10 Things to Consider When Buying Grounding Wire Clip

10 Essential Factors to Consider When Buying a Grounding Wire Clip

Before finalizing your decision, make sure to consult the latest testing data.

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Proper grounding is not just a safety requirement—it’s a critical element for the reliable operation of electrical systems. Yet, many questions still surround the topic. Common inquiries include:

• Why do designers, utilities, and contractors prefer different grounding conductors?

• If copper and aluminum are used for power transmission, why aren’t they universally used for grounding as well?

• Which conductor offers the best performance for grounding applications?

How to Choose the Right Grounding Conductor

Start with these two crucial steps:

1. Refer to Section 9 of the National Electrical Safety Code, which recommends selecting a conductor that can handle a ground fault—this will also handle lightning due to its shorter high-current duration.

2. Understand that fault currents are fast and powerful, generating intense heat. Your chosen conductor must efficiently manage this thermal energy.

Common Types of Grounding Conductors

Let’s take a closer look at the grounding conductors commonly used in the U.S.—ranked from least to most preferred.

Galvanized Steel

While cost-effective, galvanized steel offers poor conductivity. Its zinc coating is prone to deterioration due to cracking and corrosion, increasing the risk of stray voltage. It's not suitable for grounding in utility environments.

Aluminum Conductor Steel Reinforced (ACSR)

ACSR is a popular choice for high-voltage transmission but falls short for grounding purposes. Aluminum’s low melting point (1,220F) makes it vulnerable to the extreme heat generated by fault currents or lightning strikes. In contrast, copper melts at 1,980F and steel at 2,500F, making them more heat-resistant and reliable for grounding.

Copper-Clad (Welded) Steel

First used in rural electrification during the 1930s and ’40s, this bimetallic option offers strength and reduced copper usage. Historically considered inferior to pure copper, newer tests challenge that assumption. Fault-current testing at Powertech Labs reveals that some copper-weld steel conductors outperform traditional copper in durability and longevity under stress.

All-Copper Stranded Cable

The most widely used grounding conductor in the U.S., copper stranded cable offers excellent conductivity and the highest fusing current. However, it’s not always the most cost-effective or durable solution. In Canada, copper-weld steel is more commonly used for its strength and theft deterrence. This shift raises important questions about the long-term value of copper-only systems.

Answering Your Top Grounding Questions

1. Why isn’t there a universal standard for grounding conductors?

Choices are often based on utility experience, regional needs, availability, cost, and concerns like theft. After World War II, copper was abundant and affordable. However, copper prices surged in the 2000s—reaching $4.73/lb as recently as October—making it a target for theft and pushing utilities to consider alternatives like copper-weld steel for poles and substations.

2. If ACSR is widely available, why isn’t it used for grounding?

ACSR’s low melting point and poor performance under lightning conditions make it unreliable for grounding. Despite its use in transmission, ACSR is not safe for grounding applications where rapid heat spikes are common.

3. What’s the best grounding conductor?

Reliability, electrical sufficiency, and longevity are key. Oversizing all-copper cables for safety is common, but this raises costs and theft risk. The best choice balances performance with durability and cost-effectiveness.

• Longevity: Utilities are increasingly prioritizing materials that reduce the need for costly and risky replacements.

• Reliability: The conductor must perform consistently throughout its service life.

• Electrical Performance: It must safely carry both fault currents and lightning strikes without excessive oversizing.

What the Latest Testing Tells Us

Powertech Labs in British Columbia, home to the most powerful current-testing facility in North America, conducted extensive tests from 2017 to 2020. These experiments evaluated copper and copper-weld steel conductors under real-world fault conditions, including the effects of connectors.

Key takeaways:

• Failure typically occurred at the connector-conductor interface, suggesting the importance of connection quality.

• Some copper-weld steel conductors outperformed copper in terms of fault endurance, challenging outdated IEEE 80 assumptions.

The data supports a shift in perspective—away from copper-only solutions and toward smarter, more resilient alternatives like copper-weld steel for utility grounding systems.

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