6 Aluminum & Copper Cables

hplooi@unifi.my 26th May 2011

 4 6 WIRING DESIGN – AL & CU CABLES

C u r r e n t l y t h e m a r ke t f o r c o p p e r i s u n s t a b l e
and copper price has become high. This has
affected the demand for copper cables with
Clients and contractors requesting
designers to change from copper to
aluminum cables.

What are the possible impact on design, cost and future

operation. Is AL cables a fire hazard?

Unfortunately professional engineers faced with such

request cannot brush them off easily due to the cost
implication neither can they satisfactorily answer their
clients.
hplooi@unifi.my 26th May 2011
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hplooi@unifi.my 26th May 2011

 7 6 WIRING DESIGN – AL & CU CABLES

Properties of Material
Material Thermal Volumetric Electric Melting
expansion, at coefficient, β, Resistivity Point
25 °C at 20 °C ρ [nΩ·m] at
µm-m-1 K-1 (10−6/°C) 20 °C
Aluminum 23.1 87 28.2 933 °C

Copper 16.5 51 16.8 1084.6 °C

Steel 17.3 51.9 ~ 100 ?? °C

 AL has higher coefficient of expansion

 A L h a s a h i g h e r e l e c t r i c r e s i s t i v i t y. A l c a b l e s i z e w i l l
have to be one size larger

hplooi@unifi.my 26th May 2011

 8 6 WIRING DESIGN – AL & CU CABLES

Possible hazard for Copper Cables

 Galvanic reaction between AL and copper terminals.
Proper AL-Cu terminals will be required.
 Al has a higher coefficient of expansion. Cable
connections may loosen in the long run.
 AL wiring not properly installed is a fire hazard mainly
due to loosening connections at terminals.
 AL subject to galvanic reaction with copper and steel
terminals.

hplooi@unifi.my 26th May 2011

 9 6 WIRING DESIGN – AL & CU CABLES

Best Practice for AL cabling systems

 A l l c a b l e s < 7 0 m m ² s h o u l d b e c o p p e r. I n d i a
h a s t h e m o s t ex p e r i e n c e i n u s i n g A l c a b l e
system inbuilding. In India the rule of <
70mm² to be copper holds.
 Cables used outdoor may be AL.
 Proper cable connectors at terminals should
be used. Al cable terminations and
connectors are recognised as a major cause of
fire from overheating.
 Al cabling system should be subject to annual
check of cable terminations.
hplooi@unifi.my 26th May 2011
 10 6 WIRING DESIGN – AL & CU CABLES

Conclusion
1. Engineers should ensure proper terminations and cable
bimetal joints/lugs are used.
2. Practitioners should properly advise client and property
manager on the need for regular check due to risk of fire
hazard from AL cable terminations.
3. Cost savings in AL cables may have consequences for
maintenance!

hplooi@unifi.my 26th May 2011