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ACS Alumoweld Aluminium Clad Steel Wire ASTM B416 Standard
Standard: ASTM B416 (Aluminum-Clad Steel Wire — Alumoweld)
Related Standards: ASTM B502 (ACSR/AW) / ASTM B415 / AS 1222.2
Aluminium Cladding Ratio: 25% of total cross-sectional area
Conductivity: ~20.3% IACS
Construction: 3-wire / 7-wire / 19-wire / 37-wire concentric-lay stranded
Wire Size: No. 10 AWG to No. 5 AWG (individual wire diameter)
Nominal Area Range: 15.78 mm² (3×10AWG) to 620.6 mm² (37×5AWG) — 26 standard configurations
Max. Operating Temperature: 150°C
Packaging: Wooden / steel drum; custom lengths available
Product Overview
ACS — Alumoweld Aluminum Clad Steel Wire (ASTM B416) is a composite conductor consisting of a high-tensile steel core with a continuous metallurgically bonded aluminium outer layer, manufactured to ASTM B416 — Standard Specification for Aluminum-Clad Steel Wire. Commercially known as Alumoweld (a registered trademark of Copperweld / Nexans), ACS wire combines the high tensile strength of steel with the corrosion resistance and moderate conductivity of aluminium — at a significantly lower weight than copper clad steel (CCS) of equivalent tensile strength, making it the preferred choice for overhead earth wire, OPGW core, and long-span ground wire applications where mechanical performance and light weight are the primary design requirements.
The aluminium cladding has a cross-sectional area ratio of 25% (the aluminium layer constitutes 25% of the total wire cross-section by area), delivering a conductivity of approximately 20.3% IACS — adequate for overhead earth fault current duty and superior to galvanised steel wire (~17% IACS) while maintaining steel-class tensile strength. The aluminium-steel interface is a true metallurgical bond formed during the cladding and wire-drawing process — the aluminium layer cannot separate from the steel core under any mechanical or thermal stress encountered in service. Available in 3-wire, 7-wire, 19-wire, and 37-wire concentric-lay constructions, wire sizes from 10 AWG to 5 AWG, covering nominal cross-sections from 15.78 mm² to 620.6 mm².
ASTM B416 — North American Standard
Full compliance with the ASTM standard for aluminium-clad steel wire — accepted by US and Canadian utilities for overhead earth wire, OPGW core, ACSR/AW core, messenger wire, and guy wire under NESC-compliant project specifications.
Alumoweld — Metallurgical Bond
The aluminium cladding is co-drawn with the steel core during manufacture, creating a true metallurgical bond — not plating, not coating. The aluminium layer cannot delaminate under bending, stringing tension, vibration fatigue, or fault current thermal cycling throughout the conductor's service life.
25% Al Cross-Section — 20.3% IACS
The standard 25% aluminium cladding ratio delivers 20.3% IACS conductivity — higher than galvanised steel (17% IACS) and adequate for overhead earth wire fault current duty, while maintaining the high tensile strength that makes ACS suitable for long spans and heavy loading conditions.
Lighter Than CCS for Equal Tensile Strength
Aluminium density (2.70 g/cm³) is significantly lower than copper density (8.89 g/cm³). For equivalent rated tensile strength, ACS is substantially lighter than CCS of the same wire count and gauge — reducing dead load on towers, poles, and hardware, and enabling longer spans on the same support structure.
Superior Corrosion Resistance
The aluminium outer layer self-passivates on atmospheric exposure, forming a stable Al₂O₃ protective layer — eliminating the progressive zinc depletion that eventually exposes the steel core in galvanised wire. ACS maintains corrosion protection for 40+ years in coastal, industrial, and high-humidity environments where galvanised steel wire requires periodic inspection and replacement.
OPGW & ACSR/AW Core Material
ACS wire is the standard core element for OPGW (Optical Ground Wire) — the aluminium cladding provides corrosion resistance for the steel core that carries the optical fibre tube, while the steel provides the mechanical strength required for long-span overhead fibre installations. ACS is also used as the steel core in ACSR/AW (aluminium conductor, Alumoweld reinforced) for superior corrosion resistance over standard galvanised ACSR.
Technical Specifications
Basic Parameters
| Standard | ASTM B416 — Standard Specification for Aluminum-Clad Steel Wire (Alumoweld) |
|---|---|
| Related Standards | ASTM B502 (ACSR/AW conductor); ASTM B415 (tensile requirements); AS 1222.2 (Australian standard) |
| Conductor Structure | High-tensile steel core with continuous metallurgically bonded aluminium outer layer |
| Aluminium Cladding Ratio | 25% of total cross-sectional area (by area) |
| Conductivity | Approximately 20.3% IACS |
| Steel Core Tensile Strength | High-strength steel; rated strength per ASTM B416 breaking load table |
| Construction | 3-wire, 7-wire, 19-wire, 37-wire concentric-lay stranded |
| Wire Size Range | No. 10 AWG to No. 5 AWG individual wire diameter |
| Nominal Area Range | 15.78 mm² (3×10 AWG) to 620.6 mm² (37×5 AWG) |
| Max. Operating Temperature | Up to 150°C (limited by aluminium cladding integrity — higher than galvanised steel) |
| Packaging | Wooden or steel drum; custom lengths available |
Full Parameter Table — ASTM B416 ACS Conductor (Hongda Data)
| Code Number | Area (mm²) | No. of Wires | Wire Ø (mm) | Overall Ø (mm) | Weight (kg/km) | Rated Strength (kN) | DC Resistance (Ω/km, 20°C) |
|---|---|---|---|---|---|---|---|
| 3×5AWG | 50.32 | 3 | 4.62 | 9.96 | 334.1 | 54.42 | 1.6990 |
| 3×6AWG | 39.00 | 3 | 4.11 | 8.87 | 265.0 | 45.74 | 2.1420 |
| 3×7AWG | 31.65 | 3 | 3.67 | 7.90 | 210.1 | 38.36 | 2.7010 |
| 3×8AWG | 25.10 | 3 | 3.26 | 7.03 | 166.7 | 32.06 | 3.4060 |
| 3×9AWG | 19.90 | 3 | 2.91 | 6.26 | 132.2 | 25.43 | 4.2940 |
| 3×10AWG | 15.78 | 3 | 2.59 | 5.58 | 104.8 | 20.16 | 5.4150 |
| 7×5AWG | 117.40 | 7 | 4.62 | 13.90 | 781.1 | 120.27 | 0.7426 |
| 7×6AWG | 93.10 | 7 | 4.11 | 12.40 | 619.5 | 101.14 | 0.9198 |
| 7×7AWG | 73.87 | 7 | 3.67 | 11.00 | 491.1 | 84.81 | 1.1600 |
| 7×8AWG | 58.56 | 7 | 3.26 | 9.78 | 389.6 | 70.88 | 1.4630 |
| 7×9AWG | 46.44 | 7 | 2.91 | 8.71 | 308.9 | 56.20 | 1.8440 |
| 7×10AWG | 36.83 | 7 | 2.59 | 7.76 | 245.1 | 44.58 | 2.3250 |
| 7×11AWG | 29.21 | 7 | 2.30 | 6.91 | 194.4 | 35.35 | 2.9320 |
| 7×12AWG | 23.16 | 7 | 2.05 | 6.16 | 154.2 | 28.03 | 3.6970 |
| 19×5AWG | 318.70 | 19 | 4.62 | 23.10 | 2129.0 | 326.39 | 0.2698 |
| 19×6AWG | 252.70 | 19 | 4.11 | 20.60 | 1688.0 | 274.55 | 0.3402 |
| 19×7AWG | 200.40 | 19 | 3.67 | 18.30 | 1339.0 | 230.18 | 0.4290 |
| 19×8AWG | 158.90 | 19 | 3.26 | 16.30 | 1062.0 | 192.41 | 0.5409 |
| 19×9AWG | 126.10 | 19 | 2.91 | 14.50 | 842.0 | 152.58 | 0.6821 |
| 19×10AWG | 99.96 | 19 | 2.59 | 12.90 | 667.7 | 121.00 | 0.8601 |
| 37×5AWG | 620.60 | 37 | 4.62 | 32.30 | 4170.0 | 635.43 | 0.1394 |
| 37×6AWG | 492.20 | 37 | 4.11 | 28.80 | 3307.0 | 534.85 | 0.1757 |
| 37×7AWG | 390.30 | 37 | 3.67 | 25.70 | 2623.0 | 448.09 | 0.2216 |
| 37×8AWG | 309.50 | 37 | 3.26 | 22.90 | 2080.0 | 374.67 | 0.2794 |
| 37×9AWG | 245.50 | 37 | 2.91 | 20.30 | 1649.0 | 279.11 | 0.3523 |
| 37×10AWG | 194.70 | 37 | 2.59 | 17.90 | 1308.0 | 235.61 | 0.4443 |
ACS vs CCS vs Galvanised Steel Wire — Comparison
| Parameter | ACS (Alumoweld) | CCS (Copper Clad Steel) | Galvanised Steel Wire |
|---|---|---|---|
| Cladding material | Aluminium (25% area) | Copper (40% or 30% area) | Zinc (coating, not structural) |
| Conductivity | ~20.3% IACS | 30–40% IACS | ~17% IACS |
| Tensile strength | High (steel core) | High (steel core) | High (steel) |
| Weight (same strength) | Lightest (Al cladding) | Heavier (Cu cladding) | Similar (no Cu) |
| Corrosion resistance | Excellent (Al passivation) | Excellent (Cu patina) | Good until zinc depletes |
| Long-term burial | Good | Excellent | Limited (zinc depletes) |
| OPGW core suitability | ✅ Standard choice | ⚠️ Heavier | ❌ Corrosion risk |
| Theft resistance | Good (low Al scrap value) | Excellent (no Cu scrap value) | Good |
| Primary use | Overhead earth wire, OPGW core, ACSR/AW core | Buried grounding grid, overhead earth wire | Guy wire, ACSR core, fence |
Key Features & Technical Advantages
Weight Advantage Over CCS
For the same tensile strength requirement, ACS weighs significantly less than CCS — aluminium cladding (2.70 g/cm³) versus copper cladding (8.89 g/cm³) on the same steel core. Reduced conductor weight means lower dead load on towers and poles, lower combined wind/ice loading, and the possibility of longer spans on the same support structure without increasing tower height or strength.
Permanent Corrosion Protection
Aluminium's self-passivating Al₂O₃ layer provides permanent atmospheric corrosion protection without zinc depletion — unlike galvanised steel wire where the zinc sacrificial layer is progressively consumed. ACS overhead earth wire and OPGW cores maintain structural integrity in coastal, tropical, and industrial pollution environments for 40+ year design lives.
Standard OPGW Core Material
ACS wires are the standard core element in OPGW (Optical Ground Wire) cables worldwide — the high tensile strength sustains the fibre tube under stringing and operational tension, while the aluminium cladding protects the steel from corrosion in the aggressive outdoor environment encountered over a 25–40 year OPGW service life.
ACSR/AW — Enhanced ACSR Corrosion Performance
In ACSR/AW (ASTM B502), ACS wire replaces the conventional galvanised steel core of standard ACSR. The aluminium-clad core eliminates the galvanic corrosion at the aluminium-steel interface that causes core failure in standard ACSR in coastal and high-humidity environments — delivering ACSR mechanical performance with AAAC-class corrosion reliability.
Higher Operating Temperature Than Galvanised Steel
ACS wire withstands continuous operating temperatures up to 150°C — significantly higher than galvanised steel wire (zinc begins to diffuse into the steel above 250°C, but embrittlement concerns arise at lower operating temperatures). ACS is compatible with high-temperature conductor applications where HTLS (High Temperature Low Sag) conductors operate above the conventional 75–80°C limit.
Multi-Standard Compliance
ASTM B416 ACS wire is also available to DIN 48201 (German standard) and IEC 61232 (international standard) — the same wire construction with metric sizing and different test and acceptance criteria. For projects requiring dual-standard certification, ACS can be produced and documented to two standards simultaneously.
Certifications & Standards
Typical Applications
Overhead Earth Wire (Shield Wire)
Ground wire on HV and EHV transmission lines — ACS provides high tensile strength for long spans with better corrosion resistance than galvanised steel and lighter weight than CCS.
OPGW Core Wire
Core element of Optical Ground Wire — ACS tensile strength sustains the optical fibre tube while aluminium cladding provides permanent corrosion protection for 25–40 year OPGW service life.
ACSR/AW Conductor Core
Replaces galvanised steel core in ACSR/AW (ASTM B502) — eliminating galvanic corrosion at the aluminium-ACS interface for coastal and tropical transmission line applications.
Messenger Wire
Support strand for ADSS fibre, aerial cables, and figure-8 self-supporting cables — ACS messenger is lighter than CCS and more corrosion-resistant than galvanised steel for long-term outdoor service.
Coastal & Marine Overhead Lines
Overhead earth wire in salt-laden marine atmospheres where galvanised steel wire zinc depletion is a documented 15–20 year service life issue — ACS provides permanent corrosion protection.
Long-Span & Mountain Lines
High-altitude and long-span transmission where light weight is critical — ACS's weight advantage over CCS reduces span loads and enables longer spans on the same tower configuration.
Rural Distribution Earth Wire
Earth wire on rural distribution lines — ACS combines the tensile strength for long spans with corrosion resistance that outlasts galvanised steel in all climatic zones.
Marine & Island Infrastructure
Island power supply overhead lines and marine structure earthing — aluminium cladding provides the corrosion resistance essential in salt-spray environments where galvanised steel wire fails within a decade.
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Frequently Asked Questions
As a factory, we offer flexible MOQ depending on the cable type. For standard stock items, MOQ is low; for customized specifications, please contact our sales team for a detailed quote.
Yes, Qiangli cables are manufactured in compliance with international standards such as UL, CE, TUV, and VDE. We provide full test reports and certificates upon request.
Absolutely. We have a dedicated R&D team that can customize cable structure, material, color, and printing to meet your specific project needs.
For standard products, lead time is usually 7-15 days. For large-scale project orders or customized products, it typically ranges from 20 to 30 days.
Yes, we provide free samples for most standard cables. You only need to cover the international courier costs. Contact us to arrange your sample shipment.