To: Dave Bryant

Composite Technology Corporation

2026 McGaw Avenue
Irvine, CA 92614
USA

SALT SPRAY CORROSION TEST ON

1020 KCMIL ACCC/TW CONDUCTOR FOR COMPOSITE TECHNOLOGY CORPORATION

Kinectrics North America Inc. Report No.: K-422024-RC-0007-R00

December 3, 2004

M. Colbert
Transmission and Distribution Technologies Business

1.0 INTRODUCTION

A Salt Spray Corrosion Test was performed on samples of Aluminum Conductor, Composite
Core – Trapezoidal Wires (ACCC/TW) conductor for Composite Technology Corporation (CTC).
The conductor consists of a Composite Fiberglass/Carbon Fiber Core and annealed, trapezoidal
aluminum alloy wires. The conductor was stranded by General Cable. The code name for
conductor is 1020 kcmil ACCC/TW Custom Design (16 wire).

The test was performed from February 20, 2004 to April 2, 2004 by Kinectrics North America
Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada.

2.0 TEST OBJECTIVE AND STANDARD

The objective of the Salt Spray Corrosion Test was to observe the effects on the whole
conductor and the composite core of the ACCC conductor when exposed to a salt spray
atmosphere for 1000 hours. A “Drake” 795 kcmil ACSR was also tested for comparison
purposes. It should be noted that the aluminum strands of the ACCC conductor are annealed
and trapezoidal and those for the ACSR are hard drawn and round. The test was performed
using an environmental chamber that complied with ASTM B117-03, “Standard Practice for
Operating Salt Spray Apparatus”.

PRIVATE INFORMATION
Contents of this report shall not be disclosed without authority of the client.
Kinectrics North America Inc., 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4
3.0 TEST SET-UP

The chamber has a salt-solution reservoir that is capable of maintaining an adequate solution.
There is equipment to atomize the salt-solution including suitable nozzles and compressed air to
provide a uniform spray within the chamber. The temperature of the chamber can also be
controlled. The facility used to perform the test was an Industrial Filter and Pump 411.3ACD
salt spray chamber and is shown in Figure 1.

The measuring instruments used in this test are listed in Appendix A.

4.0 TEST PROCEDURE

The fog chamber was programmed to provide a finely divided, wet dense fog while the air
supply to the atomizer was maintained at a relative humidity of 95% to 98%. The chamber air
temperature was maintained at 35 °C ± 1. The salt solution was 5% concentration and was
prepared by dissolving by weight, 5 +/-1 parts of de-mineralized salt in 95 parts of de-ionized
water. The quantity of collected salt spray was maintained at between about 1.0 to 2.0 ml/hour,
as measure by a collecting area of 80 square cm. The pH of the collected solution was
maintained between 6.5 to 7.2, at 25ºC, by adding the appropriate amount of sodium hydroxide.

The following samples were exposed to the salt spray for 1000 hours.

- one (1) whole ACCC conductor sample.

- one (1) intact composite core sample.
- one (1) composite core sample split lengthwise in two to expose the cross-section.
- one (1) whole ACSR conductor sample.

All samples were cut to about 50 cm in length and were placed in the chamber with an angle
20° from vertical. They were exposed to a salt spray for 1000 hours. Prior to insertion into the
chamber, the samples were gently wiped to remove any loose particles. Tie-wraps were used
to hold both ends of the sample in place. Silicon rubber was used to seal the ends of the
sample.

A cross-sectional photo of the ACCC conductor is shown in Figure 2.

5.0 TEST RESULTS

Photographs of the cable samples during the test in the chamber, before the test, and after the
test are shown in Figures 3a, 3b, and 3c, respectively.

The results for the weight of the samples before and after the salt spray test are shown in
Table 1. There was no indication of loss of material.

After completion of the test, observations and dissections were performed. The results are in
Table 2, 3, and 4. Photographs are shown in Figures 4a to 6e.

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Table 1: Salt Spray Test Results for CTC 1020 ACCC-TW and Drake 795 ACSR Conductors

Weight Before Weight After Weight

Sample Insertion 1000 hours Difference
(grams) (grams) (grams)
CTC – One Whole Conductor 758 758 0
CTC – One Whole Core 65.503 67.546 +2.04
CTC – Half a Core (whole core split
34.748 34.750 +0.002
down the middle)
CTC – Half a Core (whole core split
32.101 32.119 +0.018
down the middle)
795 ACSR – One Whole Conductor 821 823 +2

The increase in weight of the ACSR was due to the salt deposits that had collected between the
layers. The salt was concentrated at the bottom end.

Table 2: CTC 1020 ACCC-TW - Conductor

Photographs
Component Observations after Salt Spray Test
Before After

Outside
- was mostly dull in color (not shiny anymore) Figure Figure
Aluminum
Layer - showed some discolored (darkened) patches. 4a 4b
Inner Aluminum
- showed no signs of discoloration and deterioration. Figure
Layer -
(2nd layer) - the oily film was no longer present. 4c

- showed no signs of deterioration. Figure

Core -
- the oily film was still present on the surface. 4d

Table 3: CTC 1020 ACCC-TW – Whole and Half Core Only

Photographs
Component Observations after Salt Spray Test
Before After

- did not appear to have been affected by the salt fog Figure Figure
Whole Core
test.
and 5a 5b
- there were no signs of discoloration or deterioration.
Half Core 5c 5d
- there were no signs of softening of the material.

3 K-422024-RC-0007-R00
 Table 4: Drake 795 ACSR – Conductor

Photographs
Component Observations after Salt Spray Test
Before After
Outside
- was dull (not shiny anymore), and showed some Figure Figure
Aluminum
Layer discolored (darkened) patches. 6a 6b
Inner Aluminum
- exhibited some surface discoloration and dulling. Figure
Layer -
(2nd layer) - the bottom end had collected white salt deposits. 6c

- showed some discoloration (darkening).

Outer Steel - small amounts of salt deposits were spread throughout Figure
-
Wires the surface. 6d
- the bottom end had collected white salt deposits.
- showed some discoloring (darkening).
- it had some small amounts of salt deposits spread Figure
Core Steel Wire -
throughout its surface. 6e
- the bottom end had collected white salt deposits.

Prepared by:
M. Colbert
Technologist
Transmission and Distribution Technologies Business

Reviewed by:
C.J. Pon
Principal Engineer
Transmission and Distribution Technologies Business

Approved by:
Dr. J. Kuffel
General Manager
Transmission and Distribution Technologies Business

MC:CJP:JK
DISCLAIMER

Kinectrics North America Inc., has prepared this report in accordance with, and subject to, the terms
and conditions of the contract between Kinectrics North America Inc. and Composite Technology
Corporation.

© Kinectrics North America Inc., 2004.

4 K-422024-RC-0007-R00
 Figure 1: Industrial Filter and Pump, Model 411.3ACD Salt Spray Chamber

Figure 2: Cross-sectional photo of 1020 kcmil ACCC/TW Custom Design (16 wire).

5 K-422024-RC-0007-R00
Figure 3a: Test Samples in Salt Spray Chamber

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Figure 3b: Test Samples ‘Untested’, BEFORE Salt Corrosion Test

Figure 3c: Test Samples AFTER 1000 hours Salt Corrosion Test

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Figure 4a: Test Sample - Outside Aluminum Layer
BEFORE Salt Corrosion Test

Figure 4b: Test Sample - Outside Aluminum Layer

AFTER Salt Corrosion Test

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Figure 4c: Test Sample - Inner Aluminum Layer
AFTER Salt Corrosion Test

Figure 4d: Test Sample - Core

AFTER Salt Corrosion Test

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Figure 5a: Test Sample – Whole Core
BEFORE Salt Corrosion Test

Figure 5b: Test Sample – Whole Core

AFTER Salt Corrosion Test

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Figure 5c: Test Sample – Half Core
BEFORE Salt Corrosion Test

Figure 5d: Test Sample – Half Core

AFTER Salt Corrosion Test

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Figure 6a: Test Sample – ACSR, Outside Aluminum Layer
BEFORE Salt Corrosion Test

Figure 6b: Test Sample – ACSR, Outside Aluminum Layer

AFTER Salt Corrosion Test

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Figure 6c: Test Sample – ACSR, Inner Aluminum Layer
AFTER Salt Corrosion Test

Figure 6d: Test Sample – ACSR, Outer Steel Wires

AFTER Salt Corrosion Test

13 K-422024-RC-0007-R00
Figure 6e: Test Sample – ACSR, Core Steel Wire
AFTER Salt Corrosion Test

14 K-422024-RC-0007-R00
 ISO-9001 APPENDIX A
Form: QF11-1 INSTRUMENT SHEET
Rev 0, 97-10
Salt Spray Corrosion Test on 1020 KCMIL ACCC/TW Conductor

Test Description: Cable QualificationTests Test Start Date: February 20, 2004
Project Number: K-422024 Test Finish Date: April 2, 2004

TEST EQUIPMENT ASSET # or ACCURACY CALIBRATION CALIBRATION TEST

MAKE MODEL
DESCRIPTION DESCRIPTION SERIAL # CLAIMED DATE DUE DATE USE

Digital Scale Mettler Toledo PB153-S 1120133358 ±0.001 June 4, 2003 June 4, 2004 Wire Weight

Balance Scale Mettler Toledo SB32000 10000640-0 ±5 grams May 6, 2003 May 6, 2004 Cable Weight
Salt Spray
Corrosion Digital Scale Mettler Toledo PC 4400 13875-0 ±10 gram March 1, 2004 March 1, 2005 Salt Weight
A-1

Test Digital Meter Fluke 52 KIN-00033

Thermocouple Omega Type K KIN-00035 Exposure Zone

& Tower Air
Thermocouple Omega Type K KIN-00036 ±1 degree June 19, 2003 June 19, 2004 Temperature
K-422024-RC-0007-R00
DISTRIBUTION

Mr. D. C. Bryant (2) Composite Technology Corporation

2026 McGaw Avenue
Irvine, CA 92614
USA

Mr. C. Pon Transmission and Distribution – KB104