What is Copper Clad Wire: Choose Between Copper Clad and Solid Copper Wire


Cables are essential parts of any electrical application, and the quality and type of cables decide the entire application’s performance. While by partnering with reliable cable harness manufacturers, we can get high-quality cables; the type of cables you need is for you to decide.

There are two basic types of cables you could use – copper-clad cables and solid copper cables. Both these kinds of wires are different from each other, and this article will look into details about whether you use clad or solid cables to maintain data integrity. 

Table of Contents

Types of Copper Clad Cables

When it comes to Copper clad cables, it has an upper coating of Copper, and the inside is of either steel or Aluminum. 

What is copper-clad aluminum wire?

While manufacturing a Copper-Clad aluminum cable, you need to encase the aluminum rod with a thin layer of copper strip. Then, you need to weld it along the seam to make it flawlessly coat the inside. 

Copper Coated Aluminum has a lot of advantages since it is lighter in weight and cost. Also, in some applications, you can handle Copper-clad aluminum much efficiently. Moreover, Aluminum core has less cost, a third of the price of Copper. As the price is less, theft of scarp also reduces. Copper Coated Aluminum cables have a better corrosion resistance than plain Aluminum wire. 

What is Copper Clad Wire: Cross-section of electrical aluminum wire

Caption: Cross-section of electrical aluminum wire

CCS Cable

Like Copper-Clad Aluminum Wiring, the CCS cable contains the steel inner with an outer copper strip layer. It may give a higher mechanical strength of steel to the electrical cables. Still, the CCS is less flexible and heavier. 

As the mechanical strength is more extensive, physical damage in the installation process is more likely to reduce, giving you reliable connections. Thus, in most wire harnessing, you may have to choose the Copper cladding steel wires to connect the devices.

What are the cables affected?

The cables that may get affected are the alarm cables, coaxes, and internal telephone cables of CW1308 style. Also, some manufacturers may offer Cat-5 or other data cables as CCA.

What is Copper Clad Wire: Hazards of CCA and CCS

The main hazards associated with CCA and CCS are:

  • Aluminum and Copper conductors have more resistance to electricity than Copper. That makes the current carrying capacity in the overall wire decrease as you increase the distance of application.
  • Copper is rigid, but Aluminum is far more brittle, and thus, the CCA wires are more prone to breaking during the installation process.
  • Also, CCA and CCS can be fatigued at the termination points, leading to a faulty connection.
  • The Copper clad can send false readings to awaken false alarms when you use it on alarm systems. On the other hand, the coaxial cables can ruin the picture quality over large distances.
What is Copper Clad Wire: Internal view of stranded twisted pair cable

Caption: Internal view of stranded twisted pair cable

Choosing the Right between Copper Clad Cables and Solid Copper Cables

Remember, neither CCS nor CCA is suitable for applying pure copper wires since it can result in long-term problems.

What is Copper Clad Wire:What are Solid copper cables?

Solid copper cables are made of 100% copper, where the entire wire is made of Copper, whether it is the inner or the outer coating of the cable. 

The significant benefits of using solid conductor cables are durability and flexibility. Due to these features, you can easily bend the wires back and forth. Also, as Copper has the highest conductivity, it is ideal for transmitting signals a long way with minimal current to push the signals to the end. 

The only negative point of choosing solid copper cables is the fact that it is heavier. Thus, you need to have help hands to carry a single bundle of it. Overall, it does not matter as the performance of the wire compensates for the thing. 

What is Copper Clad Wire: Solid Copper Wire

Caption: Solid Copper Wire

What’s your choice?

 If you ever have to choose between the two types, first, you have to consider the pros and cons of each cable. In case of the lack of money and other resources, you can choose the Copper clad cables. Also, the CCS or CCA can be a good option for short-distance coverage. 

On the other hand, if you want durability, flexibility and you do not want to change it after some time, go for the solid copper wire for cable harnessing. 


To wrap up, many manufacturers make wires that are not purely Copper. Some of them have Aluminum or steel on the inside. It does not mean that they are for making the quality of the product wrong, but they are necessary for some cases. Moreover, the copper-clad cables are less in cost. Yet you cannot use them in critical systems as they are not reliable. 

Here at Cloom, we offer help in wire harnessing and cable connection. So, to get your quote, contact us now.