OnyxCCS offers the same benefits as standard Copperclad Steel (CCS) while protecting against copper theft.
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AFL's Copperclad Steel Wire is the ideal solution for grounding wire for power type applications Composed of a steel core with coppercladding, the steel wire gives the wire its strength and the consistent layer of copper 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 coppercladding to achieve 30% and 40% IACS (International Annealed Copper Standard) conductivities The material is available in a single wire, 3, 7 and 19 cable strands with some sizes jacketed to give the wire a different appearance to copper OnyxCCS offers the same benefits as standard Copperclad Steel (CCS) while protecting against copper theft In addition to the inherent strength of a CCS product, OnyxCCS has a chemically-etched surface treatment which permanently darkens the standard CCS This process discourages theft of a utility's copper infrastructure and does not compromise mechanical nor electrical properties OnyxCCS is offered in all sizes of the AFL Copperclad product line To order OnyxCCS, the part number pre-fix "CCX" replaces "CCS" EX: CCX 07074DR1000F Copperclad Steel Wire OnyxCCS ® Copperclad Steel Wire Features • Demonstrates the same corrosion-resistant properties as copper while maintaining the high strength of steel • Reduces damage caused during installation or fatigue from vibration or bending • Special heat treat process results in a very malleable wire called Dead Soft Annealed (DSA) • Copper permanently bonded to the steel core prevents corrosion of the steel core • Very little scrap value, discouraging theft and leaving the grounding system intact • Compliant with IEEE 80 • Manufactured in accordance with ASTM specifications (B258, B910/B910M, B229, B228, B227) Single strand Copperclad Steel Wire in large and small diameters OnyxCCS ® Copperclad Steel Wire 3 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 3 7-strand Copperclad Steel Wire 19-strand Copperclad Steel Wire 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 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 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
4 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 4 AFL’s Swage Grounding Coupler compressed onto 19-strand Copperclad Steel Wire 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 copper is physically oversized 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 Table 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 Selecting the Right Size for the Application 40% CCS Overview CONDUCTOR SIZE STRANDS STRAND DIAMETER OVERALL DIAMETER AREA FAULT CURRENT WEIGHT/LENGTH WIRE RESISTANCE MIN. BREAK LOAD AWG In. MM In. MM cmil (mm^2) Amps at 0.5 Sec. lbs/kft kg/km Ω/kft Ω/kM lbf kgf 19#4 19 0 2043 5 19 1 022 25 95 793,000 401 8 107 28 2251 7 3350 9 0 0338 0 1110 21755 9868 19#5 19 0 1819 4 62 0 910 23 10 628,700 318 6 85 05 1785 0 2656 3 0 0427 0 1400 17246 7823 19#6 19 0 1620 4 11 0 810 20 57 498,600 252 6 67 46 1415 8 2106 9 0 0538 0 1765 13679 6205 19#7 19 0 1443 3 67 0 722 18 33 395,600 200 5 53 52 1123 3 1671 7 0 0678 0 2224 10853 4923 19#8 19 0 1285 3 26 0 643 16 32 313,700 159 0 42 44 890 8 1325 6 0 0855 0 2805 8606 3904 19#9 19 0 1144 2 91 0 572 14 53 248,700 126 0 33 64 706 0 1050 7 0 1079 0 3539 6821 3094 4/0 19 0 1055 2 68 0 528 13 40 211,500 107 2 28 61 600 4 893 6 0 1268 0 4161 5801 2631 19#10 19 0 1019 2 59 0 510 12 94 197,300 100 0 26 69 560 2 833 6 0 1359 0 4460 5412 2455 7#4 7 0 2043 5 19 0 613 15 57 292,200 148 1 39 53 826 3 1229 7 0 0914 0 3000 8015 3635 7#5 7 0 1819 4 62 0 546 13 86 231,600 117 4 31 33 655 0 974 8 0 1153 0 3784 6354 2882 7#6 7 0 1620 4 11 0 486 12 34 183,700 93 1 24 85 519 6 773 2 0 1454 0 4771 5040 2286 7#7 7 0 1443 3 67 0 433 11 00 145,800 73 9 19 72 412 2 613 5 0 1833 0 6013 3998 1814 2/0 7 0 1379 3 50 0 414 10 51 133,100 67 4 18 01 376 5 560 2 0 2007 0 6584 3652 1656 7#8 7 0 1285 3 26 0 386 9 79 115,600 58 6 15 64 326 9 486 5 0 2311 0 7583 3171 1438 1/0 7 0 1228 3 12 0 368 9 35 105,600 53 5 14 28 298 5 444 3 0 2531 0 8303 2896 1313 7#9 7 0 1144 2 91 0 343 8 72 91,610 46 4 12 39 259 1 385 6 0 2916 0 9567 2513 1140 7#10 7 0 1019 2 59 0 306 7 76 72,690 36 8 9 83 205 6 305 9 0 3675 1 2058 1994 904 3#4 3 0 2043 5 19 0 440 11 18 125,200 63 4 16 94 353 4 526 0 0 2129 0 6986 3626 1645 3#5 3 0 1819 4 62 0 392 9 96 99,260 50 3 13 43 280 2 416 9 0 2686 0 8812 2874 1304 3#6 3 0 1620 4 11 0 349 8 86 78,730 39 9 10 65 222 2 330 7 0 3386 1 1110 2280 1034 3#7 3 0 1443 3 67 0 311 7 90 62,470 31 7 8 45 176 3 262 4 0 4268 1 4003 1809 820 3#8 3 0 1285 3 26 0 277 7 04 49,540 25 1 6 70 139 8 208 1 0 5382 1 7658 1434 651 3#9 3 0 1144 2 91 0 247 6 27 39,260 19 9 5 31 110 8 164 9 0 6791 2 2279 1137 516 3#10 3 0 1019 2 59 0 220 5 59 31,150 15 8 4 21 87 9 130 8 0 8559 2 8080 902 409 #2 AWG 7 0 0860 2 18 0 258 6 55 51,770 26 2 7 00 146 4 217 9 0 5160 1 6929 1435 651 #4 AWG 7 0 0680 1 73 0 204 5 18 32,370 16 4 4 38 91 5 136 2 0 8253 2 7078 897 407 #2 AWG 1 0 2576 6 54 0 258 6 54 66,370 33 6 8 98 185 8 276 6 0 3985 1 3075 2023 918 #4 AWG 1 0 2043 5 19 0 204 5 19 41,740 21 2 5 65 116 9 173 9 0 6337 2 0791 1272 577 #6 AWG 1 0 1620 4 12 0 162 4 12 26,250 13 3 3 55 73 5 109 4 1 0076 3 3058 800 363 #8 AWG 1 0 1285 3 26 0 129 3 26 16,510 8 4 2 23 46 2 68 8 1 6018 5 2554 503 228 #9 AWG 1 0 1144 2 91 0 114 2 91 13,090 6 6 1 77 36 6 54 5 2 0210 6 6307 399 181 #10 AWG 1 0 1019 2 59 0 102 2 59 10,380 5 3 1 40 29 1 43 3 2 5473 8 3572 316 144
5 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 5 30% CCS Overview CONDUCTOR SIZE STRANDS STRAND DIAMETER OVERALL DIAMETER AREA FAULT CURRENT WEIGHT/LENGTH WIRE RESISTANCE MIN. BREAK LOAD AWG In. MM In. MM cmil (mm^2) Amps at 0.5 Sec. lbs/kft kg/km Ω/kft Ω/kM lbf kgf 19#4 19 0 2043 5 19 1 022 25 95 793,000 401 8 92 96 2231 3 3320 5 0 0451 0 1479 24474 11101 19#5 19 0 1819 4 62 0 910 23 10 628,700 318 6 73 70 1768 8 2632 3 0 0569 0 1866 19402 8800 19#6 19 0 1620 4 11 0 810 20 57 498,600 252 6 58 45 1403 0 2087 9 0 0717 0 2352 15389 6980 19#7 19 0 1443 3 67 0 722 18 33 395,600 200 5 46 38 1113 2 1656 6 0 0904 0 2965 12210 5538 19#8 19 0 1285 3 26 0 643 16 32 313,700 159 0 36 78 882 7 1313 6 0 1140 0 3739 9682 4392 19#9 19 0 1144 2 91 0 572 14 53 248,700 126 0 29 15 699 6 1041 2 0 1438 0 4717 7674 3481 4/0 19 0 1055 2 68 0 528 13 40 211,500 107 2 24 79 595 0 885 5 0 1691 0 5547 6526 2960 19#10 19 0 1019 2 59 0 510 12 94 197,300 100 0 23 13 555 1 826 1 0 1812 0 5946 6089 2762 7#4 7 0 2043 5 19 0 613 15 57 292,200 148 1 34 25 818 8 1218 5 0 1219 0 3999 9017 4090 7#5 7 0 1819 4 62 0 546 13 86 231,600 117 4 27 15 649 1 966 0 0 1538 0 5045 7148 3242 7#6 7 0 1620 4 11 0 486 12 34 183,700 93 1 21 54 514 9 766 2 0 1939 0 6360 5670 2572 7#7 7 0 1443 3 67 0 433 11 00 145,800 73 9 17 09 408 5 607 9 0 2443 0 8016 4498 2040 2/0 7 0 1379 3 50 0 414 10 51 133,100 67 4 15 60 373 1 555 2 0 2675 0 8777 4108 1863 7#8 7 0 1285 3 26 0 386 9 79 115,600 58 6 13 55 323 9 482 1 0 3081 1 0108 3567 1618 1/0 7 0 1228 3 12 0 368 9 35 105,600 53 5 12 37 295 8 440 2 0 3374 1 1069 3258 1478 7#9 7 0 1144 2 91 0 343 8 72 91,610 46 4 10 74 256 7 382 1 0 3887 1 2754 2827 1282 7#10 7 0 1019 2 59 0 306 7 76 72,690 36 8 8 52 203 7 303 1 0 4900 1 6075 2243 1017 3#4 3 0 2043 5 19 0 440 11 18 125,200 63 4 14 68 350 2 521 2 0 2838 0 9313 4079 1850 3#5 3 0 1819 4 62 0 392 9 96 99,260 50 3 11 64 277 6 413 2 0 3581 1 1747 3234 1467 3#6 3 0 1620 4 11 0 349 8 86 78,730 39 9 9 23 220 2 327 7 0 4514 1 4811 2565 1163 3#7 3 0 1443 3 67 0 311 7 90 62,470 31 7 7 32 174 7 260 0 0 5690 1 8667 2035 923 3#8 3 0 1285 3 26 0 277 7 04 49,540 25 1 5 81 138 6 206 2 0 7175 2 3540 1614 732 3#9 3 0 1144 2 91 0 247 6 27 39,260 19 9 4 60 109 8 163 4 0 9053 2 9700 1279 580 3#10 3 0 1019 2 59 0 220 5 59 31,150 15 8 3 65 87 1 129 7 1 1410 3 7433 1015 460 #2 AWG 7 0 0860 2 18 0 258 6 55 51,770 26 2 6 07 145 1 215 9 0 6879 2 2568 1614 732 #4 AWG 7 0 0680 1 73 0 204 5 18 32,370 16 4 3 79 90 7 135 0 1 1002 3 6097 1009 458 #2 AWG 1 0 2576 6 54 0 258 6 54 66,370 33 6 7 78 184 2 274 1 0 5313 1 7430 2276 1032 #4 AWG 1 0 2043 5 19 0 204 5 19 41,740 21 2 4 89 115 8 172 4 0 8448 2 7716 1431 649 #6 AWG 1 0 1620 4 12 0 162 4 12 26,250 13 3 3 08 72 8 108 4 1 3432 4 4069 900 408 #8 AWG 1 0 1285 3 26 0 129 3 26 16,510 8 4 1 94 45 8 68 2 2 1354 7 0059 566 257 #9 AWG 1 0 1144 2 91 0 114 2 91 13,090 6 6 1 53 36 3 54 0 2 6942 8 8393 449 204
6 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 6 40% CONDUCTIVITY CONDUCTOR SIZE STRANDS AFL NO. I2T NOM. DC RESISTANCE FAULT CURRENT 3 CYCLES 6 CYCLES 9 CYCLES 30 CYCLES 60 CYCLES 120 CYCLES AWG kA2s ohm/kft 0.05S 0.10S 0.15S 0.50S 1.00S 2.00S 19#4 19 CCS19044D 5755 00 0 0331 339 26 239 90 195 87 107 28 75 86 53 64 19#5 19 CCS19054D 3616 62 0 0418 268 95 190 17 155 28 85 05 60 14 42 52 19#6 19 CCS19064D 2275 27 0 0527 213 32 150 84 123 16 67 46 47 70 33 73 19#7 19 CCS19074D 1432 31 0 0664 169 25 119 68 97 72 53 52 37 85 26 76 19#8 19 CCS19084D 900 71 0 0837 134 22 94 91 77 49 42 44 30 01 21 22 19#9 19 CCS19094D 565 82 0 1057 106 38 75 22 61 42 33 64 23 79 16 82 4/0 19 CCS4/04D 409 24 0 1242 90 47 63 97 52 23 28 61 20 23 14 30 19#10 19 CCS19104D 356 18 0 1332 84 40 59 68 48 73 26 69 18 87 13 35 7#4 7 CCS07044D 781 15 0 0896 124 99 88 38 72 16 39 53 27 95 19 76 7#5 7 CCS07054D 490 90 0 1130 99 09 70 06 57 21 31 33 22 16 15 67 7#6 7 CCS07064D 308 83 0 1424 78 59 55 57 45 37 24 85 17 57 12 43 7#7 7 CCS07074D 194 41 0 1795 62 36 44 09 36 00 19 72 13 94 9 86 2/0 7 CCS2/04D 162 15 0 1966 56 95 40 27 32 88 18 01 12 73 9 00 7#8 7 CCS07084D 122 26 0 2264 49 45 34 97 28 55 15 64 11 06 7 82 1/0 7 CCS1/04D 101 97 0 2479 45 16 31 93 26 07 14 28 10 10 7 14 7#9 7 CCS07094D 76 80 0 2856 39 19 27 71 22 63 12 39 8 76 6 20 7#10 7 CCS07104D 48 35 0 3600 31 10 21 99 17 95 9 83 6 95 4 92 3#4 3 CCS03044D 143 48 0 2086 53 57 37 88 30 93 16 94 11 98 8 47 3#5 3 CCS03054D 90 17 0 2631 42 47 30 03 24 52 13 43 9 50 6 71 3#6 3 CCS03064D 56 72 0 3317 33 68 23 82 19 45 10 65 7 53 5 33 3#7 3 CCS03074D 35 71 0 4181 26 72 18 90 15 43 8 45 5 98 4 23 3#8 3 CCS03084D 22 46 0 5272 21 19 14 99 12 24 6 70 4 74 3 35 3#9 3 CCS03094D 14 11 0 6652 16 80 11 88 9 70 5 31 3 76 2 66 3#10 3 CCS03104D 8 88 0 8384 13 33 9 42 7 69 4 21 2 98 2 11 #2 AWG 7 CCS02STR4D 24 53 0 5054 22 15 15 66 12 79 7 00 4 95 3 50 #4 AWG 7 CCS04STR4D 9 59 0 8085 13 85 9 79 7 99 4 38 3 10 2 19 #2 AWG 1 CCS01024D 40 31 0 3904 28 39 20 08 16 39 8 98 6 35 4 49 #4 AWG 1 CCS01044D 15 94 0 6207 17 86 12 63 10 31 5 65 3 99 2 82 #6 AWG 1 CCS01064D 6 31 0 9870 11 23 7 94 6 48 3 55 2 51 1 78 #8 AWG 1 CCS01084D 2 50 1 5691 7 06 5 00 4 08 2 23 1 58 1 12 #9 AWG 1 CCS01094D 1 57 1 9797 5 60 3 96 3 23 1 77 1 25 0 89 #10 AWG 1 CCS01104D 0 99 2 4952 4 44 3 14 2 56 1 40 0 99 0 70 Wire Specifications DSA Copperclad Steel Wire for Grounding Applications
7 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 7 DSA Copperclad Steel Wire for Grounding Applications (cont.) 30% CONDUCTIVITY CONDUCTOR SIZE STRANDS AFL NO. I2T NOM. DC RESISTANCE FAULT CURRENT 3 CYCLES 6 CYCLES 9 CYCLES 30 CYCLES 60 CYCLES 120 CYCLES AWG kA2s ohm/kft 0.05S 0.10S 0.15S 0.50S 1.00S 2.00S 19#4 19 CCS19043D 4321 16 0 0442 293 98 207 87 169 73 92 96 65 74 46 48 19#5 19 CCS19053D 2715 55 0 0558 233 05 164 79 134 55 73 70 52 11 36 85 19#6 19 CCS19063D 1708 39 0 0703 184 85 130 71 106 72 58 45 41 33 29 23 19#7 19 CCS19073D 1075 46 0 0886 146 66 103 70 84 67 46 38 32 79 23 19 19#8 19 CCS19083D 676 30 0 1118 116 30 82 24 67 15 36 78 26 01 18 39 19#9 19 CCS19093D 424 85 0 1410 92 18 65 18 53 22 29 15 20 61 14 57 4/0 19 CCS4/03D 307 28 0 1658 78 39 55 43 45 26 24 79 17 53 12 40 19#10 19 CCS19103D 267 44 0 1777 73 14 51 71 42 22 23 13 16 35 11 56 7#4 7 CCS07043D 586 53 0 1195 108 31 76 59 62 53 34 25 24 22 17 12 7#5 7 CCS07053D 368 59 0 1508 85 86 60 71 49 57 27 15 19 20 13 58 7#6 7 CCS07063D 231 89 0 1901 68 10 48 15 39 32 21 54 15 23 10 77 7#7 7 CCS07073D 145 98 0 2396 54 03 38 21 31 20 17 09 12 08 8 54 2/0 7 CCS2/03D 121 75 0 2624 49 35 34 89 28 49 15 60 11 03 7 80 7#8 7 CCS07083D 91 80 0 3021 42 85 30 30 24 74 13 55 9 58 6 77 1/0 7 CCS1/03D 76 56 0 3308 39 13 27 67 22 59 12 37 8 75 6 19 7#9 7 CCS07093D 57 67 0 3812 33 96 24 01 19 61 10 74 7 59 5 37 7#10 7 CCS07103D 36 30 0 4805 26 94 19 05 15 56 8 52 6 02 4 26 3#4 3 CCS03043D 107 73 0 2784 46 42 32 82 26 80 14 68 10 38 7 34 3#5 3 CCS03053D 67 70 0 3511 36 80 26 02 21 24 11 64 8 23 5 82 3#6 3 CCS03063D 42 59 0 4427 29 19 20 64 16 85 9 23 6 53 4 61 3#7 3 CCS03073D 26 81 0 5580 23 16 16 37 13 37 7 32 5 18 3 66 3#8 3 CCS03083D 16 86 0 7036 18 36 12 98 10 60 5 81 4 11 2 90 3#9 3 CCS03093D 10 59 0 8877 14 55 10 29 8 40 4 60 3 25 2 30 3#10 3 CCS03103D 6 67 1 1189 11 55 8 17 6 67 3 65 2 58 1 83 #2 AWG 7 CCS02STR3D 18 42 0 6746 19 19 13 57 11 08 6 07 4 29 3 03 #4 AWG 7 CCS04STR3D 7 20 1 0790 12 00 8 48 6 93 3 79 2 68 1 90 #2 AWG 1 CCS01023D 30 26 0 5210 24 60 17 40 14 20 7 78 5 50 3 89 #4 AWG 1 CCS01043D 11 97 0 8284 15 47 10 94 8 93 4 89 3 46 2 45 #6 AWG 1 CCS01063D 4 73 1 3172 9 73 6 88 5 62 3 08 2 18 1 54 #8 AWG 1 CCS01083D 1 87 2 0941 6 12 4 33 3 53 1 94 1 37 0 97 #9 AWG 1 CCS01093D 1 18 2 6421 4 85 3 43 2 80 1 53 1 08 0 77 #10 AWG 1 CCS01103D 0 74 3 3301 3 85 2 72 2 22 1 22 0 86 0 61 Wire Specifications
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
9 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 9 Copperclad Steel Wire—High Strength/Extra High Strength 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 The core carbon steel is bonded with a uniform layer of oxygen-free coppercladding to ensure that the copper will not flake, crack or peel when the wire is twisted, installed or buried 7-strand Copperclad Steel Wire Specifications and Ordering Information 30% CONDUCTIVITY—HIGH STRENGTH CONDUCTOR SIZE STRANDS AFL NO. OVERALL DIAMETER AREA MIN. BREAKING LOAD WEIGHT/LENGTH NOM. DC RESISTANCE AWG in. mm cmil (mm^2) lbf kgf lbs/kft kg/km Ω/kft Ω/kM 19#4 19 CCS19043H 1 022 25 95 793,000 401 8 65264 29603 2231 3 3320 5 0 0442 0 1451 19#5 19 CCS19053H 0 910 23 10 628,700 318 6 53893 24445 1768 8 2632 3 0 0558 0 1830 19#6 19 CCS19063H 0 810 20 57 498,600 252 6 44456 20165 1403 0 2087 9 0 0703 0 2307 19#7 19 CCS19073H 0 722 18 33 395,600 200 5 36629 16615 1113 2 1656 6 0 0886 0 2908 19#8 19 CCS19083H 0 643 16 32 313,700 159 0 30123 13663 882 7 1313 6 0 1118 0 3667 19#9 19 CCS19093H 0 572 14 53 248,700 126 0 24727 11216 699 6 1041 2 0 1410 0 4626 4/0 19 CCS4/03H 0 528 13 40 211,500 107 2 21030 9539 595 0 885 5 0 1658 0 5440 19#10 19 CCS19103H 0 510 12 94 197,300 100 0 20431 9267 555 1 826 1 0 1777 0 5831 7#4 7 CCS07043H 0 613 15 57 292,200 148 1 24045 10906 818 8 1218 5 0 1195 0 3922 7#5 7 CCS07053H 0 546 13 86 231,600 117 4 19855 9006 649 1 966 0 0 1508 0 4947 7#6 7 CCS07063H 0 486 12 34 183,700 93 1 16379 7429 514 9 766 2 0 1901 0 6237 7#7 7 CCS07073H 0 433 11 00 145,800 73 9 13495 6121 408 5 607 9 0 2396 0 7861 2/0 7 CCS2/03H 0 414 10 51 133,100 67 4 12324 5590 373 1 555 2 0 2624 0 8608 7#8 7 CCS07083H 0 386 9 79 115,600 58 6 11098 5034 323 9 482 1 0 3021 0 9913 1/0 7 CCS1/03H 0 368 9 35 105,600 53 5 10135 4597 295 8 440 2 0 3308 1 0855 7#9 7 CCS07093H 0 343 8 72 91,610 46 4 9110 4132 256 7 382 1 0 3812 1 2507 7#10 7 CCS07103H 0 306 7 76 72,690 36 8 7527 3414 203 7 303 1 0 4805 1 5764 3#4 3 CCS03043H 0 440 11 18 125,200 63 4 10877 4934 350 2 521 2 0 2784 0 9132 3#5 3 CCS03053H 0 392 9 96 99,260 50 3 8982 4074 277 6 413 2 0 3511 1 1520 3#6 3 CCS03063H 0 349 8 86 78,730 39 9 7409 3361 220 2 327 7 0 4427 1 4524 3#7 3 CCS03073H 0 311 7 90 62,470 31 7 6105 2769 174 7 260 0 0 5580 1 8306 3#8 3 CCS03083H 0 277 7 04 49,540 25 1 5020 2277 138 6 206 2 0 7036 2 3084 3#9 3 CCS03093H 0 247 6 27 39,260 19 9 4121 1869 109 8 163 4 0 8877 2 9126 3#10 3 CCS03103H 0 220 5 59 31,150 15 8 3405 1545 87 1 129 7 1 1189 3 6709 #2 AWG 7 CCS02STR3H 0 258 6 55 51,770 26 2 5416 2457 145 1 215 9 0 6746 2 2132 #4 AWG 7 CCS04STR3H 0 204 5 18 32,370 16 4 2691 1221 90 7 135 0 1 0790 3 5399 #2 AWG 1 CCS01023H 0 258 6 54 66,370 33 6 6069 2753 184 2 274 1 0 5210 1 7093 #4 AWG 1 CCS01043H 0 204 5 19 41,740 21 2 3817 1731 115 8 172 4 0 8284 2 7180 #6 AWG 1 CCS01063H 0 162 4 12 26,250 13 3 2600 1180 72 8 108 4 1 3172 4 3216 #8 AWG 1 CCS01083H 0 129 3 26 16,510 8 4 1762 799 45 8 68 2 2 0941 6 8704 #9 AWG 1 CCS01093H 0 114 2 91 13,090 6 6 1446 656 36 3 54 0 2 6421 8 6683 #10 AWG 1 CCS01103H 0 102 2 59 10,380 5 3 1195 542 28 8 42 9 3 3301 10 9254
10 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 10 Copperclad Steel Wire—High Strength (cont.) Specifications and Ordering Information 40% CONDUCTIVITY—HIGH STRENGTH CONDUCTOR SIZE STRANDS AFL NO. OVERALL DIAMETER AREA MIN. BREAKING LOAD WEIGHT/LENGTH NOM. DC RESISTANCE AWG in. mm cmil (mm^2) lbf kgf lbs/kft kg/km Ω/kft Ω/kM 19#4 19 CCS19044H 1 022 25 95 793,000 401 8 58738 26643 2251 7 3350 9 0 0331 0 1087 19#5 19 CCS19054H 0 910 23 10 628,700 318 6 48719 22099 1785 0 2656 3 0 0418 0 1371 19#6 19 CCS19064H 0 810 20 57 498,600 252 6 40353 18303 1415 8 2106 9 0 0527 0 1729 19#7 19 CCS19074H 0 722 18 33 395,600 200 5 33373 15138 1123 3 1671 7 0 0664 0 2179 19#8 19 CCS19084H 0 643 16 32 313,700 159 0 27541 12492 890 8 1325 6 0 0837 0 2747 19#9 19 CCS19094H 0 572 14 53 248,700 126 0 22681 10288 706 0 1050 7 0 1057 0 3466 4/0 19 CCS4/04H 0 528 13 40 211,500 107 2 19289 8749 600 4 893 6 0 1242 0 4076 19#10 19 CCS19104H 0 510 12 94 197,300 100 0 18753 8506 560 2 833 6 0 1332 0 4369 7#4 7 CCS07044H 0 613 15 57 292,200 148 1 21640 9816 826 3 1229 7 0 0896 0 2938 7#5 7 CCS07054H 0 546 13 86 231,600 117 4 17949 8142 655 0 974 8 0 1130 0 3707 7#6 7 CCS07064H 0 486 12 34 183,700 93 1 14867 6743 519 6 773 2 0 1424 0 4673 7#7 7 CCS07074H 0 433 11 00 145,800 73 9 12295 5577 412 2 613 5 0 1795 0 5890 2/0 7 CCS2/04H 0 414 10 51 133,100 67 4 11229 5093 376 5 560 2 0 1966 0 6450 7#8 7 CCS07084H 0 386 9 79 115,600 58 6 10147 4602 326 9 486 5 0 2264 0 7428 1/0 7 CCS1/04H 0 368 9 35 105,600 53 5 9266 4203 298 5 444 3 0 2479 0 8133 7#9 7 CCS07094H 0 343 8 72 91,610 46 4 8356 3790 259 1 385 6 0 2856 0 9371 7#10 7 CCS07104H 0 306 7 76 72,690 36 8 6909 3134 205 6 305 9 0 3600 1 1812 3#4 3 CCS03044H 0 440 11 18 125,200 63 4 9790 4440 353 4 526 0 0 2086 0 6843 3#5 3 CCS03054H 0 392 9 96 99,260 50 3 8120 3683 280 2 416 9 0 2631 0 8632 3#6 3 CCS03064H 0 349 8 86 78,730 39 9 6725 3051 222 2 330 7 0 3317 1 0883 3#7 3 CCS03074H 0 311 7 90 62,470 31 7 5562 2523 176 3 262 4 0 4181 1 3716 3#8 3 CCS03084H 0 277 7 04 49,540 25 1 4590 2082 139 8 208 1 0 5272 1 7297 3#9 3 CCS03094H 0 247 6 27 39,260 19 9 3780 1715 110 8 164 9 0 6652 2 1823 3#10 3 CCS03104H 0 220 5 59 31,150 15 8 3125 1418 87 9 130 8 0 8384 2 7506 #2 AWG 7 CCS02STR4H 0 258 6 55 51,770 26 2 4971 2255 146 4 217 9 0 5054 1 6583 #4 AWG 7 CCS04STR4H 0 204 5 18 32,370 16 4 2579 1170 91 5 136 2 0 8085 2 6524 #2 AWG 1 CCS01024H 0 258 6 54 66,370 33 6 5462 2477 185 8 276 6 0 3904 1 2808 #4 AWG 1 CCS01044H 0 204 5 19 41,740 21 2 3435 1558 116 9 173 9 0 6207 2 0366 #6 AWG 1 CCS01064H 0 162 4 12 26,250 13 3 2360 1071 73 5 109 4 0 9870 3 2382 #8 AWG 1 CCS01084H 0 129 3 26 16,510 8 4 1611 731 46 2 68 8 1 5691 5 1479 #9 AWG 1 CCS01094H 0 114 2 91 13,090 6 6 1326 602 36 6 54 5 1 9797 6 4951 #10 AWG 1 CCS01104H 0 102 2 59 10,380 5 3 1097 497 29 1 43 3 2 4952 8 1863
11 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 11 Copperclad Steel Wire—Extra High Strength Specifications and Ordering Information 30% CONDUCTIVITY—EXTRA HIGH STRENGTH CONDUCTOR SIZE STRANDS AFL NO. OVERALL DIAMETER AREA MIN. BREAKING LOAD WEIGHT/LENGTH NOM. DC RESISTANCE AWG in. mm cmil (mm^2) lbf kgf lbs/kft kg/km Ω/kft Ω/kM 19#4 19 CCS19043E 1 022 25 95 793,000 401 8 77501 35154 2231 3 3320 5 0 0442 0 1451 19#5 19 CCS19053E 0 910 23 10 628,700 318 6 64887 29432 1768 8 2632 3 0 0558 0 1830 19#6 19 CCS19063E 0 810 20 57 498,600 252 6 53860 24431 1403 0 2087 9 0 0703 0 2307 19#7 19 CCS19073E 0 722 18 33 395,600 200 5 44497 20184 1113 2 1656 6 0 0886 0 2908 19#8 19 CCS19083E 0 643 16 32 313,700 159 0 36577 16591 882 7 1313 6 0 1118 0 3667 19#9 19 CCS19093E 0 572 14 53 248,700 126 0 29690 13467 699 6 1041 2 0 1410 0 4626 4/0 19 CCS4/03E 0 528 13 40 211,500 107 2 25250 11453 595 0 885 5 0 1658 0 5440 19#10 19 CCS19103E 0 510 12 94 197,300 100 0 24219 10986 555 1 826 1 0 1777 0 5831 7#4 7 CCS07043E 0 613 15 57 292,200 148 1 28553 12951 818 8 1218 5 0 1195 0 3922 7#5 7 CCS07053E 0 546 13 86 231,600 117 4 23906 10843 649 1 966 0 0 1508 0 4947 7#6 7 CCS07063E 0 486 12 34 183,700 93 1 19843 9001 514 9 766 2 0 1901 0 6237 7#7 7 CCS07073E 0 433 11 00 145,800 73 9 16394 7436 408 5 607 9 0 2396 0 7861 2/0 7 CCS2/03E 0 414 10 51 133,100 67 4 14972 6791 373 1 555 2 0 2624 0 8608 7#8 7 CCS07083E 0 386 9 79 115,600 58 6 13476 6113 323 9 482 1 0 3021 0 9913 1/0 7 CCS1/03E 0 368 9 35 105,600 53 5 12307 5582 295 8 440 2 0 3308 1 0855 7#9 7 CCS07093E 0 343 8 72 91,610 46 4 10938 4962 256 7 382 1 0 3812 1 2507 7#10 7 CCS07103E 0 306 7 76 72,690 36 8 8923 4047 203 7 303 1 0 4805 1 5764 3#4 3 CCS03043E 0 440 11 18 125,200 63 4 12917 5859 350 2 521 2 0 2784 0 9132 3#5 3 CCS03053E 0 392 9 96 99,260 50 3 10815 4905 277 6 413 2 0 3511 1 1520 3#6 3 CCS03063E 0 349 8 86 78,730 39 9 8977 4072 220 2 327 7 0 4427 1 4524 3#7 3 CCS03073E 0 311 7 90 62,470 31 7 7416 3364 174 7 260 0 0 5580 1 8306 3#8 3 CCS03083E 0 277 7 04 49,540 25 1 6096 2765 138 6 206 2 0 7036 2 3084 3#9 3 CCS03093E 0 247 6 27 39,260 19 9 4948 2245 109 8 163 4 0 8877 2 9126 3#10 3 CCS03103E 0 220 5 59 31,150 15 8 4037 1831 87 1 129 7 1 1189 3 6709 #2 AWG 7 CCS02STR3E 0 258 6 55 51,770 26 2 6420 2912 145 1 215 9 0 6746 2 2132 #4 AWG 7 CCS04STR3E 0 204 5 18 32,370 16 4 4014 1821 90 7 135 0 1 0790 3 5399 #2 AWG 1 CCS01023E 0 258 6 54 66,370 33 6 7207 3269 184 2 274 1 0 5210 1 7093 #4 AWG 1 CCS01043E 0 204 5 19 41,740 21 2 4532 2056 115 8 172 4 0 8284 2 7180 #6 AWG 1 CCS01063E 0 162 4 12 26,250 13 3 3151 1429 72 8 108 4 1 3172 4 3216 #8 AWG 1 CCS01083E 0 129 3 26 16,510 8 4 2139 970 45 8 68 2 2 0941 6 8704 #9 AWG 1 CCS01093E 0 114 2 91 13,090 6 6 1736 788 36 3 54 0 2 6421 8 6683 #10 AWG 1 CCS01103E 0 102 2 59 10,380 5 3 1416 642 28 8 42 9 3 3301 10 9254
12 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 12 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 CCC conductors feature a higher ampacity for the same wire size as standard Copperclad Steel Wire Ordering Information Contact AFL for detailed specifications not shown Type K—4 Copperclad Steel Wires and 3 Copper Wires Ordering Information Contact AFL for detailed specifications 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 7-strand Copperclad Steel Wire For additional information on Copperclad Composite Conductors, contact AFL.
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
OnyxCCS offers the same benefits as standard Copperclad Steel (CCS) while protecting against copper theft.
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