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CONTENTS
TABLE OF
Table of Contents
Alumoweld®
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Overhead Ground Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Overhead Ground Wire Physical and Electrical Characteristics . . . . . . . 427
Type M Guy Strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Type M Guy Strand Physical Characteristics . . . . . . . . . . . . . . . . . . . . 429
Pictorial Index
WIRE PRODUCTS
PICTORIAL
INDEX
Alumoweld® Copperclad
Wire & Strand: pg. 425 High Strength and Extra High Strength: pg. 437
Copperclad Copperclad
Dead Soft Annealed: pg. 434 Composite Conductors: pg. 440
Copperclad Copperclad
Jacekted Dead Soft Annealed Conductors: pg. 436 Type M Guy Strand: pg. 440
Alumoweld wire and strand is used by power utilities, as well as formed wire and optical
ground wire manufacturers. Alumoweld outlasts other options by as much as 200%
in corrosive environments, significantly lowering maintenance and replacement costs.
When compared to solid aluminum wire, Alumoweld offers tremendous savings.
Features
Corrosion Resistance
Alumoweld overhead ground wire has excellent corrosion resistance. Its strength and
conductivity remain unchanged in any atmosphere where aluminum is satisfactory,
especially those known to be corrosive from industrial or atmospheric conditions.
This assurance against corrosion is obtained through the application of a thick covering
of pure aluminum, which provides a substantial barrier of protective metal. The minimum
Applications cladding thickness of Alumoweld is 10% of the radius of the wire. The cladding has a
• Overhead ground wire continuous, strong metallic bond to the steel core that will not crack or flake.
• Shield wire protecting transmission lines
Strength Comparable to Steel
against lightning damage
Alumoweld also provides strength greater than or comparable to other overhead ground
wires. For commonly used wire sizes, the tensile strength of the individual wire can
approach 200,000 pounds per square inch. When used in a strand for overhead ground
wire, this high strength permits greater span lengths, less sag, and heavier loads under
storm loading conditions.
Lightweight
Directly related to strength and sag performance is the lighter weight of Alumoweld.
Due to its thick cladding of aluminum, Alumoweld is 15% lighter than a steel strand of
equivalent size. This lighter weight, combined with high strength, permits Alumoweld
to be installed to the same sags as steel with correspondingly lower tensions and lower
stresses on the towers or supporting structures.
Modulus of Elasticity: Strand 23,000,000; Solid Wire 23,500,000. Coefficient of Linear Expansion: 0.000,007,2 per degree F.
Modulus of Elasticity: Strand 16,200 kg/mm2; Solid Wire 16,500 kg/mm2. Coefficient of Linear Expansion: 0.000,013 per degree C.
Features
Corrosion Resistance
Alumoweld Type M guy strand is an economical, corrosion resistant guying material for
use on overhead line structures. The thick cladding of aluminum on each wire protects the
high-strength steel core from rusting and subsequent loss of strength. Costly maintenance is
eliminated, and the original safety factor of the guy is maintained throughout the life of the line.
Thick Aluminum Cladding
The Alumoweld wire used to make Type M guy strand is unique in that the aluminum
cladding thickness is guaranteed to be no less than 10% minimum of the wire radius.
Thus, a thick corrosion barrier, that is pure aluminum not zinc or an iron-aluminum alloy,
protects the steel core.
Another important feature of any coated or clad wire is the bond between the coating
material and the base metal. In the case of Alumoweld wire, the aluminum cladding
and steel core are joined by a continuous ductile weld. This assures against cracking or
separation of the protective aluminum from the steel core.
Lightweight and Convenient
Alumoweld Type M guy strand is easily handled and installed. It weighs less than any of
the other high-strength guying materials.
Applications
Guying for:
• Power lines
• Telephone lines
• Railway signals
• Communication lines
• Towers
• Masts
continued
Physical Characteristics
NOMINAL
DIAMETER OF BREAKING APPROXIMATE
DIAMETER OF NUMBER OF WEIGHT
STRAND INDIVIDUAL WIRES LOAD RESISTANCE2
STRAND INDIVIDUAL
DESIGNATION
WIRES LBS/1000 OHMS/1000 OHMS/
IN MM IN MM LBS KG KG/KM
FT FT KM
2.8M3 0.174 4.42 3 0.081 2.06 2,800 1,270 44 65.47 2.62 8.60
4M3 0.220 5.59 3 0.102 2.59 4,000 1,814 70 104.16 1.65 5.44
5M3 0.247 6.27 3 0.114 2.90 5,700 2,585 89 132.43 1.31 4.30
6M 0.242 6.15 7 0.081 2.06 6,000 2,721 104 154.75 1.13 3.71
7M3 0.277 7.04 3 0.128 3.25 7,200 3,265 112 166.66 1.04 3.41
8M 0.272 6.91 7 0.091 2.31 8,000 3,628 131 194.93 0.89 2.92
10M 0.306 7.77 7 0.102 2.59 10,000 4,535 165 245.52 0.71 2.33
12.5M 0.343 8.71 7 0.114 2.90 12,500 5,670 208 309.50 0.56 1.84
14M 0.363 9.22 7 0.121 3.07 14,000 6,350 232 345.22 0.50 1.64
16M 0.386 9.80 7 0.128 3.25 16,000 7,257 262 389.86 0.45 1.48
18M 0.417 10.59 7 0.139 3.53 18,000 8,164 306 455.33 0.38 1.25
19M3 0.433 11.00 7 0.144 3.67 19,000 8,618 330 491.10 0.35 1.16
20M 0.444 11.28 7 0.148 3.76 20,000 9,072 347 516.34 0.34 1.12
25M 0.519 13.18 7 0.173 4.39 25,000 11,340 475 706.80 0.25 0.82
1. Unless otherwise noted, the above guy strands are manufactured per Alumoweld Specification ER-3008.
2. For information only, not for calculation purposes.
3. Per ASTM B-416.
RUS Approved
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 corrosive of the steel core.
• Very little scrap value, discouraging theft and leaving the grounding system intact
• Compliant with IEEE 80, ASTM B258, ASTM B910/B910M, ASTM B339, ASTM B227
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
Single strand Copperclad Steel Wire grounding conductor is far less likely to be stolen. This feature is important not only from
in large and small diameters
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.
RUS Approved
RUS Approved
RUS Approved
RUS Approved
RUS Approved
6 AWG Solid with grey PVC Jacket 7#7 AWG with black with green stripe
PVC jacket
AFL NO.
CONDUCTOR
CONDUCTOR OVERALL DIAMETER WEIGHT/LENGTH PVC MIN BREAKING LOAD
SIZE GREY BLACK WITH GREEN
PVC 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
RUS Approved
RUS Approved
RUS Approved
RUS Approved
Ordering Information
Contact AFL for detailed specifications not shown.
Ordering Information
Contact AFL for detailed specifications.
RUS Approved
* See Jacket detail sheet for alternate jacketing configurations and part numbers.
RUS Approved
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 — — — — — — — —
Reel Specifications
OD ID WIDTH MAX CAPACITY
REEL NO.
(in.) (in.) (in.) (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
RUS Approved
RUS Approved