CCS — Copper Clad Steel Conductor

Application

Copper Clad Steel (CCS) wire combines the mechanical strength of a steel core with the electrical conductivity and corrosion resistance of a copper outer layer. It is widely used in grounding, lightning protection, and electrical bonding systems where both mechanical strength and electrical performance are important.

CCS wire is suitable for a wide range of applications, including:

• Grounding and Lightning Protection: Protective grounding, electrical earthing, electrostatic grounding, and lightning protection systems.
• Power and Petrochemical Industries: Grounding conductors for substations, power facilities, industrial plants, and petrochemical installations.
• Railway and Transportation Infrastructure: Grounding and bonding systems for electrified railways, metros, railway networks, and airports.
• Telecommunications and Networking: Grounding conductors for communication infrastructure and selected high-frequency coaxial cable applications.
• Coaxial Cables: Copper-clad steel wire can be used as an inner conductor in cable designs requiring a combination of mechanical strength and electrical performance.

CCS products are available in different conductivity grades, including 30% and 40% IACS, depending on the product design and copper cladding specifications. The appropriate grade should be selected according to the electrical requirements, mechanical properties, and intended application.

Applicable Standards

CCS wire and stranded conductors can be manufactured according to applicable international standards and agreed customer specifications.

• ASTM B228: Concentric-Lay-Stranded Copper-Clad Steel Conductors.
• ASTM B227: Hard-Drawn Copper-Clad Steel Wire, where applicable to the specified product.
• IEC Standards: Applicable standards to be confirmed according to the product construction, application, and required performance.

The applicable standard and its edition should be confirmed during the technical review and quotation process.

Construction

Copper Clad Steel (CCS) wire consists of a steel core, typically made from low-carbon steel, with a metallurgically bonded copper layer on the outer surface. This composite structure combines the high tensile strength of steel with the electrical conductivity of copper.

CCS products can be supplied as single wires or concentrically stranded conductors, depending on the application and customer requirements. The copper layer thickness and conductivity grade can vary according to the specified design.

Key construction features include:

• Steel Core: Provides mechanical strength and structural support.
• Copper Cladding: Provides the conductive outer layer and contributes to corrosion resistance.
• Stranded Construction: Available in specified wire counts and configurations for grounding and conductor applications.
• Conductivity Options: 30% and 40% IACS grades, subject to product specifications.

Technical Specifications

The following parameters should be confirmed according to the required CCS wire or stranded conductor design:

• Single-wire diameter and dimensional tolerance
• Number of wires and stranding configuration
• Finished strand diameter
• Copper cladding thickness or copper content ratio
• Electrical conductivity and test method
• Electrical resistivity and reference temperature
• Tensile strength and, where applicable, breaking load
• Copper layer bonding and adhesion performance
• Coil or reel dimensions, packaging, and delivery length

Product Benefits

• Combined Electrical and Mechanical Performance: Integrates copper conductivity with the mechanical strength of a steel core.
• Versatile Applications: Suitable for selected grounding, lightning protection, railway, industrial, and communication systems.
• Flexible Product Configuration: Conductivity grades, wire diameters, and stranding constructions can be specified to meet project requirements.
• Application-Specific Supply: Technical specifications can be reviewed against the relevant standard and the customer’s project requirements.

For technical selection and quotation, please provide the required conductivity grade, wire diameter, stranding construction, copper cladding specifications, applicable standard, and order quantity.

Parameters 

IEC

Size	Strands*single path	Diameter	Conductivity
mm2		mm	%
10	7*1.4	4.2	18%—70%
16	7*1.7	5.1	18%—70%
25	7*2.14	6.42	18%—70%
35	7*2.52	7356
50	7*3.00	9	18%—70%
70	19*1.44	10.7	18%—70%
95	19*2.52	12.6	18%—70%
120	19*2.80	14	18%—70%
150	19*3.15	15.75	18%—70%
185	37*2.52	17.64	18%—70%
240	37*2.85	19.95	18%—70%
300	37*3.15	21.7	18%—70%

Nominal Sectional Area mm2	structure Stock/diameter mm	Area mm2	Breaking load kg			D.C．Resistance Ω/km		Line quality Kg/km
			40HS	30HS	30EHS	40%	30%	30%	40%
320	19/4.62	318.71	22788	25206	30350	0.1399	0.1865	2634.0	2660.8
250	19/4.12	252.71	18849	20788	25188	0.1764	0.2352	2087.9	2110.2
200	19/3.67	200.45	15599	17118	20797	0.2225	0.2966	1656.3	1674.2
160	19/3.26	158.97	12873	14079	17096	0.2805	0.3740	1313.6	1327.2
120	19/2.91	126.06	10609	11567	13884	0.3537	0.4715	1041.7	1052.6
150	7/5.19	148.06	10120	11240	13349	0.3000	0.4000	1218.7	1231.5
120	7/4.62	117.42	8396	9285	11181	0.3783	0.5043	966.41	976.53
90	7/4.12	93.097	6954	7661	9280	0.4771	0.6359	766.25	774.29
70	7/3.67	73.871	5747	6309	7661	0.6014	0.8019	608.06	614.46
60	7/3.26	58.561	4745	5189	6300	0.7586	1.0109	482.02	487.07
50	7/2.91	46.439	3908	4261	5116	0.9564	1.2750	382.16	386.18
35	7/2.59	36.826	3230	3519	4171	1.2061	1.6077	303.14	306.26
50	3/4.62	50.322	3798	4201	5380	0.8809	1.1743	413.41	417.73
40	3/4.12	39.903	3145	3465	4424	1.1106	1.4807	327.84	331.26
30	3/3.67	31.645	2600	2854	3593	1.4007	1.8672	259.98	262.66
25	3/3.26	25.097	2145	2347	2849	1.7662	2.3544	206.11	208.34
20	3/2.91	19.903	1768	1928	2326	2.2271	2.9690	163.55	165.19
15	3/2.59	15.781	1461	1592	1887	2.8082	3.7436	129.62	130.99
10	3/2.05	9.929	1014			4.4654		81.55	82.414

ASTM-B228

Size Designation	Conductor Area		No.of Wires	Diameter mm		Min.Rated Breaking Strength kN		Weight kg/km	Max.D.C. Resistance at 20℃ Ω/km
AWG	mm²	in²		Wire	Cond.	Grade 40 HS	Grade 40 DSA	Grade 40
19 No.5	318.71	0.4940	19	4.620	23.11	216.66	76.68	2660.8	0.14423
19 No.6	252.71	0.3917	19	4.115	20.57	179.45	60.81	2110.2	0.18183
19 No.7	200.45	0.3107	19	3.665	18.31	148.29	48.23	1674.2	0.22937
19 No. 8	158.97	0.2464	19	3.264	16.31	122.46	38.27	1327.4	0.28896
19 No. 9	126.06	0.1954	19	2.906	14.53	100.86	30.33	1052.6	0.36452
7 No. 4	148.06	0.2295	7	5.189	15.57	96.15	35.61	1231.5	0.30930
7 No. 5	117.42	0.1820	7	4.620	13.87	79.84	28.25	976.5	0.38978
7 No. 6	93.10	0.1443	7	4.115	12.34	66.10	22.41	774.3	0.4915
7 No.7	73.87	0.1145	7	3.665	11.00	54.63	17.76	614.5	0.6201
7 No. 8	58.56	0.09077	7	3.264	9.78	45.12	14.10	487.1	0.7812
7 No. 9	46.44	0.07198	7	2.906	8.71	37.16	11.18	386.2	0.9859
7 No. 10	36.83	0.05708	7	2.588	7.77	30.73	8.87	306.3	1.2422
3 No. 5	50.32	0.07800	3	4.620	9.96	36.10	12.78	417.7	0.9082
3 No. 6	39.90	0.06185	3	4.115	8.86	29.91	10.14	331.3	1.1447
3 No. 7	31.65	0.04905	3	3.665	7.90	24.71	8.04	262.7	1.4440
3 N0. 8	25.10	0.03890	3	3.264	7.04	20.41	6.38	208.3	1.8193
3 No. 9	19.90	0.03085	3	2.906	6.27	16.81	5.05	165.2	2.2957
3 No. 10	15.78	0.02446	3	2.588	5.59	13.90	4.01	131.0	2.8929
3 No. 12	9.93	0.01539	3	2.052	4.42	7.32	2.55	82.4	4.5573

Size Designation	Conductor Area		No.of wires	Diameter mm		Min.Rated Breaking Strength  kN			Weight kg/km	Max. Resistance at 20℃ Ω/km
AWG	mm²	in²		Wire	Cond.	Grade 30HS	Grade 30 EHS	Grade 30 DSA	Grade 30
19 No.5	318.71	0.4940	19	4.620	23.11	239.64	288.54	86.28	2634.0	0.19227
19 No.6	252.71	0.3917	19	4.115	20.57	197.68	239.51	68.41	2087.9	0.24240
19 No.7	200.45	0.3107	19	3.665	18.31	162.74	197.72	54.23	1656.3	0.30576
19 No. 8	158.97	0.2464	19	3.264	16.31	133.98	162.65	43.06	1313.6	0.3852
19 No. 9	126.06	0.1954	19	2.906	14.53	109.93	132.02	34.12	1041.7	0.4862
7 No. 4	148.06	0.2295	7	5.189	15.57	106.86	126.87	40.07	1218.7	0.4124
7 No. 5	117.42	0.1820	7	4.620	13.87	88.28	106.28	31.78	966.4	0.5197
7 No. 6	93.10	0.1443	7	4.115	12.34	72.86	88.24	25.21	766.3	0.6552
7 No.7	73.87	0.1145	7	3.665	11.00	59.97	72.86	19.99	608.1	0.8268
7 No. 8	58.56	0.09077	7	3.264	9.78	49.34	59.92	15.86	482.0	1.0414
7 No. 9	46.44	0.07198	7	2.906	8.71	40.51	48.63	12.57	382.2	1.3144
7 No. 10	36.83	0.05708	7	2.588	7.77	33.48	39.69	9.97	303.1	1.6559
3 No. 5	50.32	0.07800	3	4.620	9.96	39.94	48.10	14.38	413.4	1.2104
3 No. 6	39.90	0.06185	3	4.115	8.86	32.95	39.92	11.41	327.8	1.5260
3 No. 7	31.65	0.04905	3	3.665	7.90	27.12	32.95	9.04	260.0	1.9250
3 N0. 8	25.10	0.03890	3	3.264	7.04	22.33	27.11	7.17	206.1	2.4253
3 No. 9	19.90	0.03085	3	2.906	6.27	18.32	22.00	5.69	163.5	3.0605
3 No. 10	15.78	0.02446	3	2.588	5.59	15.14	17.95	4.51	129.6	3.855
3 No. 12	9.93	0.01539	3	2.052	4.42	7.64	11.40	2.87	81.6	6.073

30% CCS

CONDUCTOR SIZE	STRANDS	STRAND DIAMETER		OVERALL DIAMETER		AREA		FAUI CURRENT	WEIGHT/LENGTH		WIRE RESISTANCE		MIN.BREAK LOAD
AWG		IN.	MM	lN.	MM	CMIL	(MM^2)	AMPSAT 0.5 SEC.	LBS/KFT	KG/KM	Q/KFT	Q/KM	LBF	KGF
19#4	19	0.2043	5.19	1.022	25.95	793,00o	401.8	92.96	2346.4	3491.8	0.0451	0.1479	24474	11101
19#5	19	0.1819	4.62	0.91	23.1	628,700	318.6	73.7	1860.1	2768.1	0.0569	0.1866	19402	8800
19#6	19	0.162	4.11	0.81	20.57	498,600	252.6	58.45	1475.3	2195.5	0.0717	0.2352	15389	6980
19#7	19	0.1443	3.67	0.722	18.33	395,600	200.5	46.38	1170.6	1742	0.0904	0.2965	12210	5538
19#8	19	0.1285	3.26	0.643	16.32	313,700	159	36.78	928.3	1381.4	0.114	0.3739	9682	4392
19#9	19	0.1144	2.91	0.572	14.53	248,700	126	29.15	735.7	1094.9	0.1438	0.4717	7674	3481
4/0	19	0.1055	2.68	0.528	13.4	211,500	107.2	24.79	625.7	931.1	0.1691	0.5547	6526	2960
19#10	19	0.1019	2.59	0.51	12.94	197,300	100	23.13	583.7	868.7	0.1812	0.5946	6089	2762
7#4	7	0.2043	5.19	0.613	15.57	292,200	148.1	34.25	861	1281.4	0.1219	0.3999	9017	4090
7#5	1	0.1819	4.62	0.546	13.86	231,600	117.4	27.15	682.6	1015.8	0.1538	0.5045	7148	3242
7#6	1	0.162	4.11	0.486	12.34	183,700	93.1	21.54	541.4	805.7	0.1939	0.636	5670	2572
7#7	1	0.1443	3.67	0.433	11	145,800	73.9	17.09	429.6	639.3	0.2443	0.8016	4498	2040
2/0	7	0.1379	3.5	0.414	10.51	133,100	67.4	15.6	392.3	583.8	0.2675	0.8777	4108	1863
7#8	1	0.1285	3.26	0.386	9.79	115,600	58.6	13.55	340.6	506.9	0.3081	1.0108	3567	1618
1/0	7	0.1228	3.12	0.368	9.35	105,600	53.5	12.37	311.1	463	0.3374	1.1069	3258	1478
7#9	7	0.1144	2.91	0.343	8.72	91,610	46.4	10.74	270	401.8	0.3887	1.2754	2827	1282
7#10	7	0.1019	2.59	0.306	7.76	72,690	36.8	8.52	214.2	318.8	0.490o	1.6075	2243	1017
3#4	3	0.2043	5.19	0.44	11.18	125,200	63.4	14.68	368.3	548.1	0.2838	0.9313	4079	1850
3#5	3	0.1819	4.62	0.392	9.96	99,260	50.3	11.64	292	434.5	0.3581	1.1747	3234	1467
3#6	3	0.162	4.11	0.349	8.86	78,730	39.9	9.23	231.6	344.6	0.4514	1.4811	2565	1163
3#7	3	0.1443	3.67	0.311	7.9	62,470	31.7	7.32	183.7	273.4	0.569	1.8667	2035	923
3#8	3	0.1285	3.26	0.277	7.04	49,540	25.1	5.81	145.7	216.8	0.7175	2.354	1614	732
3#9	3	0.1144	2.91	0.247	6.27	39,260	19.9	4.6	115.5	171.9	0.9053	2.97	1279	580
3#10	3	0.1019	2.59	0.22	5.59	31,150	15.8	3.65	91.6	136.3	1.141	3.7433	1015	460
#2AWG	7	0.086	2.18	0.258	6.55	51,770	26.2	6.07	152.6	227.1	0.6879	2.2568	1614	732
#4AWG	1	0.068	1.73	0.204	5.18	32,370	16.4	3.79	95.4	142	1.1002	3.6097	1009	458
#2AWG	1	0.2576	6.54	0.258	6.54	66,370	33.6	7.78	193.7	288.2	0.5313	1.743	2276	1032
#4AWG	1	0.2043	5.19	0.204	5.19	41,740	21.2	4.89	121.8	181.2	0.8448	2.7716	1431	649
#6AWG	1	0.162	4.12	0.162	4.12	26,250	13.3	3.08	76.6	114	1.3432	4.4069	9o0	408
#8AwG	1	0.1285	3.26	0.129	3.26	16,510	8.4	1.94	48.2	71.7	2.1354	7.0059	566	257
#9AwG	1	0.1144	2.91	0.114	2.91	13,090	6.6	1.53	38.2	56.8	2.6942	8.8393	449	204
#10AwG	1	0.1019	2.59	0.102	2.59	10.38	5.3	1.22	30.3	45.1	3.3957	11.1409	356	162

40% CCS

CONDUCTOR SIZE	STRANDS	STRAND DIAMETER		OVERALL DIAMETER		AREA		FAUIT CURRENT	WEIGHT/LENGTH		WIRE RESISTANCE		MIN.BREAK LOAD
AWG		IN.	MM	IN.	MM	CMIL	(MM^2)	AMPSAT 0.5 SEC.	LBS/KFT	KG/KM	/KFT	Q/KM	LBF	KGF
19#4	19	0.2043	5.19	1.022	25.95	793,00o	401.8	107.28	2251.7	3350.9	0.0338	0.111	21755	9868
19#5	19	0.1819	4.62	0.91	23.1	628,700	318.6	85.05	1785	2656.3	0.0427	0.14	17246	7823
19#6	19	0.162	4.11	0.81	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	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	33.64	706	1050.7	0.1079	0.3539	6821	3094
4/0	19	0.1055	2.68	0.528	13.4	211,500	107.2	28.61	600.4	893.6	0.1268	0.4161	5801	2631
19#10	19	0.1019	2.59	0.51	12.94	197,300	100	26.69	560.2	833.6	0.1359	0.446	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	0.3	8015	3635
7#5	7	0.1819	4.62	0.546	13.86	231,600	117.4	31.33	655	974.8	0.1153	0.3784	6354	2882
7#6	7	0.162	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	145,800	73.9	19.72	412.2	613.5	0.1833	0.6013	3998	1814
2/0	7	0.1379	3.5	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	105,60o	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	0.44	11.18	125,200	63.4	16.94	353.4	526	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	0.162	4.11	0.349	8.86	78,730	39.9	10.65	222.2	330.7	0.3386	1.111	2280	1034
3#7	3	0.1443	3.67	0.311	7.9	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	6.7	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	0.22	5.59	31,150	15.8	4.21	87.9	130.8	0.8559	2.808	902	409
#2AWG	7	0.086	2.18	0.258	6.55	51,770	26.2	7	146.4	217.9	0.516	1.6929	1435	651
#4AwG	7	0.068	1.73	0.204	5.18	32,370	16.4	4.38	91.5	136.2	0.8253	2.7078	897	407
#2AwG	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
#4AWG	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
#6AWG	1	0.162	4.12	0.162	4.12	26,250	13.3	3.55	73.5	109.4	1.0076	3.3058	800	363
#8AWG	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
#9AWG	1	0.1144	2.91	0.114	2.91	13,090	6.6	1.77	36.6	54.5	2.021	6.6307	399	181
#10AwG	1	0.1019	2.59	0.102	2.59	10,380	5.3	1.4	29.1	43.3	2.5473	8.3572	316	144