ACSR Conductors (Aluminium Conductor Steel Reinforced) for Industrial and Domestic Use

Currency Cables ACSR Conductors (Aluminium Conductor Steel Reinforced) are standard bare overhead transmission lines engineered for primary transmission networks and distribution grids. Featuring a concentric-lay stranded design, these conductors combine high-conductivity EC-grade aluminium outer strands around a solid or stranded high-tensile galvanized steel core. Manufactured in strict conformity with IS 398 (Part 2) and international utility standards, Currency ACSR conductors deliver high mechanical tensile strength with minimal thermal line sag, allowing utilities and EPC contractors to achieve extended tower spans across rivers, highways, and rugged terrains with lower overall infrastructure costs.

Features & Key Benefits

High Strength-to-Weight Ratio: High-tensile galvanized steel core provides immense breaking load capacity, allowing longer tower spans and reducing total transmission tower count.

EC-Grade Aluminium Conductivity: Outer strands of minimum 99.5% pure electrical-grade aluminium maximize current-carrying capability and minimize electrical line losses.

Reduced Mechanical Sag: Superior tensile properties keep line sag within strict clearance limits under high thermal loads and intense wind pressure.

Corrosion-Resistant Galvanized Core: Steel core wires receive a uniform Class A zinc coating to prevent galvanic corrosion and environmental oxidation.

Cost-Efficient Infrastructure Build: Higher span lengths cut line-stringing costs, tower foundation expenses, and overall right-of-way (RoW) civil overheads.

Technical Specifications Overview

Specification parameter	Standard Rating value
Applicable Standards	IS 398 (Part 2):1996 / IEC 61089 / BS 215 (Part 2) / ASTM B232
Conductor Construction	Concentric Stranded: EC Grade Aluminium (min 99.5% purity) over Galvanized Steel Core
Standard Industry Codes	Squirrel, Weasel, Rabbit, Racoon, Dog, Wolf, Panther, Zebra, Moose (and custom lay configurations)
Zinc Coating on Steel Core	Class A / Class B Heavy Galvanizing (complying with IS 4826)
Operating Temperature	Continuous: Up to 75°C – 85°C (Standard ACSR operational threshold)

Common Applications & Uses

Extra High Voltage (EHV), High Voltage (HV), and Medium Voltage (MV) overhead transmission grids.
Overhead rural, semi-urban, and industrial power distribution networks.
Long-span overhead river crossings, railway crossings, valley spans, and hilly terrain power corridors.
Primary overhead substation busbar connections and bay-to-bay interconnects.
State electricity board (SEB) transmission line upgrades and regional grid interconnectors.

Why Choose Currency Cables

Engineered with precision-drawn EC-grade aluminium and high-tensile Class A galvanized steel cores, Currency ACSR Conductors deliver unmatched mechanical span strength, low line sag, and long-term conductivity backed by over 30 years of manufacturing excellence.

Frequently Asked Questions

ACSR conductors use a dual-metal design. The outer layers consist of high-purity EC-grade aluminium wires that carry the majority of the electrical current due to the skin effect in AC transmission. The inner core consists of high-tensile galvanized steel wires that bear the mechanical pulling tension and dead weight. This combination enables high mechanical strength without adding excessive dead weight or sacrificing conductivity.

In accordance with Indian (IS 398) and British standards, ACSR conductors are designated by animal codenames denoting specific stranding configurations and current ratings: Squirrel (20 mm² alum. area): 6 Alum / 1 Steel (Rural distribution) Weasel (30 mm²): 6 Alum / 1 Steel (Sub-transmission & rural lines) Rabbit (50 mm²): 6 Alum / 1 Steel (Medium voltage distribution) Dog (100 mm²): 6 Alum / 7 Steel (33 kV / 66 kV sub-transmission) Wolf (150 mm²) & Panther (200 mm²): 30 Alum / 7 Steel (66 kV / 132 kV primary lines) Zebra (420 mm²) & Moose (520 mm²): 54 Alum / 7 Steel (220 kV / 400 kV extra-high-voltage transmission)

When two dissimilar metals like aluminium and steel contact each other in humid or coastal environments, galvanic corrosion can occur. Currency Cables counters this by applying a uniform, high-adherence Class A zinc coating to the steel wires per IS 4826. For high-humidity or coastal corridors, we can apply specialized neutral greases directly over the galvanized core prior to stranding to block moisture ingress.

All Aluminium Conductors (AAC) have high electrical conductivity but low tensile strength. On long spans between towers, AAC lines experience excessive sag and risk breaking under high wind or ice loading. The steel reinforcement in ACSR provides the tensile capacity required to double or triple tower span lengths while keeping ground clearance safe.

Every production drum undergoes routine and type testing at our testing laboratory before dispatch. Key tests include: Aluminium Wire Tests: Tensile strength, elongation, wrapping test, and DC resistance measurement. Galvanized Steel Wire Tests: Tensile breaking load, elongation, torsion test, and zinc coating uniformity (Preece Dip test and mass of zinc coating). Complete Conductor Tests: Lay ratio verification and total calculated breaking load verification. Test certificates are provided with every batch.

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