Overhead Transmission & Distribution

Aluminium & High Performance Conductors

Your Partners in High Speed Data and Ene

OF/C- Optical Fiber/ Cables FCS- Fiber Connectivity Solutions

Telecom DC- Data Cables N/w- Networks (Telecom Infrastructure)

Internet Cloud Internet Gateway Exchange Tower

OF/C + SI + FCS OF/C + SI + FCS OF/C +

Backbone networks of all Indian Telecom Sterlite’s

Sterlite’s FTTHNetwork
FTTH Network has
has
Operators deploy Sterlite’s Fiber Optic Cables been deployed in India’s top 6 metro

25% of India’s grid runs on

Power Sterlite Conductors
Cable

Overhead
T&D Conductors
including HPC

Genco OPGW
Power
Cable

2850 Km of Transmission Lines &

2 Substations owned by Sterlite Substation Tower

Power HPC- High Performance Conductors OPGW- Optical Ground Wire

Manufacturing Locations: Aurangabad (Waluj & Shendra) | Dadra | Hai Men City (China) |

Connecting Every Home on the Planet

 rgy Transmission About Sterlite

Progress has been defined by a fundamental need for

connectivity- connectivity between people, between places,
of thoughts and of ideas. Power and Telecommunication are
the two primary infrastructure platforms that have defined
the progress of individuals, enterprises and nation.
SI- System Integrations
Sterlite Technologies Limited facilitates progress across the
planet, through connectivity- by making it faster, easier, and
Home more cost-effective (for service providers) to build power and
telecom networks. Sterlite does it through its suite of
products, solutions and infrastructure.

Global Solutions

+ DC + FCS + N/w Sterlite Technologies Limited is a leader in providing

transmission solutions for the power and telecom industry,
globally. Equipped with a comprehensive portfolio that
been includes products such as overhead transmission &
cities distribution conductors, high performance conductors,
OPGW, power cables, optical fibers, telecommunication
cables, solutions for system integration, fiber connectivity
and building power & telecom infrastructure, Sterlite's vision
is to “Connect every home on the planet”. We are committed
to providing the lowest per unit cost of energy transmission
over the life cycle.

Positioned strongly in high growth geographies and high

LAN implementation in 38 universities of India growth industries, we are recognized as one of the most cost-
through Sterlite’s Integration effective manufacturers in the world. This gives us a
competitive edge to effectively address sales in our chosen
focus markets. We have also invested in several projects for
backward integration of our manufacturing processes as well
as forward integration of our technology solutions.
Enterprise
Fastest growing Today, Sterlite is the only company offering products for ultra
in the power cable high voltage power transmission and extra high speed data
industry in India transmission. Our products are suitable for use in Power,
Telecom, Defense, Aviation, Oil & Gas and Transportation
sectors. Sterlite is also executing multi-million dollar power
transmission system projects, pan-India and has been
awarded three projects for building transmission lines and
substations in India, as a developer, on a build-own-operate-
Haridwar | Jharsuguda | Piparia | Rakholi maintain (BOOM) basis.

We share a common lineage with Vedanta Resources Plc., a

globally diversified natural resources group.
Sterlite’s conductors used in the
Overhead
Transmission &
Distribution
Aluminium
Conductors

Sterlite provides power transmission &

distribution companies a holistic one-stop
window for assessment, development &
implementation of solutions for their power
transmission & distribution (T&D) networks.
Supported by a fully integrated manufacturing
facility that converts ingots to bare overhead
conductors, Sterlite’s range of standard and
custom-designed power solutions deliver
superior performance in transmission and
performance reliability.

Our offerings include:

TM
 STER-ACSR
 STER-ACSRTM/AS or /AW
TM
 STER-AAC
 STER-AAACTM
 STER-ACARTM
Overhead T&D Aluminium Conductors

TM
STER-ACSR & STER-ACSR-AW

6/1 7/1 12/7 36/1 24/7 26/7

30/7 30/19 54/7 54/19 84/19

TM TM
STER-AAC & STER-AAAC

7 19 37 61 91

TM
STER-ACAR

4/3 15/4 12/7 18/19 24/13 30/7

33/4 33/28 42/19 48/13 54/7

STER-ACSRTM

Aluminium Conductors Steel Reinforced (ACSR), also known as Bare aluminium conductors, are one of the most widely
used conductors for transmission. The conductor consists of a one or more layers of aluminium wires stranded over a
high strength steel core. The core can be single or multiple strands depending on the application or requirement. There
can be various stranding combinations of Al and steel wires giving flexibility to obtain the suitable current carrying
capacity and mechanical strength based on the application.

Advantages
Its low weight combined with its high tensile strength allow larger span runs. Electrical losses by corona effect are greatly
reduced, due to the larger diameter size of this design. Economical transmission and distribution of electrical energy can
be achieved by ACSR, at very high voltages and distances.

Applications
Overhead T&D lines- MV, HV & EHV (11 kv to 800 Kv Lines).

Manufacturing Capability
Sr. No. Description Range
1 Conductor Area 10.6 mm2 to 1393 mm2 0.0164 in2 to 2.1592 in2
2 Conductor Construction 6Al/1Steel to 84Al/19Steel
3 Conductivity of Aluminum 61%

Physical Properties
At a temperature of 200C (680F), the density of hard-drawn aluminum has been taken as 2.703 g/cm3 (168.74 lb/cf) and
for steel wire 7.78 g/cm3 (485.69 lb/cf)
Modulus of elasticity* Linear Coefficient*
Sr. No. Conductor Construction
Mpa ksi / 0C / 0F
1 6Al/1Steel 81000 11748 19.2 X 10-6 10.7 X 10-6
2 6Al/7Steel 75000 10878 19.8 X 10-6 11.0 X 10-6
3 12Al/7Steel 107000 15519 15.3 X 10-6 8.5 X 10
-6

4 18Al/1Steel 66000 9572 21.2 X 10-6 11.8 X 10-6

5 24Al/7Steel 74000 10733 19.4 X 10-6 10.8 X 10-6
6 26Al/7Steel 77000 11168 18.9 X 10-6 10.5 X 10-6
7 30Al/7Steel 82000 11893 17.8 X 10-6 9.9 X 10-6
8 26Al/19Steel 76000 11023 19.0 X 10-6 10.5 X 10-6
9 30Al/19Steel 81000 11748 17.9 X 10-6 9.9 X 10-6
10 42Al/7Steel 60000 8702 21.2 X 10-6 11.8 X 10-6
11 45Al/7Steel 61000 8847 20.9 X10-6 11.6 X 10-6
12 48Al/7Steel 62000 8992 20.5 X 10-6 11.4 X 10-6
13 54Al/7Steel 70000 10153 19.3 X10-6 10.7 X 10-6
14 54Al/19steel 68000 9863 19.4 X 10-6 10.8 X 10-6
-6
15 84Al/7steel 65000 9427 20.1 X 10 11.1 X 10-6
16 84Al/19steel 64000 9282 20.0 X 10-6 11.1 X 10-6

Sr. No. Description Range

0
1 Permissible Temp in continuous operation 85 C 1850F
2 Temp in a short circuit (duration up to 5 s) 2000C 3920F

Standards –
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant National and International standards.
STER-ACSRTM/AS or STER-ACSRTM/AW

Aluminium Conductors, Aluminium Clad Steel Reinforced (ACSR/AS or ACSR/AW) are concentrically stranded
conductors with one or more layers of hard drawn 1350-H19 aluminum wires on Aluminium Clad steel wire core. The
core can be single wire or stranded depending on the size.

Advantages
A higher UTS can be achieved by increasing core and higher current carrying capacity by increasing Al content. The
mechanical properties of ACSR/AS conductors are similar to ACSR conductors but offers improved ampacity and
resistance to corrosion because of the presence of aluminum clad steel wires in the core. These conductors are better
replacement for ACSR conductors where corrosive conditions.

Applications
High voltage overhead transmission & distribution lines , & coastal regions.

Manufacturing Capability
Sr. No. Description Range
1 Conductor Area 10.6 mm2 to 1393 mm2 0.0164 in2 to 2.1592 in2
2 Conductor Construction 6Al/1ACS to 84Al/19ACS
3 Conductivity of Aluminum 61%
4 Conductivity of ACS Wire 20.3%

Physical Properties
At a temperature of 20 C (680F), the density of hard-drawn aluminum has been taken as 2.703 g/cm (168.74 lb/cf) and
0 3

3
aluminum clad steel wires 6.59 g/cm (411.40 lb/cf)
Modulus of elasticity* Linear Coefficient*
Sr. No. Conductor Construction 0
Mpa ksi /C / 0F
1 6Al/1ACS 74000 10733 19.3 X 10-6 10.7 X 10-6
2 26Al/7ACS 71000 10298 19.1 X 10-6 10.6 X 10-6
3 30Al/7ACS 74000 10733 18.0 X 10-6 10.0 X 10-6
4 54Al/7ACS 65000 9427 19.5 X 10-6 10.8 X 10-6

Sr. No. Description Range

0
1 Permissible Temp in continuous operation 75 C 1670F
2 Temp in a short circuit (duration up to 5 s) 2000C 3920F

Standards –
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant National and International standards.
STER-AACTM

AAC conductor is also known as aluminum stranded conductor. These conductors consist of several layers of aluminium
wires stranded concentrically. AAC are manufactured from electrolytically refined aluminum, with a minimum purity of
99.7%

Advantages
All Aluminum Conductor (AAC) have high ratio of electrical conductivity to weight, high flexibility and low UTS. Also the
aluminium has low levels of brittleness.

Applications
All Aluminum Conductor (AAC) are used in low voltage overhead lines in urban areas and in high voltage substation
conductoring. Also, used in very cold areas due to low brittleness of aluminum in the MV lines.

Manufacturing Capability
Sr. No. Description Range
1 Conductor Area 10.6 mm2 to 1095 mm2 0.0164 in2 to 1.6973 in2
2 Conductor Construction 7Al to 91Al
3 Conductivity 61%

Physical Properties
At a temperature of 200 C (680F), the density of hard-drawn aluminum has been taken as 2.703 g/cm3 (168.74 lb/cf)
Modulus of elasticity* Linear Coefficient*
Sr. No. Conductor Construction 0
Mpa ksi /C / 0F
1 7 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
2 19 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
3 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
4 91 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6

Sr. No. Description Range

0
1 Permissible Temp in continuous operation 75 C 1670F
2 Temp in a short circuit (duration up to 5 s) 2000C 3920F

Standards –
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant National and International standards.
STER-AAACTM

AAAC (All Aluminium Alloy Conductors)- Several layers of aluminium alloy (generally Al-Mg-Si) stranded in concentric
layers. Designed using a highstrength aluminum alloy to achieve a high strength-to-weight ratio; affords better sag
characteristics

Advantages
AAAC has good corrosion resistance, however due to the absence of steel, the resistance of AAAC is lower as compared
to ACSR. AAAC can carry atleast 15-20% extra current as compared to ACSR of equal size. Also, it has higher life span of
60 years as compared to ACSR which has around 30 years life span. The surface hardness of AAAC is 80 BHN as compared
to 35 BHN of ACSR. This reduces the damage to surface during handling and therefore leading to lesser corona losses
and ratio interference at EHV. AAAC can be operated with stable temp 850 C against ACSR conductors which are stable
upto 750 C. Since AAAC has higher strength to weight ratio, span can be increased from 2 to 15% resulting in overall
reduction of cost in towers supports and other accessories in transmission line system.

Applications
All Aluminum Alloy Conductors (AAAC) are extensively used for primary and secondary transmission in bare overhead
distribution and transmission lines (11 kv to 800 Kv Lines) & HV substations. Also, usable in highly polluted industrial
areas and coastal regions due to corrosion resistance.

Manufacturing Capability
Sr. No. Description Range
1 Conductor Area 10.6 mm2 to 1095 mm2 0.0164 in2 to 1.6973 in2
2 Conductor Construction 7Al Alloy to 91Al Alloy
3 Conductivity 52.5% to 53%

Physical Properties
At a temperature of 200 C (680F), the density of hard-drawn aluminum has been taken as 2.70 g/cm3(168.74 lb/cf).
Modulus of elasticity* Linear Coefficient*
Sr. No. Conductor Construction 0
Mpa ksi /C / 0F
-6
1 7 Strands 62000 8992 23.0 X 10 12.8 X 10-6
2 19 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
3 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
4 61 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6

Sr. No. Description Range

1 Permissible Temp in continuous operation 850C 1850F
2 Temp in a short circuit (duration up to 5 s) 2000C 3920F

Standards –
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant National and International standards.
STER-ACARTM

Aluminium Conductor Alloy Reinforced (ACAR) is formed by concentrically stranded wires of Aluminium 1350 on high
strength Aluminium -Magnesium -Silicon (AlMgSi) alloy core. The number of wires of Aluminum1350 & AlMgSi alloy
depends on the cable design. Though the general design comprises a stranded core of AlMgSi alloy strand, in certain
cable constructions, the wires of AlMgSi alloy strands can be distributed in layers throughout the Aluminium 1350
strands.

Advantages
ACAR has better mechanical and electrical properties as compared to an equivalent ACSR, AAC or AAAC. A very good
balance between the mechanical and electrical properties therefore makes ACAR the best choice where the ampacity,
strength and light weight are the main consideration of the line design. For equal weight ACAR offers higher strength
and ampacity than ACSR. A higher U.T.S. can be obtained, by increasing aluminium alloy content, and a higher current
carrying capacity by increasing aluminium content.

Applications
Aluminum Conductors Alloy Reinforced (ACAR) are extensively used for overhead distribution and transmission lines .

Manufacturing Capability
Sr. No. Description Range
2 2
1 Conductor Area 10.6 mm to 1520 mm 0.0164 in2 to 2.356 in2
2 Conductor Construction 4Al/3Al Alloy to 72Al/19Al Alloy
3 Conductivity of Aluminum 61%
4 Conductivity of Al Alloy 52.5% to 53%

Physical Properties
At a temperature of 200 C (68 F), the density of hard-drawn aluminum has been taken as 2.703 g/cm3 (168.74 lb/cf) and
0

3
aluminum alloy wires 2.70 g/cm (168.56 lb/cf)
Modulus of elasticity* Linear Coefficient*
Sr. No. Conductor Construction 0
Mpa ksi /C / 0F
-6
1 7 Strands 62000 8992 23.0 X 10 12.8 X 10-6
2 19 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
3 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
4 61 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6

Sr. No. Description Range

1 Permissible Temp in continuous operation 850C 1850F
2 Temp in a short circuit (duration up to 5 s) 2000C 3920F

Standards –
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant National and International standards.
Sterlite’s TACSR & Al59
High Performance Conductors
installed on 1200 kV UHVAC
National Test Station in Bina
High Performance Conductors

Efficient power transmission is the need of the hour, aimed to alleviate the burgeoning demands from today’s power
utility system.

If the challenge is to transmit more power over existing lines, high ampacity conductors that are manufactured from a
range of speciality materials, offer the most optimal means to increase line capacity at a relatively low cost.

A range of speciality alloys offer superior thermal resistance that improves the efficiency in high current transmission.

®
STER-ACCC

As these new generation conductors enhance the current carrying capacity, they are favourable for use in re-
conductoring as well as new lines. This provides the user high corridor intensity and reduces congestion in existing lines.
1st ever to install
ACCC transmission
line in India

Sterlite executed a turnkey project for

Torrent Power which involved supply
and installation of the ACCC conductor
on a live 132 kV transmission line from
Pirana to Vinzol in Gujarat.

Live Stringing on 132 kV transmission line from Pirana to Vinzol in Gujarat | Double the original capacity | Eco-friendly
Reduced Loss in Transmission | Effortless Integration | Compliant with Design Standards | Improved Efficiency

Actual site photograph

Benefits in Performance & Cost

Re-conductoring
Enhanced current carrying capacity for the same diameter/wieght.
Minimum or no modification/ reinforcement to existing towers.

Green Solutions
Low losses leading to lower carbon emissions.
Run at lower temperature for the same current.

Efficiency[A/mm2]
Sterlite Eco ACCC

New lines
Enhanced current carrying capacity.
Reduction in per unit transmission cost.
Higher corrosion resistance.
Shorter project duration.
Additional Capacity of ~100% is reserved for the
future demand

Power Transmission Line Industrial Building

1,2,3,4,6,7,8,9,10 11,12 11,12
1, 2, 4, 5,6,7,8,9,10 1, 2, 3, 4, 5,6,7,8,9,10
Power Generation
Station 220,132,66,33, 11kV
1200, 765, 500, 400, 220
132kV: HVAC Residential
± 800, 500 kV HVAC Building
Transformer

Substation

1. STER-AAAC™ Conductors 6. STER-AL59™ Conductors 11. OPGW Cables

2. STER-ACSR™ Conductors 7. STER-ACSS™ Conductors 12. OPGW Accessories
®
3. STER-AACSR™ Conductors 8. STER-TACSR™ Conductors 13. STER-ACCC Conductors
4. STER-ACAR™ Conductors 9. STER-STACIR™ Conductors 14. STERLITE-ECO™ Conductors
5. STER-AAC™ Conductors 10. Special Alloy Conductors
(1120, EHC, 6101, 6201)
STER-AL59TM

These are homogenous alloy conductors belonging to Aluminium + Magnesium + Silica Alloy type. These conductors
have a conductivity of 59% and hence have lesser DC resistance & higher current carrying capacity.

Al59 Wire

Al59 Wire
Application
Al59 alloy conductors are used in power transmission and distribution lines for a
wide voltage range (low voltage to ultra high voltage). These conductors have
higher current carrying capacity in lower losses due to lower DC resistance. Al59
conductors have high corrosion resistance, making them most suited for
deployment in coastal regions.

Benefits
26% to 31% more current carrying capacity as that of ACSR of the same size, while maximum sag remains the same &
working tension is lesser than that of ACSR.
2
Resistivity is substantially lesser than that of ACSR/AAAC conductors, resulting in lower I R losses.
Higher corrosion resistance than 6201 alloy series (AAAC).

Technical Specifications
Properties Al59 (ACSR Moose Equivalent) Al59 (ACSR Zebra Equivalent) Al59 (ACSR Panther Equivalent)

Typical Factors 3.50 mm 0.1378 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in

Reference Specifications SS 4240814 SS 4240814 SS 4240814
Total Cross Section Area 587.00 mm2 0.9099 in2 484.25 mm2 0.7506 in2 261.50 mm2 0.4053 in2
Conductive Wire Al59 Al59 Al59
Core Wire Al59 Al59 Al59
Conductor Diameter 31.50 mm 1.2402 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in
Weight 1618 kg/gm 1087.2 lbs/mile 1336 kg/km 897.8 lbs/mile 720 kg/km 483.8 lbs/mile
Ultimate Tensile Strength 14350 kg 31636.3 lbs 12340 kg 27205.01 lbs 6661 kgf 14684.97 lbs
DC Resistance
at 20°C Temperature 0.05 Ω/km 0.08 Ω/mile 0.06 Ω/km 0.10 Ω/mile 0.11 Ω/km 0.18 Ω/mile

Maximum Operating
Temperature 95°C 203°F 95°C 203°F 95°C 203°F
Current Carrying Capacity at
1094 Amp 958 Amp 654 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C (113°F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
STER-TACSRTM

®
Sterlite Thermal-resistant Aluminum-alloy Conductor, Steel Reinforced (TACSR) conductors are high ampacity
conductors, wherein the inner core is composed of galvanized steel and the outer layers are composed of thermal-
resistant aluminum-alloy.
Thermal Aluminum
Alloy Wire

Wire-Galvanized
Steel
Application
TACSR conductors are recommended for new lines for high power transfer
requirement.

Benefits
New Aluminium alloys having high thermal resistance can carry 50% to 60% more current as that of ACSR of the same
size; while maximum sag & maximum working tension remains almost same as that of ACSR.
Can carry 50% to 60% more current as that of ACSR of the same size.
Higher capacity new lines can be built to deal with future demands

Technical Specifications
Properties TACSR (ACSR Moose Equivalent) TACSR (ACSR Zebra Equivalent) TACSR (ACSR Panther Equivalent)

Typical Factors 3.53 mm 0.1378 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in

Reference Specifications IEC 62004 IEC 62004 IEC 62004
Total Cross Section Area 596.99 mm2 0.9253 in2 484.25 mm2 0.7506 in2 261.50 mm2 0.4054 in2
Conductive Wire Al Zr AT1 Al Zr AT1 Al Zr AT1
Core Wire Galvanized Steel Galvanized Steel Galvanized Steel
Conductor Diameter 31.77 mm 1.2508 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in
Weight 2004 kg/gm 1346.6 lbs/mile 1621 kg/km 1089.3 lbs/mile 972 kg/km 653.2 lbs/mile
Ultimate Tensile Strength 16438 kg 36239.54 lbs 14407 kg 31761.96 lbs 10119 kg 22308.55 lbs
DC Resistance
at 20°C Temperature 0.06 Ω/km 0.09 Ω/mile 0.07 Ω/km 0.11 Ω/mile 0.14 Ω/km 0.22 Ω/mile

Maximum Operating
Temperature 150°C 302°F 150°C 302°F 150°C 302°F
Current Carrying Capacity at
1509 Amp 1302 Amp 831 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C (113°F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
STER-STACIRTM

Sterlite® Super Thermal Alloy Conductor Invar Reinforced (STACIR) conductor has outer layers composed of Super
0 0
Thermal Aluminum (STAL) alloy wires that can operate up to 210 C (410 F). The inner core is composed of aluminum
clad INVAR wires. INVAR is a metal alloy with 36% Ni in steel.
Super-thermal Resistant
Aluminum Alloy Wire
(STAL)

Aluminum-clad
INVAR Wire
Application
STACIR/AW conductors are suited for re-conductoring applications. The
capacity of the existing transmission line can be enhanced by simply
replacing the existing conductor without any modifications to the tower.

Benefits
Can carry 100% more current as that of ACSR of the same size, while maximum sag and maximum working tension
remain the same as that of ACSR.
For uprating transmission and distribution lines, no modification or reinforcement is required to the existing towers.

Technical Specifications
Properties STACIR (ACSR Moose Equivalent) STACIR (ACSR Zebra Equivalent) STACIR (ACSR Panther Equivalent)
Typical Factors 3.53 mm 0.1390 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in
Reference Specifications IEC 62004 IEC 62004 IEC 62004
Total Cross Section Area 597.00 mm2 0.9254 in2 484.50 mm2 0.751 in2 261.50 mm2 0.4054 in2
Conductive Wire Al Zr AT3 Al Zr AT3 Al Zr AT1
Core Wire Aluminum Clad Invar Aluminum Clad Invar Aluminum Clad Invar
Conductor Diameter 31.77 mm 1.2508 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in
Weight 1993 kg/gm 1339.2 lbs/mile 1582 kg/km 1063.1 lbs/mile 939 kg/km 631.0 lbs/mile
Ultimate Tensile Strength 14641 kg 32277.84 lbs 11968 kg 26384.89 lbs 8436 kg 18598.17 lbs
DC Resistance
at 20°C Temperature 0.06 Ω/km 0.09 Ω/mile 0.07 Ω/km 0.11 Ω/mile 0.13 Ω/km 0.21 Ω/mile

Maximum Operating
Temperature 210°C 410°F 210°C 410°F 210°C 410°F
Current Carrying Capacity at
1871 Amp 1626 Amp 1040 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C (113°F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
STER-ACSSTM

®
Sterlite Aluminum Conductor Steel Supported (ACSS) conductor is a composite concentric lay-stranded conductor
consisting of a stranded steel central core with one or more layers of 1350-0 (High Temperature) aluminum wires.

Al 1350-O Wires

Wire-Galvanized Steel
Application
ACSS conductors can be designed as a low loss solution, as part of efficient
transmission networks. These conductors are suitable for lines that
transmit very high or fluctuating loads.

Benefits
Improved self-damping characteristics and high degree of resistance to vibration fatigue.
Can operate continuously at high temperatures up to 250°C (482°F) with appropriate steel core coating vs. 100°C
(212°F) for standard ACSR, hence carrying twice as much as current compared to ACSR conductor.
No creep.
Less susceptible to Aeolian vibration fatigue due to the very low mechanical load on the annealed aluminum wire.
Requires conventional installation techniques.
Allows for lower overall transmission cost.

Technical Specifications
Properties ACSS Curlew ACSS Drake ACSS Hawk
Typical Factors 3.51 mm 0.1383 in 4.44 mm/3.45 mm 0.1749 in/ 0.136 in 3.51 mm/2.67 mm 0.1383 in/ 0.1051 in
Reference Specifications ASTM B856 ASTM B856 ASTM B856
2 2 2
Total Cross Section Area 591.00 mm 0.9161 in 468.50 mm 0.7262 in 2
281.00 mm2 0.4356 in2
Conductive Wire Al1350-O (Fully Annealed Al wires) Al1350-O (Fully Annealed Al wires) Al1350-O (Fully Annealed Al wires)
Core Wire Mischmetal Alloy Coated Steel Mischmetal Alloy Coated Steel Mischmetal Alloy Coated Steel
Conductor Diameter 31.62 mm 1.2449 in 28.13 mm 1.1075 in 21.77 mm 0.8571 in
Weight 1981 kg/km 1331.2 lbs/mile 1629 kg/km 1094.6 lbs/mile 976 kg/km 655.8 lbs/mile
Ultimate Tensile Strength 13807 kg 30439.19 lbs 12742 kg 28091.27 lbs 7779 kg 17149.74 lbs
DC Resistance
0.05 Ω/km 0.09 Ω/mile 0.07 Ω/km 0.11 Ω/mile 0.12 Ω/km 0.19 Ω/mile
at 20°C Temperature
Maximum Operating
Temperature 210°C 410°F 210°C 410°F 210°C 410°F
Current Carrying Capacity at
1854 Amp 1564 Amp 1120 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C (113°F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
 ®
STER-ACCC

Sterlite Aluminum Conductor Composite Core (ACCC) conductor consists of a hybrid carbon and glass fiber core which is
wrapped with trapezoidal shaped aluminum strands. The high strength structural core carries most of the conductor's
mechanical load, while the fully annealed aluminum strands carry all of the conductor's electrical current. ACCC
conductor's composite core is much lighter and stronger than conventional or high-strength steel core.

Trapezoidal Wire

Composite Core

Application
Ideal for Reconductoring
Increase capacity while improving line clearance and losses.
Reduce strain on structures increasing life.
Reduced Line Losses in New Lines:
Under equal load conditions reduces line losses by 30 to 40 % compared to conductors of the same diameter and weight.
100% more capacity build towards future demand.

Benefits
With 28% more annealed aluminum in a trapezoidal configuration the ACCC conductor of the same diameter as ACSR,
can double the current (ampacity) rating; Higher operating efficiency reduces line losses and associated emissions by
more the 35%, resulting in more power delivered and lower power generation costs.
ACCC conductors use a patented carbon/glass/thermoset resin core that provides height strength and reduces height
temperature sag.
Can re-conductor existing pathways without structural modification and reduce capital expenses on new lines.
Uses conventional installation methods, tools, and mostly conventional hardware- no special tools and limited special
training.
Resists environmental degradation– will not rust, corrode, or cause electrolysis with aluminum conductors and
components.

Technical Specifications
Properties ACCC Helsinki ACCC Lisbon ACCC Copenhagen ACCC Drake
Typical Factors 5.97 mm 0.2355 in 7.11 mm 0.2799 in 5.97 mm 0.2350 in 9.53 mm 0.3752 in
Reference Specifications ASTM B857, ASTM B609 ASTM B857, ASTM B609 ASTM B857, ASTM B609 ASTM B857, ASTM B609
2
Total Cross Section Area 176.11 mm2 0.2730 in 358.40 mm2 0.5555 in2 246.57 mm2 0.3822 in2 588.30 mm2 0.9119 in2
Conductive Wire 1350 0 temper Al 1350 0 temper Al 1350 0 temper Al 1350 0 temper Al
Core Wire Composite Core Composite Core Composite Core Composite Core
Conductor Diameter 15.65 mm 0.6161 in 21.78 mm 0.8575 in 18.30 mm 0.7205 in 28.14 mm 1.1079 in
Weight 455 kg/km 305.7 lbs/mile 957 kg/km 642.8 lbs/mile 657 kg/km 441.5 lbs/mile 1558 kg/km 1046.9 lbs/mile
Ultimate Tensile Strength 7036 kg 15511.71 lbs 10574 kg 23311.65 lbs 7443.9 kg 16410.97 lbs 18691 kg 41206.55 lbs
DC Resistance
0.19 Ω/km 0.30 Ω/mile 0.09 Ω/km 0.14 Ω/mile 0.13 Ω/km 0.21 Ω/mile 0.06 Ω/km 0.09 Ω/mile
at 20°C Temperature
Maximum Operating
Temperature 175°C 347°F 175°C 347°F 175°C 347°F 175°C 347°F
Current Carrying Capacity at
710 Amp 1079 Amp 858 Amp 1484 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
STER-ECOTM

Eco Series conductors consist of trapezoidal shaped special aluminium alloy containing magnesium, silicon and copper
stranded with round core. The trapezoidal shape provide compactness to the extent of 96%.

Trapazoidal Aluminium
Wire
Aluminum Core

Application
Eco Seriess conductors are an innovative, efficient, low loss and most
importantly an economical solution for re-conductoring power lines and
constructing new lines. The higher efficiency of Eco Series Conductors
enables significant savings when substituted in grid systems for normal
ACSR or AAAC conductors. Also for delivery of same power to the
customers, Eco Series Conductors enable power generators to reduce the
amount of power they must generate and hence lesser emissions.

Benefits
2
Upto 30% less I R losses for same sized conductor
O
For same output runs cooler by 5-10 C(41-50°F), hence lower carbon emissions
Contributing to greenhouse gases
Can be deployed with existing structural designs

Technical Specifications
Properties ECO Panther
Typical Factors 2.37 mm 0.0933 in
Reference Specifications SS42408013, 14
Total Cross Section Area 314.11 mm2 0.9161 in2
Conductive Wire Al59 wire
Core Wire Al59 wire
Conductor Diameter 20.50 mm 0.8071 in
Weight 866 kg/km 581.9 lbs/mile
Ultimate Tensile Strength 7430 kg 16379.55 lbs
DC Resistance
at 20°C Temperature 0.10 Ω/km 0.15 Ω/mile

Maximum Operating
Temperature 95°C 203°F

Current Carrying Capacity at

750 Amp
Maximum Operating Temperature

Assumptions: Ampacity is calculated based on, 45°C ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of solar absorption, 0.6 as coefficient of emmisivity and 1200Wt/sqm coefficient for solar radiation, at sea level.
Sterlite is among
the largest fully
integrated
manufacturing
facilities globally
Since the past decade, Sterlite has developed technical
expertise in manufacture of bare overhead conductors and
proven its capabilities in developing solutions that have been
tested and certified by leading independent laboratories
across the globe.

Fully Equipped Plants with

International Standards
Three fully equipped plants to manufacture Overhead T&D
conductors with International Standards.

In house Properzi Aluminium Rod rolling mills feed the

manufacturing line for Transmission & Distribution
conductors. The mills manufacture electrical grade
Aluminium and Alloy Rods.

The plants have complete facilities for rod rolling, wire

drawing, heat treatment and stranding to ensure precise
tolerances to all inter national standards and stringent
specifications.

A technology upgrade review is periodically undertaken to

keep abreast with the latest manufacturing technology. There
is a strong focus on research and development. In house
domain expertise is used for customized solutions.
Quality

Our centralized quality control department comprises a team of experienced and quality engineers. At our fully
equipped laboratories, we continuously monitor quality parameters at all stages: from raw material inflow, in process
and final inspection.

In-house State of the art NABL accredited

laboratories for Quality Control & Testing

Based on specific customer requirements,

our Transmission & Distribution
conductors are put through stringent type
tests before dispatch. These tests include:
• Ultimate Tensile Strength
• Stress Strain
• Surface Condition
• DC Resistance
• Corona Inception and Extinction Voltage
• Radio Interface Voltage

Our Conductors conform to several

international standards:
• European Norms (EN)
• Swedish Standards (SS)
• IEC
•American Standards (ASTM)
• Indian Standards (IS)
• Australian Standards (AS)
• Canadian Standards (CSA)

Our Solutions have been tested & certified by various renowned laboratories across the globe such as ERDA (India), CPRI
(India), Kinectrics (Canada), Veki VNL (Hungary), SAG FGH (Germany), EDF (France), NETFA (South Africa), SABS (South
Africa), CSERI (China), Tag Corporation (India), NABL (India).
Packaging

The packing of the conductor is an integral part of the Features and Benefits
manufacturing process, and the kind of package must
be predetermined before production can begin. Optimum mechanical protection without breaking/
splintering like wooden batten
Unless otherwise specified or agreed with in case of
order, all type of conductors shall be shipped on Sterlite Impact and puncture resistant (second layer solid sheet)
standard steel reels having dimensions that can be Environmental resistance– long lifetime, unaffected by
provided on enquiry. climate change or UV exposure, unlike wood, zero risk of
Sterlite standard reels shall have enough condition to deterioration and fungus
stand against the ordinary handling in transportation Nail free- no risk of nail damage to conductor
and shipping and be found ready and handy enough at Reusable- can be dismantled and reused as and when
the time of installation in site. The reels will be stenciled required
legibly with following information; serial/drum
number, size and kind of conductor, length of Can be stored as long as possible
conductor, and any other identification marks specified
on the order by the purchaser.

Outer Protection
Outer layer of conductor shall be protected with Thick
PE sheet and solid PP sheet in place of wooden lagging.
Inner surface of flange and barrel shall be protected with
PPE Solid Sheet. The Drums shall be painted with one
primer coat and then synthetic enamel.
Global Footprints

Overhead Aluminium Conductors

High Performance Conductors

Optical Ground Wire (OPGW)

Power transmission & distribution solutions proven in global networks

Sterlite ® has been instrumental for the supply of technologically advanced power solutions to leading
incumbents over 65 countries.

Sterlite’s conductors have been deployed extensively Globally, our high performance conductors have been
across India. Our solutions are being used by: installed in the T&D networks of the following
geographies:
PGCIL- one of the world’s largest transmission
utilities. Latin America
Major Transcos like MSETCL, UPPTCL, AP Transco, USA
KPTCL, RRVPNL, MPPTCL, TANtransco, etc. Europe
IPPs like BALCO, Jindal, Adani, Reliance as well Africa
Renewable Energy providers like Suzlon
India
The Sterlite Advantage

Global experience
 Expert in providing customized solutions to business challenges in the transmission industry, worldwide
 Significant supply record
 In India, 25% of the national grid runs on Sterlite's conductors

Building Infrastructure
On BOOM Basis,
 2850 Kms of transmission lines & 2 substations across India
 Over 3000 Kms of OPGW Live line being developed by MTCIL, 1st of its kind Joint Venture with state owned utility
of Maharashtra, India
 Fiber brought to over 1 million homes in top 6 Metro cities of India

End-to-end project implementation

Sterlite ensures complete control over the value chain and delivers end-to-end project management services.
Sterlite’s project management suite:

Network, Network
Network System Consultancy
planning operation &
build auditing services
& design management

Qualified and experience talent pool

Sterlite has a qualified talent pool, experienced in network design, project management, network implementation
and network maintenance.

Credible partners
Sterlite has partnered with reputed project management companies and Original Equipment Manufacturers (OEMs),
to ensure that the delivery of the project is streamlined.

Solution development for newer applications

Sterlite continues to enhance its portfolio taking into account the bandwidth need evolving from client applications.

Fully integrated Company

Backward integration of manufacturing processes and forward integration of our technology solutions

Local support
With offices in 10 countries, Sterlite always has a relationship manager who is a mere phone call away, to understand
your growth aspirations and to explore areas where value can be added to your business.
 Partnering India’s growth in Power sector

25% of India’s National Grid

runs on Sterlite’s conductors
Uri

Baddi
Nakodar Amritsar Hoshiarpur
Verka
Muktsar Makhu
Dhuri Sonipat
Talwandi Sabo
Mohali
Bathinda Chandigarh Shoghi
Mansa Rajokari Shanti Dist. Solan
Ludhiana Delhi
Kotkapura Gurgaon
Jatikalan Haridwar
Ratangarh
Faridabad
Sikar Surajpur
Muradnagar Roorkee Road

Sujalpur

Kawai

Barmer
Abdasan

Kolkata

Dhar Sambalpur
Mundra Purlia Kashipur
Vinzol Chaibasa Kharagpur
Juri, Hata Keonjhar
Pirana
Jetpur
Una

Amravati

Bhilai
Murbad

Secunderabad

Shapur Nagar

Bellary Bandlaguda
Mahboobnagar

Chennai

Overhead Aluminium Conductors

High Performance Conductors

Power Cables

We make it easier, faster and more cost effective to build infrastructure for power transmission and distribution.
Power Business

Sterlite provides power transmission & distribution companies a holistic one stop window for assessment,
development & implementation of solutions for their power transmission & distribution(T&D) networks.

T&D Network Assessments Development Implementation

• Assessment of existing & potential power • T&D Solution Development • T&D Solution Manufacture
demand • T&D Solution Testing • Inventory Management & Supply
• Technical Analysis • Technical Support and Service
• Assessment of suitable solution options

Sterlite’s portfolio also includes:

OPGW Power Infrastructure

Since the past two decades, Sterlite has developed Sterlite has been awarded five projects for building
technical expertise in fibre optic cables and proven its power transmission systems (line and substations) in
capabilities in the manufacture of energy efficient bare India, as a developer, on a Build-Own-Operate-
overhead transmission & distribution conductors. Maintain (BOOM) basis. For these projects, Sterlite
Sterlite has integrated these strengths in its undertakes designing, financing, construction, and
comprehensive OPGW solution, becoming the first fully maintenance of the transmission systems for
integrated manufacturer of OPGW cables in India. concession periods ranging from 25 to 30 years.
These transmission lines would help facilitate power
Hardware & Accessories evacuation and would be used for SEBs, Power Gencos
Compatible accessories like dead ends, suspension sets, for which Sterlite would earn a fixed transmission tariff.
joints/joint boxes, vibration dampers and all necessary
fittings , for a whole range of OPGW & HPC offerings , are Key Highlights:
provided as part of Sterlite’s solution. • Total value: Approx US $ 1014 Mn
• Approx 2850 Km of transmission lines + 2 substations
Power Cables • India’s first 765 kV D/C transmission line
Sterlite’s single integrated Power Cables facility at
Haridwar, manufactures and supplies MV, HV and EHV Sterlite’s Power Infrastructure portfolio of the five
cables. The plants have complete facilities for projects would evacuate and transmit power through a
sheathing, rod rolling, wire drawing, heat treatment network of 2850 km of transmission lines and 2
and stranding to ensure precise tolerance to all substations in the Indian states of Maharashtra,
international standards and stringent specification 6.6 Gujarat, Madhya Pradesh, Chattisgarh, West Bengal,
to 220 kV. Bihar, Assam and Rajasthan.
These EHV projects represent significant advancements
in the field of power transmission. These projects
would enhance the overall grid capacity significantly
and substantially reduce transmission power losses,
thus assisting the economic development of the
nation.

“Enabling lowest cost of Energy Transmission over the life cycle”

For product details/ query, contact nearest Sales representative or write to us at communications@sterlite.com
Certificates

This is to certify that: This is to certify that:

Sterlite Technologies Limited Sterlite Technologies Ltd

(Transmission Business Division) (Transmission Business Division)
Survey 99/2/22, Rakholi, Silvassa 396230 INDIA Survey 99/2/22, Rakholi, Silvassa 396230 INDIA

operates a operates a

ENVIRONMENTAL MANAGEMENT SYSTEM OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM

which complies with the requirements of which complies with the requirements of

AS/NZS ISO 14001:2004 OHSAS 18001:2007

for the following scope for the following scope

The manufacture and supply of aluminium and aluminium alloy bare overhead The manufacture and supply of aluminium and aluminium alloy bare overhead
conductors with or without galvanized/aluminised steel reinforcements, ACAR, for conductors with or without galvanized/aluminised steel reinforcements, ACAR, for
power transmission and distribution lines, aluminium and aluminium wire and wire power transmission and distribution lines, aluminium and aluminium wire and wire
rods. rods.

Certificate No: CEM21196 Certificate No: OHS20818

Issued: 2 July 2012 Originally Certified: 14 July 2009 Issued: 2 July 2012 Originally Certified: 14 July 2009
Expires: 13 July 2015 Current Certification: 29 June 2012 Expires: 13 July 2015 Current Certification: 29 June 2012

William Smith Duncan Lilley

William Smith Duncan Lilley
Certification Manager Global Head – Assurance Services
Certification Manager Global Head – Assurance Services

Registered by:
Registered by: SAI Global Certification Services Pty Ltd (ACN 108 716 669) 286 Sussex Street Sydney NSW 2000 Australia with SAI Global Limited
SAI Global Certification Services Pty Ltd (ACN 108 716 669) 286 Sussex Street Sydney NSW 2000 Australia with SAI Global Limited 11/12 Swastik Disa Business Park behind Vadhani Estate L.B.S Marg Ghatkopar (W) Mumbai 400086 India (“SAI Global”) and
11/12 Swastik Disa Business Park behind Vadhani Estate L.B.S Marg Ghatkopar (W) Mumbai 400086 India (“SAI Global”) and subject to the SAI Global Terms and Conditions for Certification. While all due care and skill was exercised in car rying out this
subject to the SAI Global Terms and Conditions for Certification. While all due care and skill was exercised in carrying out this assessment, SAI Global accepts responsibility only for proven negligence. This certificate remains the property of SAI Global and must
assessment, SAI Global accepts responsibility only for proven negligence. This certificate remains the property of SAI Global and must be returned to SAI Global upon its request. To verify that this certificate is current please refer to SAI Global On-Line Certification
be returned to SAI Global upon its request. To verify that this certificate is current please refer to SAI Global On-Line Certification register at http://www.saiglobal.com
register at http://www.saiglobal.com
Certificates
 STL/C-HPC/Jan 2014

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