Aluminum, Copper, and Steel Cable Wire: What's the Best ...

Cable wire is a type of wire that is used to transmit electricity, data, or other signals. It is made up of a conductor, which is the material that carries the current or signal, and an insulation material, which protects the conductor from moisture and other contaminants.

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The most common materials used for cable wire conductors are copper, aluminum, and steel. Each material has its own advantages and disadvantages, which makes it suitable for different applications.

Aluminum Cable Wire

Aluminum cable wire is a good conductor of electricity, but it is not as good as copper. However, aluminum is much less expensive than copper, making it a popular choice for overhead power lines and outdoor wiring. Aluminum cable wire is also lighter than copper, which makes it easier to handle and install.

One of the disadvantages of aluminum cable wire is that it is more susceptible to corrosion than copper. This is because aluminum forms a thin layer of oxide on its surface when it is exposed to air. This oxide layer can break down over time, exposing the underlying metal to corrosion.

Copper Cable Wire

Copper cable wire is the best conductor of electricity, making it the ideal choice for electrical wiring in homes and businesses. Copper is also resistant to corrosion, making it a good choice for applications where the wire will be exposed to moisture or other harsh conditions.

However, copper cable wire is more expensive than aluminum cable wire. It is also heavier, which can make it more difficult to handle and install.

Steel Cable Wire

Steel cable wire is not a good conductor of electricity, but it is very strong and durable. This makes it a good choice for wire rope and cables that are used in construction and mining. Steel cable wire is also resistant to wear and tear, making it a good choice for applications where the wire will be subjected to a lot of stress.

The Best Type of Cable Wire for Your Application

The best type of cable wire for your application will depend on the specific requirements of that application. The factors that need to be considered include the electrical conductivity, strength, durability, flexibility, and insulation requirements.

Here is a table that summarizes the properties of aluminum, copper, and steel cable wires:

PropertyAluminumCopperSteelElectrical conductivityGoodBestPoorCostLess expensiveMore expensiveMost expensiveWeightLighterHeavierHeaviestCorrosion resistanceLess resistantMore resistantMost resistantStrengthLess strongStrongStrongestDurabilityDurableDurableVery durableFlexibilityFlexibleFlexibleLess flexibleInsulation requirementsLess demandingMore demandingMost demanding

How to Choose the Right Cable Wire&#;

Here are some factors to consider when choosing the right cable wire for your application:

• Electrical conductivity: The electrical conductivity of the cable wire will determine how much current it can carry. If you need a cable wire to carry a lot of current, you will need to choose a wire with a high electrical conductivity.
• Cost: The cost of the cable wire will vary depending on the material, size, and insulation. Consider your budget when making your decision.
• Weight: The weight of the cable wire will affect its ease of installation and handling. If you are working with overhead power lines, you will need to choose a lightweight cable wire.
• Corrosion resistance: If the cable wire will be exposed to moisture or other corrosive elements, you will need to choose a wire that is resistant to corrosion.
• Strength: The strength of the cable wire will determine how much weight it can support. If the cable wire will be used to support a load, you will need to choose a wire that is strong enough to do so.
• Durability: The durability of the cable wire will affect its lifespan. If you need a cable wire that will last for many years, you will need to choose a wire that is durable.
• Flexibility: The flexibility of the cable wire will affect its ease of installation and handling. If you need a cable wire that can be bent easily, you will need to choose a flexible wire.
• Insulation requirements: The insulation requirements will depend on the application. If the cable wire will be exposed to high temperatures or other harsh conditions, you will need to choose a wire with a high-quality insulation.

Conclusion

Cable wire is a versatile material that is used in a wide variety of applications. The type of cable wire that is used for a particular application will depend on the specific requirements of that application. The factors that need to be considered include the electrical conductivity, strength, durability, flexibility, and insulation requirements

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One of the recurring questions received by Gordian&#;s engineers revolves around the question of material impact on estimates. If prices on a type of material are surging, what are the tradeoffs of selecting another comparable option? Questions like these are becoming increasingly common as squeezed supply chain and wild material cost fluctuations have unsettled the construction market and made value engineering an imperative to make the most of project budgets.

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For a practical example of the tradeoffs estimators and other considerations preconstruction professionals are making as they plan and design projects, look no further than the choice being made every day: copper versus aluminum wire.

From January to January , the price of ½&#; copper tubing increased over 50%, while the average price of electric copper wire has grown over 120% in the same time frame. Many electrical engineers faced with these cost surges for copper materials are turning to aluminum as a substitute.

To help estimators and other construction professionals answer this question, we&#;ve turned to the industry expertise of Antonio D&#;Aulerio, Engineer on the Data Team, responsible for managing the electrical divisions for Gordian&#;s RSMeans Data. Antonio discusses the trade-offs for copper and aluminum materials and how to incorporate these decisions when using RSMeans Data Online.

Copper vs. Aluminum Wire

The main criteria for the use of aluminum cable vs copper cables are the cost savings. In buildings, aluminum and copper cables can be used interchangeably for power in low voltage installations. For communications and control, copper is more commonly used. In fact, nearly all electronic cables are made from copper.

The main difference between aluminum and copper cables is the current carrying capacity and resistance. Aluminum cable has a lower current carrying capacity (by about 40%) and greater resistance (requiring 50% larger cross-sectional area on average) than the equivalent copper conductor. As a rule of thumb, using aluminum conductors two American Wire Gage sizes larger than copper are typically sufficient for replacement. Aluminum will take more space to carry the same amperage as copper, meaning it will need a bigger raceway or enclosed channel designed for holding wires, cables or bus bars with additional functions.

The drawbacks for using aluminum:

• It&#;s less flexible and more labor intensive. Aluminum is more difficult to work with, so the cost of termination is higher.
• It needs a special compound at termination (or the lug must be a special Al-Cu type) to avoid galvanic corrosion. This can be a serious risk factor in damp conditions.
• For long runs, aluminum has more voltage drop so engineers may need to upsize the cable to compensate.
• Aluminum cable is prone to cracking and failure when subjected to vibration. This may be a greater consideration for industrial building projects where installed machinery produces high quantities of low and high frequency vibration.

Copper Versus Aluminum Wire: Using RSMeans Data Online to Estimate the Difference

The example below uses RSMeans Data Online to compare a 200A service entrance. The first one uses copper cable 3/0 and a 1-1/2&#; conduit. The second one uses aluminum cable 250 MCM and 2&#; conduit. The aluminum option is slightly cheaper overall, even though the cost of the wire went down 48% from $423 to $219 and the raceway components went up in price by 23%.

Option 1: Copper Cable

Option 2: Aluminum Cable

 

RSMeans Data Online is a powerful tool that allows you to compare options and make data-driven value engineering decisions to better support your projects. Want to try this out for yourself with different estimates and location factors, or trend this over time with the Historical Cost Index? Follow the links below to learn more about how to use these tools for your estimates, or sign up for one of Gordian&#;s training sessions to get hands-on guidance.

• Already have an account? Use one of our Product Guides.
• Use the Historical Cost Index to move your estimates over time.
• Use the City Cost Index to localize your estimates.
• Sign up for in-depth RSMeans Training.

Get Started Today

Ready to explore cloud-based construction cost estimating with RSMeans Data Online?

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