Page 1 of 12 Specification no. TI/SPC/OHE/GSSW/0090 (Rev.1) Effective from ……..

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SPECIFICATION No TI/SPC/OHE/GSSW/0090 (rev.1)

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

SPECIFICATION No TI/SPC/OHE/GSSW/0090 (Rev.1)

TECHNICAL SPECIFICATION
FOR
GALVANISED STEEL STRANDED WIRE (GSSW)
FOR ANCHORING OF TRACTION MAST.

(For official use only)

Issued by:

TRACTION INSTALLATION DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW 226 011

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1.0 Scope :
This specification covers the scope of manufacture, supply and testing of
galvanized steel stranded wire of concentric lay construction for use on 25kv
a.c Traction Overhead Equipment.
2.0 Service Conditions:
The GSSW is intended to be used for stay purpose on anchored traction
masts in place of guy rod.
3.0 Environmental Conditions :
3.1 The GSSW is expected to be used in varying atmospheric and climatic
conditions. The environment factors are expected to vary in the range as
tabulated below.
(i) Ambient air temperature 00C to +500C
(ii) Maximum temperature of metallic 700C
object under sun.
(iii) Maximum relative humidity 1000C
(iv) Annual rainfall Dry and regions and also
heavy monsoon affected
regions with rainfall
ranging from 1750 to 6250
mm
(v) Maximum number of thunder storm 85
days per annum
(vi) Maximum number of dust storm 35
days per annum
(vii) Number of rainy days per annum 120
(viii) Basic wind pressure 216 kgf/m2
(ix) Altitude Upto 2500 m

4.0 Governing Specifications:

4.1 The GSSW shall generally conform to provisions of IS-2141-2000(R-2010).
4.2 All the specified tests shall be conducted in the manner indicated in the
governing Specification No IS-2141-2000(R-2010), unless otherwise
specified.
4.3 Reference has been made to the following Indian Standard Specifications in
this specification.
(i) IS 6594: 2018 -Technical Supply Conditions for Steel Wire Ropes and
Strands (Third Revision).
(ii) IS: 1755-1983 (R-2006) -Method of wrapping test for metallic wire

(iii) IS 2363:1981(R2017)-glossary of terms relating to wire ropes.

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(v) IS: 4826-1979(R-2016) - Specification for hot dipped galvanized

coatings on round steel wires.
(vi) IS 6745: 1972(R2016): Method for determination of mass of zinc
coating on zinc coated iron and steel articles.
(vi) IS: 2633-1986 (R 2016)-Methods for testing uniformity of coating on
zinc coated articles.
(vii) IS: 1608-2005-Methods for tensile testing of metals.
5.0 Technical Particulars:
5.1 Material: The wire shall be cold drawn drawn from steel made by open
hearth basic oxygen or electric furnace process and shall be of such quality
that when drawn to the specified size of wire and coated with zinc, the
finished strand and the individual wires shall be of uniform quality and shall
have the properties and characteristics as specified in this specification .The
wire shall not contain sulphur and phosphorous exceeding 0.060 percent
each.
5.2 Construction:
(i) GSSW shall be of 19 wire construction.
(ii) Dia of single wire shall be 2.5mm.
(iii) Permissible tolerance on wire dia. +0.060mm /-0.030mm.
(iv) Nominal Dia of GSSW shall be 12.5mm
(v) Permissible tolerance on GSSW’s nominal dia. +0.30mm & -0.15mm.
(vi) Length of lay: The lay length of GSSW shall be between 12 to 18 times
the GSSW’s nominal diameter.
(viii) Direction of laying: The wires in the outer layer shall be laid in Right
Hand Direction and those in inner layer in Left Hand Direction.
5.3 Strength:
(i) Minimum Tensile strength of wire: 1770 N/mm2 (Grade 1 of IS: 2141-
2000(R-2010))
(ii) Minimum breaking load of single wire : 8.70 kN
(iii) Minimum breaking load of GSSW : 145 kN
(iv) Minimum elongation of GSSW in 600mm gauge length 2%
6.0 Galvanising of Individula Wires:
6.1 The zinc coating shall conform to “Heavy coatings” as laid down in IS: 4826-
1979 (R-2016) and shall confirm to the requirement of clause 4.0 & 5.0 of
IS: 4826-1979(R-2016).
7.0 Tests:
7.1 All the tests specified in clause 9.1 & 9.2 shall normally be carried out at the
manufacturer’s works and the tests shall be arranged without making any

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claim of charges for all such tests including labour, machinery/apparatus etc.
However, the tests specified in clause 9.1(vii) can be conducted with reputed
and recognized testing agencies after specific approval of CORE/DG(TI),
RDSO or its authorized representative. In case the facilities do not exist with
the supplier, the charges for the test shall also be borne by the supplier.
7.2 Test certificate of chemical composition shall be obtained from the suppliers
of the raw material procured/processed. The manufacturer shall also check
the chemical composition of every lot of raw material purchased. The
certificates of these shall be produced at the time of inspection.
7.3 Before giving call to CORE/RDSO/Purchaser for testing of the prototype of
the GSSW, the manufacturer shall submit a detailed test schedule
consisting of the details of each test and nature of the test, venue of the test
and the duration of each test and the total number of days required to
complete the test at one stretch, if not completed in one stretch it should be
completed in second visit. Once the test schedule is approved, the test shall
invariably be done accordingly. However, during the process of type testing
or even later, CORE/RDSO/Purchaser’s representative reserves the right to
conduct any additional test(s) besides those specified herein, on any
equipment/sub-system or system so as to test the system as per
requirement or for gaining additional information and knowledge.
7.4 In case, any dispute or disagreement arises between the manufacturer and
CORE/RDSO/Purchase during the process of testing, as regards to the type
test and /or the interpretation and acceptability of the type test results, it
shall be brought to the notice of CORE/Director General (Traction
Installation), Research Designs & Standards Organisation, Manak Nagar,
Lucknow, whose decision shall be final and binding.
8.0 Sampling:
All the wires of GSSW shall belong to one heat of steel only and shall be
drawn & galvanized under identical conditions. Stranded wire made from a
particular heat & stranded under identical condition shall constitute a lot.
The manufacturer shall give undertaking conforming to heat number.
8.1 Sample size for acceptance tests:
8.1.1 GSSW:
For ascertaining the conformity of the lot to the requirement of this
specification, test shall be carried out for each offered lot separately. The
number of sample to be selected at random from each lot shall be in
accordance with column (I) & (II) of table-1. From each of the sample, a
suitable test specimen shall be cut and tested for various requirements. The
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sampling plan given in the table-I shall be followed except for chemical
analysis. One sample shall be drawn from each lot for chemical analysis.

Table-1

Lot Size (No. of lengths) Sample Size

(I) (II)
Upto 100 1
101 to 200 3
201 to 500 5
501 to above 7

8.1.2 Sampling of individual wire from GSSW:

From each sample of GSSW selected as above, approximately one-meter

length of GSSW shall be utilized for conducting tests on individual wires. The
selection of samples for tests on individual wires from the samples of GSSW
selected as per clause no. 8.1.1 above shall be as under.

Outer 6 wires at 2 wires at 4 wires at random for all

layer random for visual random for the galvanizing tests.
Wires(12 examination and wrapping test
wires) then same 6
wires for
measurement of
diameter and for
tensile test.
Inner 3 wires at 1 wire at random 2 wires at random for all
Layer random for visual for wrapping test. the galvanizing tests.
Wires examination and
(6wires) then same 3
wires for
measurement of
diameter and for
tensile test.

8.2 Sampling for type test:

All the type tests will be conducted on the three samples except that
chemical analysis, which shall be done on one sample only.
9.0 Type Tests:
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The following type tests shall be carried out in the presence of

representative of CORE/Purchaser/ Director General (Traction
Installation)/RDSO/LKO.
9.1 Tests on GSSW:
(i) Visual Examination (cl.10.1).
(ii) Measurement of diameter of GSSW (cl.10.2.1).
(iii) Measurement of lay length (cl.10.3)
(iv) Preforming (cl.10.4)
(v) Breaking force test (cl.10.5)
(vi) Percentage elongation test (cl.10.6)
(vii) Chemical Analysis (cl.5.1)
9.2 Tests on individual wires from GSSW
(i) Visual Examination (cl.10.1)
(ii) Measurement of diameter of wire (cl.10.2.2).
(iii) Tensile test (cl.10.7).
(iv) Wrapping test (cl.10.8)
(v) Galvanising test (cl.10.9)
(a) Mass of zinc coating
(b) Uniformity of zinc coating
(c) Adhesion test
10.0 Test Methods
10.1 Visual Examination:
GSSW shall be free from laying defects like loose wire or over lapped wires
or unevenly laid wires in the strand. The laying shall appear to be consistent
and regular. Wires used in GSSW shall appear to be sound, free from splits,
surface, flaws, rough, jagged and imperfect edges. The zinc coating on wire
surface shall be uniform, adherent, reasonably smooth, free from flux, ash
and dross inclusions and also free from bare patches, black spots, pimples,
lumpiness, runs, rust stains, blisters and bulky white deposits. Laying in
GSSW shall be as per clause 5.2(vii).
10.2 Measurement of diameter: the test should be carried out as per para 8.2
of IS 2141.
10.2.1Measurement of diameter of GSSW:
The diameter of GSSW shall be in accordance with Annexure-A of IS
6594:2018 and shall meet the requirement of clause 5.2(iv) read with
clause 5.2(v) of this specification.
10.2.2Measurement of diameter of wires: The measurement of diameter of
individual wire shall be done with a micrometer having a minimum
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sensitivity of 0.01mm. The two measurements at right angles of the wire

shall be taken at two different locations around 200 mm apart and average
of 4 readings shall be taken as diameter of the wire. The value of the
diameter shall be as per clause 5.2(ii).
10.3 Measurement of lay Length:
Lay length shall be measured by taking lay print by running a pencil over
carbon paper put on the outer layer of GSSW. The lay length shall be the
pitch of 12 wires of outer layer in their longitudinal axis as appearing in the
print. The value shall be as per clause 5.2(vi).
10.4 Preforming test:
A test of preforming of GSSW shall be carried out by un-laying at one end of
the GSSW, two wires opposite to each other for approx. two GSSW Lay
Lengths, When these two wires re-laid into the GSSW the wires shall
maintain their position.
10.5 Breaking Force Test:
The GSSW when tested as per annex B of IS 6594: 2018 shall have a
minimum breaking load of 145 kN.
10.6 Elongation Test:
The elongation shall be determined as the percentage increase in separation
of the grips from the position after application of initial force of 10% of the
specified breaking force and the position at the initial failure in the test
piece. The GSSW shall have elongation of minimum 2% of 600 mm gauge
length.
10.7 Tensile test:
The wire shall be tested in accordance with IS: 1608 of 2005, the value of
tensile strength shall be minimum of 1770 N/sqmm and their minimum
breaking force shall be 8.7kN.
10.8 Wrapping Test:
The wire shall be subjected to the wrapping test in accordance with IS:
1755-1983(R-2006). When wrapped eight times round its own diameter and
on being subsequently unwrapped and straightened wire under test shall not
break or split.
10.9 Galvanizing test on wires:
Wires shall be tested for mass of zinc coating as per IS 6745:
1972(R2016), uniformity of zinc coating as per IS: 2633-1986 (R 2016)
and adhesion of zinc coating as per IS: 4826-1979 (R-2016) and shall meet
the requirement of clause 6.0 of this specification.
11.0 Acceptance criteria for prototype:
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11.1 The samples offered for type tests in accordance with clause 8.2 shall pass
all the type tests.
11.2 Only after clear written approval of the results of the tests on the prototype
is communicated by CORE/Director General (TI), RDSO to the manufacturer,
he shall take up bulk manufacture of the GSSW which shall be strictly with
the same material and process of manufacture as adopted for the prototype.
In no circumstances shall material other than those adopted during the
manufacture of prototype be used for bulk manufacture.
12.0 Acceptance tests:
12.1 All the tests in clause 9.1 & 9.2 except chemical test shall be carried out.
12.2 The tests shall be conducted as laid down in the relevant clauses there of.
12.3 Retest:
If the sample of wire fails in any of the test, two more samples of the wires
shall be drawn from surplus samples from samples selected as per clause
8.1 for retest. During retest both the samples shall pass the test. If both the
samples do not pass the test, lot shall be considered not acceptable.

If the sample of GSSW fails in any of the test, fresh sample of the GSSW
shall be drawn for retest. If during retest also the sample fails, the lot shall
be considered not acceptable. Retest shall be restricted to test in which
failure occurred.
13.0 Routine Tests:
13.1 The following tests shall be carried out as routine tests
(i) Visual Examination.
(ii) Measurement of diameter of individual wire and GSSW.
(iii) Measurement of lay length.
(iv) Galvanising test.
Note: The routine tests shall be conducted by the manufacturer. The
purchaser shall have the right to witness the routine tests. The detailed
record shall be maintained for number of GSSW tested, Number rejected
and other essential date for the purpose of examination by the inspecting
official. Routine test record shall be countersigned by the inspecting official &
IC should be endorsed by the inspecting official for scrutiny of routine test
record register.
14.0 Packing:
14.1 Individual lengths of GSSW shall be coiled and tied with ties in diagonally
opposite position at four places and such coiled lengths shall be then spirally
wrapped with two layers of polythene wrapper. Upto 25 such coils shall be

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packed in a strong wooden box to avoid damage during transit. Each box
shall contain the GSSW of one production batch. The box shall carry on its
outer face the following information.
1. Manufacturer’s trade name, brand or make:
2. Specification no. and month of manufacture:
3. Nominal diameter of GSSW:
4. Length of GSSW:
5. Number of coils:
6. Production batch number:
7. Net and gross weight:
8. Contract number and consignee:
9. Date of inspection:
10. Inspector’s stamp and seal:
11. Any other particulars specified by the purchaser.
15. Marking:
Inspector shall affix an indelible stamp, punch mark or stick a label
indicating the name of inspecting agency and ID of inspecting official on the
GSSW. The label shall be affixed with special glue so that it does not come
off. The punch mark should be clearly visible and readable. Manufacturer
shall give the details of stamping in dispatch memo.
16.0 End Lugs:
End lugs to GSSW shall be as per drg.no.
TI/DRG/OHE/GSSW/RDSO/0001/09/0 the specified lengths of GSSW shall be
supplied duly crimped with the end lugs. Slipping strength of crimped
lugs shall not be less than 58kN. One sample of 2 meter long duly crimped
by end lug per lot shall be subjected to slipping strength test.
17.0 All the provisions contained in RDSO’s ISO procedures laid down in
documents no ISO9001:2015 Document No: QO-D-8.1-11 Version No: 1.3
Date Effective 01.07.2020 (Title-“Vendor change in approved status”) and
subsequent versions/amendments thereof, shall be binding and applicable on
the successful vendor/vendors in the contract floated by railways to maintain
quality of products supplied to railways”.
18.0 The “Make in India” policy-2017 of Government of India shall be applicable.

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