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wire products

Alumoweld Wire and Strand


Alumoweld wire consists of a thick cladding of pure aluminum over a high-strength steel
core. Alumoweld wire offers the advantages of each metal. It is ideal for overhead ground
wire, neutral messengers, line wire and guy strand. Alumoweld wire and strand is used by
power utilities, as well as formed wire and optical ground wire manufacturers. Alumoweld
outlasts other options by as much as 200% in corrosive environments, significantly lowering
maintenance and replacement costs. When compared to solid aluminum wire, Alumoweld
offers tremendous savings.

how is Alumoweld made?

applications
Utility Market

The Alumoweld process consists of a continuous application of pure atomized aluminum


powder to a high strength steel rod. Proper control of head and pressure refines the
cladding and develops a controlled atomic weld. The resulting bimetallic rod is then cold
drawn into finished wire sizes without changing original proportions of aluminum and steel.

Telecommunications Market

features

Military

Thick Aluminum Covering


Alumoweld wire is produced with the concentric aluminum covering comprising 25% of
the cross-sectional area, with the aluminum thickness 10% of the wire radius. The high
proportion of aluminum offers an excellent degree of electrical conductivity and permanently
protects the high strength steel core.

General Industry Applications

High Conductivity
Compared to solid aluminum wire of the same diameter, Alumoweld wire has a direct
current conductance of 33%. It has about three times the conductivity of galvanized
steel wire. For high frequency currents where skin effect is a factor, the conductivity of
Alumoweld wire approaches 100% of solid aluminum. When Alumoweld wires are combined
with aluminum wires in composite conductors, a wide range of strength and conductivity
characteristics is possible.
Corrosion Resistance
The thick aluminum cladding of Alumoweld wire provides a high degree of corrosion
resistance, resulting in longer service life and reduced maintenance. Accelerated laboratory
tests exposing Alumoweld wire to various types of corrosive conditions have proven that
Alumoweld wires have corrosion resistance comparable to EC grade aluminum. The conditions simulated in the test included industrial, marine and tropical.
Combines High Strength with Low Weight
Alumoweld wire has a higher strength-to-weight ratio than any other wire commonly used
on overhead lines. Size for size, it has about the same tensile strength as extra high strength
steel wire, but weighs approximately 15% less. It has eight times the strength of solid
aluminum wire of the same diameter and only a little more than twice the weight. This high
strength-to-weight ratio provides a maximum margin of safety for long-span construction.
The strength of Alumowelds steel core is protected by the thick aluminum covering.
5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
3

wire products
Alumoweld Overhead Ground Wire
Alumoweld wire and strand is used by power utilities, as well as formed wire and optical
ground wire manufacturers. Alumoweld outlasts other options by as much as 200% in
corrosive environments, significantly lowering maintenance and replacement costs. When
compared to solid aluminum wire, Alumoweld offers tremendous savings.

features
Corrosion Resistance
Alumoweld overhead ground wire has excellent corrosion resistance. Its strength and conductivity remain unchanged in any atmosphere where aluminum is satisfactory, especially
those known to be corrosive from industrial or atmospheric conditions.

applications
Overhead ground wire
Shield wire protecting transmission lines
against lightning damage

available sizes
Single wire, 3 strand and 7 strand
overhead ground wire are available in the
following coil sizes:
Coil Sizes

Package Code

250 feet

C250F

500 feet

C500F

All overhead ground wire products are


available in the following reel sizes:
Reel Sizes

Package Code

1,000 feet

R1000

2,500 feet

R2500

5,000 feet

R5000

10,000 feet

R10000

This assurance against corrosion is obtained through the application of a thick covering of
pure aluminum, which provides a substantial barrier of protective metal. The minimum cladding thickness of Alumoweld is 10% of the radius of the wire. The cladding has a continuous, strong metallic bond to the steel core that will not crack or flake.
Strength Comparable to Steel
Alumoweld also provides strength greater than or equal to other overhead ground wires. For
commonly used wire sizes, the tensile strength of the individual wire can approach 200,000
pounds per square inch. When used in a strand for overhead ground wire, this high strength
permits greater span lengths, less sag, and heavier loads under storm loading conditions.
Lightweight
Directly related to strength and sag performance is the lighter weight of Alumoweld. Due to
its thick cladding of aluminum, Alumoweld is 15% lighter than a steel strand of equivalent
size. This lighter weight, combined with high strength, permits Alumoweld to be installed to
the same sags as steel with correspondingly lower tensions and lower stresses on the towers or supporting structures.

ordering instructions
Step 1: Determine Catalog Number
Determine the overhead ground wire catalog number. Catalog numbers are on next page.
Step 2: Determine Package Code
Determine the package code using the charts on this page.
Step 3: Assemble Complete Part Number
Catalog Number

Package Code

Example:
For a 1000 ft reel of 7 No. 7 ground wire, the part number is:
AW0707R1000

5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
5

wire products
Alumoweld Overhead Ground Wire
physical and electrical characteristics

SINGLE END WIRE

3 STRAND

7 STRAND

19 STRAND

37 STRAND

Catalog
Number

Number
and Size
of Wires

Nominal Diameter

Breaking Loads

Weight

Resistance

Cross Section Area

AWG

In

mm

Lbs

kg

Lbs /
1000 ft

kg / km

Ohms /
1000 ft

Ohms /
km

Sq In

mm2

AW3705

37 No. 5

1.270

32.3

142,800

64,790

2,802.0

4,170.0

0.0425

0.1394

0.9615

620.6

AW3706

37 No. 6

1.130

28.8

120,200

54,500

2,222.0

3,307.0

0.0536

0.1757

0.7626

492.2

AW3707

37 No. 7

1.010

25.7

100,700

45,690

1,762.0

2,623.0

0.0675

0.2216

0.6051

390.3

AW3708

37 No. 8

0.899

22.9

84,200

38,190

1,398.0

2,080.0

0.0852

0.2794

0.4798

309.5

AW3709

37 No. 9

0.801

20.3

66,770

30,290

1,108.0

1,649.0

0.1074

0.3523

0.3803

245.5

AW3710

37 No.10

0.713

17.9

52,950

24,020

879.0

1,308.0

0.1354

0.4443

0.3017

194.7

AW1905

19 No. 5

0.910

23.1

73,350

33,270

1,430.0

2,129.0

0.0822

0.2698

0.4944

318.7

AW1906

19 No. 6

0.810

20.6

61,700

27,990

1,134.0

1,688.0

0.1037

0.3402

0.3916

252.7

AW1907

19 No. 7

0.721

18.3

51,730

23,460

899.5

1,339.0

0.1308

0.4290

0.3107

200.4

AW1908

19 No. 8

0.642

16.3

43,240

19,610

713.5

1,062.0

0.1649

0.5409

0.2464

158.9

AW1909

19 No. 9

0.572

14.5

34,290

15,550

565.8

842.0

0.2079

0.6821

0.1953

126.1

AW1910

19 No.10

0.509

12.9

27,190

12,330

448.7

667.7

0.2622

0.8601

0.1549

99.9

AW0705

7 No. 5

0.546

13.9

27,030

12,260

524.9

781.1

0.2264

0.7426

0.1819

117.4

AW0706

7 No. 6

0.486

12.4

22,730

10,310

416.3

619.5

0.2803

0.9198

0.1443

93.1

AW0707

7 No. 7

0.433

11.0

19,060

8,645

330.0

491.1

0.3535

1.1600

0.1145

73.8

AW0708

7 No. 8

0.385

9.8

15,930

7,226

261.8

389.6

0.4458

1.4630

0.0908

58.6

AW0709

7 No. 9

0.343

8.7

12,630

5,729

207.6

308.9

0.5621

1.8440

0.0719

46.4

AW0710

7 No.10

0.306

7.8

10,020

4,545

164.7

245.1

0.7088

2.3250

0.0571

36.8

AW0711

7 No.11

0.272

6.9

7,945

3,604

130.6

194.4

0.8938

2.9320

0.0453

29.2

AW0712

7 No.12

0.242

6.2

6,301

2,858

103.6

154.2

1.1270

3.6970

0.0360

23.2

AW0305

3 No. 5

0.392

10.0

12,230

5,547

224.5

334.1

0.5177

1.6990

0.0779

50.3

AW0306

3 No. 6

0.349

8.9

10,280

4,663

178.1

265.0

0.6528

2.1420

0.0619

39.9

AW0307

3 No. 7

0.311

7.9

8,621

3,910

141.2

210.1

0.8232

2.7010

0.0491

31.7

AW0308

3 No. 8

0.277

7.0

7,206

3,269

112.0

166.7

1.0380

3.4060

0.0389

25.1

AW0309

3 No. 9

0.247

6.3

5,715

2,592

88.81

132.2

1.3090

4.2940

0.0309

19.9

AW0310

3 No.10

0.220

5.6

4,532

2,056

70.43

104.8

1.6510

5.4150

0.0245

15.8

AW0104

No. 4

0.204

5.2

5,081

2,305

93.63

139.3

1.22200

4.0090

0.0328

21.2

AW0105

No. 5

0.182

4.6

4,290

1,946

74.25

110.5

1.5410

5.0560

0.0259

16.8

AW0106

No. 6

0.162

4.1

3,608

1,637

58.88

87.62

1.9430

6.3750

0.0206

13.3

AW0107

No. 7

0.144

3.6

3,025

1,372

46.69

69.48

2.4500

8.0380

0.0163

10.6

AW0108

No. 8

0.129

3.2

2,529

1,147

37.03

55.11

3.0890

10.1300

0.0129

8.37

AW0109

No. 9

0.114

2.9

2,005

909

29.37

43.71

3.8960

12.7800

0.0102

6.63

AW0110

No.10

0.102

2.6

1,590

721

23.29

34.66

4.9120

16.1200

0.0081

5.26

AW0111

No.11

0.091

2.3

1,261

572

18.47

27.49

6.1940

20.3200

0.0064

4.17

AW0112

No.12

0.081

2.1

1,000

454

14.65

21.80

7.8110

25.6300

0.0051

3.31

Modulus of Elasticity: Strand 16,200 kg/mm2; Solid Wire 16,500 kg/mm2. Coefficient of Linear Expansion: 1.3x10-5 per degree C.

5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
6

wire products
Alumoweld Type M Guy Strand
features
Corrosion Resistance
Alumoweld Type M guy strand is an economical, corrosion resistant guying material for
use on overhead line structures. The thick cladding of aluminum on each wire protects the
high-strength steel core from rusting and subsequent loss of strength. Costly maintenance is
eliminated, and the original safety factor of the guy is maintained throughout the life of the line.
Thick Aluminum Cladding
The Alumoweld wire used to make Type M guy strand is unique in that the aluminum cladding thickness is guaranteed to be no less than 10% of the wire radius. Thus, a thick corrosion barrier, that is pure aluminum not zinc or an iron-aluminum alloy, protects the steel core.

applications

Another important feature of any coated or clad wire is the bond between the coating material and the base metal. In the case of Alumoweld wire, the aluminum cladding and steel
core are joined by a continuous ductile weld. This assures against cracking or separation of
the protective aluminum from the steel core.

Guying for:
Power lines
Telephone lines

Lightweight and Convenient


Alumoweld Type M guy strand is easily handled and installed. It weighs less than any of the
other high-strength guying materials.

Railway signals
Communication lines
Towers
Mast

ordering instructions

available sizes

Step 1: Determine Catalog Number


Determine the Type M Guy Strand catalog number. Catalog numbers are on next page.

Type M Guy Strand is available in the


following coil sizes:
Coil Sizes

Package Code

250 feet

C250F

500 feet

C500F

Type M guy strand is available in the


following reel sizes:
Reel Sizes

Package Code

1,000 feet

R1000

2,500 feet

R2500

5,000 feet

R5000

10,000 feet

R10000

Step 2: Determine Package Code


Determine the package code using the charts on this page.
Step 3: Assemble Complete Part Number
Catalog Number

Package Code

Example:
For a 1000 ft reel of 10M Guy strand, the part number would be:
AW10MR1000

5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
7

wire products
Alumoweld Type M Guy Strand
physical characteristics
Catalog
Number

Strand
Designation

AW2.8M3
AW4M3

Nominal
Diameter of Strand

Diameter of
Individual Wires

Number of
Individual Wires

Breaking
Load

Weight

Approximate
Resistance

kg/km

Ohms/
1000
ft1

Ohms/
km1

44

65.47

2.62

8.60

70

104.16

1.65

5.44

2,585

89

132.43

1.31

4.30

6,000

2,721

104

154.75

1.13

3.71

3.25

7,200

3,265

112

166.66

1.04

3.41

0.091

2.31

8,000

3,628

131

194.93

0.89

2.92

0.102

2.59

10,000

4,535

165

245.52

0.71

2.33

8.71

0.114

2.90

12,500

5,670

208

309.50

0.56

1.84

0.363

9.22

0.121

3.07

14,000

6,350

232

345.22

0.50

1.64

16M

0.386

9.80

0.128

3.25

16,000

7,257

262

389.86

0.45

1.48

AW18M

18M

0.417

10.59

0.139

3.53

18,000

8,164

306

455.33

0.38

1.25

AW20M

20M

0.444

11.28

0.148

3.76

20,000

9,072

347

516.34

0.34

1.12

AW25M

25M

0.519

13.18

0.173

4.39

25,000

11,340

475

706.80

0.25

0.82

In

mm

Lbs

kg

Lbs/
1000 ft

0.081

2.06

2,800

1,270

0.102

2.59

4,000

1,814

6.27

0.114

2.90

5,700

0.242

6.15

0.081

2.06

7M3

0.277

7.04

0.128

AW8M

8M

0.272

6.91

AW10M

10M

0.306

7.77

AW12.5M

12.5M

0.343

AW14M

14M

AW16M

In

mm

2.8M3

0.174

4.42

4M3

0.220

5.59

AW5M3

5M3

0.247

AW6M

6M

AW7M3

1. For information only, not for calculation purposes.


The above guy strands may be purchased under Alumoweld Specification ER 3008.

5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
8

wire products
Alumoweld Aluminum Conductors (AWAC)
AWAC combines Alumoweld with 1350-H19 aluminum wire to provide the electric industry a
new versatility for distribution line construction. The combination of high conductivity aluminum with high strength Alumoweld wire, in varying proportions, allows the designer flexibility
for solving new designs or reconductoring. AWAC offers unsurpassed strength-to-weight
ratio. Aluminum equivalents of No. 4 AWG through 4/0 AWG each offer a complete range of
breaking strengths. In addition to its use as a phase conductor, AWAC is well suited for other
electrical-mechanical applications on distribution and transmission lines.

features

applications
Phase conductor
Neutral messengers
Combined neutral-overhead ground wires
Self-supporting primary, secondary
and service drop cables

available sizes
AWAC is available in the following reel sizes:
Reel Sizes

Package Code

2,500 feet

R2500

5,000 feet

R5000

Designed for Versatility


AWAC is a reinforced aluminum conductor of improved design. Alumoweld wires perform the
dual function of providing strength and conductance. AWAC offers both lightweight and high
strength for any given AWG conductivity. To make AWAC a more versatile conductor, the ratio
of Alumoweld to aluminum wires has been varied to provide the largest range of breaking
strengths offered by any conductor.
Corrosion Resistance
The steel core of each Alumoweld wire is protected against rust by a thick covering of
aluminum. This provides the same corrosion resistance as AWACs solid EC aluminum wires.
Thus, Alumoweld is safely used in any strand position of an AWAC conductor. This design
advantage allows conductor configurations of high strength without sacrificing conductivity or
corrosion resistance.
Unsurpassed Strength-to-Weight Ratio
AWACs Alumoweld wires act as the strength members of the conductor while the aluminum
wires reduce the overall weight. This combination results in a high strength-to-weight conductor. When more than one Alumoweld wire is used, the AWAC conductors are unmatched
by any other conductor in strength-to-weight ratio. For example, the 5/2 AWAC has approximately 50% more strength and only weighs 20% more than a 6/1 stranded ACSR conductor.

ordering instructions
Step 1: Determine Catalog Number
Determine the AWAC catalog number. Catalog numbers are on next page.
Step 2: Determine Package Code
Determine the package code using the charts on this page.
Step 3: Assemble Complete Part Number
Catalog Number

Package Code

Example:
For a 2500 ft reel of No. 2-5/2 AWAC, the part number is:
AWAC025/2
5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
9

wire products
Alumoweld Aluminum Conductors (AWAC)
physical and electrical characteristics
Conductor
Catalog
Number

Size and
Configuration

AWAC045/2

Diameter Aluminum Wires Alumoweld Wires


No.

In

Breaking Load
Lbs

Weight
Lbs/1000 ft

Resistance

Cross Section

Lbs/mile

Ohms/kft at 68 F

Sq In

In

No.

In

No. 4-5/2

0.261

0.0871

0.0871

2,790

70

368

0.4026

0.0417

AWAC044/3

No. 4-4/3

0.281

0.0937

0.0937

4,190

92

488

0.3935

0.0483

AWAC043/4

No. 4-3/4

0.307

0.1022

0.1022

6,130

124

653

0.3809

0.0574

AWAC042/5

No. 4-2/5

0.340

0.1133

0.1133

8,960

169

894

0.3656

0.0706

No. 4 AWG Aluminum/No. 6 Copper Equivalent

No. 3 AWG Aluminum/No. 5 Copper Equivalent


AWAC035/2

No. 3-5/2

0.293

0.0978

0.0978

3,500

88

464

0.3193

0.0526

AWAC034/3

No. 3-4/3

0.316

0.1053

0.1053

5,260

117

615

0.3116

0.0609

AWAC033/4

No. 3-3/4

0.344

0.1147

0.1147

7,700

156

823

0.3024

0.0723

AWAC032/5

No. 3-2/5

0.382

0.1273

0.1273

11,300

214

1,127

0.2896

0.0890

No. 2 AWG Aluminum/No. 4 Copper Equivalent


AWAC025/2

No. 2-5/2

0.330

0.1099

0.1099

4,370

111

585

0.2529

0.0663

AWAC024/3

No. 2-4/3

0.355

0.1182

0.1182

6,600

147

776

0.2473

0.0768

AWAC023/4

No. 2-3/4

0.386

0.1288

0.1288

9,690

197

1,038

0.2398

0.0912

AWAC022/5

No. 2-2/5

0.429

0.1429

0.1429

13,500

269

1,423

0.2298

0.1123

No. 1 AWG Aluminum/No. 3 Copper Equivalent


AWAC015/2

No. 1-5/2

0.370

0.1234

0.1234

5,450

140

738

0.2006

0.0837

AWAC014/3

No. 1-4/3

0.398

0.1327

0.1327

8,100

185

978

0.1962

0.0969

AWAC013/4

No. 1-3/4

0.434

0.1446

0.1446

11,200

248

1,309

0.1903

0.1150

AWAC012/5

No. 1-2/5

0.482

0.1605

0.1605

16,500

340

1,793

0.1822

0.1416

No. 1/0 AWG Aluminum/No. 2 Copper Equivalent


AWAC1/05/2

No. 1/0-5/2

0.416

0.1385

0.1385

6,580

176

930

0.1592

0.1055

AWAC1/04/3

No. 1/0-4/3

0.447

0.1490

0.1490

9,680

234

1,233

0.1556

0.1221

AWAC1/03/4

No. 1/0-3/4

0.487

0.1624

0.1624

13,800

313

1,651

0.1509

0.1450

AWAC1/02/5

No. 1/0-2/5

0.541

0.1802

0.1802

19,500

428

2,260

0.1445

0.1785

No. 2/0 AWG Aluminum/No. 1 Copper Equivalent


AWAC2/05/2

No. 2/0-5/2

0.467

0.1556

0.1556

8,030

222

1,173

0.1262

0.1330

AWAC2/04/3

No. 2/0-4/3

0.502

0.1674

0.1674

11,900

295

1,555

0.1233

0.1541

AWAC2/03/4

No. 2/0-3/4

0.547

0.1824

0.1824

16,400

394

2,082

0.1196

0.1829

No. 3/0 AWG Aluminum/No. 1/0 Copper Equivalent


AWAC3/05/2

No. 3/0-5/2

0.524

0.1747

0.1747

9,660

281

1,482

0.1001

0.1677

AWAC3/04/3

No. 3/0-4/3

0.564

0.1880

0.1880

14,200

371

1,961

0.0978

0.1942

1,613

0.0808

0.1974

No. 4/0 AWG Aluminum/No. 2/0 Copper Equivalent


AWAC4/015/14 No. 4/0-15/14

0.575

15

0.1150

0.1150

10,800

305

5.20.03
Specifications are subject to change without notice.
2003, AFL Telecommunications. All rights reserved.

www.ACAsolutions.com or 1.800.866.7385
10

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