Copper-Clad Steel (CCS) wire is a bimetallic conductor consisting of a high-strength steel core metallurgically bonded with a continuous outer layer of copper.
This structure combines steel’s exceptional tensile strength and stiffness with copper’s electrical conductivity, corrosion resistance, and surface performance. CCS wire is engineered for applications where mechanical strength and durability are more critical than maximum conductivity.
Typical Structural Composition
| Component | Typical % (by volume) |
|---|---|
| Steel core (low-carbon steel) | 80 – 90% |
| Copper cladding (Cu) | 10 – 20% |
Physical Properties
| Property | Typical Value |
|---|---|
| Density | ~7.4 – 7.8 g/cm³ |
| Melting Point | Steel ~1370 °C / Copper 1085 °C |
| Electrical Conductivity | 20 – 40% IACS |
| Thermal Conductivity | ~50 – 120 W/m·K |
| Coefficient of Thermal Expansion | ~12 × 10⁻⁶ /°C |
| Magnetic Behavior | Magnetic (steel core) |
| Weight vs Copper | ~10 – 15% lighter |
Mechanical Properties
| Property | Typical Range |
|---|---|
| Tensile Strength | 400 – 1200 MPa |
| Yield Strength | 250 – 900 MPa |
| Elongation | 2 – 10% |
| Hardness | 150 – 300 HV |
| Elastic Modulus | ~200 GPa |
| Fatigue Resistance | Very good |
Mechanical strength is the primary advantage of copper-clad steel wire.
Strengthening & Metallurgical Behavior
Structure:
Steel core with BCC ferrite/pearlite structure
Copper outer layer with FCC structure
No alloying between copper and steel
Bonding:
Solid-state metallurgical cladding via roll bonding,
extrusion, or continuous weld bonding
Strengthening:
Cold drawing of steel core
Work hardening increases tensile strength
No precipitation hardening
The copper layer remains ductile and conductive, while steel provides the load-bearing capacity.
Key Characteristics
✔ Extremely high tensile strength
✔ Excellent corrosion resistance (copper surface)
✔ Good electrical conductivity for grounding & RF
✔ Superior mechanical durability
✔ Long service life in harsh environments
✔ Excellent skin-effect performance (RF)
✔ High resistance to theft
Limitations:
Lower conductivity than copper
Magnetic behavior (not suitable for some electronics)
More difficult cutting and termination
Refining & Processing
Low-carbon steel rods are prepared and clad with copper using roll bonding, hot extrusion, or continuous weld bonding. The composite rod is then drawn through multi-stage wire drawing.
✔ Strong bond integrity
✔ Excellent straightness and stiffness
✔ Copper layer maintains surface integrity
✔ Suitable for long continuous lengths
Available Forms
Round wire
Stranded CCS wire
Grounding and earthing wire
Messenger wire
Overhead conductors
CCS grounding rods
Braided CCS conductors
Sizes typically range from 0.5 mm to 20+ mm.
Applications
Grounding & Earthing
Ground rods, earth mats,
lightning protection systems
Telecom & RF
Coaxial cable center conductors,
antenna wires, RF shielding
Power & Utilities
Overhead ground wires (OPGW),
railway signaling,
power line messengers
Defense & Infrastructure
Perimeter fencing,
security systems,
military communication lines
Renewable Energy
Wind turbine grounding,
solar farm earthing systems
Advantages
✔ Outstanding mechanical strength
✔ Long-term corrosion resistance
✔ Lower cost than pure copper
✔ Reduced theft risk
✔ Excellent grounding performance
✔ High fatigue resistance
Why Choose Copper-Clad Steel Wire?
CCS wire is selected when high tensile strength, long-span durability, and reliable grounding performance are required, especially in harsh outdoor environments.
Engineering Recommendation:
Copper-clad steel is the preferred solution for grounding,
lightning protection, and RF antenna systems,
where mechanical integrity is more important than
maximum current-carrying capacity.
Comparison
| Property | CCS | CCA | Pure Copper |
|---|---|---|---|
| Tensile Strength | ⭐⭐⭐⭐⭐ | ⭐⭐ | ⭐⭐⭐ |
| Conductivity | ⭐⭐ | ⭐⭐⭐ | ⭐⭐⭐⭐⭐ |
| Corrosion Resistance | ⭐⭐⭐⭐ | ⭐⭐⭐⭐ | ⭐⭐⭐⭐⭐ |
| Cost | ⭐⭐⭐⭐ | ⭐⭐⭐ | ⭐⭐ |
| Theft Resistance | ⭐⭐⭐⭐⭐ | ⭐⭐ | ⭐ |
Sustainability & Lifecycle
Reduced copper usage
Long service life
Lower maintenance requirements
Recyclable (separation required)