A Guide to Wire and Cable Construction

Table of Contents

Introduction .............................................................4
Corporate Profile ..................................................4
Quality Policy ............................................................................... 4
Mission Statement ..................................................................... 4
Standard .....................................................................5
Standard Making Bodies ......................................................... 5
Specification ............................................................5
Conductor Materials ...........................................5
Copper ........................................................................................... 5
Aluminum ..................................................................................... 5
Copperweld ................................................................................. 5
Alumoweld ................................................................................... 5
Tinsel .............................................................................................. 5
Thermocouple............................................................................. 5
Copper Materials for Electrical Conductors ...................... 5
Conductor Terminology ....................................6
Gauge ............................................................................................ 6
MCM............................................................................................... 6
KCMIL ............................................................................................. 6
CM (Circular Mil) ....................................................................... 6
IACS (International Annealed Copper Standard) ........... 6
Wire Coating ................................................................................ 6
Tinning Designations .........................................6
Bare Copper ................................................................................ 6
Tinned Copper ............................................................................ 6
Heavy Tin ...................................................................................... 6
Bare Copper Overtinned ......................................................... 6
Bare Copper Fused ................................................................... 6
Tin Copper Overtinned ............................................................ 6
Prebond ......................................................................................... 6
Topcoat .......................................................................................... 6
Overcoat ........................................................................................ 6
Annealing ..................................................................6
Conductor Making Process ........................ 6-7
Wire Bars ....................................................................................... 6
Rod.................................................................................................. 6
Stranding ....................................................................................... 6
Bunch Strand ............................................................................... 6
Concentric Strand ...................................................................... 7
Rope Lay - Bunch Stranded Members .............................. 7
Rope Lay - Concentric Stranded Members ...................... 7
Compact Round Conductor ................................................... 7
Compressed Round Conductor............................................ 7
Sector Conductor ....................................................................... 7
Segmental Conductor .............................................................. 7
Annular Conductor .................................................................... 7
Filled Strand ................................................................................. 7
Wire Drawing ...................................................... 7-8
Rod Breakdown Machines ..................................................... 7
Intermediate Machines ............................................................ 7
Fine Wire Machines................................................................... 7
Dies ................................................................................................. 7
Drawing Solution ........................................................................ 8
Wire Assembly .......................................................8
Bunchers ....................................................................................... 8
Tubular or Barrel Stranders ..................................................... 8
Strander ......................................................................................... 8
ASTM Standards for Copper Conductors .......................... 8
Lay ................................................................................................... 8
Direction of Lay .......................................................................... 8
Bird Caging ................................................................................. 8-
Insulation and Jackets ................................ 8-10
User needs that determine the material selection
for Insulation and Jackets ....................................................... 8
Classes (Thermosetting and Thermoplastics) ................. 8
Special Definitions ..................................................................... 8
Types of Insulations and Jackets .................................. 9-10
Assembly Operations...................................... 10
Shieldind and Armoring .......................... 10-11
Purpose of Shielding ............................................................. 10
Types of Shielding and Armoring ...................................... 11
Color Coding (ICEA Methods) ............... 11-12
Technical Data ................................................ 13-19
Color Coding Tables ........................................................13-16
Nominal Temperature Operating Ranges for
Insulation Materials ................................................................ 17
Properties of Rubber Used for Insulation ...................... 18
Properties of Plastic Used for Insulation ........................ 18
Check Lists for Specifying Wire and Cable .................... 19
Glossary of Terms ........................................20-22

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