Apr. 07, 2025
At present, the wire and cable industry is utilizing pure copper as their main raw material. However, since the price of copper is very high, the cable industry is making efforts in developing a new material in place or partially replace as an alternative to copper, therefore, we can see that further development has been done to copper-clad aluminum cable, copper-clad steel cable and aluminum-clad steel cable. So today let’s focus on one of those filters which are copper clad steel wires. Are they dependable with regard to the effectiveness while economizing Raw material production costs? In fact, copper clad steel wire has presented many unique advantages in application.
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Copper clad steel wire (CCS wire) is a kind of composite wire made of copper and steel. It coats the steel wire with copper by cold working, electrochemical or metallurgical processes. Copper clad steel wire has the advantages of both copper and steel: it has the strength and toughness of steel and the electrical conductivity and corrosion resistance of copper, so it has a wide range of applications in many fields.
Applications in telecommunications and power transmission: Copper-clad steel wire is used in the manufacture of power cables for long-distance, high-voltage transmission lines, utilizing its ability to withstand high tensions while maintaining stable and reliable electrical conductivity.
Applications in construction and grounding systems: Wires are essential in buried grid systems and overhead ground lines. Deployment of multilayered steel-copper wires in overhead grounding lines withstands mechanical stress, installation damage, and electricity in the event of a fault. Also in transmission and lightning protection grounding systems, this wire is used in transmission lines, substation grounding lines and anti-static grounding devices.
Applications in automotive industry and special wiring: copper clad stainless steel light weight, flexibility and durability of the characteristics of the automotive wiring harness is also used. It can be properly installed even in confined areas.
Solid copper wire and copper-clad steel look very similar, but they differ in many ways. When choosing between copper-clad steel and solid copper cable, the advantages and disadvantages must be weighed against specific needs.
Electrical Conductivity: Pure copper has an extremely high electrical conductivity of approximately 59.6 MS/m (at 20°C), which means that it is able to transmit current with minimal resistance, making it suitable for applications that require efficient electrical energy transmission. Although the copper clad wire layer provides good electrical conductivity, the overall conductivity is not as good as that of pure copper cables due to the thin layer, but at certain frequencies (e.g. high frequency coaxial cables) it can approach the performance of pure copper due to the skin effect.
Cost-effectiveness: copper-clad steel stranded wire to steel instead of copper, reducing the cost of wire, so that the consumption of copper is reduced. Recently, copper prices have risen sharply in the case of pure copper cable prices continue to rise, the use of copper-clad steel wire can reduce costs. At present, copper clad steel wire price is only equivalent to the price of pure copper wire products 1/2 ~ 1/3. when purchased on the basis of the same length of the cost can save 50% to 70%. Another option to consider if you’re keeping costs lower is copper clad aluminum cables.
Mechanical properties: copper clad steel conductor combines the high strength and toughness of steel, so that its tensile strength is far more than pure copper wire. In the same cross-section and condition, the mechanical strength of copper-clad steel wire is 1 to 2 times that of solid copper wire. It means that it can withstand greater mechanical loads and impacts, and has a longer service life in applications that require high tensile strength, such as long-distance overhead lines or in locations with harsh conditions. Pure copper is inherently softer and has good ductility, which makes it superior in terms of flexibility, but its relative tensile strength and resistance to abrasion is not as good as that of copper-clad steel wire.
Weight and Installation : Copper cables are heavier and more expensive to install and transport. Compared to solid copper cables, copper clad steel wires of the same length are much lighter. Therefore, the installation and transportation costs of copper clad steel cables can be lower than solid copper cables.
Corrosion resistance: Pure copper cable is not easy to corrode and oxidize in the open environment. It is suitable for humid or corrosive environments. Whereas in copper clad steel wires the copper layer provides some protection against corrosion, but if the copper layer is damaged, the internal steel core may be susceptible to corrosion.
Copper clad steel cable can withstand large impacts and loads, especially suitable for use in places with more demanding environments and more frequent movement. For example, in power transmission lines, especially underground or overhead high-voltage power grids. In contrast, pure copper cables are more suitable for applications where the electrical performance requirements are extremely high. For example, speaker copper wires offer lower resistance and higher data transmission speeds. As well as THHN copper wires are more widely used for power transmission in commercial buildings and industrial facilities. There is no substitute for the performance advantages of pure copper armoured cables in performance-seeking applications.
In order not to fall into the trap of low-quality copper-clad steel (CCS) cables, there are some procedures that can be followed. Briefly, solicit for compliance certificates, quality inspection reports or any other type of industry standard like UL or CE marking which indicates that the cable meets a safety or performance threshold.
Moreover, cables should be provided with clear identification and labeling of the standards. It is also helpful to use a magnet as a test, for it should be noticed that CCS cables pull towards it while pure copper cables do not; that is, testing the steel content. Evaluate the rigidity and density of the cable because CCS cables are frequently denser and stiffer than their pure copper counterparts. If feasible, conduct a skin effect test or request one to check the efficacy of signal transmission since CCS cables are more likely to sustain substantial signal transmission losses. Lastly, purchase only from recognized copper clad steel wire manufacturers who have a reputation for good customer reviews as the suppliers usually practice quality assurance in their products and services.
Copper clad steel (CCS) tracer wire combines the strength of steel with the conductivity of copper, making it a good choice for locating, pulling, and pipe bursting.
But what is CCS wire, how is it different from other types of tracer wire, and where is it used?
Copper clad steel is made by metallurgically bonding copper cladding to a steel core conductor using high heat and pressure. The result is a high break load tracer wire that can still carry a current for location purposes.
To prevent damage, manufacturers also apply high molecular weight polyethylene (HMWPE) or high-density polyethylene (HDPE) insulation. The result is a direct burial rated wire with abrasion, crush, and water resistance.
CCS wire has several types, including high strength (HS), extra high strength (EHS), stress relieved (SR), and pipe burst. The strength needed for the job depends on the break load you need.
For example, you wouldn’t use solid copper tracer wire for pipe bursting because it would easily break.
Compared to solid or stranded pure copper options, copper clad steel has several advantages.
Powerful Metal Combination
Steel is a strong alloy, giving the wire high tensile strength for drilling and pipe-bursting projects. The copper used to coat the steel core is highly conductive, making it easy for signals to pass through the cable.
Although other metals and alloys might be as strong or stronger than steel, they aren’t as cost-effective. Additionally, though aluminum is lighter than copper, it isn’t as conductive. More aluminum is needed to achieve the same conductivity, increasing gauge size.
More Cost-Effective Than Pure Copper
Steel is less expensive than copper, so it makes sense that CCS would be less costly than pure copper tracer wire.
The lower cost does come with a drawback, though. CCS isn’t as flexible as copper, making it harder for workers to manipulate.
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CCS is Theft-Resistant
How often do we read about copper thieves breaking into homes, businesses, and construction sites to steal copper?
Copper is valuable, making it an attractive target. But steel – not so much. If a thief wanted to take CCS wire from a job site, it has little resale value at scrapyards. The steel core is also difficult to cut through using regular cutting tools.
Copper clad steel tracer wire comes in handy for many applications beyond locating underground utilities.
You can easily find CCS wire used across many projects, including the developing renewables industry.
Water and Sewer Pipe Applications
CCS wire can locate underground water and sewer pipes, but it also works well for grounding.
When used as a grounding wire, copper clad steel safely reroutes electricity during a surge or fault. As a result, workers face fewer shock risks.
Code enforcement may also require grounding systems as part of an installation, so check before starting your project.
Directional Drilling and Boring
Thanks to its steel core, CCS has more tensile strength than pure copper tracer wire.
Crews can attach copper clad steel wire to drill bits used for directional drilling to track the bit’s location as it digs. Because the bit is easier to find, drilling projects are more accurate with fewer risks to other underground assets.
Although CCS isn’t as strong as pipe bursting wire, it works well for lower break load projects where strength isn’t critical to the job.
Open-Cut and Pipe Bursting
Open-cut installation is the most common way to install pipes, cables, and underground assets.
When costs are a concern, open-cut projects tend to be less expensive per linear foot than other methods. Workers also have direct access to the utility, allowing them to precisely position the tracer wire.
For pipe bursting, workers connect a wire to a bursting tool. A machine then pulls the tool through the old pipe to break it. This work often requires a high break load, meaning standard copper or stainless steel options aren’t up to the task. CCS wire can withstand the machine’s pulling power without stretching or breaking.
Copper clad steel has many other applications beyond water and sewer projects.
Gas Utilities – CCS tracer wire can locate underground gas lines. The wire is also good for bonding and grounding purposes.
Buried Conduit Projects – Tracer wire is common for many underground tracing projects, and CCS is no different. It does the same thing as solid copper tracer wire at a more economical price.
Wind Farms – In some cases, CCS can have special corrosion-resistant insulation and jacketing applied for offshore wind projects.
Overhead Ground Wiring – CCS is great for grounding, as its copper layer allows current to safely flow through it. The steel core also helps with vibrations.
Messenger Wire – Although messenger wires don’t carry current, they are critical in overhead electrical installations. These wires support other overhead cables, preventing them from sagging.
Horizontal Directional Drilling – Copper clad steel’s break load makes it a good option for lower-resistance drilling projects. For pipe bursting, a bulked-up CCS wire with a 4,700 lb. breaking strength is used.
It may seem like copper clad steel can do it all, but it’s best to understand the project’s full scope before jumping in.
Research the application, learn what APWA-approved color(s) you’ll need, and what the environment is like. Every installation is different, and sometimes a particular wire doesn’t check all the marks or may be overkill. The environment and final installation location will also dictate any special attributes the wire’s insulation or jacketing may need.
Teams should also see if there’s a need for cost-effective options. Solid copper tracer wire can become expensive for extended runs, making CCS a worthy replacement.
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