As construction and maintenance costs rise, aluminum wire offers a cost-effective alternative to copper—delivering material savings of up to 80 percent. Backed by modern alloy advancements and NEC approval, aluminum conductors provide reliable performance across industrial utilities, commercial feeders, and heavy service entrances.
Have you considered using aluminum conductors for your plants? As facilities become more expensive to construct and maintain, the necessity of looking to alternative materials becomes increasingly critical to cost-conscious builders. One of these alternative materials, aluminum wire, has drawn much attention lately in the construction industry, especially as copper prices increase and the aluminum market remains steady. Price alone is a compelling argument to consider modern aluminum conductors—one can expect to spend approximately 3.5 to 5 times more on copper wire than aluminum wire.
Key Applications of Aluminum Conductors
Aluminum conductors are already being used efficiently and are widespread within the construction industry, successfully installed in many applications:
- Utilities: Aluminum has a long-standing track record in utility applications, providing substantial performance in commercial and institutional settings.
- Commercial Buildings: Aluminum is used frequently in heavy commercial facilities, where metal-clad (MC) cable with aluminum feeders has become a staple in high-rise buildings, stadiums, wastewater treatment facilities, and manufacturing plants.
- Conductors: Contractors install them in service entrance conductors, large conductors, and power distribution conductors.
Quick Reference: Copper vs. Aluminum Comparison
| Feature / Factor | Modern Aluminum Conductors | Copper Conductors |
| Material Cost | Significantly lower (75% to 80% cheaper overall) | 3.5 to 5 times more expensive |
| Market Stability | Stable pricing with steady, minimal increases | Historically volatile with substantial price fluctuations |
| Weight | Weighs about 50 percent less than copper, aiding installation flexibility | Heavier, requiring more labor-intensive handling |
The Benefits of Using Aluminum in Your Facilities
1. Cost Savings
The most obvious advantage in selecting aluminum as a conductor is the savings incurred due to lower material prices, which can reach up to 80 percent if aluminum is utilized in every possible way. A commodity price comparison study found that the total price of aluminum wiring was 75 to 80 percent less than if the client had chosen to use only copper. Furthermore, while aluminum prices rise only steadily in minimal percentages, copper has experienced historic price jumps (such as a 91 percent increase in a single year).
2. Technical Design Advances
Historical “horror” stories associated with aluminum are largely outdated, stemming from technical design problems of older alloys and improper installations (such as landing small aluminum wire on steel screws with different expansion properties). Modern product advancements in aluminum chemistry—specifically new alloys—have eliminated many historical problems, offering better conductivity, creep resistance, strength, and workability. Additionally, aluminum weighs about 50 percent less than copper, contributing to easier construction installation methods like bending, pulling cables, and training cables in tight enclosures.
3. National Electrical Code (NEC) Approval
One of the most compelling arguments for using aluminum is that the NEC has approved its use. Section 310.14 states that aluminum conductors “shall be made of an AA-8000 series electrical grade aluminum alloy conductor material,” and Chapter 9 includes tables detailing resistance, temperature ratings, and ampacities.
Where Can You Use Aluminum?
There are numerous potential applications for aluminum in facilities, with the most significant financial savings occurring where larger cables are used:
- Service Entrances & Feeders: Recommended for use from transformers to switchboards in service entrance applications, and from switchboards to motor control centers in feeder applications, provided space considerations for panel board terminations are met.
- Sizing Recommendation: Industry guidelines recommend using aluminum wiring at 1/0 or larger, since installing smaller branch circuit conductors becomes more expensive due to space requirements for terminations. Aluminum wire is commercially available to service 50 amps and above, with a standard ampacity limit of 100 amps (though specifiers often use higher limits).
- Medium Voltage Applications: Prime targets for substituting copper with aluminum, as most medium-voltage applications involve wire that is 1/0 and larger.
Contact TSCA Electrical Group today for expert assistance with your facility requirements, or explore our complete catalog of industrial electrical products and services.