Say No to Copper Clad Aluminum! The Truth Every Low-Voltage Electrician Must Know About Wire Selection

In low-voltage projects, CCA (Copper Clad Aluminum) cables are often chosen because of their low price. However, CCA has poor conductivity, breaks easily, and oxidizes quickly—leading to problems such as CCTV black screens, LED flickering, and intermittent device failures. Electricians must refuse CCA and instead use tinned copper or pure copper cables to ensure stable system performance, reduce costly rework, and eliminate safety hazards.

1. The Hidden Risks of CCA

•  Low conductivity – Aluminum core has only about 60–70% the conductivity of copper, causing higher resistance and significant voltage drop.

•  Severe voltage drop – Up to 1.55× the resistance of copper, making PoE or low-voltage power unstable and prone to overheating.

•  Weak mechanical strength – Breaks easily during bending or at terminal connections.

•  Prone to oxidation – Aluminum forms a non-conductive oxide layer at contact points, increasing resistance and heat buildup.

•  Non-compliance and hazards – Fails to meet NEC, UL, and TIA standards, and can present a fire risk.

2. Advantages of Tinned Copper vs. Pure Copper

•  Excellent conductivity, minimal voltage drop – Both pure copper and tinned copper deliver stable power with minimal losses.

•  Superior corrosion resistance – The tin coating on tinned copper prevents oxidation, making it ideal for humid or marine environments; service life can be up to 10× longer than bare copper.

•  High mechanical reliability – Stronger, more flexible conductors that can withstand repeated bending and maintenance.

•  Meets industry standards – Certified under UL, NEC, and TIA for safe use in sensitive low-voltage applications.

3. Professional Recommendations

•  Ban CCA cables in low-voltage projects – Avoid future failures, costly repairs, and safety incidents.

•  Choose based on environment – Use pure copper for dry indoor installs; choose tinned copper for outdoor, humid, or coastal conditions.

•  Verify material quality – Request material test reports or third-party lab certifications to confirm you’re getting genuine copper.

•  Sell quality as an investment – Explain to clients that saving a small amount upfront can lead to much higher costs later.

Conclusion

Cheap cable is the most expensive mistake you can make. Choosing tinned copper or pure copper is every electrician’s responsibility and the foundation of reliable, safe, and long-lasting low-voltage systems.