alcoa - alumoweld

3www.ACAsolutions.com or 1.800.866.7385Specifications are subject to change without notice.

2003, AFL Telecommunications. All rights reserved.

5.20.03

wire products

Alumoweld Wire and StrandAlumoweld wire consists of a thick cladding of pure aluminum over a high-strength steel core. Alumoweld wire offers the advantages of each metal. It is ideal for overhead ground wire, neutral messengers, line wire and guy strand. 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.

featuresThick Aluminum CoveringAlumoweld wire is produced with the concentric aluminum covering comprising 25% of the cross-sectional area, with the aluminum thickness 10% of the wire radius. The high proportion of aluminum offers an excellent degree of electrical conductivity and permanently protects the high strength steel core.

High ConductivityCompared to solid aluminum wire of the same diameter, Alumoweld wire has a direct current conductance of 33%. It has about three times the conductivity of galvanized steel wire. For high frequency currents where skin effect is a factor, the conductivity of Alumoweld wire approaches 100% of solid aluminum. When Alumoweld wires are combined with aluminum wires in composite conductors, a wide range of strength and conductivity characteristics is possible.

Corrosion ResistanceThe thick aluminum cladding of Alumoweld wire provides a high degree of corrosion resistance, resulting in longer service life and reduced maintenance. Accelerated laboratory tests exposing Alumoweld wire to various types of corrosive conditions have proven that Alumoweld wires have corrosion resistance comparable to EC grade aluminum. The condi-tions simulated in the test included industrial, marine and tropical.

Combines High Strength with Low WeightAlumoweld wire has a higher strength-to-weight ratio than any other wire commonly used on overhead lines. Size for size, it has about the same tensile strength as extra high strength steel wire, but weighs approximately 15% less. It has eight times the strength of solid aluminum wire of the same diameter and only a little more than twice the weight. This high strength-to-weight ratio provides a maximum margin of safety for long-span construction. The strength of Alumowelds steel core is protected by the thick aluminum covering.

how is Alumoweld made?The Alumoweld process consists of a continuous application of pure atomized aluminum powder to a high strength steel rod. Proper control of head and pressure refines the cladding and develops a controlled atomic weld. The resulting bimetallic rod is then cold drawn into finished wire sizes without changing original proportions of aluminum and steel.

applications Utility Market

Telecommunications Market

Military

General Industry Applications



5.20.03

wire products

ordering instructionsStep 1: Determine Catalog NumberDetermine the overhead ground wire catalog number. Catalog numbers are on next page.

Step 2: Determine Package CodeDetermine the package code using the charts on this page.

Step 3: Assemble Complete Part Number

Example:For a 1000 ft reel of 7 No. 7 ground wire, the part number is:

AW0707R1000

applications Overhead ground wire

Shield wire protecting transmission lines against lightning damage

available sizesSingle wire, 3 strand and 7 strand overhead ground wire are available in the following coil sizes:

All overhead ground wire products are available in the following reel sizes:

Coil Sizes Package Code

250 feet C250F

500 feet C500F

Reel Sizes Package Code

1,000 feet R1000

2,500 feet R2500

5,000 feet R5000

10,000 feet R10000

Package CodeCatalog Number +

Alumoweld Overhead Ground WireAlumoweld 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.

featuresCorrosion ResistanceAlumoweld overhead ground wire has excellent corrosion resistance. Its strength and con-ductivity 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 clad-ding thickness of Alumoweld is 10% of the radius of the wire. The cladding has a continu-ous, strong metallic bond to the steel core that will not crack or flake.

Strength Comparable to SteelAlumoweld also provides strength greater than or equal 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.

LightweightDirectly 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 tow-ers or supporting structures.



5.20.03

wire products

CatalogNumber

Number and Size of Wires

Nominal Diameter Breaking Loads Weight Resistance Cross Section Area

AWG In mm Lbs kg Lbs /1000 ft kg / kmOhms /1000 ft

Ohms /km Sq In mm2

37 S

TRAN

D

AW3705 37 No. 5 1.270 32.3 142,800 64,790 2,802.0 4,170.0 0.0425 0.1394 0.9615 620.6AW3706 37 No. 6 1.130 28.8 120,200 54,500 2,222.0 3,307.0 0.0536 0.1757 0.7626 492.2AW3707 37 No. 7 1.010 25.7 100,700 45,690 1,762.0 2,623.0 0.0675 0.2216 0.6051 390.3AW3708 37 No. 8 0.899 22.9 84,200 38,190 1,398.0 2,080.0 0.0852 0.2794 0.4798 309.5AW3709 37 No. 9 0.801 20.3 66,770 30,290 1,108.0 1,649.0 0.1074 0.3523 0.3803 245.5AW3710 37 No.10 0.713 17.9 52,950 24,020 879.0 1,308.0 0.1354 0.4443 0.3017 194.7

19 S

TRAN

D

AW1905 19 No. 5 0.910 23.1 73,350 33,270 1,430.0 2,129.0 0.0822 0.2698 0.4944 318.7AW1906 19 No. 6 0.810 20.6 61,700 27,990 1,134.0 1,688.0 0.1037 0.3402 0.3916 252.7AW1907 19 No. 7 0.721 18.3 51,730 23,460 899.5 1,339.0 0.1308 0.4290 0.3107 200.4AW1908 19 No. 8 0.642 16.3 43,240 19,610 713.5 1,062.0 0.1649 0.5409 0.2464 158.9AW1909 19 No. 9 0.572 14.5 34,290 15,550 565.8 842.0 0.2079 0.6821 0.1953 126.1AW1910 19 No.10 0.509 12.9 27,190 12,330 448.7 667.7 0.2622 0.8601 0.1549 99.9

7 ST

RAND

AW0705 7 No. 5 0.546 13.9 27,030 12,260 524.9 781.1 0.2264 0.7426 0.1819 117.4AW0706 7 No. 6 0.486 12.4 22,730 10,310 416.3 619.5 0.2803 0.9198 0.1443 93.1AW0707 7 No. 7 0.433 11.0 19,060 8,645 330.0 491.1 0.3535 1.1600 0.1145 73.8AW0708 7 No. 8 0.385 9.8 15,930 7,226 261.8 389.6 0.4458 1.4630 0.0908 58.6AW0709 7 No. 9 0.343 8.7 12,630 5,729 207.6 308.9 0.5621 1.8440 0.0719 46.4AW0710 7 No.10 0.306 7.8 10,020 4,545 164.7 245.1 0.7088 2.3250 0.0571 36.8AW0711 7 No.11 0.272 6.9 7,945 3,604 130.6 194.4 0.8938 2.9320 0.0453 29.2AW0712 7 No.12 0.242 6.2 6,301 2,858 103.6 154.2 1.1270 3.6970 0.0360 23.2

3 ST

RAND

AW0305 3 No. 5 0.392 10.0 12,230 5,547 224.5 334.1 0.5177 1.6990 0.0779 50.3AW0306 3 No. 6 0.349 8.9 10,280 4,663 178.1 265.0 0.6528 2.1420 0.0619 39.9AW0307 3 No. 7 0.311 7.9 8,621 3,910 141.2 210.1 0.8232 2.7010 0.0491 31.7AW0308 3 No. 8 0.277 7.0 7,206 3,269 112.0 166.7 1.0380 3.4060 0.0389 25.1AW0309 3 No. 9 0.247 6.3 5,715 2,592 88.81 132.2 1.3090 4.2940 0.0309 19.9AW0310 3 No.10 0.220 5.6 4,532 2,056 70.43 104.8 1.6510 5.4150 0.0245 15.8

SING

LE E

ND W

IRE

AW0104 No. 4 0.204 5.2 5,081 2,305 93.63 139.3 1.22200 4.0090 0.0328 21.2AW0105 No. 5 0.182 4.6 4,290 1,946 74.25 110.5 1.5410 5.0560 0.0259 16.8AW0106 No. 6 0.162 4.1 3,608 1,637 58.88 87.62 1.9430 6.3750 0.0206 13.3AW0107 No. 7 0.144 3.6 3,025 1,372 46.69 69.48 2.4500 8.0380 0.0163 10.6AW0108 No. 8 0.129 3.2 2,529 1,147 37.03 55.11 3.0890 10.1300 0.0129 8.37AW0109 No. 9 0.114 2.9 2,005 909 29.37 43.71 3.8960 12.7800 0.0102 6.63AW0110 No.10 0.102 2.6 1,590 721 23.29 34.66 4.9120 16.1200 0.0081 5.26AW0111 No.11 0.091 2.3 1,261 572 18.47 27.49 6.1940 20.3200 0.0064 4.17AW0112 No.12 0.081 2.1 1,000 454 14.65 21.80 7.8110 25.6300 0.0051 3.31

Modulus of Elasticity: Strand 16,200 kg/mm2; Solid Wire 16,500 kg/mm2. Coefficient of Linear Expansion: 1.3x10-5 per degree C.

physical and electrical characteristics

Alumoweld Overhead Ground Wire

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5.20.03

wire products

ordering instructionsStep 1: Determine Catalog NumberDetermine the Type M Guy Strand catalog number. Catalog numbers are on next page.



Example:For a 1000 ft reel of 10M Guy strand, the part number would be:

AW10MR1000

applicationsGuying for:

Power lines

Telephone lines

Railway signals

Communication lines

Towers

Mast

available sizesType M Guy Strand is available in the following coil sizes:

Type M guy strand is available in the following reel sizes:

Coil Sizes Package Code

250 feet C250F

500 feet C500F


1,000 feet R1000

2,500 feet R2500

5,000 feet R5000

10,000 feet R10000


Alumoweld Type M Guy Strand

featuresCorrosion ResistanceAlumoweld 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 CladdingThe Alumoweld wire used to make Type M guy strand is unique in that the aluminum clad-ding thickness is guaranteed to be no less than 10% of the wire radius. Thus, a thick corro-sion 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 mate-rial 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 ConvenientAlumoweld Type M guy strand is easily handled and installed. It weighs less than any of the other high-strength guying materials.



5.20.03

wire products

Alumoweld Type M Guy Strand

CatalogNumber

StrandDesignation

NominalDiameter of Strand

Number ofIndividual Wires

Diameter of Individual Wires

BreakingLoad Weight

Approximate Resistance

In mm In mm Lbs kg Lbs/1000 ft kg/kmOhms/1000

ft1Ohms/

km1

AW2.8M3 2.8M3 0.174 4.42 3 0.081 2.06 2,800 1,270 44 65.47 2.62 8.60AW4M3 4M3 0.220 5.59 3 0.102 2.59 4,000 1,814 70 104.16 1.65 5.44AW5M3 5M3 0.247 6.27 3 0.114 2.90 5,700 2,585 89 132.43 1.31 4.30AW6M 6M 0.242 6.15 7 0.081 2.06 6,000 2,721 104 154.75 1.13 3.71AW7M3 7M3 0.277 7.04 3 0.128 3.25 7,200 3,265 112 166.66 1.04 3.41AW8M 8M 0.272 6.91 7 0.091 2.31 8,000 3,628 131 194.93 0.89 2.92AW10M 10M 0.306 7.77 7 0.102 2.59 10,000 4,535 165 245.52 0.71 2.33

AW12.5M 12.5M 0.343 8.71 7 0.114 2.90 12,500 5,670 208 309.50 0.56 1.84AW14M 14M 0.363 9.22 7 0.121 3.07 14,000 6,350 232 345.22 0.50 1.64AW16M 16M 0.386 9.80 7 0.128 3.25 16,000 7,257 262 389.86 0.45 1.48AW18M 18M 0.417 10.59 7 0.139 3.53 18,000 8,164 306 455.33 0.38 1.25AW20M 20M 0.444 11.28 7 0.148 3.76 20,000 9,072 347 516.34 0.34 1.12AW25M 25M 0.519 13.18 7 0.173 4.39 25,000 11,340 475 706.80 0.25 0.82

1. For information only, not for calculation purposes.

The above guy strands may be purchased under Alumoweld Specification ER 3008.

physical characteristics



5.20.03

wire products

ordering instructionsStep 1: Determine Catalog NumberDetermine the AWAC catalog number. Catalog numbers are on next page.



Example:For a 2500 ft reel of No. 2-5/2 AWAC, the part number is:

AWAC025/2

applications Phase conductor

Neutral messengers

Combined neutral-overhead ground wires

Self-supporting primary, secondary and service drop cables

available sizesAWAC is available in the following reel sizes:


2,500 feet R2500

5,000 feet R5000


Alumoweld Aluminum Conductors (AWAC)AWAC combines Alumoweld with 1350-H19 aluminum wire to provide the electric industry a new versatility for distribution line construction. The combination of high conductivity alumi-num with high strength Alumoweld wire, in varying proportions, allows the designer flexibility for solving new designs or reconductoring. AWAC offers unsurpassed strength-to-weight ratio. Aluminum equivalents of No. 4 AWG through 4/0 AWG each offer a complete range of breaking strengths. In addition to its use as a phase conductor, AWAC is well suited for other electrical-mechanical applications on distribution and transmission lines.

featuresDesigned for VersatilityAWAC is a reinforced aluminum conductor of improved design. Alumoweld wires perform the dual function of providing strength and conductance. AWAC offers both lightweight and high strength for any given AWG conductivity. To make AWAC a more versatile conductor, the ratio of Alumoweld to aluminum wires has been varied to provide the largest range of breaking strengths offered by any conductor.

Corrosion ResistanceThe steel core of each Alumoweld wire is protected against rust by a thick covering of aluminum. This provides the same corrosion resistance as AWACs solid EC aluminum wires. Thus, Alumoweld is safely used in any strand position of an AWAC conductor. This design advantage allows conductor configurations of high strength without sacrificing conductivity or corrosion resistance.

Unsurpassed Strength-to-Weight RatioAWACs Alumoweld wires act as the strength members of the conductor while the aluminum wires reduce the overall weight. This combination results in a high strength-to-weight con-ductor. When more than one Alumoweld wire is used, the AWAC conductors are unmatched by any other conductor in strength-to-weight ratio. For example, the 5/2 AWAC has approxi-mately 50% more strength and only weighs 20% more than a 6/1 stranded ACSR conductor.

10

www.ACAsolutions.com or 1.800.866.7385Specifications are subject to change without notice.


5.20.03

wire products

ConductorBreaking Load Weight Resistance Cross Section

CatalogNumber

Size andConfiguration

Diameter Aluminum Wires Alumoweld Wires

In No. In No. In Lbs Lbs/1000 ft Lbs/mile Ohms/kft at 68 F Sq In

No. 4 AWG Aluminum/No. 6 Copper Equivalent

AWAC045/2 No. 4-5/2 0.261 5 0.0871 2 0.0871 2,790 70 368 0.4026 0.0417AWAC044/3 No. 4-4/3 0.281 4 0.0937 3 0.0937 4,190 92 488 0.3935 0.0483AWAC043/4 No. 4-3/4 0.307 3 0.1022 4 0.1022 6,130 124 653 0.3809 0.0574AWAC042/5 No. 4-2/5 0.340 2 0.1133 5 0.1133 8,960 169 894 0.3656 0.0706

No. 3 AWG Aluminum/No. 5 Copper EquivalentAWAC035/2 No. 3-5/2 0.293 5 0.0978 2 0.0978 3,500 88 464 0.3193 0.0526AWAC034/3 No. 3-4/3 0.316 4 0.1053 3 0.1053 5,260 117 615 0.3116 0.0609AWAC033/4 No. 3-3/4 0.344 3 0.1147 4 0.1147 7,700 156 823 0.3024 0.0723AWAC032/5 No. 3-2/5 0.382 2 0.1273 5 0.1273 11,300 214 1,127 0.2896 0.0890

No. 2 AWG Aluminum/No. 4 Copper EquivalentAWAC025/2 No. 2-5/2 0.330 5 0.1099 2 0.1099 4,370 111 585 0.2529 0.0663AWAC024/3 No. 2-4/3 0.355 4 0.1182 3 0.1182 6,600 147 776 0.2473 0.0768AWAC023/4 No. 2-3/4 0.386 3 0.1288 4 0.1288 9,690 197 1,038 0.2398 0.0912AWAC022/5 No. 2-2/5 0.429 2 0.1429 5 0.1429 13,500 269 1,423 0.2298 0.1123

No. 1 AWG Aluminum/No. 3 Copper EquivalentAWAC015/2 No. 1-5/2 0.370 5 0.1234 2 0.1234 5,450 140 738 0.2006 0.0837AWAC014/3 No. 1-4/3 0.398 4 0.1327 3 0.1327 8,100 185 978 0.1962 0.0969AWAC013/4 No. 1-3/4 0.434 3 0.1446 4 0.1446 11,200 248 1,309 0.1903 0.1150AWAC012/5 No. 1-2/5 0.482 2 0.1605 5 0.1605 16,500 340 1,793 0.1822 0.1416

No. 1/0 AWG Aluminum/No. 2 Copper EquivalentAWAC1/05/2 No. 1/0-5/2 0.416 5 0.1385 2 0.1385 6,580 176 930 0.1592 0.1055AWAC1/04/3 No. 1/0-4/3 0.447 4 0.1490 3 0.1490 9,680 234 1,233 0.1556 0.1221AWAC1/03/4 No. 1/0-3/4 0.487 3 0.1624 4 0.1624 13,800 313 1,651 0.1509 0.1450AWAC1/02/5 No. 1/0-2/5 0.541 2 0.1802 5 0.1802 19,500 428 2,260 0.1445 0.1785

No. 2/0 AWG Aluminum/No. 1 Copper Equivalent AWAC2/05/2 No. 2/0-5/2 0.467 5 0.1556 2 0.1556 8,030 222 1,173 0.1262 0.1330AWAC2/04/3 No. 2/0-4/3 0.502 4 0.1674 3 0.1674 11,900 295 1,555 0.1233 0.1541AWAC2/03/4 No. 2/0-3/4 0.547 3 0.1824 4 0.1824 16,400 394 2,082 0.1196 0.1829

No. 3/0 AWG Aluminum/No. 1/0 Copper EquivalentAWAC3/05/2 No. 3/0-5/2 0.524 5 0.1747 2 0.1747 9,660 281 1,482 0.1001 0.1677AWAC3/04/3 No. 3/0-4/3 0.564 4 0.1880 3 0.1880 14,200 371 1,961 0.0978 0.1942

No. 4/0 AWG Aluminum/No. 2/0 Copper Equivalent

AWAC4/015/14 No. 4/0-15/14 0.575 15 0.1150 4 0.1150 10,800 305 1,613 0.0808 0.1974

physical and electrical characteristics

Alumoweld Aluminum Conductors (AWAC)

alcoa - alumoweld

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