What is copper clad steel used for?

When discussing the components in an electrical grounding system, we often hear the terms “copper-clad steel” and “copper-bonded steel” used interchangeably.Though it may seem inconsequential, each term represents a different copper plating process, in which the copper is composite on the steel core. In this post, we consider the question, what is the difference between copper-clad and copper-bonded steel?

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What Do Copper-Bonded and Copper-Clad Steel Have In Common?

The reason the two terms are often used interchangeably is because, on a basic level, they appear the same. Both consist of a steel core and copper exterior.

For use in grounding, both products possess the high tensile strength of steel coupled with the corrosion resistance of copper.

Compared to pure copper, the conductivity of these bi-metallic conductors is lower. To match the current carrying capability of copper, the diameter and copper thickness of bi-metallic conductors are increased. Depending on a conductor’s specific application and region, conductivity requirements may differ.

What is the Difference Between Copper-Bonded and Copper-Clad Steel?

The primary difference between these two types of processes is the way the copper is composited on the steel core.

Forming Process

Copper-bonded steel is manufactured through a continuous electro-plating process of copper over steel core, resulting in a permanent molecular bond between the two materials.

The technique, known as electrophoretic deposition (EDP), creates a homogenous layer of copper over the steel core, regardless of whether the product is a wire, solid conductor or ground rod. The copper layer thickness is measured in unit of [mils].

Copper-clad steel is manufactured by installing two copper strips over a steel core using pressure and heat to form a metallurgical bond. The copper lair thickness is adjusted to the percentage conductivity of pure copper. Most common conductors used in the U.S. are 40% conductivity of copper.

Performance and Uses

Copper-bonded steel is mainly used in manufacturing ground rods, solid wire and solid conductors. Copper-clad steel is generally used in manufacturing of stranded and solid conductors. Both copper-bonded and copper-clad steel are used in theft deterrent applications where the conductor is exposed. Both technologies are good alternatives to copper with similar corrosion resistance and higher tensile strength.

How does this apply to products?

Ground rods are used all throughout the world for connecting electrical installations to the earth. We have a series of posts that review the considerations for ground rod materials for these applications. Read more at the posts below.

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When it comes to copper-clad steel (CCS) wiring over traditional copper wiring, the choice is easy—Proline Safety’s Copper-Clad Steel Wire is preferred for many reasons and applications.

But what is CCS? CCS was first introduced in 1915. As a bi-metal conductor, it uses a uniform, continuous, lower high-carbon steel core that is chemically bonded with copper cladding. A cold rolling process ensures uniform coverage where no rehardening is necessary to prevent flaking, pitting, chipping, or cracking.

How CCS Differs from Copper

CCS clearly leads the way in added properties and economic feasibility that copper can’t compare.

The coating created in the bonding process protects the wire from breakage and abrasions, which gives it a 43 percent higher break-load than copper wire. Although one would think this would make it heavy, CCS is, in fact, ten percent lighter than copper. In addition, CCS has another leg up on copper with its conductivity strength, which makes it the natural choice across all industries.

CCS is also a cost-effective solution when compared to copper:

• The decreased weight results in lower shipping costs and ease of handling throughout installation and maintenance.
• Due to its corrosion resistance, the wire has lasting durability and longevity, lessening maintenance costs.
• The threat of theft is reduced based on its lower after-market value.

Its design of flexibility, memory, and overall feel make it a preferred copper substitute in every way.

Proline Safety’s Copper-Clad Steel Tracer Wire

Proline’s CCS wire is the preferred choice in many applications. Our products are used for tracer wire applications not exceeding 30 volts and conductively locate buried utility lines for the gas, water, sewer, telecommunication, and electrical markets. Additionally, our products are RoHS Compliant and work with connectors you already use.

Our Copper-Clad Wire products are stronger and lower in cost than traditional copper wire. Contact us to learn more about how Proline Safety’s CCS Wire is the superior wire of choice.

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