Technical data

Cable selection tables from the Alum Cable Kaveh catalogue: copper and aluminium equivalents, current ratings, correction factors and laying instructions.

This section in the catalogue (PDF)

Copper to aluminium equivalents

Copper and aluminium are the principal metals of electrical conductors. Aluminium has 1.6 times the resistance of copper but about 30% of its density, so to carry a given amount of electrical energy roughly half the weight of aluminium is needed. The tables below are a general guide to substituting aluminium cables for copper ones.

Single-core cables
Copper	1×25	1×35	1×50	1×70	1×95	1×120	1×150	1×185	1×240	1×300
Aluminium	1×50	1×70	1×95	1×120	1×150	1×185	1×240	1×300	1×400	1×500

Three-core sector cables
Copper	3×50	3×70	3×95	3×120	3×150	3×185	3×240
Aluminium	3×95	3×120	3×150	3×185	3×240	3×300	—

Three-and-a-half-core sector cables
Copper	3×25/16	3×35/16	3×50/25	3×70/35	3×95/50	3×120/70	3×150/70	3×185/95
Aluminium	3×50/25	3×70/35	3×95/50	3×120/70	3×150/70	3×185/95	3×240/120	3×300/150

Four-core sector cables
Copper	4×50	4×70	4×95	4×120	4×150	4×185
Aluminium	4×95	4×120	4×150	4×185	4×240	4×300

Multi-core cables
Copper	2×6	2×10	4×6	4×10	4×16	4×25	4×35
Aluminium	2×10	2×16	4×10	4×16	4×25	4×35	4×50

A dash in these tables: the print edition lists no equivalent for that size.

Cross-section conversion: AWG, MCM and square inch

AWG / MCM	mm²
19	0.653
18	0.823
17	1.04
16	1.31
15	1.65
14	2.08
13	2.62
12	3.31
11	4.17
10	5.26
9	6.63
8	8.37
7	10.55
6	13.3
5	16.77
4	21.15
3	26.67
2	33.63
1	42.41
1/0	53.48
2/0	67.43
3/0	85.03
4/0	107.2
250	126.61
300	152
400	202.71
500	253.35
600	304
700	354.71
800	405.35
1000	506.71

in²	mm²
0.001	0.65
0.0015	0.97
0.002	1.29
0.003	1.94
0.0045	2.9
0.005	3.23
0.007	4.52
0.008	5.16
0.01	6.45
0.013	8.39
0.0145	9.35
0.02	12.9
0.0225	14.52
0.03	19.35
0.04	25.81
0.06	38.71
0.1	64.52
0.15	96.77
0.2	129.03
0.25	161.25
0.3	193.55
0.4	258.06
0.5	322.58
0.6	387
0.75	483.87
1.0	645

Current rating of copper wiring cables

Permissible continuous current at 30 °C ambient, with the protective fuse rating. Group 1: one or more single-core wires in conduit. Group 2: light PVC-sheathed cables, flat and flexible cables. Group 3: single-core wires installed free in air, with a clearance of one diameter.

Cross-section mm²	Group 1: current (A)	Group 1: fuse (A)	Group 2: current (A)	Group 2: fuse (A)	Group 3: current (A)	Group 3: fuse (A)
0.75	—	—	12	6	15	10
1	11	6	15	10	19	10
1.5	15	10	18	10	24	20
2.5	20	16	26	20	32	25
4	25	20	34	25	42	35
6	33	25	44	35	54	50
10	45	35	61	50	73	63
16	61	50	82	63	98	80
25	83	63	108	80	129	100
35	103	80	135	100	†	125
50	132	100	168	125	198	160
70	165	125	207	160	245	200
95	197	160	250	200	292	250
120	235	200	292	250	344	315
150	—	—	335	250	391	315
185	—	—	382	315	448	400
240	—	—	453	400	528	400
300	—	—	504	400	608	500
400	—	—	—	—	726	630
500	—	—	—	—	830	630

† The printed value does not agree with its neighbouring rows and is under review.

Current rating of copper power cables

Cross-section mm²	Single-core, DC system, in ground (A)	Single-core, DC system, in air (A)	Two-core, in ground (A)	Two-core, in air (A)	Three and four-core, in ground (A)	Three and four-core, in air (A)	Three single cores flat, 3-phase, in ground (A)	Three single cores flat, 3-phase, in air (A)	Three single cores trefoil, 3-phase, in ground (A)	Three single cores trefoil, 3-phase, in air (A)
1.5	37	26	30	21	27	18	—	—	—	—
2.5	50	35	41	29	36	25	—	—	—	—
4	65	46	53	38	46	34	—	—	—	—
6	83	58	66	48	58	44	—	—	—	—
10	110	80	88	66	77	60	—	—	—	—
16	145	105	115	90	100	80	120	100	110	86
25	190	140	150	120	130	105	155	135	140	120
35	235	175	180	150	155	130	185	170	170	145
50	280	215	—	—	185	160	220	205	200	180
70	350	270	—	—	230	200	270	260	245	225
95	420	335	—	—	275	245	325	320	295	280
120	480	390	—	—	315	285	370	375	335	330
150	540	445	—	—	355	325	420	430	380	380
185	620	510	—	—	400	370	470	†	430	440
240	720	620	—	—	465	435	540	590	490	530
300	820	710	—	—	—	—	620	680	550	610
400	960	850	—	—	—	—	710	820	650	740
500	1110	1000	—	—	—	—	820	960	740	860

† The printed value does not agree with its neighbouring rows and is under review.

Current rating of aluminium power cables

Cross-section mm²	Single-core, DC system, in ground (A)	Single-core, DC system, in air (A)	Two-core, in ground (A)	Two-core, in air (A)	Three and four-core, in ground (A)	Three and four-core, in air (A)	Three single cores flat, 3-phase, in ground (A)	Three single cores flat, 3-phase, in air (A)	Three single cores trefoil, 3-phase, in ground (A)	Three single cores trefoil, 3-phase, in air (A)
4	50	36	41	29	36	26	—	—	—	—
6	64	45	51	37	45	34	—	—	—	—
10	85	62	68	51	60	46	—	—	—	—
16	115	82	89	70	78	62	93	78	84	67
25	150	110	115	94	100	82	120	105	110	91
35	180	135	140	115	120	100	145	130	130	115
50	215	165	165	140	145	125	170	160	155	140
70	270	210	200	180	175	155	210	200	190	175
95	325	260	245	215	215	190	250	245	230	220
120	375	300	275	250	245	220	290	290	260	255
150	420	350	315	290	275	250	325	335	295	295
185	480	400	355	335	310	285	365	380	330	340
240	560	480	415	395	360	340	420	460	380	410
300	640	550	465	460	410	390	475	530	430	470
400	740	660	540	550	470	460	550	640	500	570
500	860	780	—	—	—	—	630	740	570	670

Correction factors

For cables installed under water the load may be raised to 1.15 times the in-ground value. Where service conditions for buried cables differ, multiply the tabulated values by factors f1 and f2.

Factor f1: ground temperature and thermal resistivity of soil. A resistivity of 100 is for moist areas with continuous rainfall, 150 for areas with medium rainfall and 250 for dry areas and deserts.

Ground temp. °C	Resistivity 100, load factor 0.70	Resistivity 100, load factor 0.85	Resistivity 100, load factor 1.00	Resistivity 150, load factor 0.70	Resistivity 150, load factor 0.85	Resistivity 150, load factor 1.00	Resistivity 250, load factor 0.70 to 1.00
10	1.06	1.01	0.97	0.94	0.92	0.89	0.83
15	1.03	0.99	0.94	0.91	0.88	0.86	0.79
20	1.00	0.96	0.91	0.87	0.85	0.83	0.76
25	0.97	0.93	0.88	0.84	0.82	0.79	0.72
30	—	—	—	0.80	0.78	0.76	0.68
35	—	—	—	0.77	0.74	0.72	0.63

Factor f2: number of systems side by side in the ground. Three arrangements, left to right: single cores flat, 7 cm apart; trefoil groups 25 cm apart; multi-core cables or trefoil groups 7 cm apart.

No. of systems	Flat, load factor 0.70	Flat, load factor 0.85	Flat, load factor 1.00	Trefoil 25 cm, load factor 0.70	Trefoil 25 cm, load factor 0.85	Trefoil 25 cm, load factor 1.00	Multi-core 7 cm, load factor 0.70	Multi-core 7 cm, load factor 0.85	Multi-core 7 cm, load factor 1.00
1	1.00	0.92	0.85	1.00	0.93	0.87	1.00	0.93	0.87
2	0.87	0.78	0.71	0.89	0.82	0.75	0.85	0.77	0.71
3	0.78	0.69	0.62	0.81	0.74	0.67	0.75	0.67	0.61
4	0.74	0.65	0.58	0.77	0.70	0.64	0.70	0.62	0.56
5	0.70	0.61	0.55	0.73	0.67	0.60	0.65	0.58	0.52
6	0.68	0.60	0.53	0.71	0.65	0.59	0.63	0.55	0.50
8	0.65	0.57	0.51	0.68	0.62	0.56	0.58	0.52	0.46
10	0.63	0.55	0.49	0.65	0.60	0.54	0.56	0.49	0.44

If the ambient temperature for cables in air differs from 30 °C, multiply the permissible current by the factor below.

Ambient temp. °C	10	15	20	25	30	35	40	45
Factor	1.22	1.17	1.12	1.07	1.00	0.93	0.87	0.79

Group rating factors for cables in air

Group rating factors for multi-core cables in air

Arrangement	No. of troughs or racks	No. of cables
Arrangement	No. of troughs or racks	1	2	3	6	9
Laid on the ground		0.95	0.9	0.88	0.85	0.84
Laid on cable troughs	1	0.95	0.9	0.88	0.85	0.84
Laid on cable troughs	2	0.90	0.85	0.83	0.81	0.80
Laid on cable troughs	3	0.88	0.83	0.81	0.79	0.78
Laid on cable troughs	6	0.86	0.81	0.79	0.77	0.76
Laid on cable racks	1	1.00	0.98	0.96	0.93	0.92
Laid on cable racks	2	1.00	0.95	0.93	0.90	0.89
Laid on cable racks	3	1.00	0.94	0.92	0.89	0.88
Laid on cable racks	6	1.00	0.93	0.90	0.87	0.86
Arranged on the wall, one above the other, clearance d		1.00	0.93	0.90	0.87	0.86
Arranged on the wall, one above the other, clearance 2d		No restriction

Group rating factors for multi-core cables in air and touching each other

Arrangement	No. of troughs or racks	No. of cables
Arrangement	No. of troughs or racks	1	2	3	6	9
Laid on the ground		0.90	0.84	0.80	0.75	0.73
Laid on cable troughs	1	0.95	0.84	0.80	0.75	0.73
Laid on cable troughs	2	0.95	0.80	0.76	0.71	0.69
Laid on cable troughs	3	0.95	0.78	0.74	0.70	0.68
Laid on cable troughs	6	0.95	0.76	0.72	0.68	0.66
Laid on cable racks	1	0.95	0.84	0.80	0.75	0.73
Laid on cable racks	2	0.95	0.80	0.76	0.71	0.69
Laid on cable racks	3	0.95	0.78	0.74	0.70	0.68
Laid on cable racks	6	0.95	0.76	0.72	0.68	0.66
Arranged on the wall, one above the other, touching		0.95	0.76	0.73	0.68	0.66
Arranged on the wall, spaced apart, in layers		No restriction

Group rating factors for single-core cables in air

Arrangement	No. of troughs or racks	No. of cables
Arrangement	No. of troughs or racks	1	2	3
Laid on the ground		0.95	0.90	0.88
Laid on cable troughs	1	0.95	0.90	0.88
Laid on cable troughs	2	0.90	0.85	0.83
Laid on cable troughs	3	0.88	0.83	0.81
Laid on cable troughs	6	0.86	0.81	0.79
Laid on cable racks	1	1.00	0.98	0.96
Laid on cable racks	2	1.00	0.95	0.93
Laid on cable racks	3	1.00	0.94	0.92
Laid on cable racks	6	1.00	0.93	0.90
		No restriction
Arranged on the wall, one above the other, clearance d		0.89	0.86	0.84

Permissible short-circuit current chart

Permissible short-circuit current of PVC insulated cables against disconnection time

Permissible short-circuit current of PVC insulated cables, rated voltage 1 to 10 kV, against disconnection time; adiabatic formula I = k·A/√t.

k = 115 for copper and 76 for aluminium; conductor at 70 °C before the short circuit and 160 °C at its end; valid up to 300 mm².

t disconnection time in seconds, I short-circuit current in kiloamperes, A conductor cross-section in mm². Solid lines copper, dashed lines aluminium.

Current rating of 1.9/3.3 kV copper cable

Cross-section mm²	Three-core, in ground (A)	Three-core, in air (A)	Three single cores, 3-phase, in ground (A)	Three single cores, 3-phase, in air (A)
50	170	155	188	180
70	208	190	232	230
95	252	235	277	285
120	286	275	311	325
150	320	310	346	370
185	367	355	390	425
240	421	420	450	500
300	470	475	504	570
400	528	550	559	640

Laying instructions

When laying plastic-insulated power cable, the cable should not be colder than -5 °C. Below that, warm the cables adequately beforehand, for example by storing them for several days in a heated area (about 10 °C) or with hot-air equipment.
The bending radius should not be smaller than 15 times the overall diameter. For a single bend, for example before a sealing end, it may in the extreme case be halved.
When laying by machine, observe the permissible tensile force. With a pulling head on the conductors: F = A × 50 N for copper and F = A × 30 N for aluminium. With a pulling stocking: F = 9 × D² for all wire-armoured cables; for plastic cables without metal sheath (such as NYY and NYCY) the same A × 50 and A × 30.
A is the total conductor cross-section in mm² (without screen and concentric conductor); D is the overall cable diameter in mm.

Laying instructions for telecommunication cables

When laying plastic-insulated telecommunication cables, the permissible temperature range is as follows:

PVC insulated and sheathed cables-5 to +50 °C
PE insulated and sheathed cables-20 to +50 °C
Service temperature range for PE or PVC insulated and sheathed cables-30 to +60 °C

During laying of plastic telecommunication cables, particular attention must be paid to the permissible tensile force. Generally this limit is expressed as the maximum permissible cable length that can be drawn in conduits, from the following formula:

L_max = F_m / (η × w) (km)

If the cables are drawn in conduit with a pulling stocking, the force Fm is obtained from the following formula:

F_m = 1.57 (D - S) S (kgf)

Doverall diameter of cable in mm
Souter sheath thickness in mm
Fmmax. permissible tensile force in kgf

Cables armoured with round wires are generally drawn in conduit with the armouring formed into a loop, so the force Fm is obtained from the following formula:

F_m = 10.6 n d² (kgf)

nnumber of wires in the armouring
dwire armour diameter in mm
Fmmax. permissible tensile force in kgf

Pulling-in-conduit factors (η):

Where the route is unknown1.0
For cable laid in cast-concrete cable conduits0.9
For hard PE or PVC pipes0.5 to 0.3

w: cable weight in kg/km

Example: the maximum permissible length of plastic cable type A 2 Y (st) 2 Y 100 × 2 × 0.8 drawn with a pulling stocking in hard PVC pipe:

F_m = 1.57 (D - S) S = 1.57 (30.5 - 2) × 2 = 89.5 kgf

L_max = F_m / (η × w) = 89.5 / (0.5 × 1570) = 0.114 km = 114 m

The minimum bending radius for plastic insulated and sheathed telecommunication cable:

Cable with several bends in its route20 times the overall diameter
Cable with only one bend in its route15 times the overall diameter

Transporting, storing and handling cable drums

Always store and move the drum upright; never lay it on its flange.
In storage, chock every drum so it cannot roll. The wedge sits under the flanges or across the full width of the drum.
Do not stack drums. Only drums with protective lagging may be stacked flange to flange, and the full width of the lower row must be protected.
Roll a drum only in the direction of the arrow on it (the winding direction).
To lift a drum, pass a shaft through its centre and use a spreader beam.
On a forklift, the forks must be longer than the drum is wide and carried 15 to 20 cm (6 to 8 in) above the ground.

Aluminium and copperwire and cable,from Kaveh Industrial City

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Building wire and cord

Low-voltage power cable

Armoured and screened power cable

Control and instrumentation cable

Overhead conductor and cable