Copperweld's CCS conductors feature a unique metallurgical bond that integrates the best properties of both copper and steel. This innovative design allows CCS to provide enhanced strength while significantly improving resistance to corrosion. When produced with high-quality materials and precise manufacturing processes, CCS can outlast solid copper conductors, even in challenging environments where the steel core might be exposed.
One of the key benefits of CCS is its superior break-load strength, making it an ideal choice for demanding applications. Engineers have relied on CCS for decades to optimize power grids, knowing that its performance exceeds that of traditional solid copper conductors.
One of the primary questions surrounding CCS is what happens if the copper layer corrodes and exposes the steel core. Fortunately, CCS conductors are designed with the copper layer covering most of the exposed surface area. This strategic design ensures that copper is in contact with soil, air, and connectors, providing a protective shield for the underlying steel core.
While copper does undergo oxidation over time, this process actually forms a protective patina, enhancing its resistance to corrosion. In most environments, copper corrodes at an exceedingly slow rate, around 0.000005 inches per year in typical soil. With such a gradual rate, it would take approximately 2,200 years for the copper cladding on a Copperweld Century 19 No. 9 conductor to corrode through completely.
Another concern is the potential for corrosion if the steel core becomes exposed due to impacts or scraping. Even in cases where the steel is exposed, CCS conductors are designed to withstand corrosion effectively. When steel is exposed, it can form a protective rust layer or "scab," which prevents further corrosion from advancing. Research indicates that even in worst-case scenarios, corrosion typically progresses only a small distance, around 2-3 times the diameter of the wire, before halting due to this natural barrier.
Field testing supports these claims. For instance, connectors used in installations often encase the cut ends of conductors, providing additional protection for the exposed steel. Even in instances of isolated corrosion, the surrounding copper surface remains intact, ensuring continuous conductivity.
Copperweld has conducted extensive laboratory testing to assess the effects of indentation and nicks on CCS conductors. In tests conducted from 2004 to 2009, results indicated that minimal corrosion occurred even after five years of burial in various soil conditions. Specifically, only 1 out of 50 samples that experienced significant indentation showed any notable corrosion, which did not adversely affect performance.
In field studies, CCS conductors that had been in service for nearly 50 years in a Kentucky substation displayed only typical copper oxidation, with no significant corrosion beyond the protective layer. This further reinforces the idea that CCS can maintain its integrity over decades, even in challenging environments.
Comprehensive studies conducted by the National Bureau of Standards over 45 years have provided valuable insights into the long-term durability of CCS conductors. This extensive research examined 37,000 specimens across 95 soil types, concluding that CCS conductors with copper cladding thicknesses of 10-13 mils can expect service lives of 40 to 50 years. However, it is important to note that Copperweld's CCS products often exceed these conservative estimates.
While copper has long been considered the gold standard in electrical conductivity, Copper-Clad Steel offers distinct advantages. These include:
- Superior Strength: CCS conductors possess 2-3 times the break-load strength of solid copper, making them ideal for utility applications where mechanical strength is crucial.
- Extended Service Life: With five times the flex-fatigue endurance of solid copper, CCS is more resistant to bending and vibration, essential for applications with frequent mechanical stress.
- Secure Connections: The combination of a steel core and copper exterior ensures strong, durable connections that withstand harsh conditions.
- Reduced Theft Risk: Given the rising value of copper, CCS conductors are less appealing to thieves, providing an additional layer of security for utility installations.
