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.
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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.
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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.
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.
Several studies have been compiled regarding the corrosion performance of buried Copperweld® Copper-Clad Steel (CCS) conductors. These studies range from the early &#;s with the invention of the Copperweld cladding process through the present day with studies performed by independent parties and in Copperweld&#;s in-house test facilities. The purpose is to present the available information so that prospective users of Copperweld CCS wire and strands can evaluate the corrosion resistance and expected performance within their specific application and area.
Copperweld uses oxygen-free copper to manufacture Copperweld CCS conductors. The copper surface of CCS is expected to oxidize and turn a color ranging from green (patination) to brown or black &#; the same as any solid copper wire or strand when exposed to environmental stimuli. Corrosion on exposed steel at the cut tip or end of the wire is also expected. The question to be answered is, will the corrosion on either material or the interface between the copper and steel (galvanic reaction) result in degradation of the wire, making it unsuitable for use as a grounding conductor?
The oldest known underground corrosion study of bimetallic material was performed in the early &#;s as referenced in the report, &#;A Technical Report on the Service Life of Ground Rod Electrodes&#; by Chris Rempe1. This study focused on the corrosion behavior of Copperweld CCS underground rod as well as other materials such as copper and galvanized steel ground rods. The National Bureau of Standards (NBS) conducted an extensive underground corrosion study that involved 36,500 specimens which included 333 varieties of ferrous, nonferrous, and protective coating materials buried in 128 test locations throughout U.S. from to .
The study summarizes the service life of a ground rod as following:
Similarly, the Naval Civil Engineering Laboratory in collaboration with the National Association of Corrosion Engineers conducted a seven-year program of testing metal rods for electrical grounding to determine the galvanic corrosion effect. The three metals tested were stainless-clad steel, copper-clad steel (CCS), and galvanized steel. The result on the .625-inch CCS ground rod was as expected. The copper surface of the CCS was virtually free of corrosion, and the steel core had corroded at the tip, approximately two inches down the length of the rod.
Copperweld, founded in , is the inventor and sole manufacturer of Copperweld copper-bonded ground rods and Copperweld wire and strand. The corrosion behavior of a Copperweld ground rod is similar to the corrosion on Copperweld wire and strand conductor. Both materials consist of copper metallurgically bonded to a steel core. All Copperweld 40% CCS has a copper thickness of 10% of the overall diameter. For example, Copperweld® Century&#; 4/0 (4Thought&#;) has a configuration of 19 strands of 0.-inch wires. It means that each strand has a copper thickness of 10.55 mils. Based on the NBS study, Century&#; 4/0 will have at least a minimum service life of 40 years.
Copperweld has also conducted a five-year study of buried bare 21% conductivity (copper thickness is 3% of the diameter) Copperweld CCS in 10 different soil conditions in association with Southwest Research Institute2. The study reported 100% surface oxidation and various degrees of deterioration of the steel core as expected after five years. The exposed steel on the tip of the wire rusted and formed a 'scab', as shown in Figure 1. The rust appeared to 'seal-off' the un-oxidized material from the corrosive medium. The maximum depth of corrosion was 70% of the wire diameter.
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Figure 1: Example of underground corrosion of Copper-Clad Steel
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Although the copper surface oxidation was heavy, the samples showed no signs of pits or holes in the copper cladding. The copper thickness of a severely oxidized five-year sample showed no discernible difference when compared to an un-oxidized control sample that was not subjected to the corrosive environment. The mechanical and resistance testing resulted in negligible differences between the five-year samples and the control samples. Thus, the oxidation had no discernible impact on the strength or electrical performance of the wire.
An accelerated corrosion study based on ASTM B117 was conducted on bare CCS and solid copper wires to evaluate copper surface corrosion. The wires were exposed to salt fog spray for 504 hours. As a result, corrosion on the CCS surface showed no significant difference as compared to the corrosion on the surface of the copper wire.
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Figure 2: Patination of copper surface after 504 hours exposure to salt fog spray&#;
In February , three separate sample strands of copper-clad steel were un-earthed and cut out from a substation built in Louisville, Kentucky. The conductors were 40% conductivity, Low Carbon Steel, Dead Soft Annealed, 7 No. 5 (231,613 circular mil) and were installed in .
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Table 1: Physical properties of the three strands of Copperweld conductor that had been buried underground for 48 years in a Kentucky substation&#;
The conductors were manufactured by Copperweld with a nominal copper thickness of 10% of its diameter. Figure 3 shows the copper thickness ranging from 11.4 to 21.3 mils and the concentricity of the conductor averaged 81.5% (actual average thickness of copper exceeds 10% of diameter thickness requirement). Current manufacturing improvements yield concentricity of copper thickness above 85%.
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Figure 3: Copperweld 40% LC DSA 7 No. 5 made in
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Figure 4a shows no visible corrosion observed other than oxidation and patination on the copper surface. At the ends of the wires, the corrosion occurred in the form of steel rust. The maximum depth of the corrosion is 0.859 inch with an average of 0.382 inch, as shown in Figure 4b.
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Figure 4b: Corrosion occurred at the ends of the wires. Maximum penetration depth is 0.859 inch.From the corrosion studies described above, there has not been any galvanic corrosion at the interface of copper and steel reported or observed. The process of cladding for Copperweld ensures a metallurgical bond between the two metals. That metallurgical bond prevents any moisture from penetrating between the two metals precluding the corrosion process. Any propagation of corrosion on an area of exposed steel averages two times the diameter of the wire, and then stops. The corrosion rate of the copper surface is equivalent to that observed on standard solid copper wire and strand. Based on the results of these studies, it can be summarized that CCS can be expected to have a 50+-year service life as buried grounding conductors.
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