Aluminum vs Copper Wire: 2024 Cost-Benefit Analysis
Updated comparison of aluminum and copper conductors for voltage drop, including current material costs, installation considerations, and when each makes sense.
The choice between copper and aluminum conductors significantly impacts both initial costs and long-term voltage drop performance. With fluctuating material prices in 2024, understanding when each material makes sense is more important than ever.
Material Properties Comparison
Copper and aluminum have fundamentally different electrical and physical properties that affect their suitability for various applications:
| Property | Copper | Aluminum |
|---|---|---|
| Conductivity | 100% IACS | 61% IACS |
| Resistance (relative) | 1.00 | 1.64 |
| Weight | 3× heavier | Lighter |
| 2024 Price Trend | ~$4.00/lb | ~$1.10/lb |
Voltage Drop Implications
Because aluminum has 64% higher resistance than copper, aluminum conductors must be sized approximately two AWG sizes larger to achieve equivalent voltage drop. For example:
Equivalent Voltage Drop Sizing
2 AWG
1/0 AWG
When to Use Each Material
Choose Copper When
- • Branch circuits (NEC requires for small sizes)
- • Space is limited (smaller for same ampacity)
- • Corrosive environments
- • Terminations aren't AL/CU rated
- • Short runs where material cost is minimal
Choose Aluminum When
- • Large feeders (significant cost savings)
- • Service entrance conductors
- • Long runs where material cost adds up
- • Weight is a concern
- • Using AA-8000 series alloys
Compare Your Options
Use our voltage drop calculator to compare copper and aluminum options for your specific circuit. See the size requirements and voltage drop for each material to make an informed decision.
Compare MaterialsRelated Articles
When to Use Parallel Conductors for Voltage Drop
Understanding when parallel conductors make sense for managing voltage drop in large feeders, including NEC requirements and practical installation considerations.
Educational5 Common Voltage Drop Myths Debunked
Separating fact from fiction: addressing the most common misconceptions about voltage drop calculations and requirements.