Aluminium Alloy wires for Conductors & Cables Manufacturing
High-conductivity, high-strength aluminium rods and alloy wires for overhead power transmission and distribution conductors.
Overview
At Uday Aluminium, we manufacture premium-quality aluminium rods and aluminium alloy wires that form the foundation of modern overhead power transmission and distribution conductors. Our products are engineered to deliver the ideal combination of high electrical conductivity, mechanical strength, corrosion resistance, and long-term reliability, making them the preferred choice for conductor manufacturers, utilities, EPC contractors, and OEMs.
Our conductor-grade materials are used in the manufacture of AAC, AAAC, ACSR, ACAR, AACSR, and High Temperature Low Sag (HTLS) conductors, supporting applications ranging from urban distribution networks to extra-high-voltage transmission lines.
We manufacture a comprehensive range of EC Grade 1350-H19, Aluminium Alloy 6201-T81, AL-59, TAL, STAL, ZTAL, and Aged Aluminium Alloy Rods & Wires, produced under stringent quality controls to ensure consistent electrical and mechanical properties, excellent surface finish, and superior drawability for efficient conductor manufacturing.
For next-generation transmission networks, Uday Aluminium also supplies thermal-resistant aluminium alloys for HTLS conductors capable of continuous operation at 150°C to 210°C, enabling higher current-carrying capacity, reduced thermal sag, and improved transmission efficiency without major infrastructure upgrades.
With advanced manufacturing facilities, rigorous quality assurance, and compliance with national and international standards, Uday Aluminium is your trusted partner for high-performance aluminium conductor materials that power reliable and efficient transmission and distribution networks worldwide.
Applications
Uday Aluminium Product Capability
| Product | Size Range | Primary Use |
|---|---|---|
| Aluminium Rods | 9.5 mm to 1.5 mm | Conductor manufacturing / drawing stock |
| Aluminium Alloy 6201 Rod | 9.5 mm to 1.5 mm | AAAC and alloy conductor manufacture |
| AL-59 Rod / Wire | 9.5 mm rod to 3.0 mm wire | High-performance alloy conductor applications |
| ZTAL / STAL / TAL Rods | 9.5 mm | HTLS conductor inputs |
| Aged Aluminium Alloy Rods | 9.5 mm to 3.0 mm | Strengthened conductor rod feedstock |
| Aged Aluminium Alloy Wire | 9.5 mm to 1.5 mm | Conductor wire and stranding applications |
Conductor Types
| Type | Construction | Where It Wins |
|---|---|---|
| AAC — All Aluminium Conductor | EC 1350-H19 strands only | Maximum conductivity per kg; urban distribution, short spans, coastal areas where steel corrodes |
| AAAC — All Aluminium Alloy Conductor | 6201-T81 / AL59 alloy strands only | Better strength-to-weight and corrosion resistance than ACSR; coastal and polluted corridors |
| ACSR — Aluminium Conductor Steel Reinforced | 1350-H19 strands over galvanized steel core | Industry workhorse; long spans, river crossings, all transmission classes |
| ACAR — Aluminium Conductor Alloy Reinforced | 1350-H19 strands over 6201 alloy core | ACSR-class strength with no steel; used where core corrosion or weight is a concern |
| AACSR — Aluminium Alloy Conductor Steel Reinforced | Alloy strands over steel core | Maximum mechanical strength; extra-long spans and heavy ice/wind zones |
| HTLS — High Temperature Low Sag | Thermal-resistant Al / annealed Al over special cores | Re-conductoring: up to 2× ampacity on existing towers |
HTLS Variants
| Variant | Core / Aluminium | Max Continuous Temp | Key Point |
|---|---|---|---|
| TAL (TACSR) | Steel core + thermal-resistant Al-Zr strands | 150°C | Uprating standard ACSR lines with same construction and clearances |
| STAL / ZTAL | Steel core + super/extra thermal Al-Zr strands | 210°C | Higher temperature class of the same concept |
| INVAR (STACIR / ZTACIR) | Aluminium-clad Invar core + ZTAL strands | 210°C | Lowest sag of all — Invar core barely expands |
| ACCR | Aluminium-matrix composite core | 210°C (240°C short-time) | Fully metallic-compatible composite design |
| GAP (GTACSR) | High-strength steel core with grease-filled gap + TAL/ZTAL | 210°C | Steel core moves freely in grease — sag fixed at erection |
Selected ACSR Distribution Conductors
The following table highlights some of the most commonly used ACSR conductor sizes in India, along with their typical construction and technical specifications. Uday Aluminium is committed to delivering products that meet the highest standards of quality, consistency, and performance.
| Conductor | Al Area (mm²) | Stranding — Al | Stranding — Steel | Overall Ø (mm) | Weight (kg/km) | Breaking Load (kN) | Typical Use |
|---|---|---|---|---|---|---|---|
| Mole | 10 | 6 × 1.50 | 1 × 1.50 | 4.50 | ~43 | ~4 | LT spurs |
| Squirrel | 20 | 6 × 2.11 | 1 × 2.11 | 6.33 | ~85 | ~7.7 | 11 kV distribution |
| Gopher | 26 | 6 × 2.36 | 1 × 2.36 | 7.08 | ~106 | ~9.6 | 11 kV |
| Weasel | 30 | 6 × 2.59 | 1 × 2.59 | 7.77 | ~128 | ~11.1 | 11 kV distribution, messenger |
| Ferret | 42 | 6 × 3.00 | 1 × 3.00 | 9.00 | ~171 | ~14.9 | 11–33 kV |
| Rabbit | 50 | 6 × 3.35 | 1 × 3.35 | 10.05 | ~214 | ~18.2 | 11–33 kV |
| Mink | 63 | 6 × 3.66 | 1 × 3.66 | 10.98 | ~255 | ~21.6 | 33 kV |
| Raccoon | 77 | 6 × 4.09 | 1 × 4.09 | 12.27 | ~318 | ~26.9 | 33 kV sub-transmission |
| Otter | 83 | 6 × 4.22 | 1 × 4.22 | 12.66 | ~339 | ~28.4 | 33 kV |
| Cat | 95 | 6 × 4.50 | 1 × 4.50 | 13.50 | ~385 | ~32.0 | 33–66 kV |
| Dog | 100 | 6 × 4.72 | 7 × 1.57 | 14.15 | ~394 | ~32.4 | 33–66 kV |
Standards Compliance
| Standard | Description |
|---|---|
| IS 398 Parts 1–5 | Aluminium conductors for overhead transmission |
| BS 215 Parts 1 & 2 | AAC and ACSR |
| ASTM B231 | AAC |
| ASTM B232 | ACSR |
| ASTM B399 | AAAC (6201-T81) |
| IEC 61089 | Round wire concentric lay overhead electrical stranded conductors |
| EN 50182 | Conductors for overhead lines |
| DIN 48201 / DIN 48204 | German conductor standards |
| IS 1778 | Reels and drums for conductor supply |
Mechanical Properties
| Property | Value | Note |
|---|---|---|
| Ultimate Tensile Strength (UTS) — AL59/6201 strand (T81) | 300 MPa (min) | Per productSeries.js AAAC strand data |
| Yield Strength | On request | Contact for certified test data |
| Elongation | On request | Contact for certified test data |
Electrical Conductivity
Technical Data Sheet
Aluminium Alloy wires for Conductors & Cables Manufacturing — Full Technical Data Sheet
Request the complete PDF datasheet with certified mechanical, chemical and dimensional data for this product.