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CopperClad

CopperClad Steel Wire from AFL is the ideal solution for communications capabilities for both electric utilities and communications carriers. Composed of a steel core with copper cladding, the steel wire gives the wire its strength and the thin, consistent layer of copper cladding provides electrical conductivity and resistance to corrosion. 

To manufacture CopperClad Steel Wire, carbon steel (low, high strength and extra high strength) is bonded with a uniform layer of oxygen-free copper cladding 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 and 3, 7 and 19 cable strands. 

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.

Theft-deterrent Design
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.

Additionally, CopperClad Steel Wire can be jacketed to further reduce copper theft. Installation is easy. Cut the wire, remove the PVC jacket at the terminal end and connect just like copper.

CopperClad Steel Wire brochure

CopperClad Grounding Fault Cable Design Calculator





Products


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.
Composed of a steel core with copper cladding, the steel wire gives the wire its strength and the thin, consistent layer of copper cladding provides electrical conductivity and resistance to corrosion.
Jacketed CopperClad Steel Wire reduces copper theft. At first glace, its grey or black PVC jacket has the appearance of galvanized steel. Installation is easy. Cut the wire, remove the PVC jacket at the terminal end and connect just like copper.
CopperClad Type M guy wire is an economical, corrosion-resistant guying material for use on overhead lines. Copper cladding is bonded on each wire to protect the high-strength steel core from rusting and subsequent loss of strength. 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.
Dead Soft Annealed (DSA) CopperClad Steel Wire is very flexible for easy preparation and installation. 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.
High Strength (HS) and Extra High Strength (EHS) CopperClad Steel Wire 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.