Aluminium over copper solar cable? FRCABLE’s cost-efficient metal alternative

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As solar projects continue to expand across the globe, aluminium conductor cables are increasingly being adopted across DC collection systems, AC transmission lines and medium-voltage interconnections. With lower material costs than copper and advanced aluminium alloy conductors, the metal is increasingly being adopted in the solar cable sector.

FRCABLE, a China-based solar cable manufacturer, has regarded aluminium as a practical option for large-scale photovoltaic projects, citing its potential for reducing balance-of-system (BOS) costs while maintaining electrical performance and reliability standards.

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The company noted that modern solar cables implement AA-8000 series aluminium alloys, which, unlike earlier aluminium conductor technologies, offer improved flexibility, corrosion resistance and reduced creep. Upon proper installation, the cables can deliver parallel current-carrying performance at a remarkably lower cost than copper.

Growing copper prices and supply-chain constraints over the past two years have further accelerated interest in aluminium conductors. Utility-scale solar projects, especially those with long DC string runs, AC collection systems, or underground trunk cable specifications, are increasingly considering aluminium as an alternative. Using aluminium in a 500 MW project would save a considerable sum of capital, thereby improving project economics.

The equation becomes clear by studying the London Metal Exchange (LME) price graph. At present, the three-month benchmark price for copper is at USD 13774 per tonne. Meanwhile, the LME aluminium three-month Asian Reference benchmark stands at USD 3388.5 per tonne, marking the staggering 75.4 per cent pricing difference between the two metals and indicating the lower-cost edge offered by aluminium.

According to FRCABLE, its aluminium solar cable portfolio includes products designed for utility-scale, commercial and hybrid applications, with conductor sizes ranging from 10 mm² to 500 mm² and compliance with international standards such as IEC 60502 and EN 50618 adaptations.

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The manufacturer noted that it benefits from the scale of dedicated aluminium conductor extrusion lines and in-house alloy processing, maintaining shorter lead times and tighter quality control than externally sourced conductors.

Referring to the capacity of aluminium cable systems to deliver full performance at a lower cost, FRCABLE emphasises that opting for aluminium over copper is not a compromise but a choice for optimal engineering purposes.

Thus, the company believes that aluminium cables are expected to play a larger role in future renewable energy infrastructure projects.