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Indian Standard

LOWCARBONGALVANIZEDSTEELWIRES, FORMEDWIRESANDTAPESFOR ARMOURINGOFCABLES -SPECIFICATION

( Third Revision )

ICS

77.140.65

0 BIS 1999

BUREAU
MANAK

OF
BHAVAN,

INDIAN
9 BAHADUR

STANDARDS
SHAH ZAFAR MARG 110002

NEW DELHI

March

1999

Price Group

Wrought Steel Products Sectional Committee, MTD 4

FOREWORD This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by the Wrought Steel Products Sectional Committee had been approved by the Metallurgical Engineering Division Council. This standard was first published in 1967 and subsequently revised in 1979 and 1988. While reviewing the standard in the light of experience gained during these years, the Committee decided to revise it to bring it in line with the present practices being followed by the Indian industry. In this revision. the following changes have been made: a) Scope has been modified by deleting epoxy coated tapes. b) Chemical composition c) Dimensional d) Requirements e) Requirements n Requirements of the material has been provided. tolerances have been modified. for wrapping test have been included. for adhesion test for galvanized test have been included. of epoxy coating have been deleted.

For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 Rules for rounding off numerical values (m~ised). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

IS 3975 : 1999

Indian Standard

LOWCARBONGALVANIZEDSTEELWIRES, FORMEDWIRESANDTAPESFOR ARMOURINGOFCABLES -SPECIFICATION

( Third Revision )
1 SCOPE This standard covers the requirements of low carbon galvanized steel wires, formed wires and tapes for armouring of cables. This standard does not cover steel wires, formed wires and tapes for armouring of submarine cables. 2 REFERENCES The following Indian Standards contain provisions which through reference in this text, constitute provision of this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the Standards indicated below: IS No. 228 Title IS No. Title Methods of test of cables: Part 42 108 10 (Part 42) : 1984 Resistivity test of armour wires and strips and conductance test of armour (wires/strips) 3 TERMINOLOGY For the purpose of this standard, the following definitions in addition to thosagiven in IS 1956 (Part 4) and IS 1956 (Part 5) shall apply. 3.1 Acceptance Tests Tests carried out on samples taken from a lot for the purpose of acceptance of the lot. 3.2 Armouring (or Armour)

Method for chemical analysis of steel 1387: 1993 General requirements for metallurgical materials (second revision) 1608: 1995 Mechanical testing of metalsTensile testing (second revision) 1717 : 1985 Method for simple torsion test for wire (second revision) 1755: 1971 Method for wrapping test for metallic wire yirst revision) 1956 Glossary of terms relating to iron and steel (Part 4) : 1976 Steel sheets and strips (first revision) (Part 5) : 1975 Bright steel bar and steel wire (first revision) 2633 : 1986 Method for testing uniformity of coating on zinc coated articles 4826 : 1989 Hot dipped galvanized coatings on round steel wires (first revision) 4905 : 1968 Methods for random sampling 6745 : 1972 Methods for determination of mass of zinc coating on zinc coated iron and steel articles 1

A metal cover usually applied in the form of wire or formed wire or tape intended to protect the cable from mechanical damage. 3.3 Formed Wire A wire with a cross section as shown in Fig. 1. It is also known as strip in the cable armouring industry.

FIG. 1 SECTION OFARMOURFORMED WIRE

3.4 Lot All the coils of the wires, formed wires or tapes of the same nominal dimensions in any consignment,

IS 3975 : 1999 manufactured under uniform conditions at the same place. 3.5 Tape A strip of rectangular 4 SUPPLY cross section. of production Table 2 Permissible Variation for Product Analysis (Clause 6.2)
Constituent Variation Over the Specified Limit Percent, MUX

OF MATERIAL
(1)
Sulphur Phosphorus

4.1 General requirements relating to the supply of material shall be as laid down in IS 1387. 4.2 The material shall be supplied in coil form. There shall not be any joint in case the length supplied is less than 200 m. In case the length is more than 200 m, there shall be not more than three joints in the coil. The joint shall not be less than 100 m from each end of the coil. material 4.3 The shall meet the specified requirements of this specification before armouring. 5 MANUFACTURE 5.1 The processes used in making the steel and in manufacturing steel wires, formed wires and tapes are left to the discretion of the manufacturer. 5.2 Steel shall be rimming or non-rimming quality and may be supplied in any of the quality by mutual agreement between the manufacturer and the purchaser. 6 CHEMICAL COMPOSITION

(2)
0.005 0.005 quality

NOTE steel.

Product analysis shall not apply to rimming

7 DIMENSIONS

AND TOLERANCES

7.1 The dimensions of the wires, formed wires and tapes are to be taken without removing the coating. 7.2 Wires The diameter of the wire shall be determined with a micrometer by taking two measurements at right angles to each other at three places along a length of not less than 250 mm, and the average of these six measurements shall be taken as the diameter of the galvanized wire. The dimensions and tolerances of the wires shall be in accordance with Table 3. Table 3 Dimensions and Tolerances of Steel Wires
Nominal Wire Diameter mm (1) 0.30 0.45 0.70 0.90 1.25 1.40 1.60 2.00 Tolerance mm (2) xl.020 H.020 Ho.025 H.030 a.035 LQ.040 M.045 M.050 M.065 AzO.080 ZlLO.10

6.1 Ladle Analysis The ladle analysis of the steel, when carried out by the method specified in the relevant parts of IS 228 or any other established instrumental/chemical method, shall be as given in Table 1. In case of dispute the procedure given in IS 228 and its relevant parts shall be the referee method. However, where the method is not given in IS 228 and its relevant parts, the referee method shall be as agreed to between the purchaser and the manufacturer. 6.2 Product Analysis Permissible variation in case of product analysis from the limits specified in Table 1 shall be as given in Table 2. Table 1 Chemical Composition
Constituent, Pho;phorus (1) 0.035

2.50 3.15 4.00

Percent, Mar
Sulphu: (2) 0.035

7.2.1 Sizes other than those mentioned in 7.2 may be supplied with mutual agreement between the purchaser and the manufacturer. 7.3 Formed Wires Formed wires, having a cross section as shown in Fig. 1, shall have the nominal dimensions as given in Table 4.

NOTE - The nitrogen content of the steel shall not be more than 0.012 percent. This has to be ensured by the manufacturer by occasional check analysis.

IS 3975 : 1999 7.3.1 The tolerances for formed wires shall be +lO percent of the nominal dimensions subject to A being greater than B. Table 4 Dimensions of Formed Wires (Clause 7.3, and Fig. 1) Type
(1) 1 2 NOTE Dimensions, / A (2) 4.0 6.1 Dimensions ct 3.4 5.3 (2) 0.8 1.4 & i0 21.5 mm \

8.2 Torsion Test (for Round Wires only) Round wires shall be subjected to torsion test in accordance with IS 1717. The gauge length between vices and the minimum number of turns without break shall be as given in Table 6. Table 6 Torsion Test
Nominal Wire Diameter
mm

Gauge Length Minimum Number Between the of Turns Vices, mm (2) 50 15 75 15 75 150 150 150 150 150 150 (3) 67 61 43 33 24 43 37 30 24 19 15

showing against B are for guidance only.

7.3.2 Formed wires of any other combination may also be supplied subject to mutual agreement between the purchaser and the manufacturer. 7.4 Tapes 7.4.1 Thickness The thickness of tapes shall be 0.5 mm, 0.8 mm, 1.O mm or 1.25 mm with a tolerance of *lo percent. 7.4.2 Width

(1) 0.30 0.45 0.70 0.90 1.25 1.40 I .60 2.00 2.50 3.15 4.00

8.3 Wrapping Test When tested in accordance with IS 1755, the steel wire, formed wire or tape shall withstand without breaking or splitting on being wrapped and subsequent straightened. 8.3.1 In case of wires, the test specimen of 150 mm long cut from each end of the coil after discarding a length of 300 mm shall be wound for eight complete close turns around a cylindrical mandrel equal to the diameter of wire and subsequent straightened. 8.3.2 In case of formed wire and tape, the test specimen of 550 mm long cut from each end of the coil after discarding a minimum length of 300 mm shall be wound for eight complete close turns around a cylindrical mandrel equal to 15 times the nominal thickness of strip keeping the vaulted side of strip outside and subsequent straightened. 8.4 Resistance Test (for Round and Formed Wires Only) The test shall be carried IS 10810 (Part 42). out in accordance with

The tapes may be supplied in the widths of 25 mm, 32 mm, 35 mm, 50 mm, 70 mm and 80 mm. The tolerance on width shall be +5 percent. 7.4.3 Tapes of any other combination of thickness and width may also be supplied subject to mutual agreement between the purchaser and the manufacturer. 8 MECHANICAL 8.1 Tensile Test The tensile strengths of wire, formed wire and tape when tested in accordance withIS 1608 shall be within the limits given in Table 5. Table 5 Tensile Properties Sl
No. Item Tensile Strength MPa Percent Elongation at Gauge Length I%, Min /-*-, Lo=125 mm Lo=250 mm (1) (2) (3) (4) (5)

PROPERTIES

i) Wire Nominal Diameter Up to and including 1.60 mm Over 1.60 mm ii) iii) Formed wire Tape 300-500 300-500 300-500 300-450 10 10 10 10

8.4.1 The resistivity of the wire or formed wire corrected to 20C shall not exceed 14.5 x 10 ohm-cm. 9 GALVANIZING REQUIREMENTS

9.1 Mass of Zinc Coating a) Round Wires - The mass of zinc coating on round wires shall meet the requirements of medium coating as laid down in IS 4826.

IS 3975 : 1999 b) Formed Wires - The mass of zinc coating on formed wires shall be 110 g/m2 for Type 1 and 180 g/m2 for Type 2 wires and shall represent the total mass of zinc, all sides inclusive. Tapes - The mass of zinc coating on tapes shall be 2 10 g/m2 and shall represent the total mass of zinc, all sides inclusive. 10 SAMPLING Unless otherwise agreed to, the method of drawing representative samples of the material and the criteria for conformity shall be as prescribed in Annex A. 11 FREEDOM FROM DEFECTS The wires, formed wires and tapes shall be well cleaned drawn and galvanized to the dimensions specified. These shall be free from splits, surface flaws, rough, jagged and imperfect edges and other harmful surface defects. 12 RETEST a) Round Wires -The uniformity of zinc coating on round wires shall conform to the requirements as laid down in Table 2 of IS 4826. Formed Wires - The uniformity of zinc coating on formed wires shall conform to the requirements as given below: Type Minimum Number of Dips r Face Edge \ / l/2-minute 1-minute l/2-minute dips dips dips 1 1 1 1 1 1 Should any one of the test samples, first selected, fail to comply the requirements specified, two further samples shall be selected from the lot represented by the sample which failed. Should both the test samples comply with the requirements, the lot shall be deemed to have passed. Should either of the retest samples fail, the lot represented shall be rejected. In cases where it is not possible to identify the particular lot, the material from the entire cast shall be deemed as one lot for retest purposes and in case of failure, the entire cast shall be rejected. 13 PACKING Each coil of wire, formed wire and tape shall be suitably bound and fastened compactly. If required by the purchaser, each coil shall be protected by suitable wrapping. 14 MARKING 14.1 Each coil of wire, formed wire and tape shall be marked legibly with the following information:

c)

9.1.1 The average mass of zinc coating of samples shall be determined by the method as given in IS 6745 and shall conform to the values specified in 9.1. 9.2 Uniformity of Zinc Coating

b)

1 2 c)

Tapes - The uniformity of zinc coating on tapes shall withstand two dips of 1- minute for face and one dip of l/Zminute for edge.

9.2.1 The test shall be carried out in accordance with IS 2633.

NOTE - It should be pointed out that there- is no direct link between the number of dips and the mass of coating and that the result is determined as much by the condition of manufacture of the coating as by the regularity of the coating. The uniformity test is solely intended to reveal any significant eccentricity defect in the coating or any other uniformity defect which could exist even if the mass of zinc per unit of surface area complies with the mass requirements for the coating.

Manufacturers

name or trade-mark,

b) Name of material,

c> Size,

4 e) f-l 8)

Net weight, Lot/batch number, Month and year of manufacture, and Any other marking required by the purchaser.

9.3 Adhesion Test Adhesion test for galvanized wire, formed wire and tape shall be carried out by wrapping the wire, formed wire and tape eight times around a mandrel. The diameter of mandrel for wire shall be four times the wire diameter. In case of formed wire and tapes, diameter of mandrel shall be fifteen times the thickness. The zinc coating shall not crack or flake off to such an extent that the same may be removed by rubbing with bare fingers.

14.2 BIS Certification Marking The material may also be marked with the Standard Mark. 14.2.1 The use of the Standard Mark is governed by the provisions of Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under which the licence for the use of Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards.

IS 3975 : 1999

ANNEX A (Clause 10)

SAMPLING A-l LOT AND CRITERIA FOR CONFORMITY A-3 PREPARATION NUMBER OF TESTS A-3.1 OF SAMPLES AND

In any consignment, all the coils of wire/formed wires/tapes of the same dimensions manufactured under essentially similar conditions of manufacture, shall be grouped together to constitute a lot. A-l.1 Sample shall be taken from each lot and tested for conformity to the standard. A-2 SAMPLING The number of coils to be taken from a lot shall be according to column 1 and 2 of Table 7. The samples shall be taken at random by using number tables (see IS 4905). Table 7 Scale of Sampling and Permissible Number of Defectives (Clauses A-2, A-3.1 and A-3.2)
No. of Coils in a Lot (1) No. of Coils for Physical Requirements (2) 2 3 5 8 13 Permissible No. of Defective Coils (3) 0 0 0 I No. of Tests for Chemical Requirements (4) 1 I 2 2 2

Tests for Physical Requirements

From the coils selected from column 1 and 2 of Table 7, adequate length of test piece shall be cut from each end and subjected to physical tests, namely, size, surface condition, tensile, torsion, wrapping and coating tests. A test piece failing to meet any one of the requirements, shall be called a defective. If the number of defectives found is less than or equal to the permissible number of defectives specified in column 3 of Table 7, the lot shall be considered to have conformed to physical requirements. A-3.2 Tests for Chemical Requirements

Unless otherwise agreed, the following procedure shall be followed for chemical requirements: From those test pieces which have conformed to physical requirements further test pieces shall be selected at random according to column 4 of Table 7. These samples shall be tested for all the chemical requirements. If a.test piece fails to meet the respective chemical requirement, it shall be called a defective. The lot shall be considered to have conformed to the chemical requirements if all the individual test pieces tested for chemical requirements pass the test. A-4 CRITERIA FOR CONFORMITY

Upto 25
26 SO 51 150 151300 30 I and above

A lot shall be considered to have conformed to the requirements of the specification if A-3.1 and A-3.2 are satisfied.

Bureau

of Indian

Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country.
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Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of BIS Handbook and Standards: Monthly Additions. This Indian Standard has been developed from Dot : No. MTD 4 ( 4189 )_

Amendments

Issued Since Publication

Amend

No.

Date of Issue

Text Affected

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