Complete Technology Handbook on Electrical Wire and Cable Production (Aluminum Wire, Barbed Wire, Copper Wire, Wire Nail, Wire Mesh, Galvanised Wire, PVC Wire and Cable, Fiber-Optic Cable, Coaxial Cable, Power Cord Cable, XLPE Cable)

In the ever-connected, electrified world of today, electrical wires and cables are the unsung heroes that power our lives. From the simplest wiring systems that illuminate our homes to the intricate networks that enable global communication, the significance of these slender conduits cannot be overstated. "Complete Technology Handbook On Electrical Wire And Cable Production" is your gateway to unraveling the complexities and subtleties of this essential industry.

This handbook, an extensive compilation of knowledge, offers a comprehensive insight into the diverse universe of electrical wires and cables. It serves as an indispensable resource for not only professionals and engineers but also for students, aspiring entrepreneurs, and anyone intrigued by the marvels of electrical connectivity. Our exploration commences at the very foundation in Chapter 1, acquainting you with the basic components that constitute an electrical cable and delineating the distinctions between wires and cables.

The following chapters are a journey through the entire lifecycle of electrical cables, from their inception as raw materials to their final applications. We dive deep into copper wires, the workhorses of electrical systems, and uncover the countless domains where they play pivotal roles, from telecommunications to the automotive industry and even jewelry. You'll be enlightened on the remarkable properties of copper that make it indispensable for the electrical world, from high conductivity to durability and thermal resistance.

But copper is just one piece of the puzzle. This handbook traverses through the manufacturing processes of a variety of cables, including fiber optics, power cords, coaxial cables, and more. It dissects the intricacies of spring manufacturing, wire nail production, and wire mesh creation. You will learn not only the raw materials and designs but also the intricate machinery and quality control measures that shape these products.

We explore the evolution of copper wires and the upcoming trends in their utilization. Fiber optics, the lifeblood of modern communication, undergo a step-by-step breakdown, elucidating everything from the preparation of raw materials to the production of optical cable integrated jacketing.

We delve into the production of power cord cables, the essential lifelines that connect us to the electrical grid. You will understand the terminology, connectors, and the multitude of cable types employed in different settings, from computer networking to medical applications. As we unfold each chapter, the intricacies of the electrical world are laid bare before you. We highlight the processes, standards, and economic aspects of production, giving you a 360-degree understanding of this vibrant industry.

Our journey does not end with wires and cables; we delve into the processes of manufacturing, quality control, and the ins and outs of setting up your own cable manufacturing business. The book meticulously guides you through every step of the production process, shedding light on the challenges and opportunities that await.

By the time you reach the final pages of this handbook, you will have journeyed through the entire spectrum of electrical cable and wire production. Whether you are an entrepreneur looking to enter this thriving field, an engineer seeking to deepen your understanding, or a student intrigued by the marvels of modern technology, this handbook will equip you with the knowledge needed to thrive in the world of electrical wires and cables.

The book Complete Technology Handbook on Electrical Wire and Cable Production (Aluminum Wire, Barbed Wire, Copper Wire, Spring, Steel Wire Rope, Wire Nail, Wire Mesh, Galvanised Wire, PVC Wire and Cable, Fiber-Optic Cable, Coaxial Cable, Ethernet Cable, Submersible Cable, Power Cord Cable, XLPE Cable) contains chapters on Introduction, How are Electrical Wires Manufactured?, Copper Wires, Copper Wire Manufacturing Process, Copper Wires and Upcoming Trends, How to Start a Spring Manufacturing Plant?, Springs, How are Springs Made?, Wire Nail Manufacturing Business Idea, Wire Nails , Wire Nail Manufacturing Process, Wire Mesh, Welded Wire Mesh Manufacturing Process, Motions in Wire Mesh Weaving Process, Fiber Optic Manufacturing Process, Fiber Optic Patch Cord and Pigtail Production Process, Fiber-optic Cable, PVC Wire and Cable, How to Start PVC Cables Manufacturing Business?, Wire PVC Coating Line, Roll Mesh PVC Coating Line, Fence PVC Coating Line, Wire Drawing Process, Aluminum Wire, Steel Wire Rope, Wire Ropes Produce Process, Galvanised Wire, Wire Galvanising Plant, Coaxial Cable, Coaxial Cable Manufacturing Process, Ethernet Cable, Litang Cable LAN/Ethernet Ethernet Cable Manufacturing Process, Power Cord Cable, Power Cord Cable Manufacturing Process and Equipment, Submersible Cable, Submersible Winding Wire Plant, How to Start Barbed Wire Production Business, Barbed Wire, Barbed Wire Manufacturing Process, XLPE Cable, Manufacturing Process of XLPE Cable, Electrical Cable Coating, BIS Specifications, ISO Standards, Plant Economics of ABC Cable, Plant Economics of Binding Wire for Construction, Plant Economics of Copper Wire and PVC Cable, Plant Economics of Electrical Wire and Cable, Plant Economics of House Wire/Low Voltage Production Plant, Plant Economics of Mild Steel Wire Drawing, Plant Economics of Optical Fiber Cable, Plant Economics Of Submersible Copper Winding Wire, Plant Economics of Wire and Cable Manufacturing Unit, Plant Economics of Wire Nails (Ms) Manufacturing.

Embrace this journey through the wires and cables that power our world, and be prepared to unlock the boundless potential of this pivotal industry. This is your gateway to mastering the intricate art and science of electrical wire and cable production.

Chapter 1

Introduction

Components of an Electrical Cable

Wire

Cable

Different uses of Wire and Cable

Use of Wire

Use of Cable

Types of Wire and Cable

Types of Electrical Wires

Types of Electrical Cables

Different advantages of using Wire and Cable

Advantages of Wire

Advantages of Cable

Chapter 2

How are Electrical Wires Manufactured?

Wire drawing

Annealing

Wiring

Contents-cum-Index Hot extrusion

Voltage testing

Phase wiring

Additional protection

Chapter 3

Copper Wires

Types of Copper Wire

Solid Copper Wire

Stranded Copper Wire

Tinned Copper Wire

Applications

Electrical wiring

Communications wiring 

Structured wiring

Power distribution

Appliance conductors

Automotive conductors

Magnet wire

Uses of Copper Wire

Telecommunication

Electricity Supply

Automobile Industry

Jewellery

Other Uses

Properties of Copper

How Copper Conducts electricity?

Properties of Copper Useful for the Copper Wire

High Conductivity

Durability

Cost-Effective

Ductile metal

Conductor of electricity

Thermal conductor

Corrosion-resistant

Malleable

Properties of Copper

Workability

Electrical/Heat Conductivity 

Durability

Anti-Bacterial

Recyclable

Tensile strength

Ductility

Strength and ductility combination

Creep resistance

Corrosion resistance

Coefficient of thermal expansion

Thermal conductivity

Solderability 

Ease of installation

Splice Closures for Copper Cables

Types of closures

Future trends

Pure Copper & its importance

Chapter 4

Copper Wire Manufacturing Process

Drawing Process

Annealing Process

Bunching/Stranding Process

Tinning Process

Hot dip process

Electroplating process

Braiding 

Process for Tinsel Wire

Process of Glass Wire

Copper Wire Recycling Process

Negative impacts of using low temperature Burning process

Benefits of recycling copper wire

Chapter 5

Copper Wires and Upcoming Trends

Prominent use of copper wires

Copper: A preferred metal for electric wiring purpose

Superior tensile strength

Higher ductility

Incredible flexibility

Upcoming trends related to copper wire and cable 

Chapter 6

How to Start a Spring Manufacturing Plant?

Raw Materials

Design

The Manufacturing Process

Coiling

Hardening

Finishing 

Quality Control

The Future

Chapter 7

Springs 

Material Used in Springs

Classification of Springs

On the Basis of Load Applied 

Torsion Spring

Compression Spring

Extension Spring

On the Basis of Displacement Due to Force Applied

Constant Force Spring

Variable Rate Spring

Linear Spring

On the Basis of Construction

Coil Spring

Flat Spring

Molded Spring

Applications of Steel Springs

High-Carbon Spring Steels in Wire Form

High-Carbon Spring Steels in Flat Strip Form

Alloy Spring Steels 

Stainless Spring Steels 

Copper-Base Spring Alloys

Nickel-Base Spring Alloys

Nickel-Base Spring Alloys with Constant Moduli of Elasticity

Metal Springs

Introduction

Types of Springs

Helical Compression Springs

Helical Tension Springs

Helical Torsion Springs

Special Springs:

Spring End Types

Common Spring Materials

Carbon Steel Springs

Alloy Steel

Stainless Steels

Non-Ferrous Alloys

Chapter 8

How are Springs Made?

Spring Winding 

Heat Treating

Grinding

Coating and Finishing 

Custom Spring Manufacturing Process

Packaging

Chapter 9

Wire Nail Manufacturing Business Idea

Legal procedure related to manufacturing of iron wire nails

The processing: 

Related machine for nails making

Nail polishing machine 

Wire drawing machine to make nail making wire

Chapter 10

Wire Nails

Cut and Wire Nails Differently

Cut Nails

Wire Nails

How Cut and Wire Nails Differ 

Uses

Specifications 

Applications

Market Potential

Global Round Wire Nails Market: Segment Analysis 

Types of Nails 

Common Nails

Framing Nails

Sinking Nails 

Box Nails 

Deck Nails

Roofing Nails 

Masonry Nails 

Siding Nails

Duplex Nails

Joist Hanger Nails 

Pole Barn Nails 

Connectors Nails 

Cap Nails 

Finish Nails 

Trim Nails 

Brad Nails

Pin Nails 

Drywall Nails

Flooring Nails

Panel Board Nails

Furniture Nails

Chapter 11

Wire Nail Manufacturing Process 

Design

Raw Materials

The Manufacturing

Process 

Forming

Additional forming

Finishing 

Packaging

Quality Control

The Future

Technical Data of Wire Nail Making Machine

Wire Nail Making Machine N1

Wire Nail Making Machine IN3

Wire Nail Making Machine IN 2+3

Wire Nail Making Machine IN6

Wire Nail Making Machine IN4

Chapter 12

Wire Mesh

A great variety of shapes and applications

Wire mesh materials & their main characteristics

Welded wire mesh

Wire fabrics

Wire nettings

Basics of Wire Mesh

How Wire Mesh is Made

Wire Weaving 

Welded Wire Mesh

Types of Wire Mesh

Welded Wire Mesh

Galvanized Wire Mesh

Vinyl-Coated Wire Mesh

Welded Steel Bar Gratings

Stainless Steel Wire Mesh

Wire Mesh Patterns

Crimped Wire Mesh

Non-Crimped Wire

Double Weave Wire Mesh

Flat Top Weave Wire Mesh

Twill Weave Wire Mesh

Dutch Weave Wire Mesh

Off Count Wire Mesh

Stranded Weave Wire Mesh

Mesh Count

Wire Mesh Edges

Wire Used to Make Wire Mesh

Carbon Steel in Wire Mesh

Stainless Steel in Wire Mesh

Aluminum Wire in Wire Mesh

Copper in Wire Mesh

Brass in Wire Mesh

Bronze in Wire Mesh

Uses for Wire Mesh

The Benefits of Wire Mesh

Market Potential

Basis and Presumptions

Chapter 13

Welded Wire Mesh Manufacturing Process

Wire rod

Cold rolling 

Straightening & cutting

Welding

Bending & cutting

Finished mesh

Chapter 14

Motions in Wire Mesh Weaving Process

Steps Involved in Weaving

Shedding motion

Weft insertion motion

Beating-up motion: pushing the newly inserted weft wire into the already woven fabric. 

Take-up motion

Let-off motion 

Modern Weaving Technology

Chapter 15

Fiber Optic Manufacturing Process

Step 1: Preparation and Purification of Fiber Optic Raw Materials

Step 2: Fiber Optic Core-rod Melting and Surface Treatment.

Step 3: Wire Drawing and Primary Coating Process. 

Primary Coating process

Step 4: Fiber Optic Cable Tension Sorting and Coloring Process.

Tension Sorting

Fiber Optic Coloring Process

Step 5: Secondary Coating or Plastic Coating of Fiber Optic

Step 6: Fiber Optic Cable Core Manufacturing Process (Cable Forming Process)

Cable Forming Technology of Layer Stranded Optical Cable

Step7: Extrusion Technology of Optical Cable Integrated Jactketing

Water Blocking Technology of Optical Cable

Longitudinal Jacketing Process

Plastic Extrusion Process

Armored Technology 

Integrated Jacketing Production Line

Chapter 16

Fiber Optic Patch Cord and Pigtail Production Process

Tools & Equipment for Inspection, Tuning, Measurement and Cleaning

Step.1 Fiber Optic Patch Cord Cable Cutting

Step.2 Fiber Optic Patch Cable Cleaning & Pre-handling 

Step.3 Fiber Patch Jumper Cable Stripping & Identifying

Step.4 Fiber Optic Ferrule Glue Injection & Fiber Inserting

Step.5 Fiber Patch cord Fiber Solidifying 

Step.6 Fiber Patch Cable Ultrasonic Cleaning & Polishing 

Step.7 Microscope Inspection for fiber jumper

Step.8 FQC for a fiber patch cord 

Step.9 Kits Fast connector assembly to fiber optic patch cords

Step.10 Packaging a fiber patch cord

Chapter 17

Fiber-optic Cable 

Capacity and market

Reliability and quality

Cable types 

Jacket material 

Fiber material 

Color coding

Patch cords 

Cord jacket (or buffer) color

Connector boot (or shell) colors 

Multi-fiber cables 

Safety 

Hybrid cables

Types 

Placement

How fiber-optics works 

Types of fiber-optic cables 

Single-mode

Multi-mode

Fiber Optics vs. Copper Cables 

Advantages and disadvantages of fiber optics

Disadvantages 

Fiber optics uses 

Computer networking and broadcasting

Internet and cable television 

Undersea environments 

Military and space

Medical 

Fiber vs Cable: Structure

Fiber vs Cable: Availability 

Fiber vs Cable: Reliability

Fiber vs Cable: Speed 

Fiber vs Cable: Cost 

Fibre optic deployment strategies

Aerial Deployment

Buried Cable Deployment

Ocean Deployment 

Importance of terrain for deployment and rollout of fiber cables

Speeding up fiber rollout 

Chapter 18

PVC Wire and Cable

Introduction 

Basis & Presumptions 

Technical Aspects: 

Process of Manufacture

Quality Control & Standards

Energy Conservation 

PVC Cable Advantages 

Types 

Special PVC Wires and Cables 

Cold Resistant PVC

Heat Resistant PVC

Oil Resistant PVC

PVC Wire and Cable Uses

PVC Cable and Wire Manufacturing Process

Chapter 19

How to Start PVC Cables Manufacturing Business? 

PVC Cables Manufacturing – Market Potential

Permits and Licenses for PVC Cables Manufacturing

Incorporation Certificate

Key points to ponder 

Factory License

Trade License

NOC from SPCB

BIS Certification 

PVC Cables Manufacturing Equipment and Testing Apparatus

Requirement of Raw Material for PVC Cables Manufacturing

Manufacturing Process of PVC Cables

PVC Cables Manufacturing: Quality Control & Standards

Chapter 20

Wire PVC Coating Line

Structure description

Wire Payoffs & Wire Decoilers

Fine Wire

Features of the Novo Precision FWPO

Medium & Heavy Wire 

PVC Wire Extruder Machine

Wire & Cable Extrusion Line

Chapter 21

Roll Mesh PVC Coating Line

Description of auto continous powder coating line

Equipment list

Auto eletrical pre-heating & curing furnace

Fluidized bed, vibration generator:

Chapter 22

Fence PVC Coating Line

Fence PVC coating equipment

Main technical parameters

Process flow

Composition of a complete coating line

Chapter 23

Wire Drawing Process

Required Tools

The Process

Step-By-Step Instructions

Working Process

Application

Chapter 24

Aluminum Wire

Aluminum wiring

How does aluminum wiring work?

Aluminum Conductors

Aluminium Cable

Aluminium Single Core Cable

Aluminium Wire Rod

Wire Rod Alloy – Mechanical Aluminum Alloy Rod

Wire Rod Deoxi – (Aluminum Continuous Cast Rod)

General Information

Advantages of Rod 

Aluminum and Copper Wiring Together 

Remediation for Aluminum Wiring 

Aluminum Oxidation 

Does Aluminum Corrode or Oxidise?

How do you Stop Aluminum Oxidation? 

How to Protect Aluminium from Oxidation 

Chapter 25

Steel Wire Rope 

Components of a Steel Wire Rope 

Steel wire 

Strands 

Core 

Direction and types of wire rope lay 

Lubrication of wire ropes 

Wire rope characteristics

Deformation behaviour

Modulus of elasticity

Radial stability

Structural stability

Causes of wire rope failure

Usage of wire ropes 

Running ropes 

Stationary ropes 

Track ropes

Wire rope slings

Wire Rope Construction

Steel Wire Rope Constructions

Number of Wires in a Strand

Types of Strand (Strand Construction)

Standard

Seale 

Filler

Warrington

Other Types of Strand

Number of Strands

Types of Core

Fibre Core 

Steel Core 

Lay Directions (Steel Wire Rope and Strand) 

Chapter 26

Wire Ropes Produce Process 

Wire rod 

Surface treatment 

First Drawing

Patenting 

Intermediate Drawing

Stranding 

Closing

Chapter 27

Galvanised Wire

Benefits of GI WIre

Resistance to Rust & Corrosion

Ease of Installation

Easier to Maneuver and Handle

Low Maintenance Costs

Low Maintenance Costs

Long Lifespan

Affordability 

Strong and Durable 

Withstand Extreme Temperature

Galvanized Iron Wire Used for Arts and Crafts 

Chapter 28

Wire Galvanising Plant 

Market Outlook 

Clientele 

Quality assurance 

Methods 

Hot dip galvanizing process steps 

Cleaning cycle

Post treatment

Flow Diagram of Galvanizing Process 

Size of galvanized articles 

Galvanizing Before and After Manufacturing Wire Mesh 

Chapter 29

Coaxial Cable 

Structure of Coaxial Cable

Types of Coaxial cables 

Applications of Coaxial cable 

Advantages 

Disadvantages 

Hard line coaxial cable

Flexible coaxial cable 

Semi-rigid coaxial cable 

Formable coaxial cable

Rigid coaxial cable 

Twinaxial cable 

Triaxial cable 

Other types of coaxial cable 

Uses of coaxial cables

Coax standards 

Interference issues with coax

Difference between RG-59 and RG-6

Triaxial Cable (Triax) 

Quadrax Cable 

Twinax Cable 

Chapter 30

Coaxial Cable Manufacturing Process 

The Market for Fabricated Coax Cable 

Cutting Semi-Rigid Coax with a Saw 

Cutting Flexible Coax with a Saw System 

After the Cutoff – Stripping the Ends 

Making Production Quality Bends 

Quality Concerns when Fabricating Coax 

Chapter 31

Ethernet Cable 

Ethernet cable basics 

Types of Ethernet Cables 

Coaxial Cables 

Types of Coaxial cables

Types of Connectors used in Coaxial cable 

Twisted Pair Cable

Types of twisted pair cable

Types of Fiber Optics 

Types of Connectors Used 

Chapter 32

Litang Cable LAN/Ethernet Ethernet Cable Manufacturing Process 

Step 1: Wire Drawing

Wire Drawing,Reducing the Diameter of Copper Wire (Wire Drawing Machine)

Wire Drawing, Once Again Reducing the Diameter of Copper Wire (Wire Drawing machine)

Step 2: Annealing the Copper Wire to Soften the Copper Wire and Increase the Ductility

Step 3: Extruding Copper Wire and Insulating (Extruder, Sheath Machine)

Step 4: Wire Insulation Diameter Testing (calipers and performance testers)

Step 5: Twisting and Stranding Wire (twisting machine) 

Step 6: Cabling (Cabling machine)

Step 7: Jacketing (Jacketing machine) 

Cross Filling (Separator filling)

Metal sheath filling 

Braided Wire Filling

Drain Wire Filling 

Rid Cord Filling 

Outer Cable Jacketing

Cooling and Printing 

Step 8: Pre-shipment Testing 

Step 9: Packing

Step 10: Delivery

Chapter 33

Power Cord Cable

Construction

Higher voltages

Flexibility of cables (stranding class)

Features of a high voltage power cable 

Appearance 

Terminology 

Electric Cords 

Power Supply Cord 

Cord Set 

Interconnection Cord Set 

AC Power Cords

Custom Power Cords

Extension Cords 

Generator Power Cords 

NEMA Power Cords

NEMA 5-15P Power Cords

Electrical Plug

Sockets or Electrical Receptacles 

Plug Adapters 

Connector 

Appliance Inlet 

Flexible cord 

Pin

Live Pin 

Neutral Pin 

Earth Pin

Insulated Sleeves

Polarized Connection 

Shutters 

Plug Covers 

Retainers 

Current and Voltage Rating 

Rewireable Connector 

Power Cord Splitter 

Fuse 

NEMA 5-15-P 

Chapter 34

Power Cord Cable Manufacturing Process and Equipment

Step1: Cutting and stripping the cable to the length and outer jacket 

Step 2: Stripping & twisting the cable inner wire

Description 

Step3: crimping the plug to cable for making the cable head plug 

Description 

Step 4: Crimping the AC terminal to cable for making the cable tail plug

Features 

Step 5: After crimped the tail plug then manual insert the plastic cover 

Step 6: Injection and Molding 

Step 7: Cable Performance Testing

Step 8: Packing the Power cord

Features

Characters

Chapter 35

Submersible Cable 

Features 

Applications 

Standard length cable packing

Types of Submersible Pump Cables

Standards 

Conductor

Insulation 

Sheath

Approvals 

Marking:

Packing: 

Specification 

Color Code 

Red Wires: Hot 

White Wires with Black or Red Tape: Hot

Green and Bare Copper Wires: Ground 

Bare Copper Wires: Ground

Black And Blue Wires: Hot 

Green Wires: Ground 

White or Gray Wires: Neutral 

Blue And Yellow Wires: Hot

UK Wiring Colors

Benefits 

They are Highly Durable 

They are Available in Different Shapes and Sizes 

These Cables are Safe to Use

The Cables are very Reliable

They can Take Heavy Loads

They have Colour Coding for Identification

They are very Versatile 

Manufacturing Process

Manufacturing of Cables 

Conductor

Insulation 

Pair Screening 

Armouring 

Final Testing

Chapter 36

Submersible Winding Wire Plant 

Submersible Winding Wire and Cables

Manufacturing Process: 

Wrapping Machine (Vertical)

Product Information 

Wrapping Machine (Horizontal) 

3 Way Switches For Control The Machine from Different Locations 

Slitting Machine with Single Color Printing

Product Information

Industrial Oven 

Product Information

Submersible Winding Wire Machine

Chapter 37

How to Start Barbed Wire Production Business

Barbed Wire Production Market Potential

Barbed Wire Production Business Registration

Cost & Investment for Barbed Wire Manufacturing Business 

Machines & Raw Materials for Barbed Wire Production Business 

Barbed Wire Production Process

Process Flow Chart

Chapter 38

Barbed Wire

Materials 

Strand structure 

Barb structure

Twist type 

Installation 

Gates 

Uses 

Agriculture 

Different Varieties of Barbed Wire 

Stirred Barbed Wire 

PVC Coated Barbed Wire 

High Tensile Steel Barbed Wire 

Concertina Wire 

Welded Razor Wire 

Benefits of the Zinc Coating 

Benefits of Heavy Zinc Coating 

Protection against corrosion

Efficiency

Risk 

Cost-effectiveness 

Compatibility with different plating methods 

Finish 

Texture

Undercoat 

Ease of application 

Benefits of Barbed Wire Fencing 

Impenetrable protection: 

Versatile

Cost-effective

Easy to install:

Chapter 39

Barbed Wire Manufacturing Process 

Raw Materials

Manufacturing Process 

Making steel ingots 

Making billets 

Making wire

Making barbed wire 

Quality Control

Chapter 40

XLPE Cable 

Types of XLPE Wire or Cable 

Features & Advantages of XLPE Wire & Cable 

Common applications of XLPE:

Extra High Voltage Power Cables 

The Insulated Cable Engineers Association (ICEA)

Chapter 41

Manufacturing Process of XLPE Cable

Introduction 

Conductor 

Insulation 

Laying Up 

Innersheathing 

Armour 

Outersheath 

Testing 

Packing 

Tests

Routine Tests:

Acceptance Tests:

Optional Tests 

Special Tests 

Chapter 42

Electrical Cable Coating

Types of Cable coating 

Insulation 

Semiconductor 

Metal Screen 

Filling In

Seat 

Armour

Cover (Outer Sheath)

Fire Protection Coatings

Ablative coatings

Intumescent coatings

Fire protection coating of electric cables in a cable tunnel 

Chapter 43

BIS Specifications 

Benefits of BIS Certification

List of the BIS ISI for Wires & Cables 

Documents Required to Obtain BIS ISI for Wires & Cables 

Procedure to Obtain BIS ISI for Wires & Cables 

Chapter 44

ISO Standards

Electrical wires and cables 

Steel wire ropes - Requirements 

Chapter 45

Plant Economics of ABC Cable 

Manufacturing Process 

Construction

Process flow chart for abc cable

Material 

Process 

Stranding 

Insulation 

Degassing

Quality Control 

Plant Economics 

Land & Building

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum

Chapter 46

Plant Economics of Binding Wire for Construction

Introduction

Wire Drawing Process

Raw material 

Inspection of Raw Material 

Preparation of Raw Material 

Mechanical Descaling of Wire Rod 

Chemical Descaling (Pickling) of Wire Rod 

Application of Soap (Lubricant) Carrier

Drawing 

Dry Drawing of Wire

Wet Drawing of Wire

Heat Treatment of Wire 

Annealing 

Batch Annealing of Low Carbon Steel Wire 

Continuous (In-Line) Annealing of Low Carbon Steel Wire 

Patenting 

Inline Pickling 

Surface preparation 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum

Chapter 47

Plant Economics of Copper Wire and PVC Cable

Introduction 

Types of electrical wires 

Process Flow Chart

Copper Wire

Manufacturing Process 

Drawing 

Annealing 

Stranding 

Insulation 

Quality Control

Plant Economics 

Land & Building

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 48

Plant Economics of Electrical Wire and Cable

Plant Economics 

Land & Building 

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum 

Chapter 49

Plant Economics of House Wire/Low Voltage Production Plant

Introduction

Cables are manufactured and undergo the following Tests

Process Flow Chart

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 50

Plant Economics of Mild Steel Wire Drawing

Introduction 

Manufacturing Process 

(2) Raw Material (Wire Rod) Preparation 

Drawing 

Heat Treatment of Wire

In-line Pickling

Final Inspection

Packaging & Dispatch 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum

Chapter 51

Plant Economics of Optical Fiber Cable

Introduction

Raw Material 

Finished Product Details

Plant Economics 

Land & Building

Plant & Machinery

Process Flow Schematic 

Fixed Capital

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum 

Chapter 52

Plant Economics of Submersible Copper Winding Wire

Introduction

Dimension Test:

Specification:

Process Flow Chart

Electrical Resistance Test 

Elongation Test 

Springiness Test

Flexibility & Adherence Test

Heat Shock Test 

Cut through Test

Solvent Test 

Breakdown Voltage 

Continuity of Insulation 

Temperature Index 

Abrasion resistance (Unidirectional)

Tan Delta Bending Point 

Shrinkage Test 

High Voltage Test 

Insulation Resistance Test 

Coiling and packing 

Pollution Control 

Energy Conservation 

Plant Economics 

Land & Building

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 53

Plant Economics of Wire and Cable Manufacturing Unit

Introduction

Type Test

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 54

Plant Economics of Wire Nails (Ms) Manufacturing

Manufacturing Process

Raw Material

Main Process 

Forming 

Finishing 

Packaging

Quality Control 

Plant Economics 

Land & Building

Plant & Machinery

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum