08 Wire Products Catalog

Wire Products
CONTENTS
TABLE OF
Table of Contents
Wire Products Pictorial Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Alumoweld®
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Overhead Ground Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Overhead Ground Wire Physical and Electrical Characteristics . . . . . . . 427
Type M Guy Strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Type M Guy Strand Physical Characteristics . . . . . . . . . . . . . . . . . . . . 429
Copperclad Steel Wire

Copperclad Steel Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Dead Soft Annealed Copperclad Steel Wire . . . . . . . . . . . . . . . . 432
Jacketed Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Grounding Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Selecting the Right Size for the Application . . . . . . . . . . . . . . . . 434
DSA Copperclad Steel Wire for Grounding Applications . . . . . . . 436
Copperclad Steel Wire—High Strength/Extra High Strength . . . . 440
Copperclad Composite (CCC) Conductors . . . . . . . . . . . . . . . . . 444
Copperclad Type M Guy Wire . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Electrical Characteristics of Copperclad Steel Wire Conductors . . 450
Copperclad Part Number Nomenclature. . . . . . . . . . . . . . . . . . . 454
Recommended Maximum Footage per Reel. . . . . . . . . . . . . . . . 455
Green Spool Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
© 2003, AFL, all rights reserved. PP-3-00780, Revision 8, 4.24.17

www.AFLglobal.com or 800-866-7385 Specifications are subject to change without notice.
423
Wire Products
Pictorial Index
WIRE PRODUCTS
PICTORIAL
INDEX
Alumoweld® Copperclad
Wire & Strand: pg. 425 High Strength and Extra High Strength: pg. 440
Copperclad Copperclad
Jacekted Dead Soft Annealed Conductors: pg. 432 Composite Conductors: pg. 444
Copperclad Copperclad
Dead Soft Annealed: pg. 432 Type M Guy Strand: pg. 448

424
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?

The Alumoweld process consists of a continuous application of a pure atomized aluminum
powder to a high strength steel rod. Proper control of heat and pressure refines the cladding
and develops a controlled atomic weld. The resulting bimetallic rod is then cold drawn into
Applications finished wire sizes without changing original proportions of aluminum and steel.
• Utility Market
• Telecommunications Market Features
• Military
Thick Aluminum Covering
• General Industry Applications
Alumoweld wire is produced with the concentric aluminum covering comprising 25% of
the cross-sectional area, with the aluminum thickness 10% minimum of the wire radius.
The high proportion of aluminum offers an excellent degree of electrical conductivity and
permanently protects the high strength steel core.
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 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 Alumoweld’s steel core is protected by the thick aluminum covering.

425
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
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.
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
Applications cladding thickness of Alumoweld is 10% of the radius of the wire. The cladding has a
• Overhead ground wire continuous, strong metallic bond to the steel core that will not crack or flake.
• Shield wire protecting transmission lines
Strength Comparable to Steel
against lightning damage
Alumoweld also provides strength greater than or comparable 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.

426
Wire Products
Alumoweld® Overhead Ground Wire (cont.)
ALUMOWELD STRAND ASTM B-416

NUMBER & NOMINAL
NOMINAL STRAND BREAKING
SIZE OF WIRE WEIGHT RESISTANCE CROSS SECTION
DIAMETER LOAD
WIRES DIAMETER
LB/1000 KG/ OHMS/1000 OHMS/
AWG IN MM IN MM LB KG SQ IN MM2
FT KM FT@68ºF KM@20ºC
37 No. 6 0.1620 4.115 1.130 28.80 120,200 54,500 2222.00 3307.0 0.05356 0.1757 0.76264 492.20
37 No. 7 0.1443 3.665 1.010 25.70 100,700 45,690 1762.00 2623.0 0.06754 0.2216 0.60509 390.30
37 No. 8 0.1285 3.264 0.899 22.90 84,200 38,190 1398.00 2080.0 0.08516 0.2794 0.47984 309.50
37 No. 9 0.1144 2.906 0.801 20.30 66,770 30,290 1108.00 1649.0 0.10740 0.3523 0.38032 245.50
37 No.10 0.1019 2.588 0.713 17.90 52,950 24,020 879.00 1308.0 0.13540 0.4443 0.30174 194.70
19 No. 5 0.1819 4.620 0.910 23.10 73,350 33,270 1430.00 2129.0 0.08224 0.2698 0.49438 318.70
19 No. 6 0.1620 4.115 0.810 20.60 61,700 27,990 1134.00 1688.0 0.10370 0.3402 0.39163 252.70
19 No. 7 0.1443 3.665 0.721 18.30 51,730 23,460 899.50 1339.0 0.13080 0.4290 0.31073 200.40
19 No. 8 0.1285 3.264 0.642 16.30 43,240 19,610 713.50 1062.0 0.16490 0.5409 0.24641 158.90
19 No. 9 0.1144 2.906 0.572 14.50 34,290 15,550 565.80 842.0 0.20790 0.6821 0.19530 126.10
19 No.10 0.1019 2.588 0.509 12.90 27,190 12,330 448.70 667.7 0.26220 0.8601 0.15495 99.96
7 No. 5 0.1819 4.620 0.546 13.90 27,030 12,260 524.90 781.1 0.22640 0.7426 0.18193 117.40
7 No. 6 0.1620 4.115 0.486 12.40 22,730 10,310 416.30 619.5 0.28030 0.9198 0.14435 93.10
7 No. 7 0.1443 3.665 0.433 11.00 19,060 8,645 330.00 491.1 0.35350 1.1600 0.11448 73.87
7 No. 8 0.1285 3.264 0.385 9.78 15,930 7,226 261.80 389.6 0.44580 1.4630 0.09077 58.56
7 No. 9 0.1144 2.906 0.343 8.71 12,630 5,729 207.60 308.9 0.56210 1.8440 0.07198 46.44
7 No.10 0.1019 2.588 0.306 7.76 10,020 4,545 164.70 245.1 0.70880 2.3250 0.05708 36.83
7 No.11 0.0907 2.304 0.272 6.91 7,945 3,604 130.60 194.4 0.89380 2.9320 0.04527 29.21
7 No.12 0.0808 2.052 0.242 6.16 6,301 2,858 103.60 154.2 1.12700 3.6970 0.03590 23.16
3 No. 5 0.1819 4.620 0.392 9.96 12,230 5,547 224.50 334.1 0.51770 1.6990 0.07796 50.32
3 No. 6 0.1620 4.115 0.349 8.87 10,280 4,663 178.10 265.0 0.65280 2.1420 0.06185 39.90
3 No. 7 0.1443 3.665 0.311 7.90 8,621 3,910 141.20 210.1 0.82320 2.7010 0.04905 31.65
3 No. 8 0.1285 3.264 0.277 7.03 7,206 3,269 112.00 166.7 1.03800 3.4060 0.03890 25.10
3 No. 9 0.1144 2.906 0.247 6.26 5,715 2,592 88.81 132.2 1.30900 4.2940 0.03085 19.90
3 No.10 0.1019 2.588 0.220 5.58 4,532 2,056 70.43 104.8 1.65100 5.4150 0.02446 15.78
ALUMOWELD STRAND ASTM B-415

No. 4 0.2043 5.189 115 109.0 5,081 2,305 93.63 139.3 1.222 4.009 0.03278 21.15
No. 5 0.1819 4.620 165 116.0 4,290 1,946 74.25 110.5 1.541 5.056 0.02599 16.77
No. 6 0.1620 4.115 175 123.0 3,608 1,637 58.88 87.6 1.943 6.375 0.02062 13.30
No. 7 0.1443 3.665 185 130.1 3,025 1,372 46.69 69.5 2.450 8.038 0.01635 10.55
No. 8 0.1285 3.264 195 137.1 2,529 1,147 37.03 55.1 3.089 10.130 0.01297 8.37
No. 9 0.1144 2.906 195 137.1 2,005 909 29.37 43.7 3.896 12.780 0.01028 6.63
No.10 0.1019 2.588 195 137.1 1,590 721 23.29 34.7 4.912 16.120 0.00816 5.26
No.11 0.0907 2.304 195 137.1 1,261 572 18.47 27.5 6.194 20.320 0.00647 4.17
No.12 0.0808 2.052 195 137.1 1,000 454 14.65 21.8 7.811 25.630 0.00513 3.31
Modulus of Elasticity: Strand 23,000,000; Solid Wire 23,500,000. Coefficient of Linear Expansion: 0.000,007,2 per degree F.
Modulus of Elasticity: Strand 16,200 kg/mm2; Solid Wire 16,500 kg/mm2. Coefficient of Linear Expansion: 0.000,013 per degree C.

427
Wire Products
Alumoweld® Type M Guy Strand
Features
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% minimum of the wire radius.
Thus, a thick corrosion barrier, that is pure aluminum not zinc or an iron-aluminum alloy,
protects the steel core.
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.
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.
Applications
Guying for:
• Power lines
• Telephone lines
• Railway signals
• Communication lines
• Towers
• Masts
continued

428
Wire Products
Alumoweld® Type M Guy Strand (cont.)
Physical Characteristics
NOMINAL
DIAMETER OF BREAKING APPROXIMATE
DIAMETER OF NUMBER OF WEIGHT
STRAND INDIVIDUAL WIRES LOAD RESISTANCE2
STRAND INDIVIDUAL
DESIGNATION
WIRES LBS/1000 OHMS/1000 OHMS/
IN MM IN MM LBS KG KG/KM
FT FT KM
2.8M3 0.174 4.42 3 0.081 2.06 2,800 1,270 44 65.47 2.62 8.60
4M3 0.220 5.59 3 0.102 2.59 4,000 1,814 70 104.16 1.65 5.44
5M3 0.247 6.27 3 0.114 2.90 5,700 2,585 89 132.43 1.31 4.30
6M 0.242 6.15 7 0.081 2.06 6,000 2,721 104 154.75 1.13 3.71
7M3 0.277 7.04 3 0.128 3.25 7,200 3,265 112 166.66 1.04 3.41
8M 0.272 6.91 7 0.091 2.31 8,000 3,628 131 194.93 0.89 2.92
10M 0.306 7.77 7 0.102 2.59 10,000 4,535 165 245.52 0.71 2.33
12.5M 0.343 8.71 7 0.114 2.90 12,500 5,670 208 309.50 0.56 1.84
14M 0.363 9.22 7 0.121 3.07 14,000 6,350 232 345.22 0.50 1.64
16M 0.386 9.80 7 0.128 3.25 16,000 7,257 262 389.86 0.45 1.48
18M 0.417 10.59 7 0.139 3.53 18,000 8,164 306 455.33 0.38 1.25
19M3 0.433 11.00 7 0.144 3.67 19,000 8,618 330 491.10 0.35 1.16
20M 0.444 11.28 7 0.148 3.76 20,000 9,072 347 516.34 0.34 1.12
25M 0.519 13.18 7 0.173 4.39 25,000 11,340 475 706.80 0.25 0.82
1. Unless otherwise noted, the above guy strands are manufactured per Alumoweld Specification ER-3008.
2. For information only, not for calculation purposes.
3. Per ASTM B-416.

429
Wire Products

430
Wire Products
Copperclad Steel Wire

AFL's Copperclad Steel Wire is the ideal solution for communications capabilities for
both electric utilities and communications carriers. Composed of a steel core with
Coppercladding, the steel wire gives the wire its strength and the thin, consistent layer of
Coppercladding provides electrical conductivity and resistance to corrosion.
To manufacture Copperclad Steel Wire, carbon steel (low, high strength and extra high
COPPERCLAD STEEL
strength) is bonded with a uniform layer of oxygen-free Coppercladding to achieve 21%,
30% and 40% IACS (International Annealed Copper Standard) conductivities. It is then
concentrically stranded from one to three layers with left-hand lay in the outer layer
(right-hand lay optional) and individual wires of the same size. Available in a single wire
7-strand Copperclad Steel Wire and 3, 7 and 19 cable strands.
Features
• Demonstrates the same corrosion-resistant properties as copper while maintaining the
high strength of steel
• Stronger than copper and can withstand more mechanical abuse than solid copper wire
• Reduces damage caused during installation or fatigue from vibration or bending
• Low carbon steel core gives the maximum amount of flexibility while maintaining
high strength
• Special heat treat process results in a very malleable wire that is easy to handle and
install without special tools or equipment
• Coppercladding permanently bonded to the central steel core
• Very little scrap value, discouraging theft and leaving the grounding system intact
Single strand Copperclad Steel Wire
in large and small diameters Applications
• Substation grounding grid and fence ground
• Transmission lines
• Pole ground wire for distribution lines
• Communications networks

431
Wire Products
Dead Soft Annealed Copperclad Steel Wire

Copperclad Steel Wire is a strong, non-rusting, efficient grounding conductor. It is
composed of Coppercladding that is permanently bonded to the central steel core of
each wire. Copperclad provides the same conductivity and corrosion resistance as copper
while maintaining the high strength of steel. Dead Soft Annealed (DSA) Copperclad Steel
Wire is very flexible for easy preparation and installation.
COPPERCLAD STEEL
When compared to solid copper, Copperclad Steel Wire has faster impedance to
ground for better protection of lines and equipment plus a higher resistance to thermal
expansion failures. It also reduces the fatigue damage caused by more than 10 times
that of annealed solid copper.
19-strand Copperclad Steel Wire
Copperclad Steel Wire is an excellent solution for areas with high rates of copper theft as
the amount of copper used in the bonding process is minimal—6% to 10% depending
on the conductivity. When Copperclad Steel Wire is used in place of copper, the
grounding conductor is far less likely to be stolen. This feature is important not only from
an economic standpoint, but also from the standpoint of safety and reliability. Often,
the fact that a copper downlead has been removed is not evident until a surge current
causes a failure in the system.
Jacketed Material
PVC jacketed material available in grey or Copperclad Steel Wire from AFL can be jacketed to further reduce copper theft. At first
black with green stripe glace, its grey PVC jacket has the appearance of galvanized steel. Jacketed material is
also available in black with green stripe. Installation is easy. Cut the wire, remove the PVC
jacket at the terminal end and connect just like copper.
Unlike other plated products available on the market, Copperclad Steel Wire is
conductive and solid. It doesn’t crack, flake or peel.
Copperclad Jacketed is available on spools that are 12" in diameter with a 2" arbor hole.
The spools weigh approximately 25 lb. and are shipped 20 per pallet. Other packaging
options are available. Contact AFL for more information.
Grounding Applications
Grounding protects the network and eliminates damage from lightning and short-
circuit conditions. Annealed or hard drawn Copperclad Steel Wire is an ideal grounding
conductor for primary surge arresters as it allows a continuous length of conductor to
Spool of Copperclad Steel Wire be installed from the arrester to the buried grounding electrode. The steel core of the
with PVC jacketed material. Copperclad ground wire can withstand more mechanical abuse and is less susceptible to
For spool sizes and specifications,
see pages 27-28. vibration-induced fatigue than solid copper or aluminum wire.
Depending on the grounding requirement, AFL offers a Copperclad Steel Wire in
the conductor size, strength and conductivity designed for the application. Standard
connectors used for copper wire can be used on all Copperclad products including
exothermic connections.

432
Wire Products
DSA Copperclad Steel Wire
COPPERCLAD STEEL
6 AWG Solid with grey PVC Jacket 7#7 AWG with black with green stripe
PVC jacket
Table 1—Physical and Electrical Characteristics of Copperclad Jacketed DSA Conductors

40% CONDUCTIVITY
LENGTH PER MIN BREAKING
AFL NO. DIAMETER WEIGHT
CONDUCTOR SIZE SPOOL LOADS
NO. OF STRANDS
GREY BLACK WITH GREEN AWG
inch ft lbf lbs/kft
JACKET JACKET
7 CCS07094DJV CCS07094DBLK 7 #9 0.343 160 2513 260
7 CCS07104DJV 1
CCS07104DBLK 1
7#10 Stranded 7W 0.306 160 1994 238
7 CCS2STR4DJV CCS2STR4DBLK 2 AWG Stranded 7W 0.258 134 1435 171
7 CCS4STR4DJV CCS4STR4DBLK 4 AWG Stranded 7W 0.204 214 897 103
1 CCS01024JV CCS01024BLK 2 AWG Solid 0.258 134 2023 200
1 CCS01044DJV CCS01044DBLK 4 AWG Solid 0.204 214 1272 135
1 CCS01064DJV CCS01064DBLK 6 AWG Solid 0.162 338 800 85
NOTES:
1. Available in 50 lb. coil.
2. Standard green spools weigh approximately 25 lbs. (11.3 kg) and have 2 inch (5.1 cm) arbor holes. Other packaging options are available.

433
Wire Products
Selecting the Right Size for the Application

When selecting a conductor for a ground grid, it must meet the maximum fault current for
the identified duration and meet a minimum breaking load as required by the substation
design (typically 5,000 pounds). The key to properly sizing Copperclad Steel Wire is the
actual fault current requirement. Often solid copper is physically oversized to the actual
fault requirement to gain the physical strength needed in the application. With Copperclad,
the physical strength is inherent to the product so the primary consideration is electrical.
COPPERCLAD STEEL
AFL’s Swage Grounding Coupler compressed

onto 19-strand Copperclad Steel Wire
Table 2 below compares the ampacity ratings of copper and Copperclad Steel Wire which
allows the user to visually select the Copperclad equivalent. For example:
Requirements: The equivalent to 4/0 copper per the IEEE Fusing Chart is
19#9 40%. A typical maximum fault current for a distribution substation is
~18 kA at 30 cycles. Most engineers upsize to 4/0 copper in order to meet the
mechanical strength requirement.
AFL solution: A 2/0 copper or 7#6 Copperclad Steel Wire conductor will
meet this requirement instead of the larger size 4/0 copper commonly used
for ground grids. The conductor safety margin for 7#6 Copperclad Steel Wire
is 30% and meets the fault current and mechanical strength requirements.
Table 2—Ampacity Ratings

SINGLE WIRE OVERALL FAULT WIRE MIN. BREAK
AREA WEIGHT
CONDUCTOR NO. OF DIAMETER DIAMETER CURRENT RESISTANCE LOAD
SIZE (AWG) WIRES AT
IN. MM IN. MM CMIL MM2 0.5 SEC. LBS/KFT KG/KM Ω/KFT Ω/KM LBF KGF
19 No. 4 19 0.2043 5.19 1.02 25.95 793031 401.83 107.27 2254.69 3355.44 0.0338 0.1110 21755 9868
19 No. 5 19 0.1819 4.62 0.91 23.10 628665 318.55 85.03 1787.38 2659.98 0.0427 0.1400 17246 7823
19 No. 6 19 0.1620 4.11 0.81 20.57 498636 252.66 67.45 1417.68 2109.81 0.538 0.1765 13679 6205
19 No. 7 19 0.1443 3.67 0.72 18.33 395627 200.47 53.51 1124.82 1673.96 0.0678 0.2224 10853 4923
19 No. 8 19 0.1285 3.26 0.64 16.32 313733 158.97 42.44 891.98 1327.45 0.0855 0.2805 8606 3904
19 No. 9 19 0.1144 2.91 0.57 14.53 248660 126.00 33.63 706.97 1052.12 0.1079 0.3539 6821 3094
4/0 19 0.1055 2.68 0.53 13.40 211475 107.16 28.60 601.25 894.78 0.1268 0.4161 5801 2631
19 No. 10 19 0.1019 2.59 0.51 12.94 197289 99.97 26.69 560.92 834.76 0.1359 0.4460 5412 2455
19 No. 11 19 0.0907 2.30 0.45 11.52 156303 79.20 21.14 444.39 661.34 0.1716 0.5629 4288 1945
7 No. 4 7 0.2043 5.19 0.61 15.57 292169 148.04 39.52 827.40 1231.34 0.0914 0.3000 8015 3636
7 No. 5 7 0.1819 4.62 0.55 13.86 231613 117.36 31.33 655.91 976.13 01153 0.3784 6354 2882
7 No. 6 7 0.1620 4.11 0.49 12.34 183708 93.09 24.85 520.24 774.23 0.1454 0.4771 5040 2286
7 No. 7 7 0.1443 3.67 0.43 11.00 145757 73.86 19.72 412.7719 614.29 0.1833 0.6013 3998 1814
2/0 7 0.1379 3.50 0.41 10.51 133115 67.45 18.01 376.9694 561.01 02007 0.6584 3652 1656
7 No. 8 7 0.1285 3.26 0.39 9.79 115586 58.57 15.63 327.3285 487.13 0.2311 0.7583 3171 1438
7 No. 9 7 0.1144 2.91 0.34 8.72 91612 46.42 12.39 259.4356 386.09 0.2916 0.9567 2513 1140
7 No. 10 7 0.1019 2.59 0.31 7.76 72685 36.83 9.83 205.8382 306.33 0.3675 1.2058 1994 904
No. 2 7 0.0860 2.18 0.26 6.55 51772 26.23 7.00 146.6137 218.19 0.5160 1.6929 1420 644
No. 4 7 0.0680 1.73 0.20 5.18 32368 16.40 4.38 91.6633 136.41 0.8253 2.7077 888 403
No. 2 1 0.2576 6.54 0.26 6.54 66368 33.63 8.98 186.0875 276.94 0.3985 1.3075 2023 918
No. 4 1 0.2043 5.19 0.20 5.19 41738 21.15 5.65 117.0294 174.16 0.6337 2.0790 1272 577
No. 6 1 0.1620 4.12 0.16 4.12 26250 13.30 3.55 73.6030 109.54 1.0076 3.3057 800 363

434
Wire Products
Wire 3-Wire3-Wire Strand 7-Wire

7-Wire Strand 19-Wire
19-Wire Strand
Wire Wire 3-Wire Strand
3-Wire Strand7-Wire Strand
7-Wire Strand 19-Wire Strand
19-Wire Strand
Copperclad Copperclad Copperclad
Steel Wire Steel Wire Steel Wire
COPPERCLAD STEEL
Table 3—Approximate Short-Time Fusing Currents of DSA Copperclad Conductors
DURATION OF CURRENT IN CYCLES OR SECONDS
CONDUCTOR SIZE 3 CYCLES 6 CYCLES 9 CYCLES 30 CYCLES 60 CYCLES 120 CYCLES
AWG (0.05 SEC) (0.10 sec) (0.15 SEC) (0.5 sec) (1.0 SEC) (2.0 sec)
CURRENT IN KA
40% CONDUCTIVITY
19-Wire Strand
19 No. 5 269.02 190.22 155.32 85.07 60.15 42.54
19 No. 6 213.33 150.85 123.17 67.46 47.70 33.73
19 No. 7 169.17 119.62 97.67 53.50 37.83 26.75
19 No. 8 134.17 94.87 77.46 42.43 30.00 21.21
19 No. 9 106.40 75.23 61.43 33.65 23.79 16.82
4/0 90.45 63.96 52.22 28.60 20.23 14.30
7-Wire Strand
7 No. 4 124.97 88.37 72.15 39.52 27.94 19.76
7 No. 5 99.11 70.08 57.22 31.34 22.16 15.67
7 No. 6 78.60 55.58 45.38 24.85 17.57 12.43
7 No. 7 62.33 44.07 35.98 19.71 13.94 9.85
7 No. 8 49.43 34.95 28.54 15.63 11.05 7.82
7 No. 9 39.20 27.72 22.63 12.40 8.77 6.20
7 No. 10 31.08 21.98 17.95 9.83 6.95 4.91
2 AWG 22.14 15.66 12.79 7.00 4.95 3.50
4 AWG 13.84 9.79 7.99 4.38 3.10 2.19
Single Wire Strand
2 AWG 28.39 20.07 16.39 8.98 6.35 4.49
4 AWG 17.85 12.62 10.31 5.65 3.99 2.82
6 AWG 11.23 7.94 6.48 3.55 2.51 1.78
30% CONDUCTIVITY
19-Wire Strand
19 No. 5 232.99 164.75 134.52 73.68 52.10 36.84
19 No. 6 184.76 130.65 106.67 58.43 41.31 29.21
19 No. 7 146.52 103.60 84.59 46.33 32.76 23.17
19 No. 8 116.20 82.17 67.09 36.75 25.98 18.37
19 No. 9 92.15 65.16 53.20 29.14 20.60 14.57
4/0 78.34 55.39 45.23 24.77 17.52 12.39
7-Wire Strand
7 No. 4 108.23 76.53 62.49 34.23 24.20 17.11
7 No. 5 85.84 60.70 49.56 27.14 19.19 13.57
7 No. 6 68.07 48.13 39.30 21.53 15.22 10.76
7 No. 7 53.98 38.17 31.17 17.07 12.07 8.54
7 No. 8 42.81 30.27 24.72 13.54 9.57 6.77
7 No. 9 33.95 24.01 19.60 10.74 7.59 5.37
7 No. 10 26.92 19.04 15.54 8.51 6.02 4.26
2 AWG 19.18 13.56 11.07 6.06 4.29 3.03
4 AWG 11.99 8.48 6.92 3.79 2.68 1.90
Solid Wire
2 AWG 24.59 17.38 14.19 7.77 5.50 3.89
4 AWG 15.46 10.93 8.93 4.89 3.46 2.44
6 AWG 9.72 6.88 5.61 3.08 2.17 1.54

435
Wire Products
DSA Copperclad Steel Wire for Grounding Applications
Single Wire Wire 3-Wire3-Wire Strand 7-Wire

19-Wire
WireWire Wire
Copperclad
3-Wire
3-Wire Strand
3-Wire
Strand
Copperclad
Strand 7-Wire
7-Wire Strand
7-Wire
Strand Strand
Copperclad
19-Wire
19-Wire Strand
19-Wire
Strand Strand
Copperclad
COPPERCLAD STEEL
Strand Strand Strand Strand
Specifications and Ordering Information

40% CONDUCTIVITY
CONDUCTOR OVERALL MIN BREAKING CROSS APPROXIMATE
WEIGHT I2t NOMINAL
CONFIGURATION DIAMETER LOADS SECTION AREA SHORT-TIME
DC
CONDUCTOR FUSING
AFL NO. RESISTANCE
SIZE AWG CURRENT AT
STRANDING AWG inch mm lbf kN lbs/kft kg/km cmil mm2 kA2s AT 68°F
30 CYCLES
(Ω /KFT)
(kA)
1 2 CCS01024D No. 2 0.258 6.54 2023 9.0 186.1 276.94 66368 33.63 40.29 8.98 0.3907
1 4 CCS01044D No. 4 0.204 5.19 1272 5.7 117.0 174.16 41738 21.15 15.94 5.65 0.6212
1 6 CCS01064D No. 6 0.162 4.12 800 3.6 73.6 109.54 26250 13.30 6.30 3.55 0.9877
3 4 CCS03044D 3 No. 4 0.440 11.18 3626 16.1 353.9 526.67 125215 63.45 143.43 16.94 0.2087
3 5 CCS03054D 3 No. 5 0.392 9.96 2874 12.8 280.5 417.51 99263 50.30 90.13 13.43 0.2633
3 6 CCS03064D 3 No. 6 0.349 8.87 2280 10.1 222.5 331.16 78732 39.89 56.70 10.65 0.3319
3 7 CCS03074D 3 No. 7 0.311 7.90 1809 8.0 176.6 262.75 62467 31.65 35.70 8.45 0.4184
3 8 CCS03084D 3 No. 8 0.277 7.03 1434 6.4 140.0 208.36 49537 25.10 22.45 6.70 0.5276
3 9 CCS03094D 3 No. 9 0.247 6.26 1137 5.1 111.0 165.14 39262 19.89 14.10 5.31 0.6657
3 10 CCS03104D 3 No. 10 0.220 5.58 902 4.0 88.0 131.02 31151 15.78 8.88 4.21 0.8390
3 12 CCS03124D 3 No. 12 0.174 4.42 567 2.5 55.4 82.38 19586 9.92 3.51 2.65 1.3344
7 4 CCS07044D 7 No. 4 0.613 15.57 8015 35.7 827.4 1231.34 292169 148.04 780.87 39.52 0.0896
7 5 CCS07054D 7 No. 5 0.546 13.86 6354 28.3 655.9 976.13 231613 117.36 490.72 31.33 0.1131
7 6 CCS07064D 7 No. 6 0.486 12.34 5040 22.4 520.2 774.23 183708 93.09 308.72 24.85 0.1425
7 7 CCS07074D 7 No. 7 0.433 11.00 3998 17.8 412.8 614.29 145757 73.86 194.34 19.72 0.1797
7 8 CCS07084D 7 No. 8 0.386 9.79 3171 14.1 327.3 487.13 115586 58.57 122.21 15.63 0.2266
7 9 CCS07094D 7 No. 9 0.343 8.72 2513 11.2 259.4 386.09 91612 46.42 76.77 12.39 0.2858
7 10 CCS07104D 7 No. 10 0.306 7.76 1994 8.9 205.8 306.33 72685 36.83 48.33 9.83 0.3603
19 5 CCS19054D 19 No. 5 0.910 23.10 17246 76.7 1787.4 2659.98 628665 318.55 3615.33 85.03 0.0418
19 6 CCS19064D 19 No. 6 0.810 20.57 13679 60.8 1417.7 2109.81 498636 252.66 2274.45 67.45 0.0527
19 7 CCS19074D 19 No. 7 0.722 18.33 10853 48.3 1124.8 1673.96 395627 200.47 1431.80 53.51 0.0665
19 8 CCS19084D 19 No. 8 0.643 16.32 8606 38.3 892.0 1327.45 313733 158.97 900.39 42.44 0.0838
19 9 CCS19094D 19 No. 9 0.572 14.53 6821 30.3 707.0 1052.12 248660 126.00 565.62 33.63 0.1057
19 - CCS4/0 - 0.528 13.40 5801 25.8 601.2 894.78 211475 107.16 409.10 28.60 0.1243
19 10 CCS19104D 19 No. 10 0.510 12.94 5412 24.1 560.9 834.76 197289 99.97 356.05 26.69 0.1333
7 - CCS2/0 2/0 0.414 10.51 3652 16.2 377.0 561.01 133115 67.45 162.09 18.01 0.1967
Coils
All 3- and 7-strand Copperclad Steel Wire is available in 50 lb, 100 lb and 200 lb coils.

436
Wire Products
DSA Copperclad Steel Wire for Grounding Applications (cont.)
Single Wire Wire 3-Wire3-Wire Strand 7-Wire

19-Wire
WireWire Wire
Copperclad
3-Wire
3-Wire Strand
3-Wire
Strand
Copperclad
Strand 7-Wire
7-Wire Strand
7-Wire
Strand Strand
Copperclad
19-Wire
19-Wire Strand
19-Wire
Strand Strand
Copperclad
COPPERCLAD STEEL
Strand Strand Strand Strand

30% CONDUCTIVITY
CONDUCTOR MIN BREAKING CROSS APPROXIMATE
DIAMETER WEIGHT I2t NOMINAL
CONFIGURATION LOADS SECTION AREA SHORT-TIME
DC
CONDUCTOR FUSING
AFL NO. RESISTANCE
SIZE AWG CURRENT AT
STRANDING AWG inch mm lbf kN lbs/kft kg/km cmil mm2 kA2s AT 68°F
30 CYCLES
(Ω /KFT)
(kA)
1 2 CCS01023D No. 2 0.258 6.54 2276 10.1 184.1 274.04 66368 33.63 30.26 7.78 0.5209
1 4 CCS01043D No. 4 0.204 5.19 1431 6.4 115.8 172.34 41738 21.15 11.97 4.89 0.8283
1 6 CCS01063D No. 6 0.162 4.12 900 4.0 72.8 108.39 26250 13.30 4.73 3.08 1.3169
3 4 CCS03043D 3 No. 4 0.440 11.18 4079 18.1 350.2 521.17 125215 63.45 107.73 14.68 0.2761
3 5 CCS03053D 3 No. 5 0.392 9.96 3234 14.4 277.6 413.15 99263 50.30 67.70 11.64 0.3483
3 6 CCS03063D 3 No. 6 0.349 8.87 2565 11.4 220.2 327.70 78732 39.89 42.59 9.23 0.4391
3 7 CCS03073D 3 No. 7 0.311 7.90 2035 9.1 174.7 260.00 62467 31.65 26.81 7.32 0.5534
3 8 CCS03083D 3 No. 8 0.277 7.03 1614 7.2 138.5 206.18 49537 25.10 16.86 5.81 0.6979
3 9 CCS03093D 3 No. 9 0.247 6.26 1279 5.7 109.8 163.42 39262 19.89 10.59 4.60 0.8805
3 10 CCS03103D 3 No. 10 0.220 5.58 1015 4.5 87.1 129.66 31151 15.78 6.67 3.65 1.1098
3 12 CCS07043D 3 No. 12 0.174 4.42 638 2.8 54.8 81.52 19586 9.92 2.64 2.30 1.7650
7 4 CCS07043D 7 No. 4 0.613 15.57 9017 40.1 818.8 1218.48 292169 148.04 586.53 34.25 0.1183
7 5 CCS07053D 7 No. 5 0.546 13.86 7148 31.8 649.1 965.93 231613 117.36 368.59 27.15 0.1493
7 6 CCS07063D 7 No. 6 0.486 12.34 5670 25.2 514.8 766.15 183708 93.09 231.89 21.54 0.1882
7 7 CCS07073D 7 No. 7 0.433 11.00 4498 20.0 408.5 607.87 145757 73.86 145.98 17.09 0.2372
7 8 CCS07083D 7 No. 8 0.386 9.79 3567 15.9 323.9 482.04 115586 58.57 91.80 13.55 0.2991
7 9 CCS07093D 7 No. 9 0.343 8.72 2827 12.6 256.7 382.06 91612 46.42 57.67 10.74 0.3774
7 10 CCS07103D 7 No. 10 0.306 7.76 2243 10.0 203.7 303.13 72685 36.83 36.30 8.52 0.4756
19 5 CCS19053D 19 No. 5 0.910 23.10 19402 86.3 1768.7 2632.20 628665 318.55 2715.55 73.70 0.0550
19 6 CCS19063D 19 No. 6 0.810 20.57 15389 68.5 1402.9 2087.77 498636 252.66 1708.39 58.45 0.0693
19 7 CCS19073D 19 No. 7 0.722 18.33 12210 54.3 1113.1 1656.48 395627 200.47 1075.46 46.38 0.0874
19 8 CCS19083D 19 No. 8 0.643 16.32 9682 43.1 882.7 1313.59 313733 158.97 676.30 36.78 0.1102
19 9 CCS19093D 19 No. 9 0.572 14.53 7674 34.1 699.6 1041.13 248660 126.00 424.85 29.15 0.1390
Coils
All 3- and 7-strand Copperclad Steel Wire is available in 50 lb, 100 lb and 200 lb coils.

437
Wire Products
Dead Soft Annealed Copperclad Conductors (cont.)

Approximate Short-Time Fusing Currents—40% Conductivity
CONDUCTOR SIZE
IN kA
NO. OF 3 CYCLES 6 CYCLES 9 CYCLES 30 CYCLES 60 CYCLES 120 CYCLES
AWG I2t
STRANDS (0.05 SEC.) (0.10 SEC.) (0.15 SEC.) (0.5 SEC.) (1.0 SEC.) (2.0 SEC.)
19 19 No. 5 3616.62 268.95 190.17 155.28 85.05 60.14 42.52
19 19 No. 6 2275.27 213.32 150.84 123.16 67.46 47.70 33.73
COPPERCLAD STEEL
19 19 No. 7 1432.31 169.25 119.68 97.72 53.52 37.85 26.76

19 19 No. 8 900.71 134.22 94.91 77.49 42.44 30.01 21.22
19 19 No. 9 565.82 106.38 75.22 61.42 33.64 23.79 16.82
19 CCS4/0 409.24 90.47 63.97 52.23 28.61 20.23 14.30
7 7 No. 4 781.15 124.99 88.38 72.16 39.53 27.95 19.76
7 7 No. 5 490.90 99.09 70.06 57.21 31.33 22.16 15.67
7 7 No. 6 308.83 78.59 55.57 45.37 24.85 17.57 12.43
7 7 No. 7 194.41 62.36 44.09 36.00 19.72 13.94 9.86
7 7 No. 8 122.26 49.45 34.97 28.55 15.64 11.06 7.82
7 7 No. 9 76.80 39.19 27.71 22.63 12.39 8.76 6.20
7 7 No. 10 48.35 31.10 21.99 17.95 9.83 6.95 4.92
7 2 AWG 24.53 22.15 15.66 12.79 7.00 4.95 3.50
7 4 AWG 9.59 13.85 9.79 7.99 4.38 3.10 2.19
7 CCS2/0 162.09 56.94 40.26 32.87 18.00 12.73 9.00
1 2 AWG 40.31 28.39 20.08 16.39 8.98 6.35 4.49
1 4 AWG 15.94 17.86 12.63 10.31 5.65 3.99 2.82
1 6 AWG 6.31 11.23 7.94 6.48 3.55 2.51 1.78

438
Wire Products
Dead Soft Annealed Copperclad Conductors (cont.)

Approximate Short-Time Fusing Currents—30% Conductivity
CONDUCTOR SIZE
IN kA
NO. OF 3 CYCLES 6 CYCLES 9 CYCLES 30 CYCLES 60 CYCLES 120 CYCLES
AWG I2t
STRANDS (0.05 SEC.) (0.10 SEC.) (0.15 SEC.) (0.5 SEC.) (1.0 SEC.) (2.0 SEC.)
19 19 No. 5 2715.55 233.05 164.79 134.55 73.70 52.11 36.85
19 19 No. 6 1708.39 184.85 130.71 106.72 58.45 41.33 29.23
COPPERCLAD STEEL
19 19 No. 7 1075.46 146.66 103.70 84.67 46.38 32.79 23.19
19 19 No. 8 676.30 116.30 82.24 67.15 36.78 26.01 18.39
19 19 No. 9 424.85 92.18 65.18 53.22 29.15 20.61 14.57
19 19 No. 10 267.44 73.14 51.71 42.22 23.13 16.35 11.56
7 7 No. 4 586.53 108.31 76.59 62.53 34.25 24.22 17.12
7 7 No. 5 368.59 85.86 60.71 49.57 27.15 19.20 13.58
7 7 No. 6 231.89 68.10 48.15 39.32 21.54 15.23 10.77
7 7 No. 7 145.98 54.03 38.21 31.20 17.09 12.08 8.54
7 7 No. 8 91.80 42.85 30.30 24.74 13.55 9.58 6.77
7 7 No. 9 57.67 33.96 24.01 19.61 10.74 7.59 5.37
7 7 No. 10 36.30 26.94 19.05 15.56 8.52 6.02 4.26
1 2 AWG 30.26 24.60 17.40 14.20 7.78 5.50 3.89
1 4 AWG 11.97 15.47 10.94 8.93 4.89 3.46 2.45
1 6 AWG 4.73 9.73 6.88 5.62 3.08 2.18 1.54

439
Wire Products
Copperclad Steel Wire—High Strength/Extra High Strength

High Strength (HS) and Extra High Strength (EHS) Copperclad Steel Wire from AFL
provides the same conductivity and corrosion resistance as copper while maintaining
the high strength of steel. Frequently used for overhead ground wire and messenger
wire, HS and EHS Copperclad Steel Wire can resist mechanical damage caused during
installation plus electrical damage during a fault condition. Carbon steel is bonded with
a uniform layer of oxygen-free Coppercladding to ensure that the copper will not flake,
COPPERCLAD STEEL
crack or peel when the wire is twisted, installed or buried.
Applications
Overhead Ground Wire

Grounding protects transmission networks and eliminates damage from lightning
7-strand Copperclad Steel Wire and short-circuit conditions. HS and EHS Copperclad Steel Wire is an ideal grounding
conductor to provide conductivity, corrosion resistance and high strength.
Guy Wire
The corrosion resistance of HS and EHS Copperclad Steel Wire is perfect to use as guying
material for distribution and transmission lines. The layer of Coppercladding protects the
high strength steel core from rusting and subsequent loss of strength.
Messenger Wire
When used in messenger wire applications, HS and EHS Copperclad Steel Wire provides
overhead support and electrification of catenary systems due to its high strength and
conductivity.

440
Wire Products
Copperclad Steel Wire—High Strength (cont.)

30% CONDUCTIVITY—HIGH STRENGTH

MIN
NOMINAL DC CROSS SECTION
CONDUCTOR DIAMETER BREAKING WEIGHT
AFL NO. RESISTANCE AT AREA
SIZE AWG LOADS
68°F (Ω/kft)
Inch lbf lbs/kft cmil in2
COPPERCLAD STEEL
CCS03043H 3 No. 4 0.440 10878 350.2 0.2783 125215 0.0983
CCS03053H 3 No. 5 0.392 8983 277.6 0.3511 99263 0.0780
CCS03063H 3 No. 6 0.349 7410 220.2 0.4426 78732 0.0618
CCS03073H 3 No. 7 0.311 6105 174.7 0.5578 62467 0.0491
CCS03083H 3 No. 8 0.277 5022 138.5 0.7034 49537 0.0389
CCS03093H 3 No. 9 0.247 4121 109.8 0.8875 39262 0.0308
CCS03103H 3 No. 10 0.220 3406 87.12 1.1186 31151 0.0245
CCS03123H 3 No. 12 0.174 1719 54.78 1.7792 19586 0.0154
CCS07043H 7 No. 4 0.613 24047 818.8 0.1195 292169 0.2295
CCS07053H 7 No. 5 0.546 19858 649.1 0.1507 231613 0.1819
CCS07063H 7 No. 6 0.486 16380 514.8 0.1901 183708 0.1443
CCS07073H 7 No. 7 0.433 13495 408.5 0.2395 145757 0.1145
CCS07083H 7 No. 8 0.386 11101 323.9 0.3021 115586 0.0908
CCS07093H 7 No. 9 0.343 9110 256.7 0.3811 91612 0.0720
CCS07103H 7 No. 10 0.306 7529 203.7 0.4804 72685 0.0571
CCS07123H 7 No. 12 0.242 3799 128.1 0.7640 45700 0.0359
CCS19053H 19 No. 5 0.910 53899 1769 0.0558 628665 0.4938
CCS19063H 19 No. 6 0.810 44460 1403 0.0703 498636 0.3916
CCS19073H 19 No. 7 0.722 36628 1113 0.0886 395627 0.3107
CCS19083H 19 No. 8 0.643 30130 882.7 0.1117 313733 0.2464
CCS19093H 19 No. 9 0.572 24727 699.6 0.1410 248660 0.1953
CCS19103H 19 No. 10 0.510 20435 555.1 0.1777 197289 0.1550
Breaking load of 7-wire and 19-wire Copperclad strands are taken as 90% of the sum of the breaking loads of the individual wires;
breaking load of 3-wire Copperclad strand is taken as 95% of the sum of the breaking loads of the individual wires used in the
manufacturing of the strand.
NOTE:
Modulus of Elasticity: Strand, 23 x 106 psi
Coefficient of Linear Expansion: 7.2 X 10-6/°F.
Temperature Coefficient of Resistance: 2.1 x 10-3/°F.

441
Wire Products
Copperclad Steel Wire—High Strength (cont.)

40% CONDUCTIVITY—HIGH STRENGTH

MIN
SIZE AWG LOADS
68°F (Ω/kft)
inch lbf lbs/kft cmil in2
COPPERCLAD STEEL
CCS03044H 3 No. 4 0.440 9790 353.9 0.2087 125215 0.0983

CCS03054H 3 No. 5 0.392 8120 280.5 0.2633 99263 0.0780
CCS03064H 3 No. 6 0.349 6726 222.5 0.3319 78732 0.0618
CCS03074H 3 No. 7 0.311 5563 176.6 0.4184 62467 0.0491
CCS03084H 3 No. 8 0.277 4591 140.0 0.5276 49537 0.0389
CCS03094H 3 No. 9 0.247 3779 111.0 0.6657 39262 0.0308
CCS03104H 3 No. 10 0.220 3126 88.04 0.8390 31151 0.0245
CCS03124H 3 No. 12 0.174 1713 55.36 1.3344 19586 0.0154
CCS07044H 7 No. 4 0.613 21641 827.4 0.0896 292169 0.2295
CCS07054H 7 No. 5 0.546 17949 655.9 0.1131 231613 0.1819
CCS07064H 7 No. 6 0.486 14868 520.2 0.1425 183708 0.1443
CCS07074H 7 No. 7 0.433 12298 412.8 0.1797 145757 0.1145
CCS07084H 7 No. 8 0.386 10149 327.3 0.2266 115586 0.0908
CCS07094H 7 No. 9 0.343 8354 259.4 0.2858 91612 0.0720
CCS07104H 7 No. 10 0.306 6911 205.8 0.3603 72685 0.0571
CCS07124H 7 No. 12 0.242 3786 129.4 0.5730 45700 0.0359
CCS19054H 19 No. 5 0.910 48718 1787 0.0418 628665 0.4938
CCS19064H 19 No. 6 0.810 40356 1418 0.0527 498636 0.3916
CCS19074H 19 No. 7 0.722 33379 1125 0.0665 395627 0.3107
CCS19084H 19 No. 8 0.643 27548 892.0 0.0838 313733 0.2464
CCS19094H 19 No. 9 0.572 22675 707.0 0.1057 248660 0.1953
CCS4/0 19 No. 10 0.510 18759 560.9 0.1333 197289 0.1550
NOTE:

442
Wire Products
Copperclad Steel Wire—Extra High Strength

30% CONDUCTIVITY—EXTRA HIGH STRENGTH

MIN
SIZE AWG LOADS
68°F (Ω/kft)
inch lbf lbs/kft cmil in2
COPPERCLAD STEEL
CCS03043E 3 No. 4 0.440 12916 350.2 0.2783 125215 0.0983
CCS03053E 3 No. 5 0.392 10816 277.6 0.3511 99263 0.0780
CCS03063E 3 No. 6 0.349 8978 220.2 0.4426 78732 0.0618
CCS03073E 3 No. 7 0.311 7416 174.7 0.5578 62467 0.0491
CCS03083E 3 No. 8 0.277 6096 138.5 0.7034 49537 0.0389
CCS03093E 3 No. 9 0.247 4948 109.8 0.8875 39262 0.0308
CCS03103E 3 No. 10 0.220 4036 87.12 1.1186 31151 0.0245
CCS03123E 3 No. 12 0.174 2565 54.78 1.7792 19586 0.0154
CCS07043E 7 No. 4 0.613 28552 818.8 0.1195 292169 0.2295
CCS07053E 7 No. 5 0.546 23909 649.1 0.1507 231613 0.1819
CCS07063E 7 No. 6 0.486 19845 514.8 0.1901 183708 0.1443
CCS07073E 7 No. 7 0.433 16393 408.5 0.2395 145757 0.1145
CCS07083E 7 No. 8 0.386 13476 323.9 0.3021 115586 0.0908
CCS07093E 7 No. 9 0.343 10937 256.7 0.3811 91612 0.0720
CCS07103E 7 No. 10 0.306 8921 203.7 0.4804 72685 0.0571
CCS07123E 7 No. 12 0.242 5670 128.1 0.7640 45700 0.0359
CCS19053E 19 No. 5 0.910 64895 1769 0.0558 628665 0.4938
CCS19063E 19 No. 6 0.810 53865 1403 0.0703 498636 0.3916
CCS19073E 19 No. 7 0.722 44494 1113 0.0886 395627 0.3107
CCS19083E 19 No. 8 0.643 36577 882.7 0.1117 313733 0.2464
CCS19093E 19 No. 9 0.572 29686 699.6 0.1410 248660 0.1953
NOTE:

443
Wire Products
Copperclad Composite (CCC) Conductors

Copperclad Composite (CCC) Conductors provide strength and conductivity by
combining hard drawn copper with 30% conductivity EHS Copperclad Steel Wire. With
its steel component, the CCC conductor achieves a higher tensile strength. Additionally,
it weighs less than solid copper. Together this adds up to a minimum sag over maximum
span lengths. The flexibility of CCC allows for seasonal temperature changes and stresses
without permanent stretch.
COPPERCLAD STEEL
CCC conductors feature a higher ampacity for the same wire size as standard Copperclad
Steel Wire.
The steel core within Copperclad Steel Wire allow the composite conductors to perform
better than solid copper under stress. It is less susceptible to fracture from repeated
flexing and mechanical vibration.
The rust resistance of EHS Copperclad Steel Wire components are equivalent to all-copper
Type K—4 Copperclad Steel Wires wire of equal size. CCC conductors are uniquely suited in coastal locations, moist foggy
and 3 Copper Wires
regions and industrial and metropolitan areas.
Features Just like Copperclad Steel Wire, CCC conductors have very little scrap value and are an
excellent solution for areas with high rates of copper theft. The amount of copper used
• Higher tensile strength and weighs less
in the bonding process is minimal—6% to 10% depending on the conductivity—which
than solid copper
discourages theft and leaves the electrical system intact.
• Minimum sag over maximum span
lengths
Ordering Information
• Elasticity allows for seasonal temperature
changes without permanent stretch Available in standard reels of 600 lbs. Contact AFL for more information or other reel sizes.
• Less susceptible to fracture from
repeated flexing and mechanical
vibration
• Suitable for high-moisture environments
and industrial and metropolitan areas
• Very little scrap value—discourages theft
and leaves the grounding system intact
Applications
• Neutral messenger for aerial cable
• Catenary messenger
• Grounding and power conductor for
electrified railroads
• Electrical conductor for utilities

444
Wire Products
Copperclad Composite (CCC) Conductors (cont.)
COPPERCLAD STEEL
TYPE E: 7 Copperclad Wires TYPE EK: 4 Copperclad Wires TYPE F: 1 Copperclad Wire
12 Copper Wires 15 Copper Wires 6 Copper Wires
TYPE G: 2 Copperclad Wires TYPE J: 3 Copperclad Wires TYPE N: 5 Copperclad Wires

5 Copper Wires 4 Copper Wires 2 Copper Wires
TYPE P: 6 Copperclad Wires TYPE K: 4 Copperclad Wires TYPE A / TYPE C: 1 Copperclad Wire
1 Copper Wire 3 Copper Wires 2 Copper Wires
TYPE D: 2 Copperclad Wires

1 Copper Wire

445
Wire Products

Physical and Electrical Characteristics
DESIGN OF CONDUCTOR
MINIMUM
NUMBER AND
TYPE OF DIAMETER NUMBER AND BREAKING WEIGHT CROSS SECTION
AFL NO. DIAMETER OF HARD
CONDUCTOR (IN) DIAMETER OF EHS LOAD (LBS/ 1000 FT) (SQ IN)
DRAWN COPPER
30% CCS WIRES (IN) (LBS)
WIRES (IN)
350,000 CIRCULAR MILS COPPER EQUIVALENT -.03143 OHMS/K FT AT 68°F
COPPERCLAD STEEL
CCC350E E 0.788 7 X .1576 12 X .1576 32420 1403.00 0.3704

CCC350EK EK 0.735 4 X .1470 15 X .1470 23850 1238.00 0.3224
CCC300E E 0.729 7 X .1459 12 X .1459 27770 1203.00 0.3175
CCC300EK EK 0.680 4 X .1361 15 X .1361 20960 1061.00 0.2763
CCC250E E 0.666 7 X .1332 12 X .1332 23920 1002.00 0.2646
CCC250EK EK 0.621 4 X .1242 15 X .1242 17840 884.20 0.2303
4/0 AWG CIRCULAR MILS COPPER EQUIVALENT (211,600 CIRCULAR MILS) -.05199 OHMS/K FT AT 68°F
CCC4/0E E 0.613 7 X .1225 12 X .1225 20730 848.30 0.2239
CCC4/0EK EK 0.571 4 X .1143 15 X .1143 15370 748.40 0.1949
CCC4/0F F 0.550 1 X .1833 6 X .1833 12290 710.20 0.1847
CCC2/0K K 0.534 4 X .1780 3 X .1780 17600 645.90 0.1742
CCC2/0J J 0.494 3 X .1648 4 X .1648 13430 560.60 0.1493
CCC2/0F F 0.436 1 X .1454 6 X .1454 8094 446.80 0.1162
CCC1/0K K 0.475 4 X .1585 3 X .1585 14490 512.00 0.1381
CCC1/0J J 0.440 3 X .1467 4 X .1467 10970 444.30 0.1184
CCC1/0F F 0.388 1 X .1294 6 X .1294 6536 354.10 0.0921
NO. 1 AWG CIRCULAR MILS COPPER EQUIVALENT (83,690 CIRCULAR MILS) -.1315 OHMS/K FT AT 68°F
CCC1K K 0.423 4 X .1412 3 X .1412 11900 406.20 0.1096
CCC1J J 0.392 3 X .1307 4 X .1307 9000 352.50 0.0939
CCC1F F 0.346 1 X .1153 6 X .1153 5266 280.90 0.0730
CCC2K K 0.377 4 X .1257 3 X .1257 9730 322.10 0.0869
CCC2J J 0.349 3 X .1164 4 X .1164 7322 279.50 0.0745
CCC2A A 0.366 1 X .1699 2 X .1699 5876 256.80 0.0680
CCC2F F 0.308 1 X .1026 6 X .1026 4233 222.80 0.0579
CCC4D D 0.348 2 X .1615 1 X .1615 7340 225.50 0.0615
CCC4A A 0.290 1 X .1347 2 X .1347 3938 161.50 0.0428
CCC6D D 0.276 2 X .1281 1 X .1281 4942 141.80 0.0387
CCC6A A 0.230 1 X .1068 2 X .1068 2585 101.60 0.0269
CCC6C C 0.225 1 X .1046* 2 X .1046 2143 97.34 0.0258
CCC8D D 0.219 2 X .1016 1 X .1016 3256 89.21 0.0243
CCC8A A 0.199 1 X .1127 2 X .0797 2233 74.27 0.0200
CCC8C C 0.179 1 X .0808*. 2 X .0834 1362 60.67 0.0160

446
Wire Products

Loading Tables
VERTICAL, HORIZONTAL, AND RESULTANT* LOADS (LOADING IN LBS PER LINEAR FOOT OF CONDUCTOR)
AREA OF MODULUS LIGHT LOADING DISTRICT MEDIUM LOADING DISTRICT HEAVY LOADING DISTRICT
TYPE OF DIAMETER WIRE HORIZONTAL HORIZONTAL
AFL NO. (A) X AREA VERTICAL HORIZONTAL VERTICAL VERTICAL
CONDUCTOR IN WIND 4 LBS WIND 4 LBS
SQ IN (EA) CONDUCTOR WIND 9 LBS RESULTANT CONDUCTOR RESULTANT CONDUCTOR RESULTANT
PER SQ FT PER SQ FT
ONLY PER SQ FT +¼" OF ICE +½" OF ICE
¼" OF ICE ½" OF ICE
350,000 CIRCULAR MILS COPPER EQUIVALENT
COPPERCLAD STEEL
CCC350E E 0.788 0.3704 7,223,000 1.4030 0.5910 1.5720 1.7260 0.4293 1.9790 2.2040 5.6900 2.5830
CCC350EK EK 0.735 0.3224 5,964,000 1.2380 0.5513 1.4050 1.5440 0.4117 1.7980 2.0060 0.5786 2.3880
CCC300E E 0.729 0.3175 6,191,000 1.2030 0.5468 1.3710 1.5070 0.4097 1.7620 1.9670 0.5763 2.3500
CCC300EK EK 0.68 0.2763 5,112,000 1.0610 0.5100 1.2270 1.3500 0.3933 1.6060 1.7950 0.5600 2.1800
CCC250E E 0.666 0.2646 5,160,000 1.0020 0.4995 1.1700 1.2870 0.3887 1.5440 1.7270 0.5553 2.1140
CCC250EK EK 0.621 0.2303 4,261,000 0.8842 0.4658 1.0490 1.1550 0.3737 1.4140 1.5810 0.5403 1.9710
4/0 AWG CIRCULAR MILS COPPER EQUIVALENT (211,600 CIRCULAR MILS)
CCC4/0E E 0.613 0.2239 4,366,000 0.8483 0.4598 1.0150 1.1170 0.3710 1.3770 1.5400 0.5377 1.9310
CCC4/0G G 0.583 0.2077 3,946,000 0.7894 0.4373 0.9524 1.0480 0.3610 1.3090 1.4630 0.5277 1.8550
CCC4/0EK EK 0.571 0.1949 3,606,000 0.7484 0.4283 0.9123 1.0040 0.3570 1.2650 1.4140 0.5237 1.8080
CCC4/0F F 0.55 0.1847 3,325,000 0.7102 0.4125 0.8713 0.9589 0.3500 1.2210 1.3630 0.5167 1.7580
CCC2/0K K 0.534 0.1742 3,658,000 0.6459 0.4005 0.8100 0.8896 0.3447 1.1540 1.2890 0.5113 1.6870
CCC2/0J J 0.494 0.1493 2,986,000 0.5606 0.3705 0.7220 0.7919 0.3313 1.0580 1.1790 0.4980 1.5800
CCC2/0G G 0.463 0.1307 2,483,000 0.4966 0.3473 0.6560 0.7183 0.3210 0.9301 1.0290 0.4877 1.4350
CCC2/0F F 0.436 0.1162 2,092,000 0.4468 0.3270 0.6037 0.6601 0.3120 0.9301 1.0290 0.4787 1.4350
CCC1/0K K 0.475 0.1381 2,900,000 0.5120 0.3563 0.6737 0.7374 0.3250 1.0060 1.1180 0.4917 1.5220
CCC1/0J J 0.44 0.1184 2,368,000 0.4443 0.3300 0.6034 0.6588 0.3133 0.9295 1.0290 0.4800 1.4350
CCC1/0G G 0.412 0.1036 1,968,000 0.3936 0.3090 0.5504 0.5994 0.3040 0.8721 0.9607 0.4707 1.3700
CCC1/0F F 0.388 0.09207 1,657,000 0.3541 0.2910 0.5083 0.5524 0.2960 0.8267 0.9062 0.4627 1.3180
NO. 1 AWG CIRCULAR MILS COPPER EQUIVALENT (83,690 CIRCULAR MILS)
CCC1N N 0.464 0.1315 2,893,000 0.4813 0.3480 0.6439 0.7033 0.3213 0.9732 1.0810 0.4880 1.5220
CCC1K K 0.423 0.1096 2,302,000 0.4062 0.3173 0.5654 0.6154 0.3077 0.8880 0.9801 0.4743 1.3890
CCC1J J 0.392 0.0939 1,878,000 0.3525 0.2940 0.5090 0.5521 0.2973 0.8271 0.9071 0.4640 1.3190
CCC1G G 0.367 0.08216 1,561,000 0.3122 0.2753 0.4662 0.5040 0.2890 0.7810 0.8513 0.4557 1.2660
CCC1F F 0.346 0.07303 1,315,000 0.2809 0.2595 0.4324 0.4662 0.2820 0.7448 0.8069 0.4487 1.2230
CCC2P P 0.462 0.1303 2,997,000 0.4711 0.3465 0.6348 0.6925 0.3207 0.9631 1.0690 0.4873 1.4750
CCC2N N 0.413 0.1043 2,295,000 0.3817 0.3098 0.5416 0.5878 0.3043 0.8619 0.9494 0.4710 1.3600
CCC2K K 0.377 0.08688 1,824,000 0.3221 0.2828 0.4786 0.5170 0.2923 0.7940 0.8674 0.4590 1.2810
CCC2J J 0.349 0.07447 1,489,000 0.2795 0.2618 0.4329 0.4657 0.2830 0.7450 0.8074 0.4497 1.2240
CCC2A A 0.366 0.06799 1,292,000 0.2568 0.2745 0.4259 0.4483 0.2887 0.7332 0.7953 0.4553 1.2160
CCC2G G 0.327 0.06516 1,238,000 0.2476 0.2453 0.3985 0.4270 0.2757 0.7082 0.7618 0.4423 1.8180
CCC2F F 0.308 0.05792 1,043,000 0.2228 0.2310 0.3709 0.3963 0.2693 0.6791 0.7252 0.4360 1.1460
CCC4P P 0.366 0.08196 1,885,000 0.2963 0.2745 0.4539 0.4878 0.2887 0.7668 0.8348 0.4553 1.2510
CCC4N N 0.328 0.06556 1,442,000 0.2400 0.2460 0.3937 0.4197 0.2760 0.7023 0.7548 0.4427 1.1750
CCC4D D 0.348 0.06147 1,352,000 0.2255 0.2610 0.3949 0.4114 0.2827 0.6692 0.7528 0.4493 1.1770
CCC4A A 0.29 0.04276 812,400 0.1615 0.2175 0.3209 0.3294 0.2633 0.6217 0.6527 0.4300 1.0820
CCC6D D 0.276 0.03866 850,500 0.1418 0.2070 0.3009 0.3053 0.2587 0.6002 0.6243 0.4253 1.0550
CCC6A A 0.23 0.02689 510,900 0.1016 0.1725 0.2502 0.2508 0.2433 0.5495 0.5555 0.4100 0.9904
CCC6C C 0.225 0.02577 489,600 0.0973 0.1688 0.2448 0.2450 0.2417 0.5441 0.5481 0.4083 0.9835
CCC8D D 0.219 0.02491 534,800 0.0892 0.1643 0.2369 0.2350 0.2397 0.5357 0.5363 0.4063 0.9728
CCC8A A 0.199 0.01995 419,000 0.0743 0.1493 0.2167 0.2139 0.2330 0.5163 0.5089 0.3997 0.9471
CCC8C C 0.179 0.01604 304,800 0.0607 0.1343 0.1973 0.1940 0.2263 0.4981 0.4829 0.3930 0.9226
*Based on Rule 251, National Electrical Safety Code, 1990 Edition

447
Wire Products
Copperclad Type M Guy Wire

Copperclad Type M guy wire is an economical, corrosion-resistant guying material for use
on overhead lines. The Coppercladding that is bonded on each wire protects the high-
strength steel core from rusting and subsequent loss of strength. Additionally, the copper
provides more ampacity within the strand to protect from fault condition damage. Since
Copperclad Steel Wire is corrosion resistant, costly maintenance is eliminated and the
guy wire maintains its original safety factor throughout the life of the line.
COPPERCLAD STEEL
The steel core of Type M guy strand withstands more mechanical abuse and is less
susceptible to vibration-induced fatigue when compared to solid copper wire. The steel
core allows for double the breaking strength of solid copper conductors.
7-strand Copperclad Steel Wire
There is no scrap value in Copperclad Type M guy strand which discourages theft and
leaves the guying system intact.
Applications Features
• Power lines • Low corrosion resistance
• Telephone lines • Higher ampacity protects from fault condition damage
• Railway signals • Withstands more mechanical abuse
• Communication lines • Less susceptible to vibration-induced fatigue
• Towers • Steel core allows for double the breaking strength of solid copper
• Masts • Very little scrap value—discourages theft and leaves the guying system intact
Copperclad Type M Guy Wire is available in the following coil and reel sizes:
COIL SIZES REEL SIZES

250 feet 2,500 feet
500 feet 5,000 feet
1,000 feet 10,000 feet
Contact AFL for more information.

448
Wire Products
Copperclad Type M Guy Wire (cont.)

Physical Characteristics
STANDARD PACKAGE
NOMINAL NUMBER AND RATED WEIGHT
DIAMETER OF DIAMETER OF STRENGTH lbs/
AFL NO. DESIGNATION
STRAND INDIVIDUAL WIRES (lbs) 1000 FT APPROXIMATE
COIL LENGTH
WEIGHT
(ft)
(lbs)
COPPERCLAD STEEL
in mm in mm lbs kg lbs/1000 ft kg/km
CCS2.2M 2.2M 0.1640 4.17 3 X .076 1.93 2200 998 49 73 1000 45
CCS4M 4M 0.2090 5.31 3 X .097 2.46 4000 1814 79 118 2-500 50
CCS6M3 6M3 0.258 6.55 3 X .120 3.05 6000 2722 121 180 500 65
CCS6M 6M 0.2370 6.02 7 X .079 2.01 6000 2722 122 182 500 65
CCS8M 8M 0.2760 7.01 7 X .092 2.31 8000 3629 166 247 500 85
CCS10M 10M 0.3030 7.70 7 X .101 2.57 10000 4536 200 298 500 100
CCS12.5M 12.5M 0.3450 8.76 7 X .115 2.92 12500 5670 259 385 2501 65
CCS14M 14M 0.3600 9.14 7 X .120 3.05 14000 6350 283 421 2501 70
CCS16M 16M 0.3860 9.80 7 X .128 3.25 16000 7257 324 482 2501 80
CCS18M 18M 0.4140 10.52 7 X .138 3.51 18000 8165 374 557 2501 95
CCS20M 20M 0.4380 11.13 7 X .146 3.71 20000 9072 418 622 2501 100
Notes:
1. Put up in 500-ft. coils when specified. Reels of 2,500, 5,000 and 10,000 feet are available.
2. Copperclad Type M Guy Strand is composed of 30% conductivity EHS Copperclad wire.

449
Wire Products
Electrical Characteristics of Copperclad Steel Wire Conductors
Single Wire 3-Wire Type A Type D 7-Wire Type F Type G 19-Wire Type E Type EK
CopperClad CopperClad 1 CopperClad 2 CopperClad CopperClad 1 CopperClad 2 CopperClad CopperClad 7 CopperClad 4 CopperClad
2 Copper 1 Copper 6 Copper 5 Copper 12 Copper 12 Copper
COPPERCLAD STEEL
The electrical properties of AFL’s Copperclad conductors for The capacitive reactances are also given for conductors at one
determining the electrical performance of transmission and foot spacing with supplementary tables for spacings greater than
distribution lines are listed in the accompanying tables. These one foot. Basic values for each conductor are tabulated in Tables
tables include values of resistance, inductive and shunt capacitive 1 and 4 as x’a (Capacitive) and the capacitive reactance adders
reactances, and the geometric mean radius, together with the x’d are tabulated in Table 3.
approximate ampacity for 60 Hz frequency. Ampacity
Resistance The ampacities are in accordance with the Schurig and Frick
The resistance of Copperclad conductors is shown for temperatures formula, assuming a two foot per second cross wind and an
of 25°C and 50°C and those of Copperclad conductors for 25°C emissivity factor of 0.5 (average tarnished surface). The data for
and 75°C. Then 25°C values are for small currents, approximately Copperclad conductors are based on a 50°C rise over a 25°C
equivalent to 1000 amperes per square inch of copper ambient or a maximum temperature of 75°C. For Copperclad
conductance. The higher temperature values are for heavy currents, conductors, the temperature rise is 100°C over a 25°C ambient or
or approximately 75% of the ampacities shown in the table. a maximum temperature of 125°C. These maximum temperatures
Resistance are based on 97.5% conductivity copper. represent permissible values to which the conductor can be
Inductive and Capacitive Reactance subjected, without annealing or loss of strength.
The inductive reactances are given for the conductors at one foot
spacing with supplementary tables of adders for spacings greater
than one foot. The basic values are tabulated in Tables 1 and 4
as xa (Inductive). The adders xa are the same for all conductors
and are tabulated in Table 2. As the inductive reactances are
substantially independent of the current these values are
applicable for either small or large current. The relation between
the inductive reactance for one foot spacing and geometric mean
radius is shown in the following formulas:
1
xa = .2794 log10 G.M.R.
G.M.R. = Conductor radius in feet
Antilog10 .1083 µ
xInt = .03026
where: xa = Inductive reactance (60 Hz)
for 1 ft. spacing — ohms per conductor per mile
G.M.R. = Geometric mean radius in feet
µ = Effective permeability ratio of conductor
xInt = Internal reactance (60 Hz)
450
Wire Products
Table 1—Electrical Characteristics of Copperclad Steel Wire Conductors
REACTANCE PER CONDUCTOR PER MILE

RESISTANCE OHMS PER CONDUCTOR PER MILE
ONE FOOT SPACING
GEOMETRIC MEAN RADIUS
CONDUCTOR AT 60 HZ
RA AT 25°C (77°F) RA AT 50°C (122°F) CURRENT XA INDUCTIVE XA CAPACITIVE
SMALL CURRENTS APPROX. 75% OF AMPACITY* OHMS MEGOHMS
DC 60 HZ DC 60 HZ 60 HZ 60 HZ FEET AMPS
350 E .1658 .1812 .1812 .204 .463 .1014 .0220 660
COPPERCLAD STEEL
350 EK .1658 .1705 .1812 .1882 .450 .1034 .0245 680
300 E .1934 .209 .211 .235 .473 .1037 .0204 600
300 EK .1934 .1981 .211 .219 .460 .1057 .0227 610
250 E .232 .248 .254 .279 .484 .1064 .01859 540
250 EK .232 .237 .254 .261 .471 .1084 .0207 540
4/0 E .274 .290 .300 .326 .493 .1088 .01711 480
4/0 G .273 .298 .299 .342 .517 .1103 .01409 460
4/0 EK .274 .279 .300 .308 .481 .1109 .01903 490
4/0 F .273 .287 .299 .322 .505 .1120 .01558 470
3/0 E .346 .361 .378 .407 .508 .1123 .01521 420
3/0 J .344 .372 .377 .428 .541 .1118 .01156 410
3/0 G .344 .369 .377 .423 .531 .1137 .01254 400
3/0 EK .346 .351 .378 .386 .495 .1143 .01697 420
3/0 F .344 .358 .377 .401 .519 .1155 .01388 410
2/0 K .434 .466 .475 .535 .570 .1129 .00912 360
2/0 J .434 .462 .475 .530 .555 .1152 .01029 350
2/0 G .434 .459 .475 .525 .545 .1171 .01119 350
2/0 F .434 .448 .475 .501 .533 .1189 .01235 350
1/0 K .548 .579 .599 .664 .584 .1164 .00812 310
1/0 J .548 .576 .599 .659 .569 .1186 .00917 310
1/0 G .548 .573 .599 .654 .559 .1206 .00996 310
1/0 F .548 .562 .599 .627 .547 .1224 .01099 310
1N .691 .726 .755 .832 .614 .1171 .00638 280
1K .691 .722 .755 .825 .598 .1198 .00723 270
1J .691 .719 .755 .820 .583 .1221 .00817 270
1G .691 .716 .755 .815 .573 .1240 .00887 260
1F .691 .705 .755 .786 .561 .1258 .00980 270
2P .871 .909 .952 1.040 .643 .1172 .00501
240
2N .871 .906 .952 1.035 .627 .1205 .00568
240
2K .871 .902 .952 1.028 .612 .1232 .00644
230
2J .871 .899 .952 1.022 .598 .1255 .00727
240
2A .869 .882 .950 .979 1 .592 .1241 .00763
230
2G .871 .896 .952 .016 .587 .1275 .00790
230
2F .871 .885 .952 .985 .575 .1292 .00873
3P 1.098 1.136 1.200 1.296 .657 .1207 .00445 220
3N 1.098 1.133 1.200 1.289 .641 .1239 .00506 210
3K 1.098 1.129 1.200 1.281 .626 .1266 .00574 210
3J 1.098 1.126 1.200 1.275 .611 .1289 .00648 200
3A 1.096 1.109 1.198 1.229 .606 .1275 .00679 210
4P 1.385 1.423 1.514 1.616 .671 .1241 .00397 190
4N 1.385 1.420 1.514 1.610 .655 .1274 .00451 180
4D 1.382 1.399 1.511 1.542 .628 .1256 .00566 190
4A 1.382 1.395 1.511 1.545 .620 .1310 .00604 180
5P 1.747 1.785 1.909 2.02 .685 .1275 .00353 160
5D 1.742 1.759 1.905 1.939 .642 .1290 .00504 160
5A 1.742 1.755 1.905 1.941 .634 .1345 .00538 160
* Resistance at 50°C total temperature, based on ambient of 25°C plus 25°C rise due to heating effect of current. The approximate
magnitude of current necessary to produce the 25°C rise is 75% of the “Approximate Ampacity at 60 Hz.”
† Based on a conductor temperature of 75°C and an ambient of 25°C.

451
Wire Products
Table 1—Electrical Characteristics of Copperclad Steel Wire Conductors (cont.)

RESISTANCE OHMS PER CONDUCTOR PER MILE
ONE FOOT SPACING
CONDUCTOR AT 60 HZ
6D 2.20 2.22 2.40 2.44 .656 .1325 .00449 140
COPPERCLAD STEEL
6A 2.20 2.21 2.40 2.44 .648 .1379 .00479 140

6C 2.20 2.21 2.40 2.44 .651 .1386 .00469 130
7D 2.77 2.79 3.03 3.07 .670 .1359 .00400 120
7A 2.77 2.78 3.03 3.07 .658 .1388 .00441 120
8D 3.49 3.51 3.82 3.86 .684 .1393 .00356 110
8A 3.49 3.51 3.82 3.87 .672 .1422 .00394 100
8C 3.49 3.51 3.82 3.86 .679 .1453 .00373 100
9½D 4.91 4.93 5.37 5.42 .712 .1462 .00283 85
† Based on a conductor temperature of 75°C and an ambient of 25°C.
Table 2—Inductive Reactance Adders for Separations Greater than One Foot
Xd—Equivalent Separation in Feet
FEET 0 1 2 3 4 5 6 7 8 9
0 — 0 .084 .133 .168 .195 .217 .236 .252 .267
10 .279 .291 .302 .311 .320 .329 .336 .344 .351 .357
20 .364 .369 .375 .380 .386 .391 .395 .400 .404 .409
30 .413 .417 .421 .424 .428 .431 .435 .438 .441 .445
NOTE: Total inductive reactance equals inductive reactance for one foot plus adder for conductor separation.
Impedance (line to neutral) in ohms Z = N (ra + j (xa + xd))

per conductor for line N miles long.
Table 3—Inductive Reactance Adders for Separations Greater than One Foot
Xd—Equivalent Separation in Feet
FEET 0 1 2 3 4 5 6 7 8 9
0 — 0 .021 .033 .041 .048 .053 .058 .062 .065
10 .068 .071 .074 .076 .078 .080 .082 .084 .086 .087
20 .089 .090 .092 .093 .094 .096 .097 .098 .099 .100
30 .101 .102 .103 .104 .105 .106 .106 .107 .108 .109
NOTE: Total inductive reactance equals inductive reactance for one foot plus adder for conductor separation.
Shunt Capacitive Reactance (line to neutral) in x’ = —j x’a + x’d

megohms per conductor for line N miles long. N

452
Wire Products
Table 4—Electrical Characteristics of Copperclad Steel Wire Conductors

RESISTANCE—OHMS PER CONDUCTOR PER MILE
ONE FOOT SPACING
CONDUCTOR AT 60 HZ
40% CONDUCTIVITY
COPPERCLAD STEEL
7/8” 19 No. 5 .229 .254 .272 .391 .539 .0971 .01175 690
13/16” 19 No. 6 .289 .314 .343 .472 .553 .1005 .01046 610
23/32” 19 No. 7 .365 .390 .433 .573 .567 .1040 .00931 530
21/32” 19 No. 8 .460 .484 .546 .698 .582 .1074 .00829 470
9/16” 19 No. 9 .580 .605 .688 .853 .595 .1109 .00739 410
5/8” 7 No. 4 .492 .512 .584 .680 .587 .1088 .00792 470
9/16” 7 No. 5 .620 .640 .736 .840 .601 .1122 .00705 410
1/2” 7 No. 6 .782 .802 .928 1.040 .615 .1157 .00628 350
7/16” 7 No. 7 .986 1.006 1.170 1.291 .629 .1191 .00559 310
3/8” 7 No. 8 1.244 1.264 1.476 1.606 .644 .1226 .00497 270
11/32” 7 No.9 1.568 1.588 1.861 2.00 .658 .1260 .00443 230
5/16” 7 No.10 1.978 1.998 2.35 2.50 .671 .1294 .00395 200
3 No. 5 1.445 1.457 1.714 1.772 .617 .1221 .00621 250
3 No. 6 1.821 1.833 2.16 2.22 .631 .1255 .00553 220
3 No. 7 2.30 2.31 2.73 2.79 .645 .1289 .00492 190
3 No. 8 2.90 2.91 3.44 3.51 .659 .1324 .00439 160
3 No. 9 3.65 3.66 4.33 4.41 .673 .1358 .00391 140
3 No.10 4.61 4.62 5.46 5.55 .687 .1392 .00348 120
3 No.12 7.32 7.34 8.69 8.78 .715 .1462 .00276 90
No. 2 Solid 2.14 2.14 2.54 2.54 .612 .1345 .00645 190
No. 4 Solid 3.41 3.41 4.05 4.05 .640 .1415 .00506 140
No. 6 Solid 5.42 5.42 6.44 6.44 .669 .1483 .00403 100
30% CONDUCTIVITY
7/8” 19 No. 5 .306 .331 .363 .499 .592 .0971 .00758 620
13/16” 19 No. 6 .386 .411 .458 .605 .606 .1005 .00675 540
23/32” 19 No. 7 .486 .511 .577 .737 .621 .1040 .00601 470
21/32” 19 No. 8 .613 .638 .728 .902 .635 .1074 .00535 410
9/16” 19 No. 9 .773 .798 .917 1.106 .649 .1109 .00477 360
5/8” 7 No. 4 .656 .676 .778 .887 .640 .1088 .00511 410
9/16” 7 No. 5 .827 .847 .981 1.099 .654 .1122 .00455 360
1/2” 7 No. 6 1.042 1.062 1.237 1.364 .668 .1157 .00405 310
7/16” 7 No. 7 1.315 1.335 1.560 1.697 .683 .1191 .00361 270
3/8” 7 No. 8 1.658 1.678 1.967 2.12 .697 .1226 .00321 230
11/32” 7 No. 9 2.09 2.11 2.48 2.64 .711 .1260 .00286 200
5/16” 7 No. 10 2.64 2.66 3.13 3.30 .725 .1294 .00255 170
3 No. 5 1.926 1.938 2.29 2.35 .654 .1221 .00457 220
3 No. 6 2.43 2.44 2.88 2.95 .668 .1255 .00407 190
3 No. 7 3.06 3.07 3.63 3.71 .682 .1289 .00363 160
3 No. 8 3.86 3.87 4.58 4.66 .696 .1324 .00323 140
3 No. 9 4.87 4.88 5.78 5.86 .710 .1358 .00288 120
3 No.10 6.14 6.15 7.28 7.38 .724 .1392 .00257 110
No. 2 Solid 2.86 2.86 3.40 3.40 .662 .1345 .00427 160
No. 4 Solid 4.54 4.54 5.40 5.40 .690 .1415 .00339 120
No. 6 Solid 7.22 7.22 8.58 8.58 .718 .1483 .00269 90
† Based on a conductor temperature of 125°C and an ambient of 25°C. A 2 ft./sec. wind and Emissivity = 0.5.

453
Wire Products
Copperclad Part Number Nomenclature

Step 1: Determine Catalog Number.
Step 2: Determine Package Code.
Step 3: Assemble complete part number—Catalog Number + Package Code
• Example: For a 2,000 ft. reel of 40% and 7#8 DSA, the complete part number is CCS07084DR2000F.
COPPERCLAD STEEL
Step 1—Catalog Number Step 2—Package Code

CATALOG NUMBER (NOT ALL SIZES LISTED) Select preference of packaging type.
CONDUCTOR 30% 40%
CONFIGURATION CONDUCTIVITY CONDUCTIVITY COILS REELS SPOOLS
6 Covered CCS01064D-JV CODE CODE CODE CODE CODE CODE
4 Covered CCS01044D-JV (LBS) (FT) (LBS) (FT) (LBS) (FT)
2 Covered CCS01024D-JV C50P C334F R500P R500F S25P S318F
4 Stranded Covered CCS4STR4D-JV C100P R1000P R1000F
2 Stranded Covered CCS2STR4D-JV C200P R2000P R2000F
2 Stranded CCS2STR4D R3521P R3521F
4 Stranded CCS4STR4D
Not all sizes listed.
2 CCS01023D CCS01024D
4 CCS01043D CCS01044D
6 CCS01063D CCS01064D
Step 3—Assemble Complete Part Number
3#5 CCS03053D CCS03054D
3#6 CCS03063D CCS03064D
3#7 CCS03073D CCS03074D
SW2TC
CCS01064D-JV R3521P
3#8 CCS03083D CCS03084D
Catalog Package
3#9 CCS03093D CCS03094D Number Code
3#10 CCS03103D CCS03104D
7#5 CCS07053D CCS07054D
7#6 CCS07063D CCS07064D
7#7 CCS07073D CCS07074D
7#8 CCS07083D CCS07084D
7#9 CCS07093D CCS07094D
7#10 CCS07103D CCS07104D
19#5 CCS19053D CCS19054D
19#6 CCS19063D CCS19064D
19#7 CCS19073D CCS19074D
19#8 CCS19083D CCS19084D
19#9 CCS19093D CCS19094D

454
Wire Products
Recommended Maximum Footage per Reel

3 Strand
REEL 3 NO. 12 3 NO. 11 3 NO. 10 3 NO. 9 3 NO. 8 3 NO. 7 3 NO. 6 3 NO. 5 3 NO. 4
BA 8,650 6,850 5,450 4,300 3,400 2,700 2,150 1,700 —
CA 12,600 10,000 7,900 6,300 5,000 3,950 3,150 2,500 1,950
DA 23,050 18,300 14,500 11,500 9,100 7,200 5,750 4,550 3,600
EA/EH — — — 20,000 15,850 12,550 10,000 7,900 6,250
FA — — — — — — 17,800 14,100 11,200
COPPERCLAD STEEL
7 Strand
REEL 7 NO. 12 7 NO. 11 7 NO. 10 7 NO. 9 7 NO. 8 7 NO. 7 7 NO. 6 7 NO. 5
BA 3,850 3,050 2,450 1,950 1,550 1,200 950 750
CA 6,500 5,150 4,100 3,250 2,550 2,050 1,600 1,300
DA 11,900 9,450 7,450 5,950 4,700 3,750 2,950 2,350
EA/EH 20,700 16,400 13,000 10,300 8,200 6,500 5,150 4,100
FA — — 20,900 16,550 13,150 10,400 8,250 6,550
19 Strand
REEL 19 NO. 12 19 NO. 11 19 NO. 10 19 X 1055 19 NO. 9 19 NO. 8 19 NO. 7 19 NO. 6 19 NO. 5
CA 1,850 1,450 1,150 1,100 900 950 750 600 475
DA 4,300 3,400 2,700 2,500 2,150 1,700 1,350 1,050 850
EA/EH 7,450 5,900 4,700 4,350 3,700 2,950 2,350 1,850 1,450
FA 12,200 9,700 7,650 7,150 6,100 4,800 3,800 3,050 2,400
Guy Strand
REEL BA CA DA EA/EH FA
2.2M 9,800 14,250 26,050 0 0
4M 6,000 8,750 16,000 0 0
6M3 3,950 5,700 10,450 18,200 0
6M 4,100 6,800 12,450 21,650 0
8M 3,000 5,000 9,150 15,950 25,900
10M 2,500 4,150 7,600 13,250 21,500
12.5M 1,950 3,200 5,850 10,200 16,550
14M 1,750 2,950 5,400 9,400 15,200
16M 1,550 2,600 4,750 8,250 13,400
18M 1,350 2,250 4,050 7,100 11,500
20M 1,200 2,000 3,650 6,350 10,300

455
Wire Products
Green Spool Specifications

ARBOR HOLE SPOOL DIMENSIONS WIRE LENGTH
SIZE WEIGHT DSA JACKET TYPE
SIZE (INCHES) (FT.)
#6 Bare Solid 2 inch 25 12 x 4 x 5 40 Bare 338
#6 Solid Covered 2 inch 29 13 x 4 x 5 40 Vinyl 338
#4 Stranded 2 inch 20 12 x 4 x 5 40 Bare 214
#4 Stranded Covered 2 inch 22 12 x 4 x 5 40 Vinyl 214
COPPERCLAD STEEL

#2 Stranded 2 inch 20 12 x 4 x 5 40 Bare 134
#2 Stranded Covered 2 inch 23 12 x 4 x 5 40 Vinyl 134

456

08 Wire Products Catalog

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

08 Wire Products Catalog

Hochgeladen von

Copyright:

Verfügbare Formate

Wire Products

Wire Products Pictorial Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

Copperclad Steel Wire

© 2003, AFL, all rights reserved. PP-3-00780, Revision 8, 4.24.17

© 2003, AFL, all rights reserved. PP-3-00780, Revision 8, 4.24.17

Alumoweld® Wire and Strand

Alumoweld wire consists of a thick cladding of pure aluminum over a high-strength

How is Alumoweld made?

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

Alumoweld® Overhead Ground Wire

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

Alumoweld® Overhead Ground Wire (cont.)

ALUMOWELD STRAND ASTM B-416

ALUMOWELD STRAND ASTM B-415

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

Alumoweld® Type M Guy Strand

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

Alumoweld® Type M Guy Strand (cont.)

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

© 2003, AFL, all rights reserved. PP-3-00778, Revision 3, 3.6.14

Copperclad Steel Wire

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Dead Soft Annealed Copperclad Steel Wire

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

DSA Copperclad Steel Wire

Table 1—Physical and Electrical Characteristics of Copperclad Jacketed DSA Conductors

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Selecting the Right Size for the Application

AFL’s Swage Grounding Coupler compressed

Table 2—Ampacity Ratings

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Wire 3-Wire3-Wire Strand 7-Wire

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

DSA Copperclad Steel Wire for Grounding Applications

Single Wire Wire 3-Wire3-Wire Strand 7-Wire

Strand Strand Strand Strand

Specifications and Ordering Information

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

DSA Copperclad Steel Wire for Grounding Applications (cont.)

Single Wire Wire 3-Wire3-Wire Strand 7-Wire

Specifications and Ordering Information

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Dead Soft Annealed Copperclad Conductors (cont.)

19 19 No. 7 1432.31 169.25 119.68 97.72 53.52 37.85 26.76

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Dead Soft Annealed Copperclad Conductors (cont.)

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Steel Wire—High Strength/Extra High Strength

crack or peel when the wire is twisted, installed or buried.

Overhead Ground Wire

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Steel Wire—High Strength (cont.)

30% CONDUCTIVITY—HIGH STRENGTH

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Steel Wire—High Strength (cont.)

40% CONDUCTIVITY—HIGH STRENGTH

CCS03044H 3 No. 4 0.440 9790 353.9 0.2087 125215 0.0983

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Steel Wire—Extra High Strength

30% CONDUCTIVITY—EXTRA HIGH STRENGTH

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Composite (CCC) Conductors

© 2016, AFL, all rights reserved. PP-3-00817, Revision 3, 4.24.17

Copperclad Composite (CCC) Conductors (cont.)