged with cotton wool or a
similar material that will not adhere to the specimen.
R5 PROCEDURE
The test shall be conducted as follows:
(a) The test specimens shall be maintained at the specified temperature in Table R1 for
120 h in an air circulating oven.

(b) The specimens shall be allowed to cool to 23 ±2°C, re-weighed and the loss in weight
determined.
R6 CALCULATIONS
(a) The volatile loss for each test specimen shall be determined using the following
equation:
Weight loss (g)
Volatile loss(g/m 2 ) = × 2122 . . . R(1)
Sample diameter (mm)
(b) The volatile loss shall be calculated as the mean of the five results.
(c) Alternatively the mean of the volatile loss can be calculated on the total weight loss
using the following equations:
Total weight loss (g)
Mean volatile loss for insulation (g/m 2 ) = × 424.4 . . . R(2)
Mean sample diameter (mm)
Total weight loss (g)

Mean volatile loss for sheath (g/m 2 ) = × 1061 . . . R(3)
Mean sample diameter (mm)
R7 REPORT
The volatile loss in grams per square metre shall be reported.

AS 1049—2003 110
APPENDIX S
TEST METHOD 21: DETERMINATION OF CARBON BLACK
CONCENTRATION
(Normative)
S1 SCOPE
This Appendix sets out the method for determining the carbon black content of compounds
or of sheath and jacket material taken from completed cable.
Other methods of determining the carbon black content may be used provided that they
have been demonstrated to give an accuracy of the same or a higher degree than that of the
method in this Appendix. In the event of a dispute, the method of this Appendix shall be the
referee method.
S2 PRINCIPLE
The carbon black content is determined by heating a sample of the material at 500°C to
completely decompose the material and hence leave the carbon black as a residue.
S3 APPARATUS
(a) Combustion boat, the minimum dimensions of which are length 75 mm, width 9 mm
and height 8 mm.
(b) Hard glass combustion tube of bore approximately 30 mm and length 400 ±50 mm.
(c) Supply of nitrogen free from oxygen.
(d) Means for measuring and controlling a rate of flow of nitrogen of 1.7 ±0.3 L/min.
(e) Means for measuring temperatures from 300°C to 550°C, e.g. thermometer.
(f) Furnace to accommodate the combustion tube and to give temperatures up to at least
500°C.
(g) Desiccator.
(h) Balance to weigh to 0.1 mg.
S4 TEST SPECIMEN
The test specimen shall be taken from compound, sheath or jacket.
S5 PROCEDURE
(a) The combustion boat shall be heated to red heat, allowed to cool in the desiccator for
at least 30 min and weighed to the nearest 0.1 mg.
(b) 1.0 ±0.1 g of the test specimen shall be placed in the boat and the whole shall be
weighed to the nearest 0.1 mg.
(c) The boat and the sample shall be placed in the middle of the hard glass combustion
tube. A stopper carrying the temperature-measuring device and a tube for the
admission of nitrogen shall be inserted into one end of the combustion tube. The
temperature measuring device should touch the boat.

111 AS 1049—2003
(d) Nitrogen shall be passed through the combustion tube at 1.7 ±0.3 L/min and this rate
maintained during the subsequent heating.
(e) The furnace shall be heated so that the temperature is between 300°C and 350°C after
about 10 min, about 450°C after a further 10 min, and 500 ±5°C after a third period of
10 min. This temperature shall be maintained for a further 10 min.
(f) At the end of this time, the tube containing the boat shall be withdrawn from the
furnace and allowed to cool for 5 min with the flow of nitrogen being maintained as
before.
(g) The boat shall be removed from the combustion tube through the nitrogen inlet end,
allowed to cool in the desiccator for 20 min to 30 min and re-weighed to the nearest
0.1 mg.
(h) The temperature of the furnace shall be allowed to reduce to 300°C or less between
successive determinations.
S6 CALCULATIONS
The carbon black content of the material under test shall be calculated as follows:
mass of residue
Carbon black content, (g/kg) = × 1000 . . . S(1)
mass of sample
S7 REPORT
The carbon black concentration in grams per kilogram shall be reported.

AS 1049—2003 112
APPENDIX T
TEST METHOD 22: DETERMINATION OF CARBON BLACK DISPERSION
(Normative)
T1 SCOPE
This Appendix sets out the method for determining the dispersion of carbon black in
compound, sheath or jacket.
Other methods of determining the carbon black dispersion such as ISO 18553 may be used
provided that they have been demonstrated to give an accuracy of the same or a higher
degree than that of the method in this Appendix. In the event of a dispute, the method of
ISO 18553 shall be the referee method.
T2 PRINCIPLE
The carbon black dispersion is determined by preparing the specimens by either of two
methods and then comparing these specimens at a magnification of x 100 with that of
standard photomicrographs. The hot-stage method of preparation squeezes a small specimen
of the material into a thin layer between microscope slides at a temperature high enough to
melt the material. The cut method of preparation microtomes or razor cuts the specimens.
T3 APPARATUS
(a) Hotplate.
(b) Microscope slides.
(c) Microscope capable of at least a linear magnification of 100 and a circular field of
view of 0.7 ±0.07 mm in diameter.
(d) Microtome or razor.
T4 TEST SPECIMEN
T4.1 Hot stage preparation for compound
Specimens of material shall be prepared as follows:
(a) Two clean microscope slides shall be placed on the hotplate maintained at 170°C to
210°C.
(b) Six samples, each of approximate mass 0.2 mg, shall be cut.
(c) The six specimens shall be placed on one of the hot microscope slides so that each
one is approximately equidistant from its neighbour(s) and from adjacent edge(s) of
the slide.
(d) The second slide shall be placed over the first and the specimens pressed out by
applying an even pressure for 1 min to 2 min over the whole area of the face of the
upper slide. An amount of pressure shall be exerted for a period necessary for each
specimen to be pressed out to a thickness of between 20 µm and 30 µm.
NOTE: Shims of metal or some other suitable material may be used to achieve the required
specimen thickness and uniformity of thickness.
(e) After the specimens have been placed on the slide, that the slide shall not remain on
the hotplate for more than 3 min.
(f) The slide shall be removed from the hotplate and allowed to cool.
113 AS 1049—2003
T4.2 Cut preparation for sheath and jacket

Specimens shall be prepared as follows:
(a) Six separate radial samples shall be microtomed or razor-cut to a thickness between
10 µm and 20 µm.
(b) The sections shall be placed on a microscope slide and covered with another slide.
NOTE: It may be convenient to add a small amount of castor oil to the sections in order to
obtain a clearer view.
T5 PROCEDURE
(a) Each of the six specimens shall be examined through a microscope at a linear
magnification of x 100 ±10 and with a circular field of view of 0.7 ±0.07 mm in
diameter, using any suitable means to ensure that the correct field of view is obtained.
(b) The whole of each specimen shall be scanned and the worst field of view of each
compared with the standard photomicrographs numbered 1 to 7 (a graded series from

best to worst) shown in Figures T1 and T2. The comparison shall be made with
respect to the number and size of agglomerates, taking into consideration all black
particles in the field of view.
(c) A numerical rating corresponding to the number of the photomicrograph equivalent to
the worst field of view of each specimen shall be assigned to each of the six
specimens. The overall rating of the material shall be calculated as the average of the
six ratings rounded to the nearest whole number.
(d) The six specimens shall also be examined for uniformity of appearance with respect
to smears and streaks. The worst field of view for each specimen shall be compared
with photomicrograph A of Figure T2. It shall be noted whether the specimen appears
better or worse in relation to the standard photomicrograph.
T6 REPORT
The following information shall be reported:
(a) A numerical rating shall be assigned to each specimen in relation to the comparison
with the standard micrographs, in accordance with Paragraph T5(b). The average
shall be calculated and reported as an overall rating of the material.
(b) The specimens shall be compared with standard micrograph A in accordance with
Paragraph T5(d) and the result of the comparison reported.

AS 1049—2003
114
FIGURE T1 PHOTOMICROGRAPHS 1 TO 4
115
FIGURE T2 PHOTOMICROGRAPHS 5 TO 7 AND A

AS 1049—2003
AS 1049—2003 116
APPENDIX U
TEST METHOD 23: DETERMINATION OF COLOUR DIFFERENCE BY
VISUAL ASSESSMENT
(Normative)
U1 SCOPE
This Appendix sets out the method for determining the colour of specimens of insulation
and sheath/jacket cut from the finished cable.
U2 PRINCIPLE
Insulation and sheath/jacket is viewed under standard lighting conditions by an operator
with good colour vision and the test specimens are compared with the selected colour
standard.
U3 APPARATUS
(a) Colour matching booth meeting the minimum specification of AS 4004 for daylight
illuminant or, a colour assessment area illuminated by either natural daylight from
north-facing windows or fluorescent tubes of correlated colour temperature 6500 K,
colour rendering index greater than 92 and minimum illuminance of 1000 lx.
(b) Colour cards from EIA 359-A, EIA Standard colour identification and coding, and
wire and cable limit chips.
(c) Colour cards from IEC 60304.
(d) Colour cards either from fandeck or as an individual colour from AS 2700, both
purchased separately from the standard. The accompanying colour chart in the
standard shall not be used for colour matching.
(e) White cards with a hole cut in them the same size as the area of the colour of the
standard colour cards.
NOTE: The white cards are used to cover the standard colour and the sample and therefore
give the same background colour when comparing colours.
U4 TEST SPECIMEN
U4.1 Insulation
For air-core cables the test specimen shall be insulation and for filled cable, the test
specimen shall be insulation prior to contact with filling compound prepared as follows:
(a) Sufficient 50 mm lengths of the same sample of insulation shall be cut to give a
15 mm to 20 mm width when the lengths are laid side by side.
(b) The lengths shall be laid on a piece of masking tape to keep them together as a mat.
U4.2 Sheath/jacket
Sufficient sheath/jacket shall be cut from the cable to enable a colour comparison.

117 AS 1049—2003
U5 PROCEDURE
(a) The operator shall be ensured to have good colour vision as assessed by a suitable
colour vision test, e.g. the Farnsworth Munsell 100-Hue Test.
(b) The test specimen and the Standard, open at the page of the relevant colour, shall be
placed under the light source so that they are illuminated at 45° and viewed at 90°, or
the reverse of this. A white card shall be placed over the standard colour and the
sample.
(c) One of the three standard colour cards shall be used, as follows:
(i) EIA 359-A as the standard colour card The test specimen shall be compared
with the nominated colour of the centroid and limit colour cards of the standard
from Table U1 by separately assessing the attributes of hue, value and chroma
in turn. The colour of the test specimen shall be deemed unacceptable if it
obviously falls outside any of the limits. If there is any doubt, then the
specimen shall be acceptable.
NOTE: The test specimen being assessed may vary in more than one of its Munsell
attributes; e.g. it may be both lighter in colour and of a different hue to the centroid. In
this case the lightness is assessed against the light (value) limit, and the hue against the
hue limit.
(ii) IEC 60304 or AS 2700 as the standard colour card The test specimen shall be
compared with the single nominated colour of the Standard. The colour of the
test specimen shall be deemed acceptable if it is reasonably close to the colour
of the Standard and can not be confused with any other colour of the Standard.
U6 REPORT
The result of the assessment carried out in accordance with Paragraph U5(c), as to whether
the insulation or sheath/jacket is within the limits stated, shall be reported.

AS 1049—2003 118
TABLE U1
MUNSELL COLOUR CENTROIDS AND TOLERANCE LIMITS FOR PLASTICS
Hue Value Chroma
Colour Centroid
−− ++ −− ++ −−
H H V V C C ++
Red 2.5R 4/12 10RP 4/12 5.5R 4/12 2.5R 3.5/12 2.5R 5/12 2.5R 4/10 None
Orange 2.5YR 6/14 10R 6/14 5YR 6/14 2.5YR 5/14 2.5YR 7/12 2.5YR 6/10 None
Brown 2.5YR 3.5/6 7.5R 3.5/6 7.5YR 3.5/6 2.5YR 2.5/6 2.5YR 4.5/6 2.5YR 2.5YR
3.5/4.5 3.5/8
Yellow 5Y 8.5/12 1.25Y 8.5/12 8.75Y 8.5/12 5Y 7.5/12 None 5Y 8.5/8 None
Green 2.5G 5/12 9GY 5/12 5G 5/12 2.5G 4/10 2.5G 6/12 2.5G 5/8 None
Blue 2.5PB 4/10 7.5B 4/10 5PB 4/10 2.5PB 3/10 2.5PB 5.2/10 2.5PB 4/8 None
Violet 2.5P 4/10 10PB 4/10 5P 4/10 2.5P 3/10 2.5P 5.5/10 2.5P 4/5.5 None
White N 9/ — N 8.75/ None 5R 9/1 5G 9/0.5
5YR 9/1 5B 9/0.5

5Y 9/1 5P 9/0.5
Grey N 5/ N 4.5/ N 6/ 5R 5/0.5 5B 5/0.5
—
5Y 5/0.5 5P 5/0.5
5G 5/0.5
Black N 2/ None N 2.3/ 5R 2/0.5 5B 2/0.5
—
5Y 2/0.5 5P 5/0.5
5G 2/0.5
Cloud N 22 5.5Y — — —
grey
7.9/0.5
Manilla Y45 2.2Y — — —
8.4/2.8
NOTE: The centroid values for the colours cloud grey and manilla are taken from AS 2700. The remainder of this table
is taken from the Wire and Cable Limit Chip table of EIA 359-A.

119 AS 1049—2003
APPENDIX V
TEST METHOD 24: DETERMINATION OF COLOUR DIFFERENCE BY
INSTRUMENTAL ASSESSMENT
(Normative)
V1 SCOPE
This Appendix sets out the method for determining the colour difference between a colour
reference standard and the material.
V2 PRINCIPLE
A plaque manufactured from the material is instrumentally measured for colour and
compared to an agreed colour.
V3 APPARATUS
A suitable colour meter which includes a spectrophotometer meeting the requirements of
AS/NZS 1580.601.3 is required.
V4 TEST SPECIMENS
A plaque shall be moulded by any appropriate means, with sufficient thickness such that
light is not transmitted through it. The sample plaque shall be of uniform surface finish and
free from defects.
V5 PROCEDURE
(a) The spectral reflectance characteristics of the test specimen shall be measured in
accordance with AS/NZS 1580.601.3 using a spectrophotometer, 10-degree Standard
Observer, Standard Illuminant D 65 , diffuse illumination/normal geometry (d/0),
specular component included, wavelength range 380 to 700 nm and wavelength
increment of 20 nm or less.
(b) The spectrophotometer shall be calibrated using the manufacturer’s instructions.
(c) The CIE L*a*b* colour coordinates of the reference standard shall be measured
according to the manufacturer's instructions. These coordinates (Ls *as*bs*) may be
retained for future reference provided that the same colour meter is used to measure
the test specimen.
(d) The CIE L*a*b* colour coordinates of the test specimen shall be measured at three
points on the sample. The average colour coordinates (Lt *a t*bt *) of the sample shall
then be calculated.
V6 CALCULATION
The colour difference (∆E*ab ) between the colour reference standard and the test specimen
shall be calculated as follows:
∆E ∗ab = ( Ls ∗ − Lt ∗) 2 − (as∗ − at ∗) 2 − (bs ∗ − bt ∗) 2
V7 REPORT
The colour difference, ∆E* ab , shall be reported.

AS 1049—2003 120
APPENDIX W
TEST METHOD 25: QUALITATIVE EVALUATION OF BLEEDING OF
COLORANTS
(Normative)
W1 SCOPE
This Appendix sets out the method of qualitatively evaluating the suitability of a colorant
added to a plastic, by examining the tendency of the colorant to bleed from the plastic into
another material when they are in close contact with one another at an elevated temperature.
NOTE: Refer to the definition of colour bleeding in Clause 1.5.2.1.
W2 PRINCIPLE
An insulated conductor sample of the colour to be tested is twisted together with a white
insulated conductor (or an insulated conductor of contrasting colour if white is not possible)
and heated in an oven at the specified temperature for 24 h. The sample is cooled and then
untwisted, and then the white/contrasting insulated conductor is examined for any colour
bleeding.
W3 APPARATUS
An air oven capable of maintaining a temperature as specified in Table W1 for the sample
type with a tolerance of ±2°C is required.
TABLE W1
INSULATION TEMPERATURE RATINGS AND OVEN AGEING TEMPERATURES
Temperature
Section Insulation
°C
75 90 105 125 150 200 250
2 PE
3 PA 12
4 PPO
5 PVC
6 PP
12 ECTFE
ETFE
FEP
PFA
PTFE
PVDF
13 PEFR
14 SRPVC
15 XLPE
XLPVC
XLEVA
XLPO
NOTE: Where there is a choice of temperature for a material, the oven ageing temperature shall be the same
as the temperature rating for the particular grade being tested.

121 AS 1049—2003
W4 SPECIMENS
The test and control specimens shall be prepared as follows:
(a) The specimen shall be an insulated conductor of approximately 300 mm in length.
(b) The control specimen shall also be an insulated conductor which is prepared in the
same manner as the test specimen. It shall be the same plastic as that used in the test
specimen, but shall be white or a contrasting colour.
W5 PROCEDURE
(a) The test specimen and control specimen shall be twisted together so that there is one
complete turn every centimetre.
(b) The sample shall be suspended in the air oven at the temperature specified in
Table W1 for 24 h.
(c) The sample shall be removed and allowed to cool to ambient temperature.
(d) The sample shall be untwisted and the control specimen examined for any colour
bleeding.
W6 REPORT
Any colour bleeding shall be reported.

AS 1049—2003 122
APPENDIX X
TEST METHOD 26: DETERMINATION OF COLOURFASTNESS TO
DAYLIGHT
(Normative)
X1 SCOPE
This Appendix sets out the method for determining the effect of exposure to daylight on the
colour of the specimens of insulation, sheath or jacket.
X2 PRINCIPLE
Specimens of insulated wire, or sheathed or jacketed cable are exposed to daylight, under
glass where the effects of wind and rain are excluded. The exposure period is standard 5 of
the blue dyed wool standards (see Table X1), after which any colour change in the
specimens is determined visually by comparison with the unexposed specimens using the
ISO Grey Scale.
X3 APPARATUS
(a) Exposure rack The exposure case shall consist essentially of an open-bottomed box
covered with a framed lid of glass and containing a removable rectangular rack for
carrying the test specimens and standards. The rack shall rest upon a supporting
screen made of wire cloth, and ventilating holes covered with wire mesh made from
corrosion-resistant material shall be provided in the upper side of the exposure case.
An example of the apparatus and nominal dimensions is given in Figures X1 and X2.
The exposure case shall be situated in the open, facing true north.
The exposure case shall be so placed that no obstruction in an easterly, northerly or
westerly direction subtends an angle of more than 20 degrees with the horizontal at
the centre of the case. No obstruction in a southerly direction shall subtend an angle
of more than 70 degrees with the horizontal at the centre of the case.
(b) Lid The lid of the exposure case shall consist of a framed sheet of good quality flat
glass 3 mm thick, uniformly transparent and without defects, and having a
transmittance of approximately 90% at 370 nm and throughout the visible region of
the spectrum and a transmittance of less than 1% at 300 nm and shorter wavelengths.
NOTE: To maintain these characteristics it is usually necessary to replace the glass at
intervals of not more than two years.
The lid shall be spaced from the rack carrying the specimens to ensure adequate
ventilation, and its unobstructed area shall be greater than that of the rack to avoid
shading. The lid shall fit snugly and symmetrically into the case.
(c) Rack The removable rack shall consist of horizontal wooden battens attached at each
end to side frames, as shown in Figure X1. The battens shall be arranged apart as
shown in Figure X2.
A series of flaps made from an inert material may be hinged to the battens so that part
of each specimen is covered. The material used and the holder design shall take
account of the need to minimize heat build-up in the specimen.
The rack should fit snugly into the exposure case with the lower surface resting
immediately on the upper surface of the wire screen.

123 AS 1049—2003
(d) Wire screen The screen shall be made from corrosion-resistant woven wire cloth with
mesh aperture about 0.16 mm.
It shall be supported on a rectangular frame, removable for cleaning, which fits
snugly into the exposure case.
(e) Blue dyed wool standards Blue dyed wool standards 1 to 5, as specified in
AS 2001.4.1.
(f) Grey Scale Grey Scale for assessing change of colour, as specified in AS 2001.4.1.
In this scale, Grade 1 corresponds to the greatest degree of contrast and Grade 5 to
zero contrast (two samples of identical colour).
(g) Colour matching booth Colour matching booth meeting the minimum specification
of AS 4004 for daylight illuminant or a colour assessment area illuminated by either
natural daylight from north-facing windows or fluorescent tubes of correlated colour
temperature 6500 K, colour rendering index greater than 92 and minimum
illuminance of 1000 1ux.
X4 TEST SPECIMEN
The test specimens shall be prepared as follows:
(a) For air-core cable the test specimen shall be insulated wire, and for filled cable the
test specimen shall be insulated wire taken prior to contact with the filling compound.
(b) A sufficient sample of insulated wire, or sheathed or jacketed cable, shall be taken for
five specimens of each colour for exposure and five specimens of each colour for
comparison.
(c) The comparison specimens shall be stored in the dark at room temperature.
X5 PROCEDURE
X5.1 Mounting of test specimens
Test specimens shall be mounted as follows:
(a) The specimens shall be attached using a clamping device of inert material or by tying
to adjacent battens so that the central portion which is used for determination of
colour change spans the space between battens. A space of 6 mm shall be allowed on
each side of each set of five specimens for ventilation. Any solid backing shall be
avoided.
(b) If desired, a portion of each test specimen may be covered by an opaque cover
throughout the test. This gives an unexposed area adjacent to the exposed area for
comparison. This is useful for checking the progress of exposure but the data reported
shall always be based on the contrast with the unexposed comparison specimens.
X5.2 Mounting of standards
The standards adjacent to the test specimens shall be attached to adjacent battens, e.g. by
using a clamping device of inert material, so that the central portion which is used for
determination of colour change spans the space between battens.
X5.3 Glass lid
The glass lid of the exposure case shall be kept clean during the test.

AS 1049—2003 124
X5.4 Determination of exposure stage

A set of blue dyed wool standards comprising one strip each from standards 1 to 5 shall be
exposed simultaneously with the test specimens for 24 h/day. The standards shall be used to
determine the stages of radiation dosage (exposure stages) in accordance with Table X1,
comparing the difference in contrast between the exposed and unexposed blue standards
with contrast grade 4 on the Grey Scale. Thus, Stage 1 is reached when Standard 1 gives a
contrast equal to grade 4 on the Grey Scale, Stage 2 when Standard 2 shows a similar
contrast, and in the same manner to Stage 5 showing a contrast of 4 on the Grey Scale.
TABLE X1
EXPOSURE STAGES
Description
Stage reached Contrast of blue Equal to contrast of
standard Grey Scale grade
1 1 4
2 2 4
3 3 4
4 4 4
5 5 4
X5.5 Determination of change in colour after exposure

Colour change in the specimens shall be determined as follows:
(a) At Stage 5 of the exposure period, any colour change in the specimens shall be
visually determined by comparing the contrast between the exposed and comparison
specimens kept in the dark with the steps of the Grey Scale.
(b) The comparison shall be made in a colour matching booth so that the specimen and
Grey Scale are illuminated at 45 degrees and viewed at 90 degrees or the reverse of
this.
The degree of colour change is the number of the Grey Scale step which shows
similar contrast to that between the exposed and comparison specimens. The term
'colour change' includes not only true fading by the destruction of colouring matter,
but also changes in hue, depth, brightness or any combination of these characteristics.
(c) If the contrast lies between two steps of the Grey Scale an intermediate rating shall be
given; e.g. a rating 3 to 4 indicates that at the stated exposure stage the contrast
between the exposed specimen and the comparison specimen was greater than Grey
Scale 4 but less than Grey Scale 3.
X6 REPORT
The result shall be reported as follows:
(a) The numerical value of the colour change.
(b) The nature of the colour change, variation in gloss or appearance of surface defects,
e.g. marbled appearance, exudation, efflorescence or cracking shall be recorded.

125
FIGURE X1 EXPOSURE CASE

AS 1049—2003
AS 1049—2003
126
FIGURE X2 RACK
127 AS 1049—2003
APPENDIX Y
TEST METHOD 27: DETERMINATION OF COLOURFASTNESS TO WATER
(Normative)
Y1 SCOPE
This Appendix sets out the method for determining the effect on colour of specimens of
insulation, sheath or jacket when heated in water.
Y2 PRINCIPLE
Samples of insulation, sheath or jacket are heated in water and any discolouration of the
water observed.
Y3 APPARATUS

(a) 100 mL beaker with watch-glass.
(b) Oven maintained at 50 ±1°C.
(c) Nessler cylinders, of suitable capacity.
Y4 TEST SPECIMEN
Y4.1 Insulation
The test specimens from insulation shall be prepared as follows:
(a) For air-core cables the test specimen shall be insulation, and for filled cables the test
specimen shall be insulation prior to contact with filling compound.
(b) The metal conductor shall be removed from sufficient insulation to provide
approximately 5 g of test specimens.
(c) The insulation shall be cut into approximately 5 mm lengths.
Y4.2 Sheath or jacket
The test specimens from sheath or jacket shall be prepared as follows:
(a) For filled cable, the sheath shall be removed from the cable and the filling compound
shall be wiped from the inner surface with a soft cloth.
(b) Sufficient sheath or jacket shall be removed to provide approximately 5 g of test
specimens.
(c) The sheath or jacket shall be cut into approximately 5 mm lengths.

AS 1049—2003 128
Y5 PROCEDURE
The procedure for determining whether the material is colourfast to water at 50°C shall be
as follows:
(a) The test specimens and 50 mL of distilled water shall be placed into a 100 mL beaker.
The beaker shall be covered with a watch glass.
(b) The assembly shall be placed in an oven at 50 ±1°C for 24 ±1 h.
(c) At the end of this time, the water shall be poured into a Nessler cylinder of suitable
size and examined for any colouration by viewing vertically through the length of the
column of liquid against a white background. For comparison, distilled water shall be
used in an identical Nessler cylinder.
Y6 REPORT
Any colouration of water shall be reported.

129 AS 1049—2003
APPENDIX Z
TEST METHOD 28: PLASTICIZER COMPATIBILITY
(Normative)
Z1 SCOPE
This Appendix sets out the method for determining the plasticizer compatibility in PVC
insulation, sheath or jacket.
Z2 APPLICATION
This test may be applied to compounds, to material taken from insulated conductors or to
the sheath or jacket taken from completed cable.
Z3 PROCEDURE

(a) A moulded sheet of the material under test shall be prepared in accordance with the
procedure outlined in Appendix II and with a thickness of 1.25 ±0.1 mm.
(b) From this sheet, a strip 25 ±1 mm wide and 100 ±1 mm long shall be cut. This piece
shall be folded through 180 and clamped so that the distance from the clamp to the
outside of the fold is 20 ±1 mm.
(c) The folded sample shall be stored for a minimum of 24 h at 23 ±3°C and 60 ±5% RH.
At the end of this time the inner surface of the loop shall be examined for drops of
liquid or signs of greasiness.
Z4 REPORT
Any drops of liquid or signs of greasiness shall be reported.

AS 1049—2003 130
APPENDIX AA
TEST METHOD 29: VOLUME RESISTIVITY
(Normative)
AA1 SCOPE
This Appendix sets out the method for determining the volume resistivity of an insulating
material.
AA2 PRINCIPLE
A sample of insulated core is immersed in water and the resistance of the insulation
measured.
AA3 APPARATUS

(a) A suitable d.c. voltage supply.
(b) A suitable resistance bridge.
AA4 TEST SPECIMEN

AA4.1 Insulation conductors
The test specimen shall be of a length to provide a minimum of 5 m of insulated conductor
for immersion.
AA4.2 Completed cables
A minimum of 5 m of completed cable shall have the sheath carefully removed, avoiding
damage to the underlying insulated conductors. Individually screened insulated conductors,
pairs, triples or quads shall have the screens removed. The test specimen shall be of a
length to provide a minimum of 5 m of the insulation conductor for immersion.
AA5 PROCEDURE
(a) A minimum of 5 m of the test specimen shall be immersed in water at room
temperature with the ends well clear of the water.
(b) At the end of one hour immersion, a voltage of 500 ±50 V d.c. shall be applied
between each conductor and water. The water shall be electrically connected to earth.
The resistance shall be measured between 1 min and 5 min after the application of the
voltage.
(c) Immediately after completion of the test in Step (b), and while still immersed in
water, the test specimen shall be raised to 60 ±1°C by heating the water.
Alternatively, the test specimen may be immersed in water heated to 60 ±1°C. The
test specimen shall be maintained at the relevant temperature for a minimum of 2 h.
The resistance shall again be measured as in Step (b).

131 AS 1049—2003
AA6 CALCULATION
The volume resistivity shall be calculated as follows:
2πlR
ρ= . . . AA(1)
 D
log n  
d
where
ρ = volume resistivity, in ohm metres
l = length of insulated conductor immersed in water, in metres
R = measured resistance, in ohms
D = outer diameter of insulation, in millimetres
d = inner diameter of insulation, in millimetres.
AA7 REPORT
The volume resistivity of the test specimen shall be reported.

AS 1049—2003 132
APPENDIX BB
TEST METHOD 30: DIELECTRIC STRENGTH
(Normative)
BB1 SCOPE
This Appendix sets out the method for determining the resistance of insulation materials to
direct electric current. The test is applicable to insulated conductors or to completed cables.
BB2 PRINCIPLE
A sample of insulated conductor or completed cable is immersed in water, subjected to a
direct voltage and any breakdown of the insulation noted.
BB3 APPARATUS
A stable d.c. voltage supply with a suitable means of detecting breakdown of the insulation
is required.
BB4 TEST SPECIMEN

The test specimen shall be a sample of insulated conductor or completed cable.
BB5 PROCEDURE
(a) In the case of insulated conductors, a length of not less than 5 m shall be immersed in
water at room temperature for 1 h. The voltage shall be applied for 1 min between the
conductor and the water. The water shall be electrically connected to earth.
(b) In the case of multicore cables with individually screened insulated conductors, the
voltage shall be applied for 1 min between each insulated conductor and the metallic
screen or covering.
(c) In the case of multicore cables with screened pairs, triples or quads, the voltage shall
be applied for 1 min between each conductor and the other conductor(s) connected to
the screen.
(d) In the case of multicore cables without individually screened insulated conductors,
pairs, triples or quads, the voltage shall be applied for 1 min between each insulated
conductor and all adjacent insulated conductors and if present, the metallic coverings.
The conductors may be suitably connected in groups to reduce the number of tests.
(e) The direct voltage shall be gradually raised to 2.8 kV and maintained at that value for
1 min.
BB6 REPORT
Any breakdown of insulation shall be reported.

133 AS 1049—2003
APPENDIX CC
TEST METHOD 31: SPARK TEST
(Normative)
CC1 SCOPE
This Appendix sets out the method for determining the resistance of insulation to an applied
d.c. voltage during manufacture. This method is applicable only to insulated conductors.
CC2 PRINCIPLE
A sample of insulated conductor is subjected to an applied d.c. voltage and any faults noted.
CC3 APPARATUS
The apparatus as specified in AS/NZS 1660.3 shall be used.
CC4 PROCEDURE
The procedure as described in AS/NZS 1660.3 shall be followed, except that the voltages
used in that Standard shall be replaced by the voltages in Table CC1.
TABLE CC1
SPARK TEST VOLTAGES FOR TYPES OF INSULATION
Conductor Radial thickness Spark test
Section Insulation diameter of insulation voltage
mm mm kV d.c.
0.32 0.09 (min) 1.0
0.40 0.12 to 0.16 1.1
Cellular PE*
0.64 0.17 to 0.25 1.3
2 0.90 0.22 to 0.35 1.7
0.40 0.16 (min) 2.5
Solid PE* 0.60 0.25 (min) 7.5
0.90 0.35 (min) 10.0
3 PA 12 All All 2.5
4 PPO All All 2.5
5 PVC All All 2.5
6 PP All All 2.5
12 Fluoropolymer All All 2.5
13 PEFR All All 2.5
14 SRPVC All All 2.5
15 Crosslinked polymer All All 2.5
* If a spark test is required on polyethylene insulation of a different dimension to that specified in the
above table the test voltage chosen shall be by agreement between the purchaser and supplier.
CC5 REPORT
All spark test faults shall be reported.

AS 1049—2003 134
APPENDIX DD
TEST METHOD 32 AND 33: DETERMINATION OF DIELECTRIC
DISSIPATION FACTOR AND RELATIVE PERMITTIVITY
(Normative)
DD1 SCOPE
This Appendix sets out the method for determining the dielectric dissipation factor and
relative permittivity of PE compound.
DD2 PRINCIPLE
The liquid displacement method consists of determining the small change of capacitance
(∆C) resulting when two essentially identical plaques of PE 1.27 ±0.12 mm thick are placed
in separate slots of 1.52 ±0.05 mm width between the fixed parallel plate electrodes of the
test cell. The cell contains standard liquid silicone oil having a precisely known relative
permittivity and chosen to be as close as possible to that of the PE under test. From the
determined change of capacitance, the dimensions of the cell and specimens, and the known
relative permittivity of the liquid at test temperature, the relative permittivity, K, of the PE
is calculated. The dielectric dissipation factor, D, of the PE is calculated from
measurements on the cell with—
(a) the liquid alone; and
(b) the test specimens immersed in it.
DD3 APPARATUS
(a) Measuring circuit A resonant-rise circuit (Q-meter) having a capacitance sensitivity
and readability of approximately 0.01 pF and a dissipation factor sensitivity and
readability of at least 1 x 10-5 .
(b) Leads and connectors Low-loss coaxial leads with small solid copper alligator clips
for connecting the cell to the measuring instrument. The leads should be as short as
possible, about 150 mm long.
(c) Measuring cell A suitable cell in which the test specimens are immersed in the
liquid is shown in Figure DD1, comprising a two-terminal, central, rectangular, gold-
plated brass electrode 6.35 mm thick, having flat parallel faces each of 5806 mm2 in
area. This electrode is supported by five polytetrafluoroethylene post insulators and
is located midway between two gold-plated brass electrodes which form an integral
part of the outer walls of the cell. The standard spacing between plates shall be
1.52 ±0.05 mm. The centre electrode slides in grooves and can be removed to permit
easy cleaning. The cell is equipped with an overflow pipe in order to maintain a
constant level of the liquid with the test specimen either in or out.
(d) Thermometer A thermometer having a range from 18°C to 28°C and complying with
the requirements for Thermometer 23°C of ASTM E1.
(e) Standard liquid Silicone liquid of viscosity 1.0 mm2 /s, dielectric dissipation factor
less than 5 x 10 -6 and a relative permittivity of nominal value 2.299 at 1 MHz. When
purchasing the standard liquid, the relative permittivity at 23.0°C and the temperature
coefficient for relative permittivity should be obtained from the manufacturers. The
liquid may be reused until an increase in dielectric dissipation factor exceeds 1 x 10−5.
NOTE: Silicone liquid is available from Ajax Chemicals.

135 AS 1049—2003
DD4 TEST SPECIMEN

Test specimens shall be prepared as follows:
(a) Two plaques of thickness 1.27 ±0.12 mm shall be moulded for each determination in
accordance with Appendix HH using—
(i) pellets; or
(ii) pellets plus colour masterbatch at the concentration used in the production
process.
(b) Test specimens of dimensions 68.3 mm x 100 mm shall be cut from the plaques.
(c) The plaques/test specimens shall be kept in suitable envelopes and handled only with
metal tweezers. The dielectric properties of moulded PE compounds are adversely
affected by surface contamination, sunlight and moisture. Care should be exercised
not to fingerprint the test specimens or in any way contaminate them prior to test.
(d) The thickness of each test specimen shall be measured to the nearest 0.01 mm. Five
measurements for each plaque shall be made; one in the centre and one near each
corner. The overall average (t) shall be calculated from 10 measurements.
DD5 CONDITIONING OF TEST SPECIMENS, CELL AND STANDARD LIQUID

All specimens shall be conditioned in the standard atmosphere of 23 ±1°C and
50 ±2 percent relative humidity for a period of not less than 40 h immediately before being
tested.
The cell and the standard liquid held in a container shall also be stored in the standard
atmosphere for a sufficient length of time to reach the specified temperature. The
temperature of the specimens and liquid shall be exactly the same to obtain the desired
degree of accuracy.
DD6 PROCEDURE
DD6.1 Preliminary
The procedure for the determination of relative permittivity and dielectric dissipation factor
for PE shall be as follows:
(a) The area (A) of both faces of the centre electrode shall be determined, in square
millimetres.
(b) The average spacing between the plates shall be measured in millimetres.
(c) A high-Q coil of 100 µH or greater shall be connected to the 'coil' terminals of the Q-
meter. The coil should not rest on the case of the Q-meter. The order of connection is
not important.
(d) The cell shall be connected to the capacitor terminals of the Q-meter using the low-
loss leads and connectors. The outer conductor (screen) of the coaxial leads shall be
connected to the shield terminal of the Q-meter. The order of connection is not
important. The thermometer shall be inserted into the cell.
DD6.2 Cell containing standard liquid only
The procedure to determine Q1 shall be as follows:
(a) The cell shall be filled slowly with the standard liquid, about 50 mL, either directly
from the original bottle or from a chemically clean glass container equipped with a
small glass tube. The cell shall be filled until a small quantity flows out of the
overflow tube into a catch bottle.
(b) The frequency of 1 MHz shall be selected on the Q-meter.

AS 1049—2003 136
(c) ∆C shall be selected to zero and the capacitance shall be adjusted to give resonance.
Resonance occurs when the maximum value of Q is obtained.
(d) The ∆Q circuitry shall be switched on and ∆Q set to zero. The ∆Q circuitry shall then
be switched off and Q checked. The Q value shall be recorded as Q1.
DD6.3 Determination of system constant
The system constant, B, is a constant of the measuring circuit and only needs to be
determined once for each series of measurements. The procedure to determine B shall be as
follows:
(a) A Q value, Q´ 1 shall be selected on one side of the resonance Q1. The capacitance
CV1 shall be recorded.
(b) The circuit shall be tuned through resonance noting that Q1 is the same as before and
then to Q´ 2 where Q´ 1 Q´ 2 . The new reading of capacitance CV2 shall then be
recorded.
(c) Using Equation DD(2) given in Paragraph DD7, the value of B shall be calculated.
(d) The procedure in Steps (a) to (c) shall be repeated for another two values of Q´ 1. The
value of B used in the calculation of the dielectric dissipation factor shall be the
arithmetic mean of the three calculated values.
(e) The Q-meter shall be returned to resonance, Q1.
DD6.4 Cell containing standard liquid and PE
The procedure to determine T, ∆C and ∆Q shall be as follows:
(a) The two test specimens shall be carefully inserted between the plates of the test cell
using clean metal tweezers.
(b) The ∆Q circuitry shall be switched on and ∆C adjusted to give a minimum value for
∆Q. The values for both ∆C and ∆Q shall be recorded. ∆Q is always positive while
∆C may be either positive or negative. The sign of ∆C shall always be taken into
account in the calculations.
(c) The temperature of the standard liquid shall be recorded.

137 AS 1049—2003
DD7 CALCULATIONS
The relative permittivity (Kp) and the dielectric dissipation factor (D), of the PE at 23°C
shall be calculated using the following equations:
Kp = K T + 0.0013 (T − 23.0) . . . DD(1)

D = B ∆Q t . . . DD(2)
o
(Q1 - ∆Q ) (C + ∆C )t
o
where
KT = relative permittivity of the PE at the test temperature
(Co + ∆C )
= Ko
(Co − M∆C )
Ko = relative permittivity of the standard liquid at the test temperature
= K 23 + Tc (T − 23.0)
K 23 = relative permittivity of the standard liquid at 23.0°C
Tc = temperature coefficient for relative permittivity of the standard liquid
T = test temperature, in degrees celsius
Co = a constant for the cell at a given temperature
= K o C v (pF)
8.8583 × 10 −3 A
C v (pF) =
to
A = area of both faces of the centre electrode, in square millimetres
to = average spacing of the cell electrodes, in millimetres
∆C = change in cell capacitance when the specimens are inserted, in
picofarads. (May be positive or negative.)
to
M = −1
t
t = the overall average thickness of the specimens, in millimetres
CV 1 − CV 2
B = 1/ 2
2
 Q1 
2   − 1
 Q'1 
|CV1 − CV2| = capacitance change (pF) required to tune the measuring circuit from
a conveniently selected Q voltmeter reading Q´ 1 on one side of the
resonance, through resonance, and back again to the value of Q´ 1 on
the other side of the resonance
Q1 = resonance value of Q when the cell contains the standard liquid only
∆Q = decrease in Q when the specimens are inserted.
DD8 REPORT
The values of relative permittivity (Kp) and dissipation factor (D) calculated shall be
reported.

AS 1049—2003 138
DD9 REFERENCE
Thomas Hazen, Recent Improvements in Methods of Measuring the Dielectric Constant and
Loss Characteristics of Polyethylene for Primary Insulation of Communication Cables,
Proceedings of the 13 th International Wire and Cable Symposium. December 2–4, 1964.
FIGURE DD1 LIQUID DISPLACEMENT TEST CELL

139 AS 1049—2003
APPENDIX EE
TEST METHOD 34: DETERMINATION OF COMBUSTION
(Normative)
EE1 SCOPE
This Appendix sets out the method of determining the combustion for insulation, sheath or
jacket.
EE2 PRINCIPLE
The combustion of the specimen is determined in an apparatus for measuring the minimum
oxygen concentration by igniting the specimen in atmosphere of known oxygen
concentration and observing the time for the flame to extinguish and the length of specimen
burnt.
EE3 APPARATUS
(a) Main equipment The description and calibration of the equipment for conducting
this test is specified in AS/NZS 2122.2.
NOTE: A suitable apparatus is the Critical Oxygen Index Flammability Tester described by
Stanton-Redcroft. Other apparatus may be used if results are comparable.
(b) Igniter A soft yellow flame issuing from an orifice of 2 ±1 mm diameter. The flame
fuel shall be LPG and the supply adjusted so that the flame is burning within the
chimney and the flame projects approximately 10 mm vertically from the orifice.
EE4 TEST SPECIMEN

EE4.1 Insulation
Four lengths of insulated conductor shall be loosely twisted together such that there is one
complete twist of the unit every 20 to 40 mm. The length of the specimen shall be not less
than 80 mm.
EE4.2 Sheath or jacket
A test specimen approximately 100 mm long and 7 ±1 mm wide shall be cut from the sheath
or jacket of completed cable.
EE5 CONDITIONING
The test specimen shall be conditioned at 23 ±2°C for a minimum of 16 h.
EE6 PROCEDURE
(a) The test specimen shall be clamped vertically in the centre of the glass column with
the top of the specimen at least 100 mm below the top of the open column.
(b) The concentration of gases flowing up the column shall be set as specified in
Table EE1.

AS 1049—2003 140
(c) The temperature of gases flowing up the chimney shall be 23 ±2°C at the
commencement of each test. The gas flow rate in the column shall be 40 ±10 mm/s
calculated at standard temperature of 0°C and pressure of 760 mm Hg from a total
flow of gas, measured in cubic millimetres per second, divided by the cross-sectional
area of the column, measured in square millimetres.
(d) The gas shall be allowed to purge for at least 30 s. The top of the specimen shall be
ignited for 10 s with the igniter.
(e) The time for the burning to cease after removing the igniter and the length of the test
specimen burnt shall be observed, including that initially burnt by the igniter.
(f) In the event of the first test specimen failing the test, two further test specimens from
the same sample shall be tested and both shall pass for the material to be accepted.
TABLE EE1
MINIMUM OXYGEN CONCENTRATION FOR
PPO, PVC AND NHMH
Minimum oxygen
Section Material concentration
%
4 PPO 30
5, 10 PVC 28
11 NHMH 30
EE7 REPORT
The results of the test shall be reported as a pass or a fail, including whether additional test
specimens were tested according to Paragraph EE6(f).

141 AS 1049—2003
APPENDIX FF
TEST METHOD 35: SIMULTANEOUS DETERMINATION OF IGNITABILITY,
FLAME PROPAGATION, HEAT RELEASE AND SMOKE RELEASE
(Normative)
FF1 SCOPE
This Appendix sets out the method of determining the simultaneous determination of
ignitability, flame propagation, heat release and smoke release for sheath or jacket.
FF2 PRINCIPLE
The test procedure is based on AS/NZS 1530.3. The main difference between this Appendix
and AS/NZS 1530.3 is the preparation of specimens and the reporting of results.
The test specimen consists of multiple lengths of abutting cables (a core of a 64 wire,
0.40 mm copper conductor insulated with PPO and sheathed or jacketed with NHMH) held
in a vertical plane parallel to a radiant heater. The specimen is moved towards the heater in
steps over a period of 20 min or until ignition, induced by a pilot flame, occurs.
The sheath or jacket on the cable may be classified according to—
(a) the tendency to ignite;
(b) the tendency to spread flame;
(c) the heat developed once ignition has occurred; and
(d) the tendency to produce smoke.
Having a sheath or jacket which meets this specification allows this sheath or jacket to be
used on any cable construction including an optical fibre cable. For different cable designs,
different values for the four criteria may be obtained. For the purposes of this Appendix the
performance of these other cable designs is not considered. It is the sheath or jacket that is
specified, not the cable design itself.
FF3 APPARATUS
(a) Apparatus conforming with the requirements for test apparatus in AS/NZS 1530.3.
(b) A 450 mm × 600 mm backing board of 5 ±0.5 mm thickness. The backing board shall
have the following properties at 20°C and 65% RH:
(i) Density of 1300 ±100 kg/m 3 .
(ii) Conductivity at 100°C of 0.3 ±0.05 W/(m.K).
(iii) A specific heat of 850 ±100 J/(kg.K).
NOTE: Hardiflex has been found to be satisfactory.
FF4 TEST SPECIMEN

(a) The test specimen is a single layer of 64 wire/0.4 mm AXE exchange cable which is
attached to a flat panel.

AS 1049—2003 142
NOTES:
1 A suitable cable is Telstra Serial/Item No. 323/6868, manufactured in accordance with the
latest issue of the Telstra Internal Cable Schedule.
2 Ageing of the test specimens may be needed to establish specimens typical of the cable
used.
(b) Nine test specimens shall be prepared, each 600 ±5 mm x 450 ±5 mm.
(c) The test specimens shall be prepared by fixing sufficient 600 mm lengths of cable
side by side to cover the 450 mm width of the backing board. The cables shall be
packed as closely as possible. The cables shall be held onto the backing board either
by wire ties of diameter not exceeding 1 mm or by nailing from the back of the board
into the cables.
NOTE: Cables may need to be straightened prior to being fixed on the backing board.
FF5 CONDITIONING
The test specimens shall be conditioned in an atmosphere having a temperature of 20 ±2°C
and 65 ±5% RH for a minimum of 7 d.
FF6 PROCEDURE
(a) The apparatus shall be calibrated in accordance with the requirements for calibration
in AS/NZS 1530.3.
(b) The test shall be conducted in accordance with the requirements of AS/NZS 1530.3.
Only six of the nine specimens shall be initially evaluated in accordance with the
requirements for computations for individual specimens in AS/NZS 1530.3.
(c) The remaining three specimens shall be tested, if required, in accordance with the
requirements for supplementary testing in AS/NZS 1530.3. If supplementary testing is
required, the results shall be based on all nine specimens.
FF7 REPORT
The values of ignition time in minutes, flame spread time in minutes, heat evolved in
kilojoules per square metre and optical density in inverse metres (m− 1) shall be reported.

143 AS 1049—2003
APPENDIX GG
TEST METHOD 36: DETERMINATION OF DRIP
(Normative)
GG1 SCOPE
This Appendix sets out the method of determining the drip for the sheath or jacket
manufactured from NHMH.
GG2 PRINCIPLE
The specimen is ignited by a Bunsen burner and the drip characteristics are observed.
GG3 APPARATUS
(a) Apparatus to allow the specimen to be held as described in Paragraph GG7(a) and
Figure GG1.
(b) Bunsen burner, typically a barrel length of 100 mm and internal diameter of 9.5 mm.
The barrel may be equipped with an end attachment such as a stabilizer.
(c) Dry, absorbent surgical cotton.
GG4 REAGENT
Technical grade methane gas or other gas mixture having a heat content of approximately
37 MJ/m 3 is required.
GG5 TEST SPECIMEN

All specimens shall be cut from a representative sample of the sheath or jacket. A plaque
may need to be compression moulded. The thickness of the specimens shall be 1.1 to
1.5 mm. After any cutting operation, care shall be taken to remove all dust and any particles
from the surface; cut edges shall have a smooth finish.
GG6 CONDITIONING
The test specimens shall be conditioned at 23 ±2°C and 50 ±5% RH for a minimum of 48 h.
GG7 PROCEDURE
Directly after conditioning, the procedure for determination of drip shall be as follows:
(a) Clamp the specimen from the upper 6 mm of its length with the longitudinal axis
vertical so that the lower end of the specimen is 300 mm above a horizontal
50 mm x 50 mm layer of dry, absorbent surgical cotton thinned to a maximum
uncompressed thickness of 6 mm.
(b) With the central axis of the burner tube vertical, set the burner to produce a blue
flame 20 ±2 mm high by adjusting the gas supply and air ports of the burner until an
approximately 20 mm yellow-tipped blue flame is produced and then increase the air
supply until the yellow tip disappears. Measure the height of the flame again and
adjust it if necessary.

AS 1049—2003 144
(c) Apply the flame of the burner centrally to the middle point of the bottom edge of the
specimen so that the top of the burner is 10 mm below the point and maintain it at the
distance for 10 s, moving the burner as necessary in response to any changes in the
length or position of the specimen.
(d) If the specimen drips molten or flaming material during the flame application, tilt the
burner at an angle of up to 45° and withdraw it just sufficiently from beneath the
specimen to prevent material from dropping into the barrel of the burner while
maintaining the 10 mm spacing between the centre of the outlet of the burner and the
remaining portion of the specimen, ignoring any strings of molten material.
After the application of the flame to the specimen for 10 s, immediately withdraw the
burner to a distance of at least 150 mm away from the specimen.
(e) When this specimen ceases flaming, immediately place the burner again under the
specimen and maintain the burner at a distance of 10 mm from the remaining lower
edge of the specimen for 10 s while moving the burner clear of dropping material as
necessary, as described in Step (c).
(f) After this application of the flame to the specimen for 10 s, immediately extinguish
the burner or remove it to a distance of at least 150 mm from the specimen.
(g) Note whether any particles or drips fall from the specimen and, if so, whether they
ignite the cotton pad.
(h) Repeat the procedure until at least 10 specimens have been tested.
GG8 REPORT
The sheath or jacket shall be reported on, as to whether or not the test specimens dripped
flaming droplets that ignited the cotton indicator.

145
FIGURE GG1 DRIP TEST APPARATUS

AS 1049—2003
AS 1049—2003 146
APPENDIX HH
PREPARATION OF COMPRESSION MOULDED PE PLAQUE
(Normative)
HH1 SCOPE
This Appendix sets out a procedure for preparing compression moulded plaques of PE for
use in other test methods.
HH2 PRINCIPLE
Where moulded test specimens are required they are prepared by homogenizing the material
on a two-roll mill to form a crepe and then compression moulding the crepe to form a
plaque from which the test specimens are die-punched.
The main stages in the compression moulding are as follows:

(a) The heating of the press platens to the moulding temperature.
(b) The filling of the mould with the crepe.
(c) The closing of the mould slightly and waiting until the temperature of the material
has risen sufficiently.
(d) The application of pressure to the material so that it will flow into the shape of the
mould.
(e) The cooling of the material under pressure to a temperature sufficiently low to permit
removal of the moulded part without causing deformation.
HH3 APPARATUS
(a) Two-roll mill capable of operating at a temperature high enough to flux the PE
material.
(b) Moulding press of the hydraulic type and capable of applying to the moulding
material a pressure (the ratio of clamping force to area of the mould cavity) of at least
7 MPa. The pressure shall be maintained to within 0.1 MPa during the moulding
cycle.
The platens shall be capable of being heated to at least 200°C and cooled at a rate of
6°C/min to 11°C/min. The temperature variation across the surface of the platens
shall be less than 5°C at the nominated moulding temperature.
(c) A single cavity flash (picture frame) mould of corrosion-resistant, hard chromed steel
polished on all surfaces. Table HH1 is a guide to the depth of chase which will give
the specified plaque thickness.

147 AS 1049—2003
TABLE HH1
PLAQUE AND CHASE DIMENSIONS
Guide in chase dimensions
Test method Plaque thickness
Test Depth Cavity
(Appendix) mm
mm mm
Environmental L 3.15 ±0.15 1) 3.40 ±0.15 250 x 150
stress cracking
1.89 ±0.14 2) 2.04 ±0.14 250 x 150
Electrical C 1.27 ±0.12 1.37 ±0.12 110 x 80
properties
NOTES:
1) Thickness for Type I PE.
2) Thickness for Type II and III PE.
(d) Two flat backing plates for the chase which shall be at least as long and wide as the
outside dimensions of the chase. They shall be 12 mm to 13 mm thick, be made of
non-corrosive hard-chromed steel and highly polished on one surface. This surface
which contributes to the finish of the material shall be free of imperfections. The
plate sizes are shown in Figure HH1. At least one of the backing plates shall have
means of measuring the temperature at the geometric centre of the plate, i.e. holes to
accommodate either a thermometer or thermocouple.
(e) Parting sheets of films 0.05 mm to 0.3 mm thickness of either aluminium or polyester.
NOTE: A suitable aluminium sheet is alloy A5005, temper H/18 of thickness 0.15 mm. A
suitable polyester sheet is Melinex type 226 of 0.25 mm thickness.
(f) Calibrated thermometer or thermocouple linked to a recorder.
HH4 TEST SPECIMENS

Test specimens shall be prepared by moulding the following materials to the thickness in
Table HH1:
(a) PE compound The test specimens shall be pellets.
(b) Cable The test specimens shall be as follows:
(i) For air-core cables, the specimen shall be sheath and, if the cable is moisture
barriered, the aluminium foil shall be removed.
(ii) For filled moisture-barriered cables, the test specimen shall be sheath stripped
of the aluminium foil and, for unbarriered filled cables, the sheathing
compound shall be tested as extrudate from the extruder head.
HH5 PROCEDURE
HH5.1 Preparation of crepe
The material shall be homogenized on a two-roll laboratory type mill by the following
procedure:
(a) Contamination from the surfaces of the two-roll mill shall be removed and polished
with a rag wetted with alcohol.
(b) The temperature of the rolls shall be adjusted to be hot enough to flux the material but
not so hot to cause them to drip.
NOTE: A temperature of 140 ±5°C has been found suitable for Type I Category 5
polyethylene.

AS 1049—2003 148
(c) The rolls shall be closed and set moving. Sufficient material shall be added to the
rolls for the number of plaques required. The clearance between the rolls shall be
gradually increased until an active rolling bank is formed. The material shall be left
on the rotating rolls for a further 180 s, and continuously slashed and folded back to
promote mixing. The total time on the rolls shall not exceed 600 s. During milling no
antioxidant shall be added to the material.
(d) The rolls shall be cleaned after removal of each new material to prevent cross-
contamination of additive systems or the thermally degraded material, or both.
HH5.2 Preparation of plaque
A plaque is prepared from the milled material within 24 h of its removal from the mill by
the following procedure:
(a) The chase and backing plates shall be carefully cleaned and preheated in the press to
at least 150°C for Type I, 160°C for Type II and 177°C for Type III PE when
measured by the thermocouple in the platens.
(b) Sufficient parting sheet shall be used to cover the backing plate. The parting sheet
shall be free from contamination or surface imperfections. If aluminium is used,

rolling oils shall be removed by solvent cleaning. An aluminium sheet may only be
used once whereas a polyester sheet may be used for a maximum of six times, subject
to surface imperfections.
(c) Sufficient quantity of the milled material shall be placed in the chase to give up to
10% flash calculated on the mass of the finished plaque.
(d) The material shall be cut into two to four roughly equal portions, the backing plates
and chase removed from the press and the material stacked in the centre of the chase
between the parting sheets and backing plates. The assembly shall be re-inserted
between the platens of the press. The platens shall be closed until they just touch the
backing plates but do not apply pressure.
(e) The platens shall be continually heated until the temperature as indicated by a
thermocouple in a backing plate reaches at least 150°C for Type I, 160°C for Type II
and 177°C for Type III PE. The temperature shall be hot enough that —
(i) the PE melts and flows into the cavity with the heated platens in constant
contact with the backing plates; and
(ii) the time for the backing plates to reach the desired temperature takes no longer
than 10 min after the assembly is placed between the platens.
NOTE: A temperature range as high as 165°C to 175°C has been found suitable for Type I
Category 5 PE.
(f) A pressure of 6 MPa to 7 MPa calculated from the cavity dimensions of the chase
shall be quickly applied. The material shall be kept at this pressure and at the
temperature in Step (e) for 120 s to 125 s.
(g) While maintaining the pressure, the platens shall be cooled until a temperature of
70°C is reached as indicated by the thermocouple in the backing plate. For the
production of plaques for environmental stress cracking resistance, the cooling rate
for each plaque shall be monitored and shall be 6°C/min to 11°C/min, but preferably
6°C/min to 8°C/min, at all temperatures within the range 120°C to 80°C. Any plaque
not cooled under these conditions shall be rejected.
(h) The assembly shall be removed from the press and then the backing plates and parting
sheets shall be removed. If aluminium parting sheets are used, only the backing plates
shall be removed allowing the chase, with the plaque and parting sheets intact, to cool
to room temperature. This should ease the removal of the parting sheets and enhance
the surface finish of the plaque.

149 AS 1049—2003
(i) The plaque shall be inspected for imperfections such as sink marks, air bubbles and
foreign matter. If these are present, the plaque is unsatisfactory. In this case, the
plaque shall be discarded and another plaque shall be pressed from milled material.
(j) The plaque shall be stored in such a manner, e.g. PE bag, that the surface remains free
from imperfections or contamination.
(k) For plaques intended for the measurement of electrical properties, particular care
should be taken to protect the surface from sunlight, moisture, fingerprints or any
other source of contamination including migration of additives from the packaging.
Plaques should always be handled with tweezers.
HH6 CHECKING THE PLAQUE

Plaques prepared for environmental stress cracking resistance shall be checked for internal
stress by the following procedure:
(a) The plaque shall be measured to ensure it is of the specified thickness.
(b) Two specimens shall be die-punched, dimensioned approximately 40 mm x 13 mm, at
different parts of the plaque so that the long axes of the specimens are approximately
perpendicular.
(c) The length of each specimen shall be measured to the nearest 0.5 mm and placed on a
dish containing 3 mm of talc. The dish shall be placed in an oven at 130 ±2 C for
Type I and II PE and at 150 ±2 C for Type III PE for 30 min.
(d) The specimens shall be allowed to cool to room temperature and the length
re-measured to the nearest 0.5 mm. If the shrinkage of the specimens is less than
10%, the plaque is considered satisfactory, otherwise it shall be discarded and the
material remoulded from crepe.

AS 1049—2003
150
FIGURE HH1 A SUITABLE ASSEMBLY
151 AS 1049—2003
APPENDIX II
PREPARATION OF COMPRESSION MOULDED PVC PLAQUE
(Normative)
II1 SCOPE
This Appendix sets out the method for the preparation of a compression moulded PVC
plaque.
II2 PRINCIPLE
A sample of PVC is formed into a sheet on a two-roll mill, and then moulded in a heated
press to form a uniform sheet.
II3 APPARATUS

(a) Heated two-roll mill.
(b) Timer with 1 s divisions.
(c) Dial gauge with 0.01 mm divisions.
(d) Hydraulic press.
(e) Moulding platens.
(f) Moulding chase of the required thickness.
(g) Temperature probe, accurate to 1°C.
II4 PROCEDURE
II4.1 Preliminary
The apparatus shall be prepared as follows:
(a) The rolls of the mill shall be heated to 150 ±5°C, and allowed to stabilize at that
temperature for a least 10 min. Approximately 200 g of PVC compound shall be
added to the nip of the mill. The mill shall be started and the PVC allowed to band on
one roll. Any material which has fallen into the tray shall be returned under the rolls.
The nip shall be increased and the PVC cut from side to side at least three times. The
PVC shall be cut from the mill and discarded.
(b) The press shall be heated to 160 ±5°C, and allowed to stabilize at that temperature for
at least 10 min.
(c) The inner surfaces of the moulding platens shall be cleaned with methanol or another
suitable solvent.
II4.2 Preparation
The PVC plaque shall be prepared as follows:
(a) Approximately 200 g of the PVC compound or material taken from the cable shall be
added to the closed nip of the mill, and the mill started. The PVC shall be allowed to
band on one roll of the mill. Any material that has fallen into the tray shall be
returned under the rolls.
(b) The nip shall be gradually increased until the thickness of the PVC is about 0.1 mm
thicker than the required thickness of the moulded sheet.

AS 1049—2003 152
(c) The PVC shall be cut from side to side at least six times. The PVC shall then be cut
from the mill and allowed to cool on a clean heat resistant bench. The sheet shall be
marked with the required identification.
(d) A piece of the PVC shall be cut to fit the moulding chase, and marked with the
required identification.
(e) A sheet of poly(ethylene terephthalate) film shall be placed on the cleaned, polished
face of one moulding platen. The moulding chase shall be centred on the platen and
the PVC laid in the chase. Another sheet of poly(ethylene terephthalate) film shall be
placed over the PVC and the second moulding platen placed on top of the assembly.
(f) The mould assembly shall be placed in the preheated press, and the platens closed to
contact pressure only and allowed to stand for 10 min ±10 s. At the end of that time,
the pressure shall be increased on the platens to at least 5 MPa. This pressure shall be
maintained for 2 min ±5 s.
(g) At the end of this time, while maintaining the pressure, the platen heating shall be
turned off and the platens cooled to at least 40°C with circulating water. The press
shall be opened and the sheet removed from the mould. The poly(ethylene
terephthalate) film shall then be removed. The sample identification shall be checked
for legibility and remarked if necessary.
(h) The sample shall be allowed to stand at room temperature for at least 12 h before any
tests are conducted.

153 AS 1049—2003
APPENDIX JJ
PURCHASING GUIDELINES
(Informative)
JJ1 GENERAL
Australian Standards are intended to include the technical requirements for relevant
products, but do not purport to comprise all the necessary provisions of a contract. This
Appendix contains advice and recommendations on the information to be supplied by the
purchaser at the time of enquiry or order.
JJ2 INFORMATION TO BE SUPPLIED BY THE PURCHASER

The purchaser should supply at least the following information at the time of enquiry and
order, after making due reference to the explanation, advice and recommendations
contained in this Appendix:

(a) The number of this Standard, i.e. AS 1049.
(b) The plastics type for insulation material and temperature rating (if applicable).
(c) The plastics type of sheath or jacket material and temperature rating (if applicable).
(d) Tests and criteria for multiple-layer insulation.
(e) Spark-test voltages for polyethylene insulation (if not specified in Table CC1).
(f) The cable application, e.g. general indoor, telecommunication switch cable, cable to
be jointed outdoors.
(g) Whether the cable is to be exposed to direct sunlight.
(h) The colour system to be followed for colour matching of the insulation, sheath or
jacket, e.g. EIA-359-A, IEC 60304 or AS 2700.

AS 1049—2003
154
NOTES
155
NOTES
AS 1049—2003
AS 1049—2003
156
NOTES
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most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth government,
Standards Australia is recognized as Australia’s peak national standards body.
Australian Standards
Australian Standards are prepared by committees of experts from industry, governments, consumers
and other relevant sectors. The requirements or recommendations contained in published Standards are
a consensus of the views of representative interests and also take account of comments received from
other sources. They reflect the latest scientific and industry experience. Australian Standards are kept
under continuous review after publication and are updated regularly to take account of changing
technology.
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Standards Australia is responsible for ensuring that the Australian viewpoint is considered in the
formulation of international Standards and that the latest international experience is incorporated in
national Standards. This role is vital in assisting local industry to compete in international markets.
Standards Australia represents Australia at both ISO (The International Organization
for Standardization) and the International Electrotechnical Commission (IEC).
Electronic Standards
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sheath and jacket

The following are represented on Committee CT-001:

New Zealand Consulting Interests

Keeping Standards up-to-date

This Standard was issued in draft form for comment as DR 01094.

of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

SECTION 1 SCOPE AND GENERAL..................................................................................... 6

SECTION 2 PE INSULATION .............................................................................................. 18

2.3 INSULATION ...................................................................................................... 20

SECTION 3 PA 12 SOLID INSULATION............................................................................. 27

SECTION 4 NON-HALOGENATED PPO-BASED MATERIAL (CONTAINING A

SECTION 5 PVC SOLID INSULATION............................................................................... 30

SECTION 6 PP SOLID INSULATION .................................................................................. 32

SECTION 7 PE SHEATH OR PE JACKET ........................................................................... 33

SECTION 8 POLYAMIDE JACKET ..................................................................................... 38

SECTION 9 INTEGRALLY BONDED PE SHEATH AND POLYAMIDE JACKET ........... 41

SECTION 10 PVC SHEATH OR JACKET............................................................................ 43

SECTION 11 NHMH FOR SHEATH OR JACKET............................................................... 46

SECTION 12 FLUOROPOLYMER INSULATION, SHEATH OR JACKET........................ 49

SECTION 13 PEFR INSULATION, SHEATH OR JACKET ................................................ 51

SECTION 14 SRPVC INSULATION, SHEATH OR JACKET ............................................. 52

SECTION 15 CROSSLINKED POLYMER INSULATION, SHEATH OR JACKET............ 53

T TEST METHOD 22: DETERMINATION OF CARBON

EE TEST METHOD 34: DETERMINATION OF COMBUSTION............................139

SECT ION 1 SCOPE AND GENERA L

 Standards Australia www.standards.com.au

TABLE 1.1 (continued)

Section and material

1.3 MATERIAL SELECTION

 Standards Australia www.standards.com.au

Section Material Choice 1 Choice 2 Choice 3 Choice 4

6 PP insulation One choice only — — —

www.standards.com.au  Standards Australia

1.4 REFERENCED DOCUMENTS

2700 Colour Standards for general purposes

 Standards Australia www.standards.com.au

E1 Specification for ASTM Thermometers

www.standards.com.au  Standards Australia

 Standards Australia www.standards.com.au

FIGURE 1 EXAMPLES OF CABLE CONSTRUCTION

1.5.2.6 Polyethylene plastics

www.standards.com.au  Standards Australia

1.5.3.2 Integrally bonded sheath and jacket

Cable used in telecommunication network switch equipment.

 Standards Australia www.standards.com.au

XLEVA Cross-linked poly(ethylene-vinyl acetate)

www.standards.com.au  Standards Australia

SECT ION 2 PE INSU L AT I ON

2.1 SCOPE OF SECTION

 Standards Australia www.standards.com.au

grade of PE compound used by the cable manufacturer for a particular insulating

Type Range of densities Description

Category Range of melt flow rates g/600 s at

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2.2.5 Material tests

 Standards Australia www.standards.com.au

2.3.4 Insulation tests