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.
For more information, please visit Ziyu.
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.
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.
If you want to learn more, please visit our website Copper Clad Steel.
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.
Copper clad cables are available as either copper clad aluminium (CCA) or copper clad steel (CCS). It means that the conductor is made either of aluminum or steel, with a coating of copper wrapped around it. So, these are not 100% copper cables.
Advantages of Copper Clad Cables: One significant advantage of copper clad cables over solid copper cables is their lightweight nature. Replacing copper conductors with aluminum or steel reduces the cable’s weight, making them ideal for lightweight applications. Additionally, copper clad cables are more cost-effective, as the inner copper is replaced with less expensive aluminum or steel.
Disadvantages: Due to the copper coating, these cables are generally better suited for short lengths or distances and transmitting smaller amounts of data. Over longer distances, signal loss will occur and require the signal to be retransmitted multiple times to reach its endpoint. While both perform similarly over short distances, steel is typically more durable, making it especially useful for outdoor applications.
Solid copper cables are composed entirely of copper, with both the conductor and coating made of copper. It is also the most preferred cable over copper clad aluminum. Solid copper cables are also the industry standard for all Ethernet wiring.
Advantages of Solid Copper Cables – The primary benefits of solid copper ethernet cables are their durability and flexibility. These cables can bend easily, making them simple to shape and form. Additionally, a copper conductor offers superior performance. Pure copper cables are ideal for transmitting signals over long distances with no signal integrity issues, excelling in transmitting high levels of data with minimal current needed to push the signals to their endpoint.
Disadvantages – The main drawback of solid copper ethernet cables is their heavy weight. However, their excellent performance and durability often outweigh this downside.
Cable Assemblies in Chennai manufactures high-quality cables and offers various other services.
When deciding between copper clad and solid copper cables, several factors should be considered: cost, distance, weight, durability, and data load.
Cost: A pure copper cable tends to be more expensive than the more affordable copper clad aluminum cable or copper clad steel cable.
Distance: Copper clad cables are suitable for short-distance signal transmission without any performance issues. For longer distances, pure copper cables are preferred.
Weight: Copper clad cables, particularly those made of aluminum, are lightweight.
Durability: CCS cables offer greater durability, while solid or pure copper cables are also durable and perform well in high heat temperature conditions. CCA is less robust.
Data: Solid copper ethernet cables are ideal for transmitting high volumes of data. For smaller data loads, copper clad cables are usually sufficient, even for longer cables. It’s essential to consider the amount of data being transmitted relative to the cable length required.
CCS is commonly used in coaxial cables for cable television, internet, and other broadband applications. The copper layer provides the necessary conductivity for signal transmission, while the steel core offers strength and durability, especially for aerial installations.
Copper-clad aluminum (CCA) cables are used in some ethernet and applications. These cables are lighter and less expensive than solid copper, making them an ideal choice for certain installations.
In the aerospace and automotive industries, reducing weight is crucial. Copper clad aluminum cables are used in these sectors to achieve weight savings without compromising on conductivity and performance. These cables are found in wiring harnesses, battery cables, and other critical electrical systems.
Copper-clad aluminum wires are used in electrical distribution for buildings. They offer good conductivity and are less expensive than solid copper wires, making them suitable for residential and commercial wiring where cost savings are important.
CCS is often used in grounding systems due to its strength and corrosion resistance. It provides reliable grounding for electrical systems and lightning protection.
CCS is used in antenna cables for radio, television, and communication systems. The steel core provides strength to support the antenna structure, while the copper layer ensures efficient signal transmission.
RF transmission lines often use copper-clad cables due to their combination of strength and conductivity. These cables are essential in broadcasting and communication infrastructure.
In commercial and industrial buildings, pure copper cables are preferred for permanent installations in walls, ceilings, and floors, providing stable and reliable connections.
In the automotive industry, pure copper cables are used in applications where flexibility is not a primary requirement. These include battery cables and other connections that benefit from the cable’s durability and conductivity.
Pure copper cables are used in solar power installations to connect photovoltaic panels, inverters, and other components. Their high conductivity ensures efficient energy transfer from the panels to the power grid or storage systems.
Choosing between copper-clad cables and solid or pure copper cables depends on the particular requirements of the application. Pure copper cables are ideal for scenarios demanding the highest conductivity, durability, and reliability despite their higher costs and weight.
Copper-clad cables offer a more economical solution with adequate performance, particularly beneficial in applications where weight and flexibility are critical factors. Understanding these differences ensures the right cable type is selected for optimal performance and cost-effectiveness in any given application.
Cable assemblies and electrical contract manufacturing companies in Chennai offer high-quality customized services based on the client’s requirements.
Consider the amount of data you need to transmit and the length of the cable required. Solid copper is best for high data volumes and longer distances, while copper clad can handle smaller data loads efficiently.
Solid Copper Cables: These cables are easier to terminate securely due to their rigidity and consistent conductivity. However, they need careful handling to avoid damage.
Copper Clad Cables: Specific techniques are required to ensure proper termination and avoid issues like galvanic corrosion, especially where the copper coating is thinner. Proper tools and connectors should be used for these cables.
Copper clad cables can be used for longer distances if the data load is relatively small. For high data volumes over long distances, solid copper cables are recommended.
Steel copper clad cables offer excellent durability, making them suitable for demanding conditions. Solid copper cables are also highly durable and perform well in demanding environments. In contrast, copper clad aluminum is less robust and not ideal for harsh conditions.
The company is the world’s best Copper Clad Steel Wire supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.