Indian Standard: Specification For Round Steel Wire For Ropes
Indian Standard: Specification For Round Steel Wire For Ropes
(Reaffirmed 2001)
Indian Standard
SPECIFICATION FOR ROUND STEEL WIRE FOR ROPES
( Third Revision )
(Incorporating Amendment Nos. 1 & 2)
UDC
669.14-426.2 : 677.72
OF
INDIAN
STANDARDS
Price Group 4
IS : 1835 - 1976
Indian Standard
SPECIFICATION FOR ROUND STEEL WIRE FOR ROPES
( Third Revision )
Wrought Steel Products Sectional Committee, SMDC 5
Chairman DR U. N. BHRANY Members SHRI E. ABRAHAM SHRI M. ANJANEYULU Association of Indian Engineering Industry, Calcutta Mining & Allied Machinery Corporation Ltd, Durgapur Representing Modella Steel and Alloys Ltd, Bombay
SHRI D. P. SANYAL ( Alternate ) Bokaro Steel Ltd, Bokaro Steel City SHRI H. S. ASWATH SHRI S. G. TUDEKAR ( Alternate ) National Test House, Calcutta SHRI N. C. BAGCHI Metallurgical and Engineering Consultants (India) SHRI A. K. BANERJEE Ltd, Ranchi SHRI B. N. SINGH ( Alternate ) SHRI S. BANERJEE Steel Rerolling Mills Association of India, Calcutta Guest, Keen, Williams, Ltd, Howrah SHRI S. K. BASU SHRI A. ROY CHOWDHURY ( Alternate ) The Tata Iron & Steel Co Ltd, Jamshedpur SHRI P. K. CHAKRAVARTY SHRI M. C. KUMARASWAMY ( Alternate ) Hindustan Steel Ltd, Durgapur SHRI G. CHATTERJEE SHRI K. Z. MATHEN ( Alternate ) Ministry of Defence (DGI) SHRI P. K. CHATTERJEE SHRI V. RAMASWAMY ( Alternate ) National Metallurgical Laboratory (CSIR), SHRI R. CHOUBEY Jamshedpur SHRI R. SINGH ( Alternate ) DR N. S. DATAR Hindustan Steel Ltd, Rourkela SHRI K. S. SINGH ( Alternate ) Tinplate Company of India Ltd, Golmuri MAJ-GEN M. G. DEWAN SHRI S. BALASHANKAR ( Alternate ) ( Continued on page 2 ) BIS 2007 BUREAU OF INDIAN STANDARDS This publication is protected under the Indian Copyright Act (XIV of 1957) and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act.
IS : 1835 - 1976
( Continued from page 1 ) Members Representing DIRECTOR (M & C), RDSO Ministry of Railways CHEMIST & METALLURGIST, CHITTARANJAN LOCOMOTIVE WORKS ( Alternate ) SHRI A. K. GUHA Inspection Wing, Directorate General of Supplies & Disposals, New Delhi SHRI P. C. MUSTAFI ( Alternate ) Ministry of Railways JOINT DIRECTOR STANDARDS (WAGON) ADDITIONAL DIRECTOR R.S. (IRON & STEEL) ( Alternate ) DR V. C. KASHYAP Special Steels Ltd, Bombay SHRI S. S. MURANJAN ( Alternate ) SHRI M. N. KHANNA Hindustan Steel Ltd, Bhilai SHRI K. C. SOM ( Alternate ) DR D. M. LAKHIANI Indian Iron and Steel Co Ltd, Burnpur SHRI T. K. DATTA ( Alternate ) SHRI P. LAXMINARAYANA Hindustan Shipyard Ltd, Visakhapatnam SHRI R. C. MAHAJAN Indian Steel & Wire Products Ltd, Indranagar, Jamshedpur SHRI AVTAR SINGH( Alternate ) SHRI M. K. PRAMANIK Iron and steel Control, Calcutta SHRI R. A. RAMA RAO Hindustan Steel Works Construction Ltd, Calcutta SHRI R. H. G. RAU Mukand Iron & Steel Works Ltd, Bombay SHRI S. A. NIGAM ( Alternate ) SHRI D. V. REDDI Indian Institute of Metals, Calcutta SHRI D. SEN Ministry of Defence (DGOF) SHRI Y. C. SUBRAMANYA ( Alternate ) SHRI R. K. SETHI Industrial Fasteners Association of India, Calcutta DR S. J. SHAH Spinning Machinery (Cotton System) Sectional Committee, TDC 30, ISI Metals Box Co of India Ltd, Calcutta SHRI L. SIKAND SHRI K. R. NARASIMHAN ( Alternate ) SHRI D. SRINIVASAN Joint Plant Committee, Calcutta SHRI B. P. GHOSH ( Alternate ) TECHNICAL ADVISER (BOILERS) Central Boilers Board, Ministry of Industrial Development, New Delhi M. N. Dastur & Co (Pvt) Ltd, Calcutta SHRI K. S. VAIDYANATHAN SHRI G. VENKATESWARLU Ministry of Defence (R & D) SHRI E. S. BHAGIRATHA RAO ( Alternate ) SHRI C. R. RAMA RAO, Director General, ISI ( Ex-officio Member ) Director (Struc & Met) Secretary SHRI SHANTI SWARUP Assistant Director (Metals), ISI ( Continued on page 13 )
IS : 1835 - 1976
Indian Standard
SPECIFICATION FOR ROUND STEEL WIRE FOR ROPES
( Third Revision )
0. F O R E W O R D 0.1 This Indian Standard (Third Revision) was adopted by the Indian Standards Institution on 21 May 1976, after the draft finalized by the Wrought Steel Products Sectional Committee had been approved by the Structural and Metals Division Council. 0.2 This standard was first issued in 1961 and was twice revised in 1966 and 1972. In this third revision the important modifications pertain to the inclusion of steel wires up to nominal diameter of 5.0 mm, chemical composition of steel wire and the adhesion test. 0.3 In this standard, an informative appendix ( see Appendix A ) has been included for the benefit of the purchaser, giving particulars to be specified while ordering for steel wires conforming to this standard. 0.4 This edition 4.2 incorporates Amendment No. 1 (June 1980) and Amendment No. 2 (October 1997). Side bar indicates modification of the text as the result of incorporation of the amendments. 0.5 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS : 2-1960*. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 1. SCOPE 1.1 This standard covers the requirements for round steel wires of nominal diameters 0.20 to 5.0 mm for use in the manufacture of wire ropes. 1.2 The chemical composition shall be suitably selected from Table 1 so as to meet with the various tensile designation of wires given in Table 2. 2. TERMINOLOGY 2.0 For the purpose of this standard, the following definitions and the definitions given in IS : 1956 (Part V)-1976 shall apply.
*Rules for rounding off numerical values ( revised ). Glossary of terms relating to iron and steel, Part V Bright steel bar and steel iron.
IS : 1835 - 1976 2.1 Bundle Two or more coils or a number of lengths of wire securely bound together. 2.2 Coil One continuous length of wire as drawn in the form of coil. 2.3 Piece A length of wire without joint or splice of any description in the finished wire. 3. TYPES 3.1 The steel wire shall be of the following types: a) Bright wire (ungalvanized wire), and b) Galvanized wire: i) Type B, ii) Type AB, and iii) Type A. 4. SUPPLY OF MATERIAL 4.1 General requirements relating to the supply of steel wire for ropes shall conform to IS : 1387-1967*. 5. CHEMICAL COMPOSITION 5.1 The chemical analysis of various grades of wire when made in accordance with the relevant parts of IS : 228 shall be as given in Table 1.
TABLE 1 CHEMICAL COMPOSITION OF STEEL WIRE FOR ROPES RANGE (2) 0.35 to 1.00 0.30 to 0.90 0.10 to 0.35 GRADES CONSTITUENT, PERCENT (1) Carbon Manganese Silicon Sulphur, Max Phosporus, Max Copper, Max Nickel, Max Chromium, Max *Acceptable within point range. P + S = 0.08, Max. *General requirements for the supply of metallurgical materials ( first revision ). Methods of chemical analysis of steels ( second revision ). (Being issued in parts).
20 15
1 (3) 5 * * * 2 (4) 5 20 15 * * * 3 (5) 5 20 15 * * * 4 (6) 5 30 20 * * * 0.020 0.025 0.06 0.05 0.05 0.025 0.025 0.10 0.10 0.10 0.04 0.04 0.10 0.10 0.10 0.05 0.05 0.15 0.10 0.10
IS : 1835 - 1976 6. MANUFACTURE 6.1 The wire shall be cold drawn from steel made by the open hearth, electric, duplex, basic-oxygen or a combination of these processes. In case any other process is employed by the manufacturer, prior approval of the purchaser should be obtained. 6.2 If so required, the manufacturer shall furnish the steel makers cast analysis to the purchaser and issue a certificate to him that the wire has been drawn from the certified steel. 7. FREEDOM FROM DEFECTS 7.1 All finished wires shall be well and cleanly drawn to the dimensions specified. The wire shall be sound, free from splits, surface flaws; rough, jagged and imperfect edges; and other harmful surface defects. 8. TENSILE DESIGNATION 8.1 The wire may be ordered in any one of the designations specified in Table 2.
TABLE 2 TENSILE STRENGTH RANGES FOR DIFFERENT WIRE SIZES ( Clauses 8.1 and 12.2.3 ) TENSILE DESIGNATION NOMINAL WIRE DIAMETER, mm
(1) 1230 (125) 1420 (145) 1570 (160) 1770 (180) 1960 (200)
2 and Over Below 2 Up to 1.5 Below 1.5 Up to 1 Below 1 Up to 0.5 Below 0.5 Tensile Strength Range N/mm2* (kgf/mm2) (2) 1 230-1 490 (125-152) 1 420-1 690 (145-172) 1 570-1 790 (160-187) 1 770-2 020 (180-207) 1 960-2 220 (200-226) (3) 1 230-1 520 (125-155) 1 420-1 710 (145-175) 1 570-1 860 (160-190) 1 770-2 060 (180-210) 1 960-2 260 (200-230) (4) 1 230-1 550 (125-158) 1 420-1 740 (145-178) 1 570-1 890 (160-193) 1 770-2 090 (180-213) 1 960-2 280 (200-232) (5) 1 230-1 580 (125-161) 1 420-1 780 (145-181) 1 570-1 920 (160-196) 1 770-2 110 (180-216) 1 960-2 300 (200-235) (6) 1 230-1 620 (125-165) 1 420-1 810 (145-185) 1 570-1 960 (160-200) 1 770-2 160 (180-220) 1960-2 340 (200-239)
IS : 1835 - 1976 9. GALVANIZING 9.1 The galvanized coating of steel wire shall conform to the requirements given in Table 3.
TABLE 3 MASS OF ZINC DEPOSITED AND NUMBER OF IMMERSIONS PER MINUTE ( Clauses 9.1 and 11.3 ) GALVANIZED WIRE DIAMETER OF BRIGHT AND GALVANIZED WIRE TYPE B, TYPE AB WIRES*, mm TENSILE DESIGNATIONS TENSILE DESIGNATIONS 1230, 1420, 1570, 1770 1420, 1570 AND 1770 AND 1960 GALVANIZED WIRE TYPE A, TENSILE DESIGNATIONS 1230, 1420, 1570 AND 1770
Number of Immersions
From (Incl)
To Minimum Number of Minimum (Excl) Mass of Immersions Mass of Zinc, Zinc 1 Mi Mi- g/m2 g/m2 nute nute dura- duration tion
(1) 0.20 0.25 0.40 0.50 0.60 0.80 1.00 1.20 1.50 1.90 2.50 3.20 3.70 4.25
(2) 0.25 0.40 0.50 0.60 0.80 1.00 1.20 1.50 1.90 2.50 3.20 3.70 4.25 5.00
(4)
(5)
(9) 75 90 110 130 150 165 180 205 230 250 260 275
No test No test 1 1 1 1 1 1
*Before removing the zinc coating. The galvanizing process is not prescribed.
1 Mi Minute nute dura- duration tion (10) 1 1 1 1 2 2 2 3 3 3 (11) 1 1 1 1 1 1
Minimum Mass of Zinc, g/m2 No. of Immersions
IS : 1835 - 1976 10. TOLERANCES ON DIAMETER 10.1 Wires shall conform to the tolerances given in Table 4.
TABLE 4 DIMENSIONAL LIMITS AND TOLERANCES (All dimensions in millimetres) DIAMETER OF WIRE TOLERANCES
From (Incl) (1) 0.20 0.40 1.00 1.60 2.00 2.40 3.70 4.25 To (Excl) (2) 0.40 1.00 1.60 2.00 2.40 3.70 4.25 5.00
11. TESTS FOR COATING 11.1 The coating of galvanized wire shall be tested on each end of one for every 5 coils or part thereof or such other portions as may be agreed to between the purchaser and the manufacturer. 11.2 Uniformity of Zinc Coating This shall be determined in accordance with the method laid down in IS : 2633-1972*. 11.3 Mass of Zinc Coating When determined in accordance with IS : 6745-1972, the mass of zinc coating shall not be less than that specified in Table 3.
*Methods for testing uniformity of coating on zinc coated articles ( first revision ). Method for determination of weight of zinc coating on zinc coated iron and steel articles.
Bright and Galvanized Wire Type B (3) 0.010 0.015 0.020 0.025 0.025 0.030 0.030 + 0.050 0.030 Galvanized Wire Type AB (4) 0.015 0.020 0.025 Galvanized Wire Type A (5) 0.030 + 0.040 0.030 + 0.040 0.030 + 0.050 0.030 + 0.060 0.030 + 0.060 0.030 + 0.080 0.030
IS : 1835 - 1976 12. MECHANICAL TEST 12.1 Selection of Test Samples Test sample of sufficient length for mechanical tests shall be cut from one end of each coil. 12.2 Tensile Test Tensile test shall be carried out in accordance with IS : 1521-1972*. 12.2.1 The test sample shall be clamped in the testing machines with the jaws set at a distance not less than the following: a) For diameter up to and including 100 times the nominal 2.00 mm diameter b) For diameter exceeding 2.00 mm 200 mm 12.2.2 The tensile strength of wire shall be calculated on the actual diameter. 12.2.3 The tensile strength of any wire shall not fall outside the limits of the range given in Table 2 for the appropriate tensile designation and nominal wire diameter. 12.3 Torsion Test Torsion test shall be carried out in accordance with IS : 1717-1971. 12.3.1 The torsion test of the wire shall be applicable to wire having a diameter of 0.5 mm and over. 12.3.2 The length of the test piece between the vices shall be 100 times the diameter of the wire. When this length is not possible, the number of torsions ( see Table 5 ) which the wire shall withstand shall be equal to the number of torsions specified for 100 diameters multiplied by the ratio of the length tested to 100 times the diameter. 12.3.3 Depending on its diameter and tensile strength, the wire shall be capable of withstanding, before fracture, the minimum number of turns given in Table 5. 12.3.4 For all the samples tested for torsion test, the torsion values shall be above the minimum acceptance limit. 12.4 Reverse Bend Test If required by the rope specification and so specified by the purchaser, the reverse bend test shall be conducted in accordance with IS : 1716-1971. 12.4.1 This test shall be applicable to wire having a diameter 0.5 mm and over. 12.4.2 The test sample shall withstand without failure the minimum number of bends as specified in Table 6, appropriate to the nominal wire diameter and the tensile designation.
*Method for tensile testing of steel wire ( first revision ). Method for simple torsion testing of steel wire ( first revision ). Method for reverse bend testing of steel wire ( first revision ).
IS : 1835 - 1976
TABLE 5 MINIMUM NUMBER OF TORSIONS IN 100 X WIRE DIAMETER ( Clauses 12.3.2 and 12.3.3 )
GALVANIZED DIAMETER OF WIRE BRIGHT AND GALVANIZED GALVANIZED WIRE mm WIRE TYPE A, WIRE TYPE B, TYPE AB, TENSILE DESIGNATIONS TENSILE DESIGNA- TENSILE DESIGNATIONS TIONS
From (Incl)
1230 1570 1770 1960 1420 1570 1770 1230 1570 1770 and and 1420 1420 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) 0.20 0.50 No No No No test test test test 0.50 1.00 34 30 28 22 30 28 26 20 19 15 1.00 1.30 33 29 26 20 29 26 23 19 18 13 1.30 1.80 33 28 25 19 28 25 22 18 17 11 1.80 2.00 33 26 24 18 26 24 21 18 17 11 2.00 2.30 32 26 24 17 18 17 11 2.30 3.00 31 24 22 16 16 14 3.00 3.70 30 22 20 14 12 3.70 4.25 27 20 18 No test 4.25 5.00 25 18 No test NOTE 1 The sample after test shall be visually examined and it shall not split. NOTE 2 A dash () indicates wires are not produced. TABLE 6 REQUIREMENTS FOR REVERSE BEND TEST ( Clause 12.4.2 ) BRIGHT AND GALVANIZED GALVANIZED WIRE TYPE B, WIRE TYPE AB, TENSILE DESIGNATIONS TENSILE DESIGNATIONS GALVANIZED WIRE TYPE A, TENSILE DESIGNATIONS
To (Excl)
DIAMETER OF WIRE
mm (1) 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00
RADIUS
mm
(2) 1.25
1.75
2.50
1230 1570 1770 1960 1420 1570 1770 1230 1570 1770 and and 1420 1420 (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) 9 7 6 6 7 6 5 6 5 5 15 13 12 12 13 12 11 11 10 8 13 11 10 10 11 10 9 9 8 7 11 9 8 8 9 8 7 8 7 5 10 8 7 7 8 7 6 7 6 5 15 15 14 11 15 14 13 13 12 9 14 14 13 10 14 13 12 12 11 7 13 13 12 9 13 12 11 11 10 5 12 12 11 8 12 11 10 10 9 5 10 11 10 7 11 10 9 9 8 4 10 10 9 7 10 9 8 9 8 4 ( Continued )
IS : 1835 - 1976
TABLE 6 DIAMETER OF WIRE REQUIREMENTS FOR REVERSE BEND TEST Contd BRIGHT AND GALVANIZED GALVANIZED WIRE TYPE B, WIRE TYPE AB, TENSILE DESIGNATIONS TENSILE DESIGNATIONS GALVANIZED WIRE TYPE A, TENSILE DESIGNATIONS
mm (1) 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.60 2.70 2.80 2.90 3.00 3.10 3.20 3.30 3.40 3.50 3.60 3.70 3.80 3.90 4.00 4.10 4.20 4.40 4.60 4.80 5.00
RADIUS
(3) (4) 17 15 13 11 10 13 12 11 10 9 13 12 11 10 9 9 8 8 7 6 9 8 8 7 7 7 7 7 7 7 10 9 8 7 6 6 (5) 16 14 12 10 9 12 11 10 9 8 12 11 10 9 8 8 7 7 6 5 8 7 7 6 6 6 6 6 6 6 9 8 7 6 5 5 (6) 14 11 9 8 7 11 9 8 7 7 12 11 10 9 9 8 6 6 5 5 8 7 (7) 17 15 13 11 10 13 12 11 10 (8) 16 14 12 10 9 12 11 10 9 (9) 15 13 11 9 8 11 10 9 8
mm (2)
1230 1570 1770 1960 1420 1570 1770 1230 1570 1770 and and 1420 1420 (10) 15 13 11 9 8 11 10 9 8 7 11 10 9 8 7 6 6 5 5 4 8 7 7 6 6 6 6 5 5 5 8 7 6 5 4 4 (11) 14 12 10 8 7 10 9 8 7 7 10 9 8 7 7 6 6 5 4 3 6 6 5 5 5 5 5 5 4 4 7 6 5 4 3 3 (12) 10 7 6 5 4 7 6 5 5 5 9 8 7 7 6 6 6 5 4 3 6 6 5 5 4 4 3 3 3 3
3.75
18 15 13 11 10 14 12 11 10 10
7.5
16 16 14 13 12 11 10 10 9 8
10
12 12 11 10 10 9 9 8 8 8
11 10 9 8 7 7
15
NOTE If the diameter of the wire is between two consecutive diameters as given above, the number of bends corresponding to the next larger diameter should be taken.
10
IS : 1835 - 1976 12.5 Wrapping Test (Bright Wires Only) When so specified by the purchaser, each end of each coil shall be subjected to a wrapping test in which case the wire shall be wrapped for eight complete close turns around a mandrel equal to its own diameter and shall not fracture when unwrapped seven turns. 12.5.1 The wrapping test shall be conducted in accordance with IS : 1755-1961*. 12.6 Adhesion Test Adhesion test for galvanized wire shall be carried out by wrapping the wire eight times around a mandrel of diameter 4 times the wire diameter for wire diameters up to and including 3.5 mm and 5 times the wire diameter for wire diameters above 3.5 mm. The zinc coating shall not crack or flake off to such an extent that the same may be removed by rubbing with bare fingers. 13. RETEST 13.1 Should any one of the test pieces first selected fail to pass any of the tests specified in this standard, two further samples shall be taken from the same end of the same coil for testing in respect of each failure. Should the test pieces from both these additional samples pass, the coil from which they are taken shall be deemed to comply with this standard. Should any of the additional test pieces fail, the coil shall not be considered as having complied with this standard. 14. MARKING 14.1 Each coil of wire shall carry a suitable lable with the type and size of wire, tensile designation number, manufacturers name or trade-mark, and such other markings as may be agreed to between the purchaser and the supplier. 14.1.1 Each coil may also be marked with the ISI Certification Mark.
NOTE The use of the ISI Certification Mark is governed by the provisions of the Indian Standards Institution (Certification Marks) Act and the Rules and Regulations made thereunder. The ISI Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by ISI and operated by the producer. ISI marked products are also continuously checked by ISI for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the ISI Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution.
11
IS : 1835 - 1976
APPENDIX A
( Clause 0.3 ) BASIS FOR ORDER A-1. The following particulars may be specified by the purchaser while placing order for steel wire for ropes: a) The number of this Indian Standard; b) The nominal diameter of the wire. In case of galvanized wire, the nominal diameter includes the galvanized coating; c) Tensile designations; d) Type of finish; e) Special requirements, such as bundling, marking, etc; and f) Tests report, if required.
12
IS : 1835 - 1976
( Continued from page 2 )
13
Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of BIS Catalogue and Standards : Monthly Additions. This Indian Standard has been developed by Technical Committee : SMDC 5 and amended by MTD 4 Amendments Issued Since Publication Amend No. Amd. No. 1 Amd. No. 2 Date of Issue June 1980 October 1997
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