Copperclad Steel Wire can be jacketed to further reduce copper theft and is available in black with green stripe or grey. Available conductor sizes are 7#9, 7#10, #2 Str, #4 Str, #2 Solid, #4 Solid and #6 Solid.
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6 AWG Solid with grey PVC Jacket 7#7 AWG with black with green stripe PVC jacket 8 AFLglobal.com 1 (800) 866-7385 © 2016, AFL, all rights reserved. PP-3-00817, Revision 9, 11.13.2023 Specifications are subject to change without notice. Copperclad Steel Wire 8 Table 1—Physical and Electrical Characteristics of Copperclad Jacketed DSA Conductors CONDUCTOR SIZE CONDUCTOR OVERALL DIAMETER AFL NO. WEIGHT/LENGTH PVC MIN BREAKING LOAD GREY PVC BLACK WITH GREEN TRACER PVC (AWG) (in.) (mm) 0.030 in. 0.030 in. (lbs/kft) (kg/km) lbf (kgf) 7#9 0 343 8 72 CCS07094DJV CCS07094DBLK 279 7 416 2 2513 1140 7#10 0 306 7 76 CCS07104DJV CCS07104DBLK 224 1 333 5 1994 904 #2 Str 0 258 6 55 CCS2STR4DJV CCS2STR4DBLK 162 3 241 5 1435 651 #4 Str 0 204 5 18 CCS4STR4DJV CCS4STR4DBLK 104 4 155 4 897 407 #2 Solid 0 258 6 54 CCS01024DJV CCS01024DBLK 201 7 300 2 2023 918 #4 Solid 0 204 5 19 CCS01044DJV CCS01044DBLK 129 8 193 2 1272 577 #6 Solid 0 162 4 12 CCS01064DJV CCS01064DBLK 84 1 125 1 800 363 DSA Copperclad Steel Wire Jacketed Material Copperclad Steel Wire from AFL can be jacketed to further reduce copper theft and is available in black with green stripe or grey Available sizes are shown in the chart below, Table 1 Please contact AFL for larger sizes not shown
13 AFLglobal com 1 (800) 866-7385 © 2016, AFL, all rights reserved PP-3-00817, Revision 9, 11 13 2023 Specifications are subject to change without notice Copperclad Steel Wire 13 CCS01064D-JV Step 1—Catalog Number CATALOG NUMBER (NOT ALL SIZES LISTED) CONDUCTOR CONFIGURATION 30% CONDUCTIVITY 40% CONDUCTIVITY #6 Jacketed CCS01064D-JV* #4 Jacketed CCS01044D-JV* #2 Jacketed CCS01024D-JV* #4 Stranded Jacketed CCS4STR4D-JV* #2 Stranded Jacketed CCS2STR4D-JV* #2 Stranded CCS2STR4D #4 Stranded CCS4STR4D #2 CCS01023D CCS01024D #4 CCS01043D CCS01044D #6 CCS01063D CCS01064D 3#5 CCS03053D CCS03054D 3#6 CCS03063D CCS03064D 3#7 CCS03073D CCS03074D 3#8 CCS03083D CCS03084D 3#9 CCS03093D CCS03094D 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 Copperclad Part Number Nomenclature Ordering Information 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 Step 2—Package Code COILS CODE (LBS) CODE (FT) C50P C334F C100P C200P REELS CODE (LBS) CODE (FT) R500P R500F R1000P R1000F R2000P R2000F R3521P R3521F SPOOLS CODE (LBS) CODE (FT) S25P S318F Not all sizes listed Select preference of packaging type R3521P Package Code Catalog Number Step 3—Assemble Complete Part Number * See Jacket detail sheet for alternate jacketing configurations and part numbers CCS Copperclad Steel (CCX = Onyx) Explanation of Copperclad Part Numbers 0707 Stranding 0707 = 7 Strands of #7 0102 = Single Strand of #2 4 Conductivity (IACS Int'l Annealed Copper) 3 = 30% 4 = 40 % D Material Type D = DSA (Dead Soft Annealed) H = High Strength E = Extra High Strength R Package Type R = Reel S = Spool C = Coil 1000 Package Quantity F Unit of Measure F = Feet (ft) P = Pounds (lbs)
14 AFLglobal com 1 (800) 866-7385 © 2016, AFL, all rights reserved PP-3-00817, Revision 9, 11 13 2023 Specifications are subject to change without notice Copperclad Steel Wire 14 Recommended Maximum Footage per Reel 19 Strands REEL SIZE 19#4 19#5 19#6 19#7 19#8 19#9 4/0 19#10 4 — — — — — 575 675 725 5 — — — — 575 750 875 950 6 — — 600 775 975 1,200 1,450 1,550 7.5 575 725 925 1,150 1,450 1,850 2,200 2,350 8 775 975 1,200 1,550 1,950 2,450 2,900 3,100 9 1,200 1,550 1,950 2,450 3,100 3,950 4,650 4,950 10 1,550 1,950 2,450 3,100 3,900 4,950 5,800 6,200 11 2,050 2,600 3,300 4,150 5,250 6,650 7,850 8,400 12 3,150 4,000 5,000 6,350 8,000 10,100 11,800 12,700 7 Strands REEL SIZE 7#4 7#5 7#6 7#7 2/0 7#8 1/0 7#9 7#10 #2 STR #4 STR 4 475 600 775 975 1,050 1,200 1,350 1,550 1,950 2,750 4,450 5 625 800 1,000 1,250 1,400 1,600 1,750 2,050 2,550 3,600 5,800 6 1,050 1,300 1,650 2,100 2,300 2,650 2,950 3,400 4,250 6,000 9,600 7.5 1,600 2,000 2,550 3,200 3,500 4,050 4,450 5,100 6,450 9,100 14,500 8 2,100 2,650 3,350 4,250 4,650 5,350 5,850 6,750 8,500 11,900 — 9 3,350 4,250 5,350 6,750 7,400 8,550 9,350 10,800 13,600 — — 10 4,200 5,300 6,700 8,450 9,250 10,700 11,700 13,500 — — — 11 5,700 7,200 9,050 11,400 12,500 14,400 15,800 — — — — 12 8,600 10,900 13,700 — — — — — — — — 3 Strands REEL SIZE 3#5 3#6 3#7 3#8 3#9 3#10 4 1,450 1,800 2,300 2,900 3,650 4,600 5 1,900 2,400 3,000 3,800 4,800 6,050 6 3,100 3,950 5,000 6,300 7,950 10,000 7.5 4,750 6,000 7,550 9,500 12,000 15,100 8 6,250 7,850 9,900 12,500 15,800 19,900 9 9,950 12,500 15,800 20,000 — — 10 12,400 15,700 19,800 — — — 11 16,800 21,200 — — — — 12 — — — — — — Single Strand REEL SIZE #2 #4 #6 4 2,150 3,450 5,500 5 2,850 4,550 7,250 6 4,700 7,500 11,900 7.5 7,150 11,400 18,100 8 — — — 9 — — — 10 — — — 11 — — — 12 — — — Reel Specifications REEL NO. OD (in.) ID (in.) WIDTH (in.) MAX CAPACITY (lbs) 4 24 0 12 0 13 0 407 5 24 0 12 0 16 9 533 6 28 0 12 0 17 9 881 8 36 0 17 9 21 1 1,751 9 40 0 17 1 29 5 2,797 10 41 9 13 8 29 5 3,496 11 48 0 26 0 30 0 5,070 12 54 0 36 0 30 0 7,140
Spool of Copperclad Steel Wire with PVC jacketed material. For spool sizes and specifications, see page 14. 15 AFLglobal.com 1 (800) 866-7385 © 2016, AFL, all rights reserved. PP-3-00817, Revision 9, 11.13.2023 Specifications are subject to change without notice. Copperclad Steel Wire 15 Green Spool Specifications SIZE ARBOR HOLE SIZE* WEIGHT SPOOL DIMENSIONS (inches) DSA JACKET TYPE WIRE LENGTH (ft.) #6 Bare Solid 2 inch 25 12 x 4 x 5 40 — 338 #6 Solid Jacketed 2 inch 29 13 x 4 x 5 40 Vinyl 338 #4 Bare Solid 2 inch 25 12 x 4 x 5 40 — 214 #4 Solid Jacketed 2 inch 29 12 x 4 x 5 40 Vinyl 214 #4 Stranded 2 inch 20 12 x 4 x 5 40 — 214 #4 Stranded Jacketed 2 inch 22 12 x 4 x 5 40 Vinyl 214 #2 Bare Solid 2 inch 25 12 x 4 x 5 40 — 134 #2 Solid Jacketed 2 inch 27 12 x 4 x 5 40 Vinyl 134 #2 Stranded 2 inch 20 12 x 4 x 5 40 — 134 #2 Stranded Jacketed 2 inch 23 12 x 4 x 5 40 Vinyl 134 * Special arbor hole sizes available upon request
Features:
- excellent solution for areas with high rates of copper theft
- Minimal amount of copper used in the bonding process (6% to 10% depending on the conductivity)
- Jacketed to further reduce copper theft; jacket available in black with green stripe or grey
- Available conductor sizes include 7#9, 7#10, #2 Str, #4 Str, #2 Solid, #4 Solid and #6 Solid
- Larger sizes also available
Applications:
- Substation
- Grounding grid
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.
Copperclad Steel Wire can be jacketed to further reduce copper theft and is available in black with green stripe or grey. Available conductor sizes are 7#9, 7#10, #2 Str, #4 Str, #2 Solid, #4 Solid and #6 Solid. Please contact AFL for larger sizes not shown.
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. 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.
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