Copper Clad Grounding Solutions

Guide for Utility Applications

The Better Alternative to Solid Copper
annealed ground strand
pole ground wire
lightning protection
surge arrestor ground leads

substation grounding
grounding mats/reflectors
structure ground leads

Copper Clad Steel (CCS) Grounding Solutions

New Challenges
The volatility of copper pricing has created a major concern for the
utility industry. As a result, copper theft is on the rise and utilities are
implementing alternatives to reduce costs and theft.
Consider the impact of copper theft on utilities in one year alone*:
95% of utilities affected
456,000 minutes of service outages
Over $60M/year in cost to the utilities to address the problem
Safety and liability concerns due to lost grounds

Alternative to Solid Copper

IEEE Std 80-2000 acknowledged the problem more than 10 years ago. Copperclad steel is usually used for underground rods and occasionally for grounding grids,
especially where theft is a problem...
CommScopes copper clad steel is more economical both short term and long term
and offers the following features:
Excellent current carrying capacity
Lower weight per liner foot
Durability and flexibility
Low impedance path
Excellent fusing current capabilities
Significantly greater fatigue resistance than solid copper

Theft Deterrent

Copper is typically used in electrical utility substations to provide equipment, utility personnel and residential protection when faults
occur on the system. Interruption to substation operation can cause power outages to thousands of homes and businesses and
cause serious injury or death to maintenance employees. If you are losing money and time due to copper theft, our products
can help protect you against future occurrences.

Protect Your Investment

Reduce the added costs associated with reinstallation of ground wire
Improve the safety by utilizing proper grounding method

CCS Reduces Theft Risk

Harder to cut
Zero scrap value
* Source: Copper Theft Baseline Survey of Utilities in the United States
Electrical Safety Foundation International (FSFI survey); January 2009
For more information, visit commscope.com

CCS Physically Stronger than Copper

Breaking Load Comparison of Selected Gauges

Bend Test Comparison of Selected Gauges

Pounds of force to
bend 90 degrees

Pounds

1500

4.5

1400

4.0

1300

3.5

1200

3.0

1100

2.5

1000

2.0

900

1.5

800

1.0

700

0.5

600

40% CCS

Annealed Copper

40% CCS

0.162 Diameter

Annealed Copper

40% CCS

Annealed Copper

40% CCS

Annealed Copper

0.204 Diameter

0.162 Diameter

0.204 Diameter

Proper Product Sizing for Copper Clad Steel Grounding Applications

Copper Clad Steel 40% DSA

Copper Product

Size

Diameter

Circular Mils

Size

Diameter

Circular Mils

Solid No. 6 AWG

0.162

26,250

Solid No. 6 AWG*

0.162

26,250

Solid No. 4 AWG

0.204

41,738

Solid No. 4 AWG*

0.204

41,738

No. 2 AWG Strand

0.292

66,407

7 No. 9 AWG

0.343

91,651

Solid No. 1 AWG

0.289

83,683

7 No. 8 AWG

0.385

115,568

1/0 Strand

0.368

105,521

7 No. 7 AWG

0.433

145,726

2/0 Strand

0.414

133,057

7 No. 6 AWG

0.486

183,754

3/0 Strand

0.464

167,779

7 No. 5 AWG

0.546

231,706

4/0 Strand

0.552

211,563

19 No. 9 AWG

0.572

248,767

250 MCM

0.574

250,000

19 No. 8 AWG

0.642

313,684

300 MCM

0.629

300,000

19 No. 7 AWG

0.721

395,542

400 MCM

0.726

400,000

19 No. 6 AWG

0.810

498,762

500 MCM

0.813

500,000

19 No. 5 AWG

0.910

628,917

Notes:

The copper clad wire shown in this table are not of

equal ampacity to copper.
According to RUS certification, #6 copper clad steel
is an acceptable replacement for #6 solid copper,
unless neutral is greater than 1/0 ACSR. In this
case, a larger size, such as #4 copper clad steel
should be used.
For information on 30% CCS product, or for additional sizes not listed in this table, please contact us.
*Pole ground use only

Quality Products
Available in a variety of gauges, engineered as single or stranded wire, C
 ommScope
CCS ground wire is ideal for all your grounding applications. Copper clad steel is available
in 30% and 40% DSA (dead-soft annealed) and meets ASTM B-193, ASTM B-452, ASTM
B-227, ASTM B-228 and ASTM B-910 requirements and is RUS (Rural Utilities Service) listed.
Allbimetallic products are processed at the companys ISO9001 and ISO14001 certified
facility located in Statesville, North Carolina.
For more information, visit commscope.com

DSA 40% Copper Clad Steel Physical and Electrical Characteristics**

Stranded Conductor
Minimum Breaking Load
Weight
Cross Section
Nominal Diameter
Individual
@ 40 ksi
End
Conductor
Count
AWG

Inches mm lbs kN lbs/ kg/
circular mils
mm2

1000 ft
km

Max.
DC Resistance

Nom. Fusing
Current
@.5 Sec

/1000 ft

Amps

Solid Wire-Pole Ground

1

0.2576

6.543

2,085

9.27

186

277

66,365

33.63 0.39865 11,026

0.2043

5.189

1,311

5.83

117

174

41,739

21.15 0.63386 6,935

0.1620

4.115

825

3.67

74

110

26,251

13.30 1.00785 4,361

7-Wire Strand
7

0.5458

13.864

6,551

29.14

656

976 231,706 117.41 0.11532 38,496

0.4861

12.346

5,196

23.11

520

774 183,755 93.11 0.14542 30,529

0.4329

10.994

4,120

18.33

413

614 145,726 73.84 0.18337 24,211

0.3855

9.791

3,268

14.54

327

487 115,568 58.56 0.23122 19,201

0.3433

8.719

2,591

11.53

260

386

91,651

46.44 0.29155 15,227

10

0.3057

7.765

2,055

9.14

206

306

72,684

36.83 0.36764 12,076

19

0.9097

23.106

17,782

79.10

1,788 2,661 628,917 318.68 0.04266 104,490

19

0.8101

20.577

14,102

62.73

1,418 2,110 498,762 252.73 0.05379 82,866

19

0.7214

18.324

11,184

49.75

1,125 1,673 395,543 200.43 0.06782 65,716

19

0.6425

16.318

8,869

39.45

892

1,327 313,685 158.95 0.08552 52,116

19

0.5721

14.532

7,034

31.29

707

1,052 248,767 126.05 0.10784 41,331

19-Wire Strand

7-Strand Pole Ground Equivalent Products

Overall AWG
Equivalent

7-Wire Strand - Pole Ground - Fusing Current Equivalent (FC)

2 FC Equivalent 0.2921

7.420

2,085

9.27

188

280

66,367

33.63 0.40263 11,026

4 FC Equivalent 0.2317

5.884

1,311

5.83

118

176

41,739

21.15 0.64020 6,935

6 FC Equivalent 0.1837

4.666

825

3.67

74

111

26,251

13.30 1.01792 4,361

7-Wire Strand - Pole Ground - Diameter Equivalent

7

2 Dia. Equivalent 0.2576

6.528

1,614

7.18

146

217

51,371

26.03 0.51774

8,575

4 Dia. Equivalent 0.2043

5.189

1,020

4.54

92

137

32,463

16.45 0.82312

5,394

6 Dia. Equivalent 0.1620

4.115

641

2.85

58

86

20,412

10.34 1.30909

3,391

*Fusing Current values are based on 30 cycles at 0.5 second durations

Other sizes and additional specifications available upon request.
**CommScope fusing current data and formulas are derived by testing Copper Clad Steel products to failure. The values listed in our tables may exceed those calculated by IEEE Standard 80. Wire sizes should
be selected based on specific application design requirements for expected fusing current and required safety factor. Local codes and standards should always be verified before making product choice.

Available Packaging

Approvals & Certifications

Reels

Stranded Products: 1000, 2500, 5000 ft. reels

Other lengths are available upon request

Coils

50 or 100 lb. coils of solid ground wire

The United States Department of Agriculture (USDA)

Rural Utilities Service (RUS) has awarded CommScope
technical acceptance of copper-clad steel pole ground
wire and steel conductor for substation grounding, as
established by the Technical Standards Committee A.

Spools 25 lb. spools of solid ground wire

C E R T I F I E D

Visit our www.commscope.com or contact your local CommScope representative for more information.
2011 CommScope, Inc. All rights reserved.
All trademarks identified by or are registered trademarks or trademarks, respectively, of CommScope, Inc.
This document is for planning purposes only and is not intended to modify or supplement any specifications or warranties relating to CommScope products or services.
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