prEN IEC 63248:2021

Conductors for overhead lines - Coated or cladded metallic wire for concentric lay stranded conductors

2019-10-31: Common mods. are included in prAA (PR=70813)

Leiter für Freileitungen – Beschichtete oder ummantelte Metalldrähte für Leiter aus konzentrisch verseilten Drähten

Vodniki za nadzemne vode - Prevlečena ali prekrita kovinska žica za koncentrično pletene vodnike

General Information

• Status: Not Published
• Technical Committee: CLC/TC 7X - Overhead electrical conductors
• Drafting Committee: IEC/TC 7 - IEC_TC_7
• Current Stage: 4020 - Enquiry circulated
• Due Date: 30-Apr-2021
• Completion Date: 30-Apr-2021
• Ref Project: oSIST prEN IEC 63248:2021 - Conductors for overhead lines - Coated or cladded metallic wire for concentric lay stranded conductors

RELATIONS

• Amended By: prEN IEC 63248:2021/prAA - Conductors for overhead lines - Coated or cladded metallic wire for concentric lay stranded conductors
• Effective Date: 05-Nov-2019

Standards Content (sample)

SLOVENSKI STANDARD
oSIST prEN IEC 63248:2021
01-julij-2021
Vodniki za nadzemne vode - Prevlečena ali oblečena kovinska žica za
koncentrične laične vodnike

Conductors for overhead lines - Coated or cladded metallic wire for concentric lay

stranded conductors
Ta slovenski standard je istoveten z: prEN IEC 63248:2021
ICS:
29.240.20 Daljnovodi Power transmission and
distribution lines
oSIST prEN IEC 63248:2021 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN IEC 63248:2021
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oSIST prEN IEC 63248:2021
7/706/CDV
COMMITTEE DRAFT FOR VOTE (CDV)
PROJECT NUMBER:
IEC 63248 ED1
DATE OF CIRCULATION: CLOSING DATE FOR VOTING:
2021-04-30 2021-07-23
SUPERSEDES DOCUMENTS:
7/702/CD, 7/703A/CC
IEC TC 7 : OVERHEAD ELECTRICAL CONDUCTORS
SECRETARIAT: SECRETARY:
China Mr Qiu Zheng
OF INTEREST TO THE FOLLOWING COMMITTEES: PROPOSED HORIZONTAL STANDARD:
TC 11
Other TC/SCs are requested to indicate their interest, if any, in
this CDV to the secretary.
FUNCTIONS CONCERNED:
EMC ENVIRONMENT QUALITY ASSURANCE SAFETY

SUBMITTED FOR CENELEC PARALLEL VOTING NOT SUBMITTED FOR CENELEC PARALLEL VOTING

Attention IEC-CENELEC parallel voting
The attention of IEC National Committees, members of
CENELEC, is drawn to the fact that this Committee Draft
for Vote (CDV) is submitted for parallel voting.
The CENELEC members are invited to vote through the
CENELEC online voting system.

This document is still under study and subject to change. It should not be used for reference purposes.

Recipients of this document are invited to submit, with their comments, notification of any relevant patent rights of which

they are aware and to provide supporting documentation.
TITLE:

Conductors for overhead lines - Coated or cladded metallic wire for concentric lay stranded

conductors
PROPOSED STABILITY DATE: 2024
NOTE FROM TC/SC OFFICERS:

Copyright © 2021 International Electrotechnical Commission, IEC. All rights reserved. It is permitted to download this

electronic file, to make a copy and to print out the content for the sole purpose of preparing National Committee positions.

You may not copy or "mirror" the file or printed version of the document, or any part of it, for any other purpose without

permission in writing from IEC.
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oSIST prEN IEC 63248:2021
IEC CDV 63248/Ed1  IEC:2021 – 2 – 7/706/CDV
1 CONTENTS

3 FOREWORD ........................................................................................................................... 4

4 INTRODUCTION ..................................................................................................................... 6

5 1 Scope .............................................................................................................................. 7

6 2 Normative references ...................................................................................................... 7

7 3 Terms and definitions ...................................................................................................... 7

8 4 Material ........................................................................................................................... 9

9 4.1 Steel ....................................................................................................................... 9

10 4.2 Aluminium ............................................................................................................... 9

11 4.3 Zinc ........................................................................................................................ 9

12 4.4 Zinc-aluminium alloy ............................................................................................... 9

13 4.5 Advanced zinc-aluminium alloy ............................................................................... 9

14 5 Freedom from defects ...................................................................................................... 9

15 6 Joints .............................................................................................................................. 9

16 7 Tests ............................................................................................................................. 10

17 7.1 General ................................................................................................................. 10

18 7.2 Place of testing ..................................................................................................... 10

19 7.3 Sampling rate ....................................................................................................... 10

20 7.4 Test methods ........................................................................................................ 10

21 7.4.1 Visual test ..................................................................................................... 10

22 7.4.2 Diameter ........................................................................................................ 10

23 7.4.3 Stress at 1% extension, tensile strength and elongation ................................ 11

24 7.4.4 Ductility tests ................................................................................................. 12

25 7.4.5 Coating or cladding tests ............................................................................... 13

26 7.4.6 Coefficient of linear expansion ....................................................................... 14

27 7.4.7 Resistivity ...................................................................................................... 14

28 7.4.8 Coating adherence heat resistance test ......................................................... 14

29 8 Acceptance and rejection .............................................................................................. 15

30 9 Certificate of compliance ............................................................................................... 15

31 10 Packaging ..................................................................................................................... 15

32 10.1 Type of packaging ................................................................................................ 15

33 10.2 Length and tolerance on length ............................................................................. 15

34 Annex A (normative) Tables of properties for recommended IEC wire materials .................. 16

35 Annex B (informative) Properties of wire for calculation purposes ....................................... 32

36 Annex C (informative) Method to measure the equivalent diameter by volume .................... 34

37 Annex D (informative) Ratio of aluminium and steel or FeNi36 cross-sectional areas .......... 36

38 Bibliography .......................................................................................................................... 38

40 Figure C.1 – OPGW composed of a formed aluminium-clad steel wires ................................. 34

41 Figure C.2 – Density measurement apparatus for example ................................................... 34

43 Table A.1 – Wire designation ................................................................................................ 16

44 Table A.2 – Schedule of tests ............................................................................................... 17

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45 Table A.3 – Zinc-aluminium alloy ingot composition (group 4 and group 5) ........................... 18

46 Table A.4 – Requirements for zinc and zinc-aluminium alloy coated steel wires (group

47 1, group 4 and group 5) ........................................................................................................ 19

48 Table A.5 – Requirements for aluminium-clad FeNi36 wires (group 2) ................................... 23

49 Table A.6 – Requirements for aluminium-clad steel wires (group 3) ...................................... 25

50 Table A.7 – Initial setting for determining stress at 1% extension .......................................... 28

51 Table A.8 – Coating requirements for zinc and zinc-aluminium alloy coated wires ................. 29

52 Table A.9 – Cladding requirements for Group 2 and Group 3 wire ......................................... 30

53 Table A.10 – Coating heat resistance test for Group 4 and Group 5 wire .............................. 30

54 Table A.11 – Temperatures for linear expansion test for Group 2 wire .................................. 31

55 Table A.12 – Minimum number of dips for Zn and Zn Alloy coatings (group 1, group 4,

56 group 5) ................................................................................................................................ 31

57 Table B.1 – Properties of wire for calculation purposes ......................................................... 32

58 Table D.1 – Standard aluminium and steel or FeNi36 ratio in the cross section for

59 Group 2 and Group 3 wires ................................................................................................... 36

60 Table D.2 – Average aluminium thickness ............................................................................. 37

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oSIST prEN IEC 63248:2021
IEC CDV 63248/Ed1  IEC:2021 – 4 – 7/706/CDV
63 INTERNATIONAL ELECTROTECHNICAL COMMISSION
64 ____________
66 CONDUCTORS FOR OVERHEAD LINES - COATED OR CLADDED
67 METALLIC WIRE FOR CONCENTRIC LAY STRANDED CONDUCTORS
71 FOREWORD

72 1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

73 all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international

74 co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and

75 in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports,

76 Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their

77 preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with

78 may participate in this preparatory work. International, governmental and non-governmental organizations liaising

79 with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for

80 Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

81 2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

82 consensus of opinion on the relevant subjects since each technical committee has representation from all

83 interested IEC National Committees.

84 3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

85 Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

86 Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

87 misinterpretation by any end user.

88 4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

89 transparently to the maximum extent possible in their national and regional publications. Any divergence between

90 any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter.

91 5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity

92 assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any

93 services carried out by independent certification bodies.

94 6) All users should ensure that they have the latest edition of this publication.

95 7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and

96 members of its technical committees and IEC National Committees for any personal injury, property damage or

97 other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and

98 expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC

99 Publications.

100 8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

101 indispensable for the correct application of this publication.

102 9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent

103 rights. IEC shall not be held responsible for identifying any or all such patent rights.

104 IEC 63248 has been prepared by IEC technical committee 7: OVERHEAD ELECTRICAL

105 CONDUCTORS. It is an International Standard.

106 This International Standard cancels and replaces IEC 61232:1993 Edition 1.0, and replaces

107 IEC 60888:1987 Edition 1.0 excluding wires with zinc coating class 2.
108 The text of this International Standard is based on the following documents:
Draft Report on voting
7/702/CD 7/703A/CC
109

110 Full information on the voting for its approval can be found in the report on voting indicated in

111 the above table.

112 The language used for the development of this International Standard is English.

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113 This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in

114 accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available

115 at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are

116 described in greater detail at http://www.iec.ch/standardsdev/publications.

117 The committee has decided that the contents of this document will remain unchanged until the

118 stability date indicated on the IEC website under webstore.iec.ch in the data related to the

119 specific document. At this date, the document will be
120 • reconfirmed,
121 • withdrawn,
122 • replaced by a revised edition, or
123 • amended.
124
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125 INTRODUCTION

126 The purpose of this standard is to group together similar wire materials that share the same

127 general characteristics and therefore the same test procedures and requirements. Included in

128 this standard are existing wire types from IEC 60888 and IEC 61232 as well as new wire

129 materials that are already in use around the world in new types of conductors.

130 Zinc coating class 2 according to IEC 60888 has not been included in this standard, as the

131 demand for this class of zinc coating is extremely rare. Extra corrosion protection can be

132 provided by other means, including the use of Zinc-aluminium alloy coatings.
133
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oSIST prEN IEC 63248:2021
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134 CONDUCTORS FOR OVERHEAD LINES - COATED OR CLADDED
135 METALLIC WIRE FOR CONCENTRIC LAY STRANDED CONDUCTORS
136
137
138
139 1 Scope

140 This document specifies the properties of wires in the diameter range of, but not limited to, 1,25

141 mm to 5,50 mm. This standard is applicable to coated or cladded metallic wires before stranding

142 used either as concentric lay overhead stranded conductors, or in the manufacture of cores for

143 concentric lay overhead stranded conductors, for power transmission purposes.

144 The various wire types and their designations are listed in Table A.1. For calculation purposes

145 the values listed in Table B.1 shall be used.
146 2 Normative references

147 The following documents are referred to in the text in such a way that some or all of their content

148 constitutes requirements of this document. For dated references, only the edition cited applies.

149 For undated references, the latest edition of the referenced document (including any

150 amendments) applies.
151 IEC 60050, International electro-technical vocabulary
152 IEC 60468, Method of measurement of resistivity of metallic materials.
153 ISO 752, Zinc ingots

154 ISO 6892-1, Metallic materials — Tensile testing — Part 1: Method of test at room

155 temperature

156 ISO 7500-1, Metallic materials — Verification of static uniaxial testing machines — Part 1:

157 Tension/compression testing machines — Verification and calibration of the force-

158 measuring system
159 ISO 7800, Metallic materials — Wire — Simple torsion test
160 ISO 7801, Metallic materials — Wire — Reverse bend test
161 ISO 7802, Metallic materials — Wire — Wrapping test

162 ISO 7989-2, Steel wire and wire products — Non-ferrous metallic coatings on steel wire —

163 Part 2: Zinc or zinc-alloy coating
164 3 Terms and definitions

165 For the purposes of this document, the terms and definitions given in IEC 60050 and the

166 following terms and definitions apply.

167 ISO and IEC maintain terminological databases for use in standardization at the following

168 addresses:
169 • IEC Electropedia: available at http://www.electropedia.org/
170 • ISO Online browsing platform: available at http://www.iso.org/obp
171 3.1
172 cladded metallic wire

173 the result of a process by which a metal is bonded under high pressure by co-rolling, co-

174 extrusion, or others, onto a wire creating a metallic bond between them
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175 3.2
176 class

177 a number attributed to aluminium-clad wires for the purpose of providing an approximate

178 conductivity value
179 3.3
180 coated metallic wire

181 the result of a process by which a metal is deposited onto a wire by hot-dip or electrolytic

182 process, creating a chemical or metallic bond between them
183 3.4
184 equivalent diameter

185 the diameter of a round wire, which would have the same cross sectional area as a given formed

186 wire
187 3.5
188 formed wire
189 a drawn or rolled metal wire having a constant non-circular cross-section
190 3.6
191 group

192 a designation given to wire types that share a common coating or cladding, or property for a

193 similar purpose
194 3.7
195 FeNi36

196 a grade of steel-nickel alloy designed to have a very low coefficient of thermal expansion

197 3.8
198 lot

199 a group of production units of one type and size of wire, which was manufactured by the same

200 manufacturer during the same time period under similar conditions of production

201 Note: A lot can consist of part or all of a purchased quantity.
202 3.9
203 nominal

204 the value of a measurable property to which tolerance is applied. Nominal values are target

205 values
206 3.10
207 production unit

208 a coil, reel, spool, or other package of wire that represents a single usable length

209 3.11
210 sample

211 specimen or specimens removed from a production unit or units which is considered to have

212 properties representative of a lot
213 3.12
214 specimen
215 a length of wire removed for test purposes
216 3.13
217 zinc-aluminium alloy

218 a mixture of zinc and aluminium coating applied onto the wire for the purpose of protecting it

219 against corrosion.
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220 Note: Some of these alloys with particular mixture are called Mischmetal.
221 3.14
222 advanced zinc-aluminium alloy

223 a zinc-aluminium alloy reaching specific requirements as specified in ISO7989-2

224 Note: Examples of advanced zinc-aluminium alloys are Zn90% + 10% aluminium and Zn95% + 5 % aluminium with

225 0,2 to 0,5 % magnesium.
226 4 Material
227 4.1 Steel

228 The base metal shall be steel produced by the open hearth, electric furnace, or basic oxygen

229 process and shall be of such composition that the finished wire shall have the properties and

230 characteristics given in this standard.
231 4.2 Aluminium

232 The aluminium used for coating or cladding shall have a minimum purity of 99,5% and of

233 sufficient quality to meet thickness and electrical resistance requirements of this standard.

234 4.3 Zinc

235 The ingot of zinc used for coating shall meet the requirements of ZN-3 according ISO 752.

236 The zinc coating shall be applied by either the hot-dip or electroplating method. Unless agreed

237 between the purchaser and the manufacturer, the method of coating shall be at the discretion

238 of the manufacturer.
239 4.4 Zinc-aluminium alloy

240 The ingot of zinc-aluminium alloy used for coating shall be in accordance with Table A.3.

241 4.5 Advanced zinc-aluminium alloy

242 The ingot of advanced zinc-aluminium alloy used for coating shall be in accordance with Table

243 A.3.
244 5 Freedom from defects

245 The wires shall be smooth and free from all imperfections such as cracks, roughness, grooves,

246 inclusions and other defects which may compromise the performance of the final product.

247 6 Joints
248 No joints shall be made in the finished coated or cladded wire.

249 Joints may be made at any stage of processing prior to final cold drawing by the electric butt-

250 weld or flash-welding process.

251 Welding equipment and procedure shall be such that it can be demonstrated that the ultimate

252 tensile strength of a finished wire specimen containing the welded section shall be

253 not less than 96 % of the specified minimum stress at 1 % extension.

254 A welded section shall meet all other requirements, except the stress at 1 % extension,

255 elongation, torsion, bend, and wrap tests.
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256 No joints are allowed after heat treatment on wires, which will be used in single wire conductors.

257 7 Tests
258 7.1 General

259 Tests shall be made by the manufacturer on the wires to demonstrate their conformance to this

260 standard. Tests shall be made in accordance with Table A.2.
261 Tests shall be performed between 10°C and 30°C.
262 7.2 Place of testing

263 Unless otherwise agreed between the purchaser and the manufacturer at time of ordering, all

264 tests shall be carried out at the manufacturer’s works.
265 7.3 Sampling rate

266 Specimen for tests specified in clause 7.4 shall be taken by the manufacturer from samples of

267 at least 10% of each lot.

268 Alternatively, if a quality assessment procedure is in place and implemented, the sampling rate

269 shall be subject to agreement between the manufacturer and purchaser.
270 7.4 Test methods
271 7.4.1 Visual test

272 The surface of the wire shall be visually examined to ensure that it is smooth and free from all

273 imperfections including but not limited to cracks, unevenness, holes and inclusion of impurities.

274 7.4.2 Diameter
275 7.4.2.1 Unit for diameter

276 The nominal diameter of a wire shall be expressed in millimetres to two decimal places.

277 7.4.2.2 Diameter from direct measurements

278 The diameter of a round wire shall be the mean of two measurements at right angle taken at

279 the same cross-section. The measurement apparatus shall have an accuracy of at least 0,001

280 mm.

281 When tested in accordance with this sub clause the diameter shall not vary from its nominal

282 value by more than the appropriate value indicated in Table A.4, Table A.5, or Table A.6.

283 7.4.2.3 Diameter from weight measurements

284 The equivalent diameter of a formed wire shall be obtained from weight measurements made

285 on a sample not less than 1,0 m in length, and its density as defined in Table B.1.

286 The equivalent diameter, D of the formed wire shall be calculated by the Formula (1).

4𝐴𝐴

287 D = (1)

𝜋𝜋𝜋𝜋𝜋𝜋
288 Where:
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289 D is the equivalent diameter of the sample in mm
290 A is the weight of the sample with Length L in g
291 L is the length of the sample in m
292 𝜌𝜌 is the density of the sample in g/cm³

293 When tested in accordance with this sub clause the equivalent diameter shall not vary from its

294 nominal value by more than the tolerance value indicated in Table A.4, Table A.5, or Table A.6.

295 7.4.2.4 Diameter from volume measurement

296 Alternatively the equivalent diameter of a formed wire shall be obtained from volume and weight

297 measurements as described in the informative Annex C.

298 When tested in accordance with this sub clause the equivalent diameter shall not vary from its

299 nominal value by more than the tolerance value indicated in Table A.4, Table A.5, or Table A.6.

300 7.4.3 Stress at 1% extension, tensile strength and elongation
301 7.4.3.1 Sample preparation

302 The wire samples shall be free from bends or kinks other than the curvature resulting from the

303 usual coiling operation. It shall be straightened before inserting in the grips of the tensile testing

304 equipment with a roller type wire straightening arrangement or by any other means designed to

305 exert the minimum effect upon the mechanical properties of the sample. Samples for tests shall

306 not be less than 450 mm long and shall be fitted in the testing machine so as to leave a free

307 length of minimum 300 mm between the grips.
308 7.4.3.2 Stress at 1% extension and tensile strength
309 The test shall be performed in accordance with ISO 6892-1.

310 The force-measuring system of the testing machine shall be calibrated in accordance with ISO

311 7500-1, class 1,or better.

312 The rate of separation of the jaws of the testing machine shall be between 25 mm/min and 100

313 mm/min.

314 In order to obtain a straight test piece and ensure the alignment of the test piece and grip

315 arrangement, a preliminary load corresponding with the initial stress in accordance with Table

316 A.7 shall be applied.

317 This load shall be maintained while a 250 mm gauge is marked on the sample and a suitable

318 extensometer applied on a 250 mm gauge length (not necessarily corresponding with the

319 marked gauge length).

320 A correction of the extension, in accordance with Table A.7, should be carried out to take into

321 account the effect of the preliminary load.

322 This load shall then be increased uniformly until the extensometer indicates an extension of 2,5

323 mm in 250 mm (1% extension).

324 At this point the tensile testing equipment may be stopped if necessary, and the load read. The

325 value of stress at 1% extension is calculated by dividing this load by the area of the wire based

326 on wire diameter measurements as per clause 7.3.2. Following this operation, the extensometer

327 may be removed. The specimen shall then be loaded to rupture and its tensile strength

328 determined.
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329 When tested in accordance with this sub clause the wire shall conform to the requirements

330 prescribed in Table A.4, Table A.5, or Table A.6.
331 7.4.3.3 Elongation after break
332 The test shall be performed in accordance with ISO 6892-1.
333 The gauge length to be applied is 250 mm.

334 When tested in accordance with this sub clause the wire shall conform to the requirements

335 prescribed in Table A.4, Table A.5, or Table A.6.
336 7.4.3.4 Elongation at break
337 The test shall be performed in accordance with ISO 6892-1.
338 The gauge length to be applied is 250 mm.

339 When tested in accordance with this clause the wire shall conform to the requirements

340 prescribed in Table A.5, or Table A.6.
341 7.4.4 Ductility tests
342 7.4.4.1 Torsion test
343 The test shall be performed in accordance with ISO 7800.
344 The free length between the grips will be 100 times the nominal diameter.

345 The number of torsions obtained shall not be less than the value given in Table A.4, Table A.5

346 or Table A.6.
347 7.4.4.2 Wrapping test
348 The test shall be performed in accordance with ISO 7802.

349 The specimen shall be wrapped 8 turns in a close spiral around a mandrel, at a rate not

350 exceeding 15 turns per minute.

351 The mandrel diameter shall be in accordance with the value given in Table A.4, Table A.5, or

352 Table A.6.

353 When tested in accordance with this clause, the sample shall not completely break.

354 7.4.4.3 Reverse bend test
355 The test shall be performed in accordance with ISO 7801.

356 The minimum number of reverse bends to be achieved shall be agreed between purchaser and

357 manufacturer.

358 Note : to have a reference on the minimum achievable reverse bends one can refer to ISO 2232 Quality A.

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359 7.4.5 Coating or cladding tests
360 7.4.5.1 Coating mass or cladding thickness test
361 7.4.5.1.1 Zinc or zinc-aluminium alloy coating mass
362
...