BS-4565-1990.pdf

BRITISH STANDARD BS 4565:1990 Specification for Galvanized steel wire for aluminium conductors, steel-reinforced BS 4565:1990 This British Standard, having been prepared under the direction of the Iron and Steel Standards Policy Committee, was published under the authority of the Board of BSI and comes into effect on 28 September 1990 © BSI 07-1999 First published February 1970 Second edition September 1990 The following BSI references relate to the work on this standard: Committee reference ISM/26 Draft for comment 88/40021 DC ISBN 0 580 18317 3 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Iron and steel Standards Policy Committee (ISM/-) to Technical Committee ISM/26, upon which the following bodies were represented: Aluminium Federation Bicycle Association of Great Britain British Cable Makers Confederation British Rubber Manufacturers Association British Steel Industry Engineering Equipment and Materials Users Association Federation of wire Rope Manufacturers of Great Britain Forestry Commission Health and Safety Executive Sheffield Stainless Steel Manufactures Association Society of Chain Link Fencing Manufactures Society of Motor Manufactures and Traders Limited Spring Research and Manufacturers Association Stainless Steel Fabricators Association of Great Britain Stainless Steel Wire Export Group Welding Manufactures Association (BEAMA Ltd) Woven Wire Association Zinc Development Association Amendments issued since publication Amd. No.Date of issueComments BS 4565:1990 © BSI 07-1999i Contents Page Committees responsibleInside front cover Forewordii Section 1. General 1Scope1 2Information to be supplied by the purchaser1 3Manufacture1 4Inspection and testing1 5Selection of test pieces and number of tests1 6Methods of testing1 7Retests2 8Identification2 Section 2. Specific requirements for standard strength wire 9Tolerance on nominal diameter3 10Tensile strength and stress at 1 % elongation3 11Torsion test3 12Elongation3 13Steel ductility wrap test3 14Galvanizing3 Section 3. Specific requirements for high strength wire 15Tolerance on nominal diameter4 16Tensile strength and stress at 1 % elongation4 17Elongation4 18Torsion test4 19Steel ductility wrap test4 20Galvanizing4 Appendix A Conversions of tensile strength and stress at 1 % elongation6 Table 1 Initial stresses to be applied2 Table 2 Tensile strength and stress at 1 % elongation3 Table 3 Properties for high strength galvanized steel wire for aluminium conductors, steel-reinforced5 Table 4 Conversions of tensile strength and stress at 1 % elongation6 Publications referred toInside back cover BS 4565:1990 ii © BSI 07-1999 Foreword This British Standard has been prepared under the direction of the Iron and Steel Standards Policy Committee and is a partial revision of BS 4565:1970, incorporating the amendment issued in 1972 together with a change which would have constituted a second amendment. The standard is classed as a partial revision because the Technical Committee has not reviewed it in great detail. The standard has been drafted in the same style as the 1970 text and changes to the text are indicated by lines in the margin. This edition replaces BS 4565:1970 which is withdrawn. In this revision, the minimum number of twists in the torsion test for standard strength wire has been changed to align with IEC 209, published by the International Electrotechnical Commission. Conversions from N/mm2 in terms of tonf/in2 are given in Appendix A. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 6, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. BS 4565:1990 © BSI 07-19991 Section 1. General 1 Scope This British Standard specifies the requirements for galvanized steel wire, as supplied by the wire manufacturer, for use in the manufacture of aluminium conductors, steel reinforced in accordance with BS 215-2. There are three sections. Section 1 deals with general requirements. Section 2 gives specific requirements for standard strength wire for all diameters from 1.18 mm to 5.0 mm. Section 3 gives specific requirements for high strength wire in three grades, identified by the specified minimum tensile strength in N/mm2, and in diameter ranges varying according to the tensile strength grade. NOTEThe titles of the publications referred to in this standard are listed on the inside back cover. 2 Information to be supplied by the purchaser When ordering steel wire complying with this standard, the following details should be stated on the enquiry and order: 1) The number of this British Standard, i.e. BS 4565. 2) The specified wire diameter. 3) The description, i.e. either “standard strength” or “high strength”. In the case of “high strength” wire, the specified tensile grade number in N/mm2 should also be included. 3 Manufacture 3.1 Steelmaking The wire shall be cold drawn from plain carbon basic steel, made by any process except that the air, and mixed air-oxygen, bottom blown basic converter processes shall not be used. The cast analysis shall show not more than 0.050 % of sulphur, nor more than 0.050 % of phosphorous. 3.2 Galvanizing The wire shall be zinc coated by the hot dip or the electrolytic process. If the hot dip process is used, the purity of the zinc fed into the bath shall be not less than Zn 3 of BS 3436. The galvanizing shall take place at any suitable stage during manufacture. Subject to agreement between the wiremaker and the conductor manufacturer, the wire shall be supplied either in the finally galvanized or the drawn galvanized conditions. 3.3 Freedom from defects The finished wire shall be clean, smooth and free from harmful defects. 3.4 Welds There shall be no joints in the finished wire, except welds which are in the base rod before or after patenting and prior to final drawing. The definition of patenting shall be as given in BS 6562-1. 4 Inspection and testing Inspection and testing of the coils of wire shall be carried out by the wire manufacturer. 5 Selection of test pieces and number of tests 5.1 Test pieces shall be taken from the production coils for the number of tests given in 5.2. Where the conductor manufacturer requires the wire to be supplied split down into smaller weight coils, the test pieces shall be taken prior to the splitting of the production coil. 5.2 The following number of tests shall be carried out on each batch of coils. A diameter and tensile test shall be carried out on each coil of wire, while 1 in every 10 coils shall be tested for stress at 1 % elongation, torsion or elongation, the steel ductility wrap test and the galvanizing tests. 6 Methods of testing 6.1 General All tests shall be carried out on straight pieces of wire and any straightening which may be required shall be done cold. 6.2 Diameter The diameter shall be measured over the zinc coating, and shall be taken as the mean of two measurements at right angles to each other at the same cross section of the wire. NOTEIt is recognized that thick coatings of zinc, obtained in the hot dip process, may not be entirely free from surface irregularities, and, provided the latter do not go beyond the limits of good practice, these are not a cause for rejection of the diameter tests. 6.3 Mechanical tests All the specified mechanical tests shall be carried out in accordance with BS 4545. For the determination of the stress at 1 % elongation in accordance with BS 4545, loads corresponding to the initial stresses given in Table 1 shall be applied to the test piece with the extensometer adjusted to the appropriate initial setting (values based on a nominal modulus of elasticity of 190 000 N/mm2). BS 4565:1990 2 © BSI 07-1999 7 Retests 7.1 Should any test piece fail any of the specified tests, retests are permitted. In this case two additional test pieces shall be taken from the same coil of wire and subjected to the test or tests in which the original test piece failed. Table 1 Initial stresses to be applied 7.2 If all the additional test pieces pass the test or tests, the coil from which they were taken shall be deemed to comply with this British Standard. If any of the additional test pieces fail, the coil shall be deemed not to comply with this standard. 7.3 If any test piece fails after retest to meet a requirement for which only a proportion of the consignment is tested, then all the coils in the consignment, or some other agreed proportion, shall be tested. 8 Identification The wire manufacturer shall attach to every coil a durable label or labels, on which the following information shall be shown, in addition to such other marks as may be agreed between the wire manufacturer and the conductor manufacturer: a) the wire manufacturers name b) the specified wire diameter; c) the description “standard strength” or “high strength” as appropriate; “high strength” being accompanied by the specified tensile grade number in N/nm2; d) the number and date of this British Standard, i.e. BS 4565:1990.1) Nominal diameter of galvanized wire Initial stress Initial extensometer setting percentage of gauge length OverUp to and including mmmmN/mm2 1.18 2.24 3.15 2.24 3.15 5.00 95 190 285 0.05 0.10 0.15 1) Marking BS 4565:1990 on or in relation to a product represents a manufactures declaration of conformity, i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of the standard. The accuracy of the claim is therefore solely the responsibility of the person making the claim. Such a declaration is not to be confused with third party certification of conformity, which may also be desirable. BS 4565:1990 © BSI 07-19993 Section 2. Specific requirement for standard strength wire 9 Tolerance on nominal diameter A tolerance of ± 2 % is permitted on the nominal diameter of the galvanized wires. The difference between the maximum and the minimum measurements, taken at the same cross section, shall not exceed 4 % of the nominal diameter. 10 Tensile strength and stress at 1 % elongation The tensile strength and the stress at 1 % elongation values, calculated on the nominal dimension of the finished wire, shall be not less than those given in Table 2. Table 2 Tensile strength and stress at 1 % elongation 11 Torsion test The wire shall withstand without fracture not less than 18 twists on a length equal to 100 times the diameter of the wire and the primary fracture shall show a smooth surface at right angles to the axis of the wire. Any secondary fracture shall be ignored. It is permitted to carry out the test on a gauge length 150 mm for all wires size, when the number of twists, which the wire shall withstand, shall be indirect ration to the number specified for 100 times the diameter of the wire. 12 Elongation As an alternative to the torsion test, the elongation test shall be carried out, in which case the elongation shall be not less than 4 % measured after fracture on an original gauge length of 200 mm. NOTEThe choice between a torsion test and an elongation test should be by agreement between the wire manufacturer and the conductor manufacturer. 13 Steel ductility wrap test The wire shall not fracture when wrapped for eight complete close turns round a mandrel of diameter equal to the wire diameter. 14 Galvanizing The weight and uniformity of coating and zinc adhesion shall be in accordance with BS 443. Nominal diameter of galvanized wire Tensile strength minimum Stress at 1 % elongation minimum OverUp to and including mmmm N/mm2N/mm2 1.18 2.24 3.15 2.24 3.15 5.00 1 400 1 320 1 320 1 180 1 140 1 100 BS 4565:1990 4 © BSI 07-1999 Section 3. Specific requirements for high strength wire 15 Tolerance on nominal diameter A tolerance ± 2 % is permitted on the nominal diameter of the galvanized wires. The difference between the maximum and the minimum measurement taken at the same cross section, shall not exceed 4 % of the nominal diameter. 16 Tensile strength and stress at 1 % elongation The tensile strength and stress at 1 % elongation values, calculated on the nominal dimensions of the finished wire, shall be not less than those given in Table 3 for the specified tensile grade and nominal diameter of the wire. 17 Elongation The elongation, measured after fracture on an original gauge length of 200 mm shall be note less than the value shown in Table 3, for the specified grade and nominal diameter of wire. 18 Torsion test As an alternative to the elongation test for wires between 1.18 mm and 2.24 mm diameter, a torsion test shall be carried out. In this case, the wire shall withstand not less than 18 twists without fracture on a length equal to 100 times the wire diameter. The type of fracture shall not be taken into account. It is permitted to carry out the test on gauge length of 150 mm for all wires sizes, when the number of twists which the wire shall withstand shall be in direct ratio to the number specified for 100 times the diameter of the wire. NOTEThe choice between an elongation test and a torsion test should be by agreement between the wire manufacturer and the conductor manufacturer. 19 Steel ductility wrap test The wire shall not fracture when wrapped for eight complete close turns round a mandrel of the appropriate diameter, as given in Table 3. 20 Galvanizing The weight and uniformity of coating and zinc adhesion shall be in accordance with BS 443. BS 4565:1990 © BSI 07-19995 Table 3 Properties for high strength galvanized steel wire for aluminium conductors, steel reinforced Tensile strength, grade, N/mm2 min 1 5501 7001 800 Nominal diameter of galvanized wire Min. stress at 1 % elongation Min. elongation L0b= 200 mm Steel wrap test dia. Min. stress at 1 % elongation Min. elongation L0b= 200 mm Steel wrap test dia. Min. stress at 1 % elongation Min. elongation L0b= 200 mm Steel wrap test dia. OverUp to and including mmmmN/mm2%N/mm2%N/mm2% 1.18 1.32 1.80 2.24 2.72 2.90 4.00 1.32 1.80 2.24 2.72 2.90 4.00 5.00 1 260 1 260 1 260 1 260 1 260 1 220 1 220 3.0 3.5 3.5 3.5 3.5 4.0 4.0 1da 1d 2d 2d 2d 3d 3d 1 320 1 320 1 320 1 320 1 320 1 280 3.0 3.0 3.0 3.5 3.5 3.5 2da 2d 2d 3d 3d 3d 1 370 1 370 1 370 1 370 1 370 3.0 3.0 3.0 3.0 3.0 3da 3d 3d 3d 3d a d = nominal diameter of galvanized wire. b Lo = original gauge length. BS 4565:1990 6 © BSI 07-1999 Appendix A Conversion of tensile strength and stress at 1 % elongation Table 4 Conversion of tensile strength and stress at 1 % elongation N/mm2tonf/in2 1 100 1 140 1 180 1 220 1 260 1 280 1 320 1 370 1 400 1 550 1 700 1 800 71.2 73.8