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Raytron Technical Review RESEARCH ARTICLE WP-07-05

Underground Cable Applications of CCA

RAYTRON Technical Team1

1RAYTRON Group, China

Published: March 2026 Version: 1.0
DOI: 10.1000/raytron.WP-07-05

1. Introduction

1.1 Underground Cable Benefits

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Figure fig1 Figure 1: Underground cable installation methods and benefits
BenefitDescription
ReliabilityWeather independent
AestheticsNot visible
SafetyNo overhead hazards
Right-of-waySmaller footprint

1.2 CCA Opportunity

FactorCuAlCCA
ConductivityHighModerateGood
CostHighLowModerate
WeightHeavyLightLight
TerminationEasyDifficultEasier than Al

2. Underground Cable Types

2.1 Distribution Cables

TypeVoltageApplication
Secondary<1 kVService to customer
Primary5-35 kVDistribution
Transmission>35 kVBulk power

2.2 Installation Methods

MethodDescriptionCCA Use
Direct burialIn groundPossible
ConduitIn pipeGood
Cable trayAbove groundGood
Duct bankMultiple conduitsGood

2.3 Insulation Types

InsulationTemperatureApplication
XLPE90°CStandard
EPR90°CFlexible
PILC85°CLegacy

3. CCA Advantages

3.1 Cost Savings

ComparisonMaterial Savings
CCA vs Cu30-50%
CCA vs AlSimilar cost, better performance

3.2 Weight Savings

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Figure fig2 Figure 2: Weight comparison per kcmil for different conductor materials
MaterialWeight per kcmil
Cu0.37 kg/m
CCA0.14 kg/m
Al0.12 kg/m

3.3 Termination Benefits

AdvantageDescription
Cu surfaceStandard terminations
No oxide issuesUnlike Al
Standard hardwareCu-rated connectors work

3.4 Corrosion Resistance

EnvironmentCuAlCCA
UndergroundGoodPoorGood
MoistureGoodPoorGood
SoilGoodVariableGood

4. Installation Considerations

4.1 Handling

PracticeCCA
Pulling tensionSimilar to Al
Bending radiusPer cable spec
TrainingStandard

4.2 Splicing

0:00
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Video 1: CCA underground cable splicing procedures
MethodCCA Suitability
CompressionGood
Resin spliceGood
Heat shrinkGood

4.3 Termination

TypeCCA Practice
Lug terminationStandard Cu lugs
Spade terminalsStandard
Stress coneStandard

4.4 Sizing

Cu SizeCCA-80% Equivalent
4/0250 kcmil
2/0175 kcmil
2 AWG3/0

5. Standards and Codes

5.1 Applicable Standards

StandardScope
ASTM B566CCA wire
ICEA S-94-649Underground cable
NEMA WC 57Distribution cable

5.2 Code Compliance

CodeRequirement
NECConductor sizing
NESCInstallation practices
Local codesJurisdiction-specific

5.3 Utility Specifications

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Figure fig3 Figure 3: Utility specification requirements for CCA cables
Utility TypeTypical Requirements
Investor-ownedPer utility spec
MunicipalMay allow CCA
Co-opCost-sensitive

6. Conclusion

6.1 Summary

AdvantageCCA Underground
Cost30-50% savings vs Cu
Weight60% lighter than Cu
TerminationEasier than Al
CorrosionGood

6.2 Recommendation

CCA is suitable for underground applications where:

  • Cost savings desired
  • Cu terminations preferred
  • Weight reduction beneficial
  • Corrosion resistance needed

7. References

  1. ICEA S-94-649. (2020). Underground Cable Standard.
  2. ASTM B566-20. (2020). Copper-Clad Aluminum Wire.

Frequently Asked Questions

Is CCA suitable for direct burial applications?

Yes, CCA is suitable for direct burial when properly insulated with XLPE or EPR. The copper surface provides good corrosion resistance, and the cable should be installed per local code requirements for burial depth and protection.

How do CCA splicing methods compare to copper?

CCA can be spliced using compression connectors, resin splices, and heat shrink methods similar to copper. Use connectors rated for the conductor type and follow manufacturer torque specifications.

What insulation types are recommended for CCA underground cables?

XLPE (cross-linked polyethylene) and EPR (ethylene propylene rubber) are standard insulation choices, both rated for 90°C operation. XLPE is most common for new installations due to excellent electrical and mechanical properties.

Do utilities accept CCA for underground distribution?

Acceptance varies by utility. Many municipal utilities and cooperatives accept CCA for cost-sensitive projects. Always verify with the specific utility's material specifications before specifying CCA.

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