4 Advice to Choose a Bare Stranded Conductor

The Ultimate Guide to Bare Copper Conductors: What You Need to Know

Posted on Nov 13,

Electrical wiring is a critical component of homes, businesses, and various applications. While many people are familiar with traditional insulated copper wires, there is another type of wire that offers unique advantages – the bare copper conductor. In this comprehensive guide, we will explore what a bare copper conductor is, its uses, manufacturing process, benefits, drawbacks, and tips for working with it. Whether you are a homeowner, electrician, or industry professional, this guide will equip you with the knowledge you need to understand and utilize bare copper conductors effectively.

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What is a Bare Copper Conductor?

A bare copper conductor is an electrical wire that is not insulated or covered in any other material. It is made from pure copper, which offers several benefits compared to other types of wire. Bare copper conductors are widely used in applications where electrical wiring is exposed, such as in electrical panels, appliances, and outdoor installations. They are known for their high conductivity, corrosion resistance, and affordability.

Uses of Bare Copper Conductors

Bare copper conductors have a wide range of applications due to their exceptional electrical and thermal conductivity. They are commonly used in the following areas:

1. Electrical Wiring

Bare copper conductors are extensively used for electrical wiring in residential, commercial, and industrial settings. Their high conductivity ensures efficient power transfer, making them suitable for both low and high-voltage applications.

2. Speaker Wiring

In speaker systems, bare copper conductors are often preferred for their low resistance and high audio signal quality. The absence of insulation allows for optimal transmission of sound signals, resulting in clearer and more accurate sound reproduction.

3. Automotive Wiring

Bare copper conductors are also utilized in automotive wiring systems. Their ability to handle high electrical loads and resist corrosion makes them ideal for automotive applications, ensuring reliable and efficient electrical connections in vehicles.

4. Grounding Systems

Bare copper conductors play a crucial role in grounding systems. They are used as earth electrodes, buried in concrete foundations, or employed in excavations to provide a low impedance path for electrical current to dissipate safely into the ground.

Manufacturing Process of Bare Copper Conductors

The manufacturing process of bare copper conductors involves several steps to ensure their quality, flexibility, and conductivity. Here is an overview of the process:

Wire Drawing: The production of bare copper conductors begins with wire drawing. A large piece of copper rod is passed through progressively smaller dies, reducing its diameter and increasing its length.

Annealing: After wire drawing, the copper wire undergoes annealing, a process that involves heating it and then allowing it to cool slowly. Annealing improves the wire’s flexibility, making it easier to handle during installation.

Coating (Optional): Depending on the specific application, bare copper conductors may be coated with a thin layer of another material to enhance their resistance to corrosion. However, the bare copper conductor is primarily used without any additional coating.

Packaging: Once the bare copper conductors are manufactured, they are packaged in coils or mounted on wooden drums for ease of transportation and storage.

Benefits of Using Bare Copper Conductors

Using bare copper conductors offers several advantages over other types of conductors. Here are the key benefits:

1. High Conductivity

Bare copper conductors have excellent electrical conductivity, allowing for efficient transmission of electrical current. This makes them particularly suitable for applications where power needs to be transferred quickly and effectively.

2. Corrosion Resistance

Copper itself is highly resistant to corrosion, making bare copper conductors an excellent choice for outdoor installations and harsh environments. Their corrosion resistance ensures long-term reliability and durability.

3. Affordability

Compared to other types of conductors, bare copper conductors are relatively inexpensive. This affordability makes them a popular choice for both commercial and industrial applications, providing cost-effective solutions without compromising performance.

4. Ease of Soldering

Bare copper conductors are easy to solder, allowing for secure and reliable connections. Their low resistance and excellent thermal conductivity make them ideal for soldering applications, ensuring efficient heat transfer and strong bonds.

5. Environmental Friendliness

Copper is a highly recyclable material, and bare copper conductors can be easily recycled at the end of their lifespan. Choosing bare copper conductors contributes to sustainable practices and reduces the environmental impact of electrical wiring.

Drawbacks of Using Bare Copper Conductors

While bare copper conductors offer numerous benefits, it is important to consider their drawbacks as well. Here are a few potential concerns:

1. Corrosion and Oxidation

Exposed bare copper conductors can develop a patina over time, which might reduce their effectiveness as conductors. If not properly sealed, they can also be vulnerable to oxidation, leading to shorts and other electrical issues.

2. Softness and Vulnerability

Bare copper is a relatively soft metal, making it susceptible to damage from miss-wiring or loose connections. Care must be taken during installation and maintenance to avoid bending or breaking the conductors.

3. Fire Hazard

A bare copper wiring system can become a fire hazard if not properly maintained. Regular inspections and adherence to electrical safety guidelines are essential to minimize the risk of electrical fires.

To mitigate these concerns, it is crucial to consult a professional electrician before installing or modifying any wiring in your home or business. They can provide expert advice and ensure compliance with safety standards.

Is Bare Copper Conductor the Right Choice for You?

Determining whether a bare copper conductor is the best option for your specific needs depends on various factors. To make an informed decision, consider the following:

1. Application Requirements

Evaluate the requirements of your electrical wiring or grounding system. Consider factors such as voltage levels, environmental conditions, and the need for flexibility or high conductivity.

2. Professional Consultation

Consult with an experienced electrician or industry expert who can assess your specific situation and recommend the most suitable conductor material. Their expertise will help you make an informed decision based on your unique requirements.

3. Comparing Options

Consider alternative conductor materials and their respective advantages and disadvantages. While bare copper conductors offer many benefits, other materials may be more suitable for certain applications or environments.

Once you have determined that a bare copper conductor is the best choice for your needs, you can find reliable suppliers and manufacturers. Conduct thorough research, compare prices, and consider factors such as product quality, certifications, and customer reviews to ensure you get the best product for your specific requirements.

Alternate Names for Bare Copper Conductors

Bare copper conductors are commonly known by different names depending on their specific applications or characteristics:

Tinned Copper: Tinned copper conductors have a thin layer of tin applied to the surface, providing enhanced resistance to corrosion.

They are often used in marine applications.

Annealed Copper: Annealed copper conductors are soft and flexible, making them ideal for use in electrical cables that require bending or maneuverability.

Bundy Copper: Bundy copper conductors are a type of alloy commonly used in water pipes, offering excellent corrosion resistance and durability.

Drawn Copper: Drawn copper conductors are often used in the manufacturing of coins and other metal objects due to their malleability and ease of shaping.

When shopping for bare copper conductors, it is important to clarify the specific type of copper you need based on your application requirements.

How to Solder a Bare Copper Conductor

Soldering a bare copper conductor is a valuable skill for electrical engineers and DIY enthusiasts alike. It allows for secure connections and repairs. Here is a step-by-step guide to soldering a bare copper conductor:

Clean the Area: Before soldering, ensure that the area where you will be soldering is clean and free from dirt or debris. Use a wire brush or sandpaper to clean the surface of the copper, promoting better solder adhesion.

Apply Solder to the Iron: Apply a small amount of solder to the tip of your soldering iron. This helps facilitate the transfer of heat and solder to the joint.

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Heat the Joint: Touch the heated soldering iron tip to the place where you want to connect the bare copper conductors. The heat from the iron will cause the solder to melt and flow into the joint, creating a strong bond.

Apply Solder: Continue applying heat and adding solder until the joint is adequately filled and smooth. Be careful not to apply excessive heat or solder, as it can lead to poor connections or damage to the conductors.

Allow Cooling: Once the joint is filled, allow it to cool before testing with a multimeter or applying any additional stress. Cooling ensures that the solder solidifies and forms a reliable connection.

Remember to practice proper safety precautions when soldering, such as wearing protective goggles and working in a well-ventilated area. If you are new to soldering or dealing with complex electrical connections, it is advisable to seek guidance from a professional.

Tips for Working with Bare Copper Conductors

Working with bare copper conductors requires attention to detail and proper techniques to ensure successful installations and reliable connections. Here are some tips to consider:

Use Proper Tools: Invest in high-quality tools specifically designed for electrical work, such as wire strippers, crimping tools, and heat shrink tubing. The right tools will make the installation process easier and help achieve secure connections.

Proper Stripping and Cutting: When stripping the insulation from the ends of bare copper conductors, be cautious not to damage the copper strands. Use the appropriate wire strippers and ensure that the exposed copper is clean and free from debris.

Secure Connections: When connecting bare copper conductors, ensure that the wires are tightly twisted or crimped together. Loose connections can lead to electrical resistance and potential hazards.

Insulation Protection: Bare copper conductors should be properly insulated to prevent accidental contact with other conductive materials or short circuits. Use heat shrink tubing or electrical tape to provide insulation and protection.

Regular Maintenance: Regularly inspect your bare copper conductors for signs of corrosion, damage, or loose connections. Proper maintenance will extend their lifespan and ensure optimal performance.

By following these tips, you can work effectively with bare copper conductors and achieve reliable electrical connections.

Where to Buy Bare Copper Conductors

When purchasing bare copper conductors, it is crucial to choose a reputable retailer or manufacturer. Consider the following factors when selecting a supplier:

Reputation: Look for suppliers with a strong reputation in the industry, known for delivering high-quality products and excellent customer service. Read reviews and testimonials to gauge their reliability.

Certification and Compliance: Ensure that the supplier’s products meet relevant industry standards and certifications. This ensures that the bare copper conductors you purchase adhere to quality and safety requirements.

Range of Products: Consider the supplier’s range of bare copper conductors, including various sizes, cross-sections, and packaging options. A wide selection allows you to find the most suitable product for your specific needs.

Pricing and Delivery: Compare prices from different suppliers to ensure competitive pricing without compromising product quality. Additionally, consider the supplier’s delivery options and timelines to meet your project requirements.

One reputable manufacturer and supplier of bare copper conductors is Ganpati-Wires. They offer a range of bare copper cables with various cross-sections and packaging options. With their focus on quality and customer satisfaction, Ganpati-Wires is a reliable choice for your bare copper conductor needs.

Conclusion

Bare copper conductors are a versatile and cost-effective option for electrical wiring, grounding systems, and various applications. Their high conductivity, corrosion resistance, and affordability make them a popular choice in residential, commercial, and industrial settings. By understanding their uses, manufacturing process, benefits, and potential drawbacks, you can make informed decisions and utilize bare copper conductors effectively. Remember to consult professionals, follow safety guidelines, and choose reputable suppliers to ensure the best results. Whether you are an electrician or a DIY enthusiast, bare copper conductors are a reliable and efficient solution for your electrical needs.

Both shielded and unshielded twisted-pair copper cable comes in either stranded or solid wire versions. There are plenty of considerations when it comes to choosing one or the other, including standards, environment, application, and cost. Let’s take a look at the differences and considerations, so you can decide whether stranded copper wire or solid copper wire cable is right for your specific installation.

Differences Between Stranded and Solid Wire Cable

Stranded and solid wire cable differ in key ways, including construction, flexibility, and performance.

What Is Stranded Wire Cable?

In a stranded cable, each of the eight copper conductors are made up of multiple “strands” of small-gauge wires that are wound together concentrically in a helix, much like a rope. Stranded wire is typically specified as two numbers, with the first number representing the quantity of strands and the second representing the gauge. For example, a 7X32 (sometimes written as 7/32) indicates that there are 7 strands of 32 AWG wire that make up the conductor.

What Is Solid Wire Cable?

In a solid cable, each of the eight conductors are made up of a single larger-gauge wire. Solid wire is specified by just one gauge number to indicate the size of the conductor, such as 24 AWG. Whether it’s a one-, two-, or four-pair cable, the gauge of the solid conductor is the specification for the cable.

Stranded Wire Cables Are More Flexible than Solid Wire Cables

Beyond the way they're made, another key difference between stranded and solid wire cable is flexibility.

• • Stranded wire cables are much more flexible and can withstand more bending. In terminations, however, those flexible strands can break or become loose over time.
• • Solid wire cables are more rigid and can break if flexed too far or too frequently. However, solid conductors will hold their shape over time and seat properly within insulation displacement connectors (IDCs) on jacks, patch panels, and connecting blocks.

Solid Wire Cables Are Better Conductors

A less-obvious difference between stranded and solid wire cable is performance.

• • In general, solid wire cables are better electrical conductors than stranded wire cables, and they provide superior, stable electrical characteristics over a wider range of frequencies. They’re also considered more rugged and less likely to be affected by vibration or susceptible to corrosion, since they have less surface area than stranded conductors.
• • Solid wire can also carry more current than stranded wire. Higher-gauge (thinner) conductors have more insertion loss than lower-gauge (thicker) conductors; stranded cables exhibit 20 to 50 percent more attenuation than solid copper conductors (20 percent for 24 AWG and 50 percent for 26 AWG). Because the cross section of a stranded conductor is not all copper (there’s some air in there), they also have higher DC resistance than solid cables.

Now that you understand the differences between stranded and solid wire cable, let’s cover what you need to consider when making a choice.

Is Stranded Wire Better Than Solid Wire?

Which type of wire is the best choice depends on the installation's requirements.

When to Use Solid Wire Cable

When it comes to 90-meter horizontal permanent links, there’s no choice: whether it's shielded or unshielded twisted pair, both TIA and ISO/IEC standards require solid wire cable. Stranded cable (24 and 26 AWG) is limited to patch cords and 10-meter lengths within a 100-meter channel.

When to Use Stranded Wire Cable

Because stranded cables are more flexible and can withstand bending, they make excellent patch cords for equipment connections and cross-connects where cables are frequently bent and manipulated; at just 10 meters of the channel, the increased insertion loss and resistance aren’t a factor in the overall channel performance. However, smaller 28 AWG stranded patch cords that have even more insertion loss and resistance due to their smaller gauge do have some limitations — get the Skinny on 28 AWG Patch Cords to learn more.

Open office environments, however, are special situations; they’re faced with regular reconfigurations and may require a more flexible cabling system. In those installations, the standards allow stranded patch cords to take up more than 10 meters of the channel. However, if you’re using more than 10 meters of stranded cable in a channel, industry standards require de-rating the overall channel length to accommodate for the greater insertion loss and DC resistance.

When it comes to de-rating stranded cable per industry standards, the overall gauge is a factor: higher-gauge (thinner) cables have a higher de-rating factor. The de-rating for 26 AWG stranded cable is 0.5, while 24 AWG is only 0.2, and 22 AWG stranded cables require no de-rating at all.

Here are the calculations to determine overall channel length, where H=horizontal cable length, D=de-rating factor, C= total stranded cable length and T=total channel length.

For example, if you’re using 60 meters of horizontal solid category 6A cable and 40 meters of stranded 24 AWG category 6A patch cable with a 0.2 de-rating factor, the total length of the channel must be reduced to 97.5 meters. (If you prefer the actual math: total stranded cable length = [105-60]/[1 + 0.2], or 37.5, and total channel length = 60+37.5, or 97.5 meters.)  If you’re using 26 AWG stranded cable with a 0.5 de-rating, the channel length needs to be reduced to 90 meters.

PoE Makes Greater Demands on Stranded Cable Patch Cords

While stranded cable is the norm for patch cords at patching areas in the telecommunications room (TR) and at the work area (perhaps longer than 10 meters in open offices), a primary application to consider in today’s LANs warrants the use of solid patch cords: Power over Ethernet (PoE). When PoE is delivered over twisted-pair copper cable, some of the power dissipates as heat. When power dissipates as heat, the cable temperature increases. With higher insertion loss and DC resistance, stranded patch cords are more likely to exhibit degraded transmission performance at elevated temperatures.

While not typically a concern in environmentally controlled spaces like the TR, stranded patch cords could become an issue once you start connecting devices in the ceiling — think wireless access points, security cameras, LED lights, and more. In best practice, if the environment isn’t temperature controlled and the cable doesn’t have to bend much, solid cable patch cords should be used. If you do use stranded patch cords in uncontrolled environments, it’s better to keep them short (about 5 meters or less). And when it comes to higher-temperature environments, industry standards require de-rating channel length for that, too; more cables in a bundle, each generating more heat, can require even more length de-rating (though there can be An Exception to Every Rule).

Balancing the Cost Difference Between Stranded and Solid Wire

While more strands in a conductor mean greater flexibility, a higher strand count also means a higher price. To keep costs down, stranded category 6 and category 6A cable are designed to strike a balance: enough strands to maintain proper flexibility, but not so many that it creates a dramatic price difference. You don’t have to compromise performance (or standards compliance) by selecting stranded wire cable instead of solid for environments and applications for which it’s not suited. Keep your stranded cables in environmentally controlled areas that require greater flexibility, and use solid wire cable where rugged performance (and little bending) is required.

Whether it’s patch cords, permanent links, or channels, you can configure a Fluke Networks Versiv™ tool to certify the cable's performance.

View the Versiv Configurator

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