Stranded Wire vs. Solid Wire in Electrical Applications

Solid and stranded wires see frequent use in electrical equipment, such as cable assemblies and wire harnesses. Solid wires consist of a solid core, whereas stranded wire consists of several thinner wires twisted into a bundle. Each has distinct advantages, with the right choice for an application depending on the specific project details. Some of the factors that may influence the choice between stranded vs. solid wire include:

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• Amperage load

• Use case

• Costs

• Metal type

• Wire gauge

Learning more about the difference between the two types of wires will make it easier to determine the best choice for your needs. The following information should help to inform the selection process.

What is Stranded Wire?

These thin, bundled wires are compressed and insulated with non-conductive materials. Stranded wire is more flexible, making it ideal for connecting electronic components in cramped spaces or for twisting and bending to fit intricate geometries. Stranded wire is more flexible and malleable than solid wire, and it won&#;t split or sever. It is often used for indoor applications such as electronic devices, circuit boards, and speaker wires.

What is Solid Wire?

Solid metal core wire is a much heavier, thicker product than stranded wire. It is ideal for outdoor use where more durability and higher currents are required. This rugged, low-cost wire is resistant to weather, extreme environmental conditions, and frequent movement. It is often used for carrying high currents throughout building infrastructure, vehicle controls, and various outdoor applications.

Stranded vs. Solid Wires: The Key Differences

Comparing stranded vs. solid wire involves exploring the advantages and disadvantages of the two very different types of wire. A comparison narrows down the choices based on how the specific wire characteristics relate to their expected use and the project requirements. You must first determine your application&#;s requirements for weather resistance, flexibility, and resistance to splitting or severing. Then, choose the wire that most closely meets those needs. 

Some key differences of stranded vs. solid copper wire include:

• Stranded vs. solid wire current capacity

  . Solid wire is thicker, which means less surface area for dissipation. The thinner wires in stranded wire contain air gaps and greater surface area with the individual strands, translating to more dissipation. When choosing between solid or stranded wire for house wiring, the solid wire offers higher current capacity. 

• Routing

  . Stranded wires offer superior bendability and flexibility, making them easier to route around obstacles than solid wires.

• Flexibility

  . Stranded wires are more flexible and can sustain more vibration and flexing without breaking. Solid wires may require more frequent replacement than stranded wires in applications with significant movement or vibrations.

• Cost

  . The production costs of solid wire are much lower than stranded wire, which makes solid wire the more affordable choice. 

• Ease of manufacturing

  . The single-core nature of solid wire makes it much simpler to manufacture. Stranded wires require more complex manufacturing processes to twist the thinner wires together. 

• Distance

  . For longer runs, solid wires are the better choice because they feature less current dissipation. Stranded wire will perform well over shorter distances.

• Superiority.

  When it comes down to stranded vs. solid wire, there is no clear choice. Each option offers distinct advantages in particular situations.

Wire Solutions From Consolidated Electronic Wire & Cable

Consolidated Electronic Wire & Cable has been a leading manufacturer of high-quality standard and custom electronic wire, molded cable assemblies, wiring harnesses, cable, and power supply cords for over 100 years. Our longevity is due to our versatility, adaptability, and commitment to continuous improvement in processes and products. Our many industry certifications are a testament to our commitment to quality and innovation, including:

• ISO

• RoHS

• CE Mark

• NEC

• UL

• CSA

• VDE

• LF

• MIL-Spec

When you partner with us, you will gain the full expertise of our entire team to ensure the success of your project. For more information on our capabilities and product lines, please contact us or submit a quote request today. 

The cable tray size is described in two dimensions: width and height. Calculating the size of a cable tray means calculating its width.

The final size of a cable tray depends on the following:

1- The number of cables on the cable tray

2- The size and overall diameter of each cable

3- The future expansion

The general rule for sizing the cable tray is that all the cables must be installed in a single layer, and there must be a space between each two cables:

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1- The space between two multi core cables equals the diameter of bigger cable.

2- The space between three single core cables in trefoil formation and other trefoil cables equals the double of the diameter of the bigger cable.

Then, we measure the overall width of the previous arrangement to find the initial cable tray width, then add the future expansion.

Final cable tray width= initial cable tray width*(1+expantion percentage)

We round the final cable width to the nearest biggest standard width, which equals 50, 100, 150, 200, 250, 300, 400, 500, 600, 700, 800, 900 mm (Can be different according to the manufacturer).

Example:

Find the cable tray size which will carry the following cables. Consider future expansion = 20%.

4x25mm2 CU/XLPE/PVC cable, diameter= 22.0 mm

4x120mm2 CU/XLPE/PVC cable, diameter= 39.9 mm

4x35mm2 CU/XLPE/PVC cable, diameter= 25.4 mm

4x50mm2 CU/XLPE/PVC cable, diameter= 28.3 mm

4x70mm2 CU/XLPE/PVC cable, diameter= 32.1 mm

Initial cable tray size= 310 mm

Final cable tray size= 310*1.2= 372 mm

We round this value to the nearest bigger cable tray standard value = 400 mm

Example:

Find the cable tray which will carry the following cables. Consider future expansion = 20%.

4No. of 3(1x240) mm2 CU/XLPE/PVC cable, diameter= 31.9

Initial cable tray size= 510 mm

Final cable tray size= 510 x 1.2= 612 mm

We round this value to the nearest bigger cable tray standard value = 700 mm

What about separate neutral and earthing conductors?

Because neutral and earthing conductors normally don't carry current, we don't put these conductors into consideration when sizing cable trays. When laying, they will be laid beside the main cable.

Why do we add space between cables?

Grouping the cables without adding space on cable trays is possible, but when calculating the maximum carrying current capacity for the cables, you have to take into account the derating factor for cables when touching on the cable tray.

With reference to the tables below in BS* standard (There are similar tables in IEC** standard), we can find the derating factors for both cases; cables are touched and cables are spaced.

When the cables are touched, the derating factors range from 0.85 to 0.6 depending on the number of cables. Which means that the size of the cables could be nearly doubled. That will lead to an increase in the cost of cables.

But, if we look at the rating factors when cables are spaced, we find that they have a range between 1 and 0.9, which has little effect on maximum carrying current capacity.

*BS &#; Table 4C4 and Table 4C5

 **IEC -5-52 &#; Table B.52.20 and Table B.52.21

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