Copper vs. Aluminum MV-105: Choosing the Right Medium Voltage Cable

Thanks for stopping by Wire America. We’re a dedicated resource for high-quality residential, commercial, industrial & utility wire & cable. Our goal is to provide the technical clarity and specialized products you need to get your project done right. Below, we’re discussing a frequent question from our customers regarding MV-105 Cable:

How to Decide Between Copper & Aluminum MV-105?

When designing a medium voltage (5kV–35kV) system, the choice between copper and aluminum conductors is one of the most significant decisions a project manager will make. While the price tag on the reel often points toward aluminum, the technical requirements of the installation might tell a different story.

At Wire America, we supply both Copper MV-105 and Aluminum MV-105, and we’ve seen where each material shines—and where it can lead to unexpected costs.

The Technical Breakdown

1. Conductivity and Conduit Space

Copper is the gold standard for conductivity and still the preferred choice by professionals for critical infrastructure. Because it carries more current in a smaller diameter, copper MV cable allows you to:

• Use smaller conduit sizes, which can significantly lower your overall material spend on PVC or steel pipe.

• Pull more circuits through existing, crowded tray systems.

• Save space in tight electrical manholes and vaults.

Aluminum has roughly 61% of the conductivity of copper, meaning you must jump up one or two wire gauges to match the same ampacity. This larger diameter requires larger conduits and more space in the cable tray.

2. Weight and Pulling Tension

Aluminum’s "Superpower" is its weight—or lack thereof. Aluminum is approximately 66% lighter than copper. This makes it the preferred choice for:

• Long Aerial Spans: Less strain on messenger wires and poles.

• Massive Direct Burial Runs: Reduced weight means lower pulling tension, often allowing for longer runs between pull points and fewer splices.

3. The Termination Factor

This is where many "budget" projects run into trouble.

• Copper: Terminations are straightforward using standard mechanical or compression lugs.

• Aluminum: Requires specialized bi-metallic lugs and anti-oxidation paste to prevent galvanic corrosion and "cold flow" (where the metal expands and contracts under load, potentially loosening the connection).

Cost Comparison:

How to Choose?

Common to choose Copper MV-105 if:

• You are working in a tight urban environment, a hospital, or data center with limited conduit space. Shop Copper MV-105 5kV-35kV.

• You want the lowest maintenance risk over a 30+ year lifespan.

• The project requires frequent "flexing" or vibration resistance.

Choose Aluminum MV-105 if:

• You are running long-distance feeders for renewable energy (Solar/Wind) or utility distribution. Shop Aluminum MV-105 5kV-35kV.

• Weight is a critical factor for aerial support structures.

• The upfront material budget is the primary driver and you have the space for larger conduit.

How Wire America Can Help

Whether you need the compact power of Copper MV-105 or the budget-friendly reach of Aluminum MV-105, we offer cut-to-length service and can readily ship directly to your job-site. 

Need a quote or the specific technical data sheet for your engineer? Contact our specialists at 833-268-8644

Sourcing Your MV-105 Project 

Wire America offers all common sizes and voltages.  Below area are a few examples. 

• 15kV Aluminum: Source our 4/0 AWG 15kV Aluminum MV-105 for utility and industrial feeders.

• 15kV Copper: Shop 500 MCM 15kV Copper MV-105 for high-density power distribution.

• 35kV Solutions: Browse our 750 MCM 35kV Copper MV-105 or 750 MCM 35kV Aluminum MV-105 Cable for heavy infrastructure projects.
  

Let’s Wire America! 🇺🇸

At Wire America, we believe in genuine conversation. You'll always talk with real people who understand that every project requires careful product selection. We're here to ensure you feel educated, confident, and great about your final purchase. Feel free to give us a call to discuss your project! You can reach us at: 833-268-8644

⚠️ Important Disclaimer: Safety and Compliance

Wire America provides this information as a guide only. Electrical installations must strictly adhere to the National Electrical Code (NEC) and all state, local, and jurisdictional requirements, which vary widely. Always consult a licensed electrician, electrical engineer, or the local inspecting authority before purchasing material or starting any electrical project. Wire America assumes no liability for the installation, use, or interpretation of these guides.