Copperweld® CCS

Copperweld® is the original Copper-Clad Steel (CCS) wire, a groundbreaking product first pioneered by our engineers in 1915. Copperweld® CCS is a bimetallic product in which highly conductive, corrosion-resistant copper cladding is metallurgically bonded to a strong, durable steel core through a continuous, solid cladding process using pressure rolling for primary bonding.

Copperweld offers standard configurations of its CCS in 21%, 30% and 40% IACS (International Annealed Copper Standard) conductivities.  The steel used at the core of the wire can be of whatever grade is best suited to our clients’ applications.


To learn more about the applications of our products, click here. For technical information, including specifications and engineering data, visit our Resource Center. Properties noted on our web site represent minimum values for typical products. If your application requires performance values beyond those noted, please contact Copperweld's Engineering Support Center via email or +1.931.433.7177.

Associated applications

Copperlite™ CCA (Copper Clad Aluminum)

Copperweld’s innovative Copperlite™ Copper-Clad Aluminum (CCA) wire represents a strong advantage in many applications over solid copper wire. Our patented cold cladding technology permanently bonds lightweight, flexible aluminum wire to a concentric layer of highly conductive copper to create components that combine the best qualities of both metals.


To learn more about the applications of our products, click here. For technical information, including specifications and engineering data, visit our Resource Center. Properties noted on our web site represent minimum values for typical products. If your application requires performance values beyond those noted, please contact Copperweld's Engineering Support Center via email or +1.931.433.7177.

Associated applications

Configurations

Sizing & Stranding Options

Single Wire

Copperweld's Copperlite™ Copper-Clad Aluminum (CCA) and genuine Copperweld® Copper-Clad Steel (CCS) wire is a bimetallic product in which a layer of highly conductive copper is permanently metallurgically bonded to a core of lightweight, flexible aluminum or durable, high-strength steel. The marriage of copper to the allied metal creates a single wire that provides value and performance that no single metal can match.

The uniform bond created by our groundbreaking cladding process will not separate, crack, or peel like methods such as hot dip or electroplate, even with the severe twisting of a torsion test. Depending on the conductivity, corrosion resistance, strength, cost, or durability, it can be more effective to use a clad wire rather than a monometal or blended alloy.

The thickness of the copper cladding in bimetallic wire can be carefully controlled to provide specific strength and conductivity performance. As the wire is drawn or annealed, the ratio of cladding to core material remains the same.

Like solid copper wire, bimetallic conductors from Copperweld® can be drawn and annealed to the proper size and flexibility for the application, ranging from AWG 3 to AWG 39. Other metals, such as tin, nickel and silver, or insulations such as polyethylene and polyvinyl chloride can be used to coat Copperweld® bimetallic wire for specific applications. We can assess your application and provide recommendations as to what bimetallic clad combination may be best for you.


Stranded Cable

Stranded cable is more flexible than a single wire of the same total cross-sectional area. Strand is used whenever ease of bending or repeated bending are required.   Genuine Copperweld® stranded CCS cable is composed of individual wires of the same size concentrically stranded in one or more layers. Standard configurations of our products are 3-wire, 7-wire, 19-wire and 37-wire strand.

Left-hand lay strand is furnished unless otherwise specified (lay is the lateral direction in which the individual wires of the outer layer of the strand run over the top of the strand, as they recede from an observer looking along the strand’s axis.)

Stringent quality controls and testing (including twist tests and tensile breakage tests) assure that Copperweld® bimetallic strand will meet or surpass technical expectations.  All wires in the strand lay naturally in their true positions in the completed strand, and remain in position when the strand is cut at any point. 


SINGLE END AND BUNCHED FINE WIRE

Copperweld® specializes in drawing both its Copperlite™ Copper-Clad Aluminum (CCA) and Copperweld® Copper-Clad steel (CCS) wires down to extraordinarily thin diameters. We can produce wire in gauges as fine as 0.089 millimeters (AWG 39), and have the capability of stranding the wire, or bunching the wire into long cables of individual fine wires twisted together in standard configurations.

One advantage of our cladding technology is that we can assure customers of the consistency of the ratio of the copper to the base metal throughout the length of the wire, irrespective of the finished diameter of the wire. Because no molten hot-dip or electroplating occurs, the copper layer of Copperweld® fine wire is evenly distributed with no variation in thickness. Such variations in other processes produce weaknesses and inconsistency of performance, particularly at fine gauges, which can have disastrous consequences in demanding applications.  As is true of all our products, lighter weight and stronger performance make Copperweld® fine wire a great value.

For use in magnet wire for motors and transformers, consumer electronics, circuitry and specialized high-frequency applications, fine wire from Copperweld® represents a high-value alternative to solid copper that transmits signal and current consistently and efficiently.


To learn more about the applications of our products, click here. For technical information, including specifications and engineering data, visit our Resource Center. Properties noted on our web site represent minimum values for typical products. If your application requires performance values beyond those noted, please contact Copperweld's Engineering Support Center via email or +1.931.433.7177.

Associated applications

Packaging & Shipping

A key component of Copperweld’s quality system is our customer service.  Our staff works closely with you to mesh our products, delivery schedules, and systems with yours.  Copperweld® offers customers a variety of packaging options, including:

  • Heavy duty returnable steel reels for CATV and telephone drop wire, with net weights up to 2200 pounds (1000 kg).
  • Stempaks up to 3300 pounds (1500 kg) for large diameter wire.
  • 25-pound (11.3 kg) spools.
  • 50, 100, and 200-pound (22.67 kg, 45 kg and 90 kg) coils, paper wrapped for protection.
  • Bulk coils stacked on a stempak, secured with stretch wrap.
  • Wire sections straightened, cut to length and boxed.
  • Non-returnable wood or metal reels, palletized, banded and loaded onto containers for ocean freight.
  • Custom design packaging meeting your specifications.

Copperweld’s transportation systems are flexible and can be matched to your production schedules.  “Shipped on time with safety in mind®” is the working mission of our shipping department.  Deliveries are coordinated for any destination in the world.  For some customers with their own truck fleets, we plan for daily “just in time” pickups at our factory.  For others, we help with long-term delivery planning so there is never a shortage of material.

That’s also part of the power of bimetallic wire.  We are ready to do the best job possible for your company.  We wouldn't ask for your business otherwise.  Let us show you what bimetallic wire – and a partnership with Copperweld® – can do for your business.


To learn more about the applications of our products, click here. For technical information, including specifications and engineering data, visit our Resource Center. Properties noted on our web site represent minimum values for typical products. If your application requires performance values beyond those noted, please contact Copperweld's Engineering Support Center via email or +1.931.433.7177.

Associated applications