2026 McGaw Avenue Tel: +1 (949) 428-8500

Irvine, CA 92614 USA Fax: +1 (949) 428-8515

Web: www.ctcglobal.com

Acceptance Test Report Page 1 of 11

Report No.: ATR 155-7.75-STER-FA

Acceptance Test Report Format

7.75 mm High Strength Grade ACCC® Composite Core
for
Project Name: Procurement of Plant for Design, Supply,
Installation and Commissioning of 132kV Transmission Line
Conductor Upgrading
OCB No.: PMD/EGMP/TLUP - 077/78 – 01 (RE)
Strander: Sterlite Power Transmission Ltd.
EPC: Hg Power Transmission Sdn Bhd, Malaysia
CTC: SOC00XXXX
Report prepared for: Nepal Electricity Authority
Transmission Line upgrading Project,
Project Management Directorate,
NEA Training Centre Complex, Kharipati, Bhaktapur, Nepal
TEST DATES TBD
TEST WITNESS
Authorized representative on behalf of Nepal Electricity Authority

REVISION HISTORY
Revision Date Changes
A 4/17/2023 Original issue

As a mutual protection to customers, the public and CTC Global, this report is submitted for the exclusive use of the client to whom it is addressed.
This report applies only to the sample(s) tested and is not necessarily indicative of the qualities of apparently similar or identical products. Use
of this report, whether in whole or in part, or of any seals or insignia connected therewith in any advertising or publicity matter, without prior
written authorization from CTC Global is prohibited. The recording of false, factious, or fraudulent statements or entries on the test report may
be punished as a felony under federal law. F122578-01-D

CTC Global is Certified

ISO 9001:2015, ISO 14001:2015
NSF International Strategic Registrations
C0357800-IS3
 Acceptance Test Report Page 2 of 11
Report No.: ATR 155-7.75-STER-FA

TABLE OF CONTENTS
Section Page

Introduction 2

Sampling 3

Specimen Preparation TBD

Acceptance Testing Requirements TBD

Testing Status TBD

Test Results TBD

Conclusion TBD

Certificate of Performance TBD

Test Procedure Details TBD

List of Appendices TBD

Report Signatories and Approval TBD

TBD = To Be Determined

INTRODUCTION
This test report covers the requirements to perform Acceptance Testing per PMD/EGMP/TLUP - 077/78 – 01 (RE),
Volume II of III, Chapter 4, Clause 2.2. This report provides the details of sampling, specimen preparation, and
testing of ACCC® Core to the requirements of the subject Contract.
1) Confirmation of selected samples was completed on [Date].
2) Specimen preparation was carried out at CTC Global’s facilities in Irvine, CA.
3) Testing was carried out at CTC Global’s facilities in Irvine, CA.
4) Witnessing of tests was performed per customer request.
5) Lot numbers are referred to as Manufacturing Order (MO) numbers at CTC Global.
6) This Acceptance Test Report (ATR) format shall be applicable to all future lots for this project. Equipment
used and calibration dates are subject to change.

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 3 of 11
Report No.: ATR 155-7.75-STER-FA

SAMPLING
Sample selection was performed by the Customer at a rate of 10%. All testing was carried out before stranding
on material retained by CTC Global at the time of manufacturing. Sample (MOs) were selected for testing by the
customer. Sample retains at CTC Global consisted of material 1.2 m long representing each manufactured reel.
From the retain samples, test specimens were chosen at random with bend testing specimens taken
from both the Start and End of the selected reel. Each sample set carried the identification of its associated
MO. For bend testing, the MO number and Start (S) or End (E) was used to identify each specimen.
Samples selected for acceptance were [list] and shown highlighted in green in Table 1.
Table 1 – Selected MO’s
# MO No. Reel length (m) # MO No. Reel length (m)
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 4 of 11
Report No.: ATR 155-7.75-STER-FA

SPECIMEN PREPARATION
Specimen preparation was performed by CTC Global personnel at CTC Global facilities in Irvine, CA.
Diameter measurement was performed on a specimen with no special preparation.
Torsion specimens were prepared with a gage length of 1143 mm consistent with CTC retain material length rather
than 170 times diameter (170D). The specimen ends were ground in three places 120° apart to aid with gripping
in 3-jaw chucks.
Specimens for breaking load and elongation were prepared with epoxy grips. Specimen preparation required 2
days for bonding and cure.
Glass Transition Temperature samples were machined into rectangular specimens which dried at 105°C for a
minimum of 2 weeks prior to testing.
Apparent shear strength specimens were prepared using a wet diamond saw.
Galvanic Layer Thickness specimens were cut using a wet diamond saw.
Bend specimens had their identification labels removed prior to testing. Specimens were visually examined, and
any pre-existing anomalies were marked.
Dye penetrant after bend specimens were prepared using a slow speed wet diamond saw.
Tensile after torsion specimens were prepared by removing the grips using a wet diamond saw and prepared for
tensile using epoxy grips.

ACCEPTANCE TESTING REQUIREMENTS

CTC prepared and tested the required quantity of specimens from each selected sample per Table 2.
Table 2 – Composite Core Testing Requirements
Annexure - A
Test No. Property and Quantity
Test Method
2.2 c) Dimensional check, quantity = 1/MO 1.20
2.2 g) Torsion, quantity = 2/MO 1.24 (ii)
2.2 g) Tensile after torsion = 2/MO 1.24 (ii)
2.2 g) Elongation, quantity = 1/MO 1.24 (i),. 1.9% min per GTP
2.2 h) Breaking Load quantity = 1/MO 1.25, 101 kN per GTP
1.31
205°C (As per GTP) – ACCC
2.2 o) Glass transition temperature, quantity = 1/MO Amsterdam
170.8°C (As per GTP) – ACCC
Cordoba
2.2 p) Apparent shear strength (Flexural) test, quantity = 1/MO 1.32, 40 MPa min per GTP
2.2 s) Bending test, quantity = 2/MO 1.35
2.2 s) Dye penetrant after ultimate bend test = 1/MO 1.35
2.2 s) Tensile after ultimate bend test = 1/MO 1.35
ASTM B987, 0.38 mm min
2.2 t) Galvanic layer thickness, quantity = 1/MO
per GTP

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 5 of 11
Report No.: ATR 155-7.75-STER-FA

TESTING STATUS
The specimens tested matched customer requirements for the quantity of samples per Table 3.
Table 3: Testing Status
Specimen # Property and Quantity Status
S1 Dimensional check __ Tested, __ Pass
S3 & E3 Torsion __ Tested, __ Pass
S3 & E3 Tensile after torsion __ Tested, __ Pass
E1 Elongation __ Tested, __ Pass
E1 Breaking load __ Tested, __ Pass
S1 Glass transition temperature (Tg) test __ Tested, __ Pass
S1 Apparent shear strength (flexural) test __ Tested, __ Pass
S2 & E2 Bending test __ Tested, __ Pass
S2 Dye penetrant after bend __ Tested, __ Pass
E2 Tensile after bend __ Tested, __ Pass
S1 Galvanic layer thickness test __ Tested, __ Pass

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 6 of 11
Report No.: ATR 155-7.75-STER-FA

TEST RESULTS
The samples tested met Contract and customer requirements per Table 4.
Table 4: Acceptance Test Results
Specimen Test
Determination Test Requirement Test Values
I.D. Results
7.70 minimum
Dimensional check (mm)
7.80 maximum
Torsion (visual) No cracks
Tensile after torsion (kN) 101
Elongation (%) 1.9 minimum
Breaking load (kN) 101 minimum

Glass transition temp test (°C) 205 minimum

Apparent shear strength (Flexural)

40 minimum average
(MPa)
Galvanic layer thickness test (mm) 0.38 minimum
No break or split during
Bending test (visual)
1-minute hold
Dye penetrant after bend (visual) 50% coverage maximum
Tensile after bend (kN) 101 minimum

CONCLUSION
The test values for above sample(s) met/do not meet Contract requirements for acceptance testing. The
acceptance is based on decision rule for simple acceptance where measurement uncertainty is not factored into
the determination of conformance.

CERTIFICATE OF PERFORMANCE
The testing was performed in accordance with Contract requirements.

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 7 of 11
Report No.: ATR 155-7.75-STER-FA

TEST PROCEDURE DETAILS

Test equipment was calibrated prior to use where applicable.

Dimensions
Testing was performed in accordance with Annexure - A. The composite core was measured in multiple locations
with measurements evenly spaced around the circumference of the cross section at both ends of the specimen.
EQUIPMENT USED
Description Calibration I.D. Date Due
Mitutoyo Micrometer, 0-25 mm

Torsion
Torsion testing was performed in accordance with Annexure A using a ratchet driven twist frame with 3-point
chucks attached to fixed and movable ends. A laser line generator was used to indicate twist on to a 360° wheel
on the movable end. Calculation of the twist was determined as Gage length*360/170/diameter that was
equivalent to a full 360°/(170 x diameter). The twist was held for 2 minutes.
Core diameter 7.75 mm
Gage length 1143 mm
Required twist 312°
EQUIPMENT USED
Description Calibration I.D. Date Due
Torsion frame 00071 N/A
Timer

Tensile after Torsion

Testing was performed in accordance with Annexure - A. Breaking load test was conducted in accordance with
ASTM B987 per test method ASTM D3916 using epoxy resin to bond the composite core to aluminum loading
blocks.
EQUIPMENT USED
Description Calibration I.D. Date Due
United Load frame 2 CTC420, 0417524
United Load cell 2 CTC419, TVI1116532

Elongation
Testing was performed in accordance with Annexure - A. Elongation at break was conducted in accordance with
test method ASTM D3916 using the same specimens tested for breaking load. Tensile elongation was calculated
from extrapolation of modulus slope at points 0.05 and 1.4% strain. The ultimate load was used to determine
elongation at the point of intersection with the modulus’ slope.
EQUIPMENT USED
Description Calibration I.D. Date Due
United Load frame 2 CTC420, 0417524
United Load cell 2 CTC419, TVI1116532
Epsilon Extensometer 2 CTC416, E97638

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 8 of 11
Report No.: ATR 155-7.75-STER-FA

Breaking Load
Testing was performed in accordance with Annexure - A. Breaking load test was conducted in accordance with
ASTM B987 per test method ASTM D3916 using epoxy resin to bond the composite core to aluminum loading
blocks.
EQUIPMENT USED
Description Calibration I.D. Date Due
United Load frame 2 CTC420, 0417524
United Load cell 2 CTC419, TVI1116532

Glass Transition Temperature

Testing was performed in accordance with Annexure - A to determine glass transition temperature (Tg) in
accordance with ASTM D7028-07(2015) by way of DMA. Test blanks were cut from preselected samples and
placed in a drying chamber a minimum of 72 hours prior to machining. Specimens were machined into a
rectangular shape meeting the requirements described in the method. Specimen dimensions were 62.7 – 64.3
mm long by 1.65 – 1.75 mm thick. Specimens were dried a minimum of 24 hours prior to testing. Tg was
determined as the peak loss modulus.
EQUIPMENT USED
Description Calibration I.D. Date Due
Micrometer
Caliper
Torque Driver 0916403921
TA DMA 1 800-1768
TA DMA 2 800-2016
TA DMA 4 850-00929

Apparent Shear Strength (by Short Beam Shear) (Flexural)

Flexural strength test per ASTM D7264 is not possible on ACCC® Core. The material exceeds the flexural limitations
of the method without failure. ASTM D4475 is used to determine apparent shear strength by the short beam
shear method. This is similar to a flexural strength test in that a 3-point bending apparatus us used, but with a
short span that induces breakage in shear rather than tension or compression which are the failure modes of a
flexural test. Testing was performed in accordance with Annexure A and ASTM D4475. The apparent shear
strength of the core was determined by loading specimens in a 3-point short beam shear fixture with a specimen
length of 7 times the core diameter and a test span of 6 times the core diameter. Apparent shear strength was
calculated per Equation 1. The results were based on the average of 5 specimens.
Apparent Shear Strength = 0.849 x ultimate load / diameter squared [1]
EQUIPMENT USED
Description Calibration I.D. Date Due
Load frame CTC588, 5567R3911
Load cell CTC588, 68041
Caliper

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 9 of 11
Report No.: ATR 155-7.75-STER-FA

Bending Test
Testing was performed in accordance with ASTM B987-20. Two composite core specimens (1 Start and 1 End)
were tested for maximum bending capability by wrapping each 180 degrees around a bending mandrel. The
specimens were tensioned to 15% RTS. This was accomplished by tensioning and measuring force on one end of
the test specimen to be 7.5% RTS.
Core diameter 7.75 mm
Rated Tensile Strength 101 kN
Test Load 778 kgf (7.58 kN)
Test Mandrel Diameter 387.5 mm
The tension was held for a minimum of 1 minute while the specimen was inspected for damage. The bending
mandrel’s tread diameter (bottom of groove) was set at 50 times the diameter of the standard composite core.
Both start and end specimens were included.
EQUIPMENT USED
Description Calibration I.D. Date Due
Bending Machine N/A
Bend Mandrel CTC
Dillon Dynamometer CTC633
Timer CTC333

Dye penetrant after bend

Testing was conducted in accordance with ASTM B987. Five adjacent specimens 25mm long were cut from the
center of a bend specimen. They were placed on glass beads in a petri dish that was filled to a level over the beads
with Magnaflux ZL 27 penetrant per ASTM D5117. A photo was taken at the end of a 30-minute test period and
examined in accordance with ASTM B987.
EQUIPMENT USED
Description Calibration I.D. Date Due
Timer
Caliper

Tensile after bend

Testing was performed in accordance with ASTM B987 and ASTM D3916. Tensile after torsion specimens were
cut on each end to remove torsion preparation (~38 mm).
EQUIPMENT USED
Description Calibration I.D. Date Due
United Load frame 2 CTC420, 0417524
United Load cell 2 CTC419, TVI1116532

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 10 of 11
Report No.: ATR 155-7.75-STER-FA

Galvanic Protection Barrier Layer Thickness

Testing was performed in accordance with ASTM B987. The minimum thickness of the fiberglass galvanic
protection barrier layer was evaluated using microscopic examination of specimen cross-sections in accordance
with Section 18 of ASTM B987-20. The minimum thickness was determined using CTC software to measure the
layer as a function of the measured diameter.
EQUIPMENT USED
Description Calibration I.D. Date Due
Micrometer, 0-25 mm

APPENDICES
Diameter test report
Torsion and tensile after torsion test reports
Breaking load and elongation test report
Glass transition temp test thermograms
Apparent shear strength (Flexural) test reports
Bending test, tensile after bend and dye penetrant after bend test reports
Galvanic layer thickness test reports
Calibration certificates

REPORT SIGNATORIES AND APPROVAL

Signed for and on behalf of CTC Global

Thomas J. (Tom) Parsons

Senior Engineer

Sterlite Power Transmission Ltd. F122578-01-D

 Acceptance Test Report Page 11 of 11
Report No.: ATR 155-7.75-STER-FA

TEST WITNESS SIGNATURES

Signed for and on behalf of NEA

Signed for and on behalf of NEA

Signed for and on behalf of NEA

END OF REPORT

Sterlite Power Transmission Ltd. F122578-01-D