Copper vs. Aluminum Medium Voltage Cables: Which Is Better for Your Project?

By JianYunCable -



Table of Contents

1. Overview of Copper and Aluminum MV Cables

Medium voltage power cables (6–35 kV) are designed for efficient power transmission in applications such as industrial plants, mining operations, and renewable energy systems. The choice of conductor material—copper or aluminum—significantly impacts performance, cost, and suitability. Copper offers superior conductivity and durability, while aluminum is lighter and more cost-effective. Both are used in MV cables with insulation (e.g., XLPE), shielding (e.g., copper tape), and armoring (e.g., SWA). Henan Province Jianyun Cable Co., Ltd. provides TUV- and CCC-certified copper and aluminum MV cables, ensuring reliability for diverse projects.

2. Key Differences Between Copper and Aluminum MV Cables

The differences between copper and aluminum MV cables influence their performance and suitability:

FeatureCopper MV CablesAluminum MV Cables
ConductivityHigher (1.68 µΩ·cm at 20°C); lower resistance (e.g., 0.017 Ω/km for 50 mm²).Lower (2.82 µΩ·cm at 20°C); higher resistance (e.g., 0.028 Ω/km for 50 mm²).
Current CapacityHigher (e.g., 200 A for 50 mm² at 11 kV).Lower (e.g., 160 A for 50 mm² at 11 kV); requires larger cross-section (e.g., 70 mm²) for equivalent capacity.
WeightHeavier (e.g., 8.96 g/cm³); increases installation complexity.Lighter (e.g., 2.70 g/cm³); easier to handle and install.
CostHigher (e.g., $15–50/m for 11 kV, 50 mm²).Lower (e.g., $8–30/m for 11 kV, 70 mm²).
DurabilityMore resistant to corrosion and mechanical stress; longer lifespan (30+ years).Prone to oxidation; requires anti-corrosion coatings in harsh environments.
FlexibilityMore flexible for tight spaces (Class 2 stranded).Less flexible; larger bending radius required.
TerminationEasier to terminate; compatible with standard connectors.Requires specialized connectors and anti-oxidation compounds.
Example ProductJianyun Cable’s 11 kV XLPE-insulated, copper conductor, SWA-armored cable.Jianyun Cable’s 11 kV XLPE-insulated, aluminum conductor, SWA-armored cable.

3. Applications of Copper and Aluminum MV Cables

3.1. Copper MV Cables

  • Industrial Plants: Powering critical machinery (e.g., motors, presses) where high conductivity and reliability are paramount.
  • Data Centers: Supporting high-power loads with minimal voltage drop.
  • Urban Infrastructure: Used in confined spaces (e.g., airports, subways) due to flexibility and durability.
  • Example: Jianyun Cable’s 15 kV copper conductor cable for data center power distribution.

3.2. Aluminum MV Cables

  • Utility Grids: Long-distance power distribution where cost and weight are critical.
  • Renewable Energy: Connecting solar farms or wind turbines to the grid, leveraging lower cost.
  • Mining Operations: Used in surface installations where weight reduction simplifies handling.
  • Example: Jianyun Cable’s 33 kV aluminum conductor cable for solar farm grid integration.

4. Technical Specifications and Standards

Both copper and aluminum MV cables must meet rigorous standards for safety and performance:

  • Conductor:
    • Copper: ≥99.9% purity, Class 2 stranded (IEC 60228), resistance <0.017 Ω/km for 50 mm².
    • Aluminum: High-purity, Class 2 stranded, resistance <0.028 Ω/km for 50 mm².
  • Insulation:
    • XLPE (90°C) or EPR; thickness 2.5–8 mm (e.g., 3.4 mm for 11 kV per IEC 60502-2).
    • Dielectric strength ≥20 kV/mm; partial discharge <10 pC.
  • Shielding:
    • Copper tape or wire for electric field management and grounding.
  • Sheathing and Armoring:
    • PVC, PE, LSZH, or PUR sheath; steel wire armor (SWA) or steel tape for mechanical protection.
  • Voltage Rating:
    • 6–35 kV (e.g., 6/10 kV, 12/20 kV, 18/30 kV).
  • Standards:
    • IEC 60502-2: MV power cables (6–30 kV).
    • IEC 60038: Voltage classification.
    • IEC 60332-3: Flame-retardant properties.
    • IEC 60754-1/IEC 61034: LSZH requirements for low smoke and toxicity.
    • RoHS/REACH: Restrictions on hazardous substances.
  • Certifications: Jianyun Cable provides TUV, CCC, and ISO 9001-certified copper and aluminum MV cables.
SpecificationCopper MV CablesAluminum MV Cables
ConductorCopper, Class 2, <0.017 Ω/km for 50 mm².Aluminum, Class 2, <0.028 Ω/km for 50 mm².
InsulationXLPE or EPR, 2.5–8 mm, ≥20 kV/mm.XLPE or EPR, 2.5–8 mm, ≥20 kV/mm.
ShieldingCopper tape/wire, <10 pC partial discharge.Copper tape/wire, <10 pC partial discharge.
SheathingPVC, PE, LSZH, or PUR; SWA or tape armoring.PVC, PE, LSZH, or PUR; SWA or tape armoring.
Voltage Rating6–35 kV.6–35 kV.
StandardsIEC 60502-2, IEC 60038, IEC 60332-3.IEC 60502-2, IEC 60038, IEC 60332-3.

5. Selection Criteria for Copper vs. Aluminum MV Cables

Choosing between copper and aluminum MV cables depends on project-specific factors:

  • Electrical Requirements:
    • Copper: Preferred for high-current applications (e.g., 200 A at 11 kV) with minimal voltage drop; ideal for compact installations.
    • Aluminum: Suitable for lower-current, long-distance runs; requires larger cross-section (e.g., 70 mm² vs. 50 mm² copper) per IEC 60364.
  • Environmental Conditions:
    • Copper: Better for corrosive environments (e.g., coastal areas, chemical plants) due to natural corrosion resistance.
    • Aluminum: Requires anti-corrosion coatings in harsh environments; suitable for dry, non-corrosive settings.
  • Installation Needs:
    • Copper: Easier to terminate and more flexible; ideal for tight spaces with 6–10D bending radius.
    • Aluminum: Lighter, reducing installation costs for overhead or long runs; requires specialized connectors.
  • Budget Constraints:
    • Copper: Higher upfront cost but lower lifecycle cost due to durability.
    • Aluminum: Lower initial cost, ideal for budget-constrained projects with long cable runs.
  • Safety and Compliance:
    • Ensure compliance with IEC 60502-2 and regional standards (e.g., G-Mark for GCC markets).
    • Verify TUV, UL, or CCC certifications via official databases (e.g., TUV Certipedia).
  • Supplier Reliability:
    • Partner with manufacturers like Jianyun Cable, offering TUV-certified copper and aluminum MV cables (e.g., showcased at Elektro 2025 in Moscow).
    • Request batch-specific test reports (e.g., insulation resistance >1000 MΩ/km) and factory audits (e.g., SGS).

6. Challenges and Solutions

ChallengeSolution
High Cost of CopperUse aluminum for budget-constrained projects with long runs; optimize conductor size (e.g., 70 mm² aluminum vs. 50 mm² copper).
Aluminum OxidationApply anti-oxidation compounds and use sealed connectors for aluminum cables in humid or corrosive environments.
OverheatingSelect appropriately sized conductors (e.g., 50 mm² copper for 200 A) and apply derating (e.g., 0.91 at 40°C per IEC 60364).
Counterfeit ProductsSource from Jianyun Cable with TUV/CCC certifications; verify via official databases.
Installation ComplexityUse copper for tight spaces and easier termination; use aluminum for lighter, long-distance runs with proper jointing.

7. Conclusion

Choosing between copper and aluminum medium voltage power cables (6–35 kV) depends on project requirements for conductivity, cost, weight, and environmental conditions. Copper offers superior conductivity, durability, and flexibility, making it ideal for high-current, compact, or corrosive environments. Aluminum is cost-effective and lighter, suitable for long-distance runs and budget-constrained projects. Both comply with standards like IEC 60502-2 and IEC 60038, ensuring safety and performance. Henan Province Jianyun Cable Co., Ltd. provides TUV- and CCC-certified copper and aluminum MV cables, tailored for industrial, utility, and renewable energy applications. By evaluating electrical, environmental, and budgetary factors, and partnering with trusted suppliers, users can select the optimal cable for safe, efficient, and durable power distribution systems lasting 20–30 years.

Source: JianYunCable.

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