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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION
FOR
37/2.25mmHard Drawn Stranded Copper Conductor

Issued by :-

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226011
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TECHNICAL SPECIFICATION
FOR
37/2.25mm Hard Drawn Stranded Copper Conductor

Amendment Date of Total number of Amendment/

Number Amendment Pages including Revision
annexures
0 NA 14 First Revision

Prepared by Checked by Approved by

SIGNATURE
Date
DESIGNATION SSE/Conductor DTI-2 EDTI

COPY NUMBER

ISSUED BY …………………………………….SIGNATURE ……………………………………..DATE ………………………………….

ISSUED TO ………………………………………………………………………………………………………………………………………………

Note : This specification is the property of RDSO. No reproduction shall be done without
permission from DG(TI), RDSO. The specification is not for general use.
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TECHNICAL SPECIFICATION
FOR
37/2.25mmHard Drawn Stranded Copper Conductor

1. SCOPE
This specification covers the requirements and methods of tests for 37/2.25mm Hard
Drawn Stranded Copper Conductor used in 25 kV ac traction.Specification no.
TI/SPC/OHE/HDCSCF/0030 of this specification is updated to
TI/SPC/OHE/HDCSCF/0031in-line with TI document no. TI-WI-7.5.1-1 ver 1.0.

The “Make in India” Policy of Government of India shall be applicable.

2. REFERENCE SPECIFICATIONS
2.1 The following specifications have been referred which shall be applied in the manner
altered, amended or supplemented by this specification.
i. IS: 191-2007or latest Specification for copper
ii. IS: 1778-1980 or latest Specification for reels and drums for bare
wires.
iii. IS: 440-1964 or latest Indian standard methods of chemical analysis
of copper.
iv. IS: 1885(Part 32)-2019 or Electro-technical vocabulary – electric cables.
latest
v. DIN 48200-Part 1-1981 or Wires for stranded conductor, copper wire
latest
vi. DIN 48201-Part 1-1981 or Stranded conductors Copper Cables
latest
vii. DIN 48203-Part 1-1984 or Copper wires and copper stranded conductors-
latest Technical delivery conditions.

2.2 In case of any conflict or disparity between the contents of the above specifications
and this specification, the later shall prevail.

3. DEVIATIONS
3.1 Any deviation from this specification proposed by the tenderer manufacturer intended
to improve the performance, utility and efficiency of the conductor, will be given due
consideration provided full particulars of the deviation(s) with justification thereof are
furnished. In such a case, the tenderer manufacturer shall quote according to this
specification and deviation(s), if any, proposed by him shall be quoted as an
alternative(s).
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4. ENVIRONMENTAL CONDITIONS
4.1 The conductor shall be suitable for outdoor use in moist tropical climate and in areas
subject to heavy rainfall, polluted due to industrial and marine atmosphere and severe
lighting. The limiting weather conditions which the conductor has to withstand in
service are indicated in TABLE-1
TABLE – 1

ENVIRONMENTAL CONDITIONS

i) Maximum Ambient air temperature : 00C to 650C

ii) Maximum temperature of metallic : 700C
object under sun..
iii) Minimum temperature : -100C
iv) Maximum relative humidity : 100%
v) Annual rainfall : Ranging from 1750mm to 6250mm
vi) Maximum number of thunder storm
Days per annum : 85
vii) Maximum number of dust storm days
Per annum : 35
viii) Number of rainy days per annum. : 120
ix) Basic wind pressure : 216 kgf/m2
x) Altitude : 2500m above mean sea level

5. MATERIAL
5.1 The wire shall be made out of the ETP copper conforming to IS:191-2007 or latest
(pt.V) or out of cathode copper conforming to IS:191-2007 or latest (Pt.IV) or out of
continuous cast copper wire rods which shall have the following chemical composition.
Element : %/ppm
Cu+Ag : 99.90%Min
Bi+Te+Se : <20ppm
Pb : <5ppm
Sb : <4ppm
As : <5ppm
Sn+Ni+Fe+Si+Zn+Co : <50ppm
Oxygen : <450ppm

6. FREEDOM FROM DEFECTS

6.1 The wire shall be smooth and free from all imperfections such as spills and spurns.
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7. JOINTS IN WIRE BEFORE STRANDING

7.1 The wire shall be drawn in continuous lengths without joints except those made in the
drawing stock prior to drawing.

8. JOINTS IN STRANDED CONDUCTORS

8.1 Normally joints in the wires during stranding are not permitted. However, in the event
of breakage of a wire during stranding, a joint in any wire shall be so permitted that
distance between two joints in the stranded conductor shall not be less than 15m.
joints shall be hard soldered or butt welded.
NOTE : Joints during stranding can be avoided by judiciously selecting the length of
wires in the spools.
8.2 Not more than four joints during stranding in 1525m length of the stranded conductor
shall be permitted. Each joint shall be painted to enable the operator to identify the
joint easily.

9. STRANDING
9.1 The conductor shall have right hand ordinary concentric lay. The successive layers
shall be twisted in opposite directions. The wires in each layer shall be evenly and
closely stranded around the underlying wire(s). The lay ratio shall be in accordance
with TABLE-4
Note : For right hand lay, the wires conform to the direction of the central part of the
letter ‘Z’ when the conductor is held vertically and viewed from the side. For left hand
lay, the wires conform to the central part of the letter ‘S’ when the conductor is held
vertically and viewed from the side.

10. STANDARD RESISTANCE, WEIGHT, AND SIZE OF SOLID WIRE AND

STRANDED CONDUCTOR.

10.1 After drawing, the wire shall have the diameter, weight and the resistance as given in
TABLE-2. The size, weight and resistance of stranded conductor shall be in accordance
with the values given in TABLE-3.

11. TOLERANCE ON DIMENSIONS AND WEIGHT

11.1 Solid Wire : After drawing, the diameter of the wire shall fall within the appropriate
maximum and minimum values specified in TABLE-2. The weight shall be in
accordance with the values specified in TABLE-2 with a permitted tolerance of ±2% .
The cross section of any wire after drawing shall not depart from circularity by more
than an amount corresponding to 2% on the standard diameter.
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11.2 Stranded Conductor: The dimensions of stranded circular conductor shall comply with
requirement laid down in TABLE-3. The weight shall be in accordance with the values
specified in TABLE-3 with a permitted tolerance of ±2%.

12. MECHANICAL PROPERTIES

12.1 The mechanical properties of the solid wire before stranding shall be such that the
tensile strength when tested in accordance with Clause No.18.6 shall not be less than
the value given in TABLE-2.

12.2 The wire shall comply with the requirements of wrapping test as given in sub Clause
No. 18.7.

TABLE -2
SOLID CIRCULAR COPPER WIRE
Diameter Weight/Km Resistance per Km Minimum Breaking Min
at 200C corrected load after drawing tensile
to std. weight strength
Std. Max. Min. Std. Std. Max. On On Std.
Min.dia dia
mm mm mm Kg Ohm Ohm Kgf Kgf Kgf/mm2
2.25 2.272 2.227 35.36 4.461 4.563 179 183 46.0

2.89 2.92 2.86 58.38 2.668 2.723 277 283 43.0

TABLE -3
STRANDED COPPER CONDUCTOR
No. of Approx, Strandard Resistance per km at 200C Approximate Calculated
strands and overall weight corrected to std. weight breaking area on
diameter of diameter load of standard
wire Std. Max. conductor diameter
mm mm Kg/Km Ohm Ohm Kgf mm2
37/2.25 15.75 1326 0.1222 0.1248 6080 147.20

61/2.89 26.00 3640 .0448 0.0457 16358.29 400.14

TABLE -4
LAY RATIO

No. of LAYERS (NUMBER OF WIRES)

wires in First Layer Second layer Third Layer Fourth Layer
conductor (six) (twelve) (eighteen) (twenty four)
Max Min Max Min Max Min Max Min
37 25 20 17.5 15 15 12.5 - -
61 17 10 16 10 15 10 14 10
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13. TESTS

13.1 After a purchase order is placed, the internal test results for all the tests specified in
clause 14 shall be furnished by the successful tenderer manufacturer to the Director
General (Traction Installation), Research Designs & Standards Organization, Manak
Nagar, Lucknow-226011, or to the Purchaser, as the case may be, within the period
stipulated for prototype approval in the purchase order.

13.2 Any changes required in the process of manufacture or the prototype as desired by the
Director General (Traction Installation), Research Designs & Standards Organization, ,
or by the Purchaser, as the case may be, shall be carried out expeditiously by the
manufacturer.

13.3 Type testing schedule : Prior to giving a call to the Director General (Traction
Installation), Research Designs & Standards Organization, or to the Purchaser, as the
case may be, for inspection and testing of the prototype, the manufacturer shall
submit a detailed test schedule consisting of number of days required to complete all
the tests at one stretch. Once the schedule is approved, the tests shall invariably be
done accordingly. However, during the process of type testing or even later, the
Director General/TI/RDSO or the purchaser, as the case may be, reserves the right to
conduct any additional test(s) besides those specified herein, to his satisfaction or for
gaining additional information and knowledge. In case any dispute or disagreement
arises between the manufacturer and the representative of the Director General
(Traction Installation), RDSO, or the Purchaser, as the case may be, during the
process of testing as regards the procedure for type tests and/or the interpretation
and acceptability of the results of type tests, it shall be brought to the notice of the
Director General (Traction Installation), RDSO or of the Purchaser, as the case may
be, whose decision shall be final and binding.

13.4 All the tests specified in this specification shall be carried out at the manufacturer’s
works. The manufacturer shall arrange all the necessary machinery, apparatus, labour
and assistance required for conducting the tests without any extra cost.

13.5 In the event of the tests not being carried through to completion at one stretch for any
reason attributable to the manufacturer and it is required for the representative of the
Director General (Traction Installation), RDSO, or of the Purchaser, as the case may
be, to go once or several times to the works of the manufacturer or other place(s) for
continuing and/or completing the tests on the prototype(s), the manufacturer shall
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reimburse to the Director General (Traction Installation), RDSO, or to the Purchaser,

as the case may be, the cost for the representative’s visit(s) to works or other
places(s) more than once. The cost as claimed shall be paid through a demand draft
as advised to the manufacturer.

14. TYPE TESTS

14.1 The manufacturer shall manufacture at least 500m length of stranded conductor and
offer for type tests. The type tests shall be conducted on the stranded conductor and
on the wires taken from stranded conductor. For carrying out the tests on wire, the
samples of stranded conductor selected shall be opened and mixed and then three
wires at random shall be selected. The following shall constitute the type tests:
i) Visual examination.
ii) Measurement of diameter of individual wire and stranded conductor
iii) Measurement of weight of wire and stranded conductor
iv) Measurement of lay length and lay ratio of each layer of stranded conductor,
v) Measurement of electrical resistance of wire and stranded conductor,
vi) Tensile test on individual wire,
vii) Wrapping test on individual wires,
viii) Chemical composition of material.
Three samples of adequate length from the manufactured length offered shall be cut
and type tests carried out on these samples.

Note: 1. The entire manufacturing process upto the finished conductor shall be
witnessed by the representative of the Director General (Traction Installation), RDSO,
Lucknowor by the Purchaser, as the case may be. In such a case the prototype tests on the
wires shall be conducted before and after stranding. For chemical composition, the Cu+Ag
content shall be determined as per IS:440-1964 or latest on one composite sample taken
from stranded conductor. The trace elements of the material of wire bar, cathode copper or
continuous cast copper wire rod shall be determined by spectrometer. The oxygen content
shall be verified from the supplier’s certificate.
Note:2. If prototype of the conductor conforming to this specification has already been
approved in connection with previous supplies to Indian Railways, fresh testing of prototype of
the conductor may be waived at the discretion of the Director General (Traction Installation),
RDSO, or of the Purchaser, as the case may be, provided that no changes whatsoever in the
material or process of manufacture have been made. However, the Director General (Traction
Installation), RDSO, or the Purchaser, as the case may be, reserves the right to test the
conductor if he deems it necessary to do so in the light of experience gained from previous
supplies.
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15. ACCEPTANCE TESTS

15.1 The following shall constitute the acceptance tests:

i) Visual examination
ii) Measurement of diameter of individual wire and stranded conductor,
iii) Measurement of weight of individual wire and stranded conductor
iv) Measurement of lay length and lay ratio of each layer of stranded conductor,
v) Measurement of electrical resistance of individual wire and stranded conductor.
vi) Tensile test on individual wire taken from stranded conductor,
vii) Wrapping test on wire,
viii) Chemical composition,
ix) Weightment of drums.

15.2 Only after clear written approval of the results of the tests on the prototype is
communicated by Director General (TI), RDSO or by the Purchaser, as the case may
be, to the manufacture, he shall take up bulk manufacture of the conductor which
shall be strictly with the same material and process of manufacture as adopted for the
prototype. In no circumstances shall be material other than that adopted during the
manufacture of prototype be used for bulk manufacture.

15.3 Sampling:
Weightment of three or one fifth of offered drums whichever is higher shall be made
for gross weight .
One sample of stranded conductor shall be taken from each drum offered for the tests
prescribed in Clause 15.1(i, ii, iii, iv, v).Three samples of wires from each sample of
stranded conductor shall be subjected to the tests of individual wire prescribed in
Clause 15.1(i, ii, iii, v, vi, vii, viii) .
After chemical composition analysis by Spectrometer, one sample(one wire) per 6
drums or minimum one sample for less than 6 drums, shall be subjected to
Electrolysis Test (IS: 440-1964 or latest) for determination of copper content.

15.4 Criteria for acceptance :

The sample of conductor taken from each drum shall be subjected to all the tests
prescribed in Clause 15.1. The wire and conductor in the drum shall be deemed to
have passed the tests if the sample passes all the tests. If a sample fails in more than
one test, the drum shall be rejected. Should the sample fail in any one of the tests,
two more samples shall be taken from the same drum and subjected to all the tests.
Should any sample fail in any test(s) out of two samples taken, the drum shall be
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rejected and the conductor in the rejected drum shall be cut into lengths of less than
50m.

16. ROUTINE TESTS:

16.1 The tests indicated in Clause 15.1 shall constitute routine tests and shall be carried out
by the manufacturer and records maintained on the samples from each drum.

17. MANUFACTURER’S TESTS:

17.1 In addition to the tests prescribed in clause No. 16.1, the following tests shall be
conducted by the manufacturer in the course of fabrication and the records should be
maintained.
i) The chemical composition including trace elements of every lot of wire bars, cathodes
and/or continuous cast copper wire rods for chemical composition. The chemical
composition shall meet the requirement laid down in clause 5.1.
ii) Tests on each spool of 2.25mm diameter wire after drawing for tensile strength,
wrapping test, measurement of diameter, weight and electric resistance. The spool
shall be rejected if wire in the spool does conform to the requirements of specification.
The rejected wire may be re-melted with new stock in small quantity.
iii) Weightment of every drum for tare weight and gross weight.

17.2 Records of these tests shall be maintained by the manufacturer and produced to the
Inspecting Engineer at the time of prototype tests and during acceptance tests
wherever applicable
.
18. TEST METHODS :

18.1 Visual examination.

18.1.1 The wire and stranded conductor shall be visually examined. The wire shall be clean,
smooth and free from harmful defects. The strands in the conductor shall be evenly
laid without any loose wires. The construction shall be checked for laying of strands of
different layers and for the total number of wires. The construction shall be as per
Clause No.9 of this specification.

18.2 Measurement of diameter of wire & stranded conductor.

18.2.1 The diameter of wire shall be measured by means of Ratchet Micrometer or a Dial
Micrometer between two flat circular studs of minimum diameter of 5 mm. The
diameter of conductor shall be measured by means of Vernier caliper. Two
measurements at right angles of the stranded conductor shall be taken at three
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sections and average of 6 readings shall be taken as diameter of the stranded

conductor. For measurement of the diameter of individual wire two measurements at
right angles at three sections shall be done the average of six readings shall be taken
as the diameter of individual wire.

18.3 Measurement of weight of wire & stranded conductor

18.3.1 The weight of wire and stranded conductor shall be measured by weighing the sample
of 50cm(approximate) length by a balance of accuracy of ± 1 gm for stranded
conductor and ± 0.1 gm for wire.

18.4 Measurement of lay length & lay ratio of each layer of stranded conductor
18.4.1 The lay length, i.e. the axial length of complete turn of the helix formed by the wire in
a layer of the stranded conductor, of each layer shall be measured by a vernier caliper
or by any other method. The measured lay length when divided by the mean
diameter of helix will be the lay ratio of that layer in case of 37/2.25 conductor. The
measured lay length when divided by the outside diameter of the layer will be the
lay ratio of that layer in case of 61/2.89 conductor.

18.5 Measurement of electrical resistance of wire and stranded conductor.

18.5.1 The D.C. electrical resistance of the wire and stranded conductor shall be measured by
digital micro-ohm meter or Double Kelvin’s Bridge at room temperature. The
conductor shall be in the test room which shall be at a reasonably constant
temperature for sufficient time. The measurement shall be carried out on a sample
length of not less than 50cm to an accuracy of one part per thousand. The purchaser
shall have the right to test the accuracy of the instrument by another wire of known
resistance.
18.5.2 The electrical resistance per kilometer of the test sample when multiplied by WxC/K
shall not exceed appropriate maximum value given in Table-2 and Table-3.
Where,
K = Standard weight per Km,
W = Weight per km of test sample and
C = Multiplier constant for correction to 200C
18.5.3 The multiplier constant for correction to 200C

TABLE– 5
MULTIPLIER CONSTANTS (C)
Temperature0C Multiplier constant
5 1.0606
5.5 1.0585
6.0 1.0563
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6.5 1.0542
7.0 1.0521
7.5 1.0500
8.0 1.0479
8.5 1.0458
9.0 1.0437
9.5 1.0417
10.0 1.0396
10.5 1.0376
11.0 1.0355
11.5 1.0335
12.0 1.0314
12.5 1.0294
13.0 1.0274
13.5 1.0254
14.0 1.0234
14.5 1.0214
15.0 1.0194
15.5 1.0174
16.0 1.0155
16.5 1.0135
17.0 1.0116
17.5 1.0096
18.0 1.0077
18.5 1.0057
19.0 1.0038
19.5 1.0019
20.0 1.0000
20.5 0.9981
21.0 0.9962
21.5 0.9943
22.0 0.9924
22.5 0.9906
23.0 0.9887
23.5 0.9868
24.0 0.9850
24.5 0.9831
25.0 0.9813
25.5 0.9795
26.0 0.9777
26.5 0.9758
27.0 0.9740
27.5 0.9722
28.0 0.9704
28.5 0.9686
29.0 0.9668
29.5 0.9651
30.0 0.9633
35.0 0.9459
40.0 0.9292
45.0 0.9130
50.0 0.8974

18.6 Tensile test on individual wire:

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18.6.1 The load on the wire shall be applied gradually and the rate of separation of the jaws
of the tensile testing machine shall not be greater than 10cm per minute and shall be
so adjusted that the total time of the testing from the moment of the application of the
load till fracture of wire is between 15 and 60 seconds.
Note : The strength of stranded conductor in terms of the sum of strengths of the
individual wires may be assumed to be not less than as indicated in TABLE-6
TABLE-6
Number of wires in Percentage strength based on Percentage strength based on
stranded conductor the strength of the wires when the strength at the wire before
taken from the stranded standing
conductor and tested
37 93 90
61 - 95

The tensile strength of any of the wire after stranding shall be not less than 93% of
the value given in TABLE-2 and average tensile strength of all the wires in a stranded
conductor shall not be less than 94% of the value specified in TABLE-2.

18.7 Wrapping test on wire:

18.7.1 The wire shall be wrapped round a wire of its own diameter to form a close helix of 8
turns. Six turns shall then be unwrapped and then closely re-wrapped in the same
direction as the first wrapping. Wire shall not break during the test.

18.8 Chemical composition:

18.8.1 For type test The trace elements in wire bar, cathode copper or continuous cast copper
wire rodshall be determined by spectrometer. The oxygen content shall be verified
from supplier’s certificate. For Cu+Ag Copper content one composite sample shall be
made from the samples selected and chemically analysed as per IS:440-1964 or
latest. The chemical composition shall be as given in Clause No.5 of this specification.
For acceptance test one composite sample selected from each drum shall be analysed
for Cu+Ag content as per IS:440-1964.

18.9 Weightment of drums :

18.9.1 Weightment of three or one fifth of offered drums whichever is higher shall be made
for gross weight and recorded.

19. LENGTH OF CONDUCTOR

19.1 The conductor shall be ordered in specified lengths and shall be supplied as per the following
tolerances:
Length under 750m : +10.0m
-0.0m
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Length of 750m & above : +20.0 m

-0.0m
20. PACKING AND MARKING

20.1 The 37/2.25 mm stranded conductor shall be delivered to the purchaser properly wound on
drums. The drums shall conform to IS:1778-1980. The spindle plates of the drums shall have
a square hole 105 mmx105 mm to permit the passage of a square axle of maximum size 100
mmx100mm. The use os spindle plates with the hole of any other shape or size shall be
subjected to agreement between the Purchase and the manufacturer. A drum shall carry only
one continuous length of standed conductor. Paper shall be provided on the drum barrel and
between each layer of conductor while winding on the drum.
i) The stranded conductor shall be delivered to the purchaser properly wound on either wooden
drums or corrugated steel drums 2.5 MT capacity (type of drum required whether wooden or
steel to be specified by the purchaser in his purchase order).
ii) In case of wooden drum, the spindle plates of the drums shall have a square hole 105 mm x
105 mm to permit the passage of a square axle of maximum size 100 mm x 100 mm. The use
of spindle plates with the hole of any other shape or size shall be subjected to agreement
between the purchaser and the manufacturer.
iii) A drum shall carry only one continuous length of stranded conductor. Paper shall be provided
between each layer of conductor while winding on the drum during manufacturing process.
iv) In order to avoid any damage to conductor, corrugated paper sheet of min. 3.00 mm
thickness shall be provided on the outer diameter of barrel, on the inner side of each flanges
of the wooden drum and also on the top layer of conductor. After that cover it from Plastic
sheet before final packing of drums with wooden lagging. “Any damage in conductor shall be
to the suppliers account”.
v) The wooden drum shall comply with IS: 1778-1980 “Specification for Reels and Drums for
bare conductors”.
vi) Corrugated Steel drums shall be of maximum capacity 2321 Kg as per Table 2.3 type RM of
NEMA WC 26. Size of the selected drum is as per table below:

Flange Barrel Dia Traverse

48 inch 24 inch 24 inch

1219.2 mm 609.6 mm 609.6 mm

20.2 The exact manufacturing lengths/weight of the conductor shall be specified by the Purchaser.

20.2.1 The marking on the drum shall include-

a) The manufacturer’s brand or mark.
b) Size of the conductor.
c) The actual length of the wire on the drum
d) Weight of drum (Net and gross)
e) Number of joints provided in wire during stranding with identification of joints.
f) Drum number and
g) Purchase Order no. and the name of the consignee.
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