---
title: 'Copper or aluminum cable? Cost comparison for underground cable and grid connection'
date: '2025-02-24T08:30:23'
featuredImage: /uploads/2024/11/medium-voltage-category.webp
locale: en
category: Kabel Technologie
---
# Copper or aluminum cable? Cost comparison for underground cable and grid connection
Particularly with cables such as **NA2XS(F)2Y** or **NAYY** for **wind turbines**, the choice of material determines costs, performance and service life. Copper impresses with its high electrical conductivity, while aluminum scores with low costs and low weight. But which material is technically and economically the better choice in the long term? This article provides a detailed analysis of the advantages and disadvantages of both options.
### Electrical and Mechanical Properties Compared
Copper has been the preferred material for electrical wiring for decades. It offers high conductivity and excellent mechanical stability. Aluminum, on the other hand, is significantly lighter but has lower electrical conductivity. This means aluminum cables require a larger cross-section to transmit the same current.
<h4>Comparison of Properties</h4>
<table>
<thead>
<tr>
<th>Property</th>
<th>Copper</th>
<th>Aluminum</th>
</tr>
</thead>
<tbody>
<tr>
<td>Electrical Conductivity</td>
<td>58 MS/m</td>
<td>35 MS/m</td>
</tr>
<tr>
<td>Density (g/cm³)</td>
<td>8.96</td>
<td>2.70</td>
</tr>
<tr>
<td>Corrosion Resistance</td>
<td>Very high</td>
<td>Medium (oxidation)</td>
</tr>
<tr>
<td>Mechanical Strength</td>
<td>High</td>
<td>Medium</td>
</tr>
<tr>
<td>Weight</td>
<td>High</td>
<td>Low</td>
</tr>
<tr>
<td>Price per ton</td>
<td>€8,000 – 9,000</td>
<td>€2,300 – 2,500</td>
</tr>
</tbody>
</table>
Although aluminum offers weight savings in transport and installation, it requires larger cross-sections to achieve the same performance. This can impact space requirements in cable trays and mechanical stability. Additionally, aluminum is more prone to oxidation, which can lead to contact issues, whereas copper maintains its conductivity over long periods without significant quality loss. In humid or salty environments, such as offshore wind farms, this can be a crucial factor.
### Costs: Acquisition, Installation, and Operation
<h4>Material Costs</h4>
The biggest advantage of aluminum is its lower purchase cost. While copper prices fluctuate significantly, aluminum remains relatively stable.
In a direct comparison, aluminum cables such as **NA2XS(F)2Y** often perform better economically for long installation routes and large power lines – despite their lower conductivity compared to copper.
**Cost per ton (as of 2024):**
- **Copper:** €8,000 – 9,000
- **Aluminum:** €2,300 – 2,500

For long cable routes, this price difference can add up to a substantial amount.
<h4>Installation Effort</h4>
- **Copper cables** are heavier, making transport and installation more labor-intensive.
- **Aluminum cables** are lighter, simplifying mounting and logistics.

Especially in offshore wind farms or hard-to-reach locations, aluminum can offer significant advantages.
<h4>Operating Costs and Energy Losses</h4>
- **Copper cables** have lower transmission losses due to their superior conductivity.
- **Aluminum cables** require larger cross-sections to transmit the same power, increasing costs for cable tray construction and materials.

Aluminum saves on initial purchase and installation but may become more expensive in the long run due to higher energy losses.
### Lifespan and Maintenance
Another crucial factor is the durability of the materials.
<h4>Corrosion Behavior</h4>
- **Copper** is highly resistant and barely oxidizes.
- **Aluminum** forms an oxide layer that can degrade electrical contacts.

In humid or salty environments, such as offshore wind farms, aluminum can become problematic.
<h4>Mechanical Durability</h4>
- **Copper cables** are more robust and less prone to material fatigue.
- **Aluminum** is softer and requires special connection techniques to ensure long-term reliability.

<h4>Maintenance Effort</h4>
- **Copper connections** remain stable for decades.
- **Aluminum connections** require regular inspections to prevent contact issues.

Copper lasts longer and requires less maintenance. Aluminum may lead to higher long-term costs.
<blockquote>
### Longevity matters: while **copper** remains maintenance-free for decades, **aluminum** requires regular inspections to prevent performance losses.
</blockquote>
### Environmental Friendliness and Sustainability
Environmental impact is becoming increasingly important in modern energy industries. Sustainability doesn’t start with operating a wind farm—it begins with selecting the right materials for its infrastructure. Copper and aluminum differ not only in production but also in recyclability and overall environmental impact.
<h4>Energy Consumption in Production</h4>
Copper is an excellent conductor, but its extraction and processing are highly energy-intensive. Mining requires massive open pits or underground mines, consuming vast resources. Refining copper also demands extremely high temperatures, leading to significant energy use. Studies show that producing one kilogram of copper requires **four to five times more energy** than the same amount of aluminum.
Aluminum, in contrast, is extracted from **bauxite**, which is more abundant than copper ore. However, refining aluminum requires the **energy-intensive Hall-Héroult process** (electrolysis). The advantage? **Recycling aluminum uses only about 5%** of the energy required for its initial production.
<h4>CO₂ Footprint and Environmental Impact</h4>
Copper production generates **significantly more CO₂ emissions** than aluminum—**if the aluminum is sourced from recycled material**. While both metals are recyclable, copper’s **primary extraction has a higher environmental toll**.
Another key factor: **lifespan and maintenance**. Aluminum cables **wear out faster** than copper cables and need more frequent replacements. This means that aluminum’s **environmental benefits rely on consistent recycling** after use.
<h4>Recyclability</h4>
Both copper and aluminum are **fully recyclable**, but in practice, there are differences:
- **Copper** has a high recycling rate because of its **high value**—it’s rarely discarded.
- **Aluminum** is easier and cheaper to recycle, but a significant portion of global production still **depends on virgin bauxite**.

<h4>Long-Term Sustainability in Wind Farms</h4>
Aluminum excels in **production efficiency and recycling**, while **copper’s durability and lower maintenance needs** make it a long-term sustainable choice. For wind farms, choosing the right material is also an **environmental decision**.
**Conclusion**
- **Aluminum** wins with its **lower CO₂ footprint** in production and excellent recyclability.
- **Copper** lasts longer, requires **fewer replacements**, and thus also contributes to sustainability.

Ultimately, the best choice depends on **whether short-term efficiency or long-term durability** is the priority.
### Which Solution is Best for Wind Farms?
<h4>Comparison of Key Factors</h4>
<table>
<thead>
<tr>
<th>Factor</th>
<th>Copper</th>
<th>Aluminum</th>
</tr>
</thead>
<tbody>
<tr>
<td>**Efficiency**</td>
<td>Better</td>
<td>Higher losses</td>
</tr>
<tr>
<td>**Cost (Material &amp; Purchase)**</td>
<td>More expensive</td>
<td>Cheaper</td>
</tr>
<tr>
<td>**Installation Effort**</td>
<td>Heavier, more complex</td>
<td>Lighter, easier</td>
</tr>
<tr>
<td>**Operating Costs (Losses &amp; Maintenance)**</td>
<td>Lower</td>
<td>Higher</td>
</tr>
<tr>
<td>**Corrosion Resistance**</td>
<td>Very good</td>
<td>Medium</td>
</tr>
<tr>
<td>**Lifespan**</td>
<td>Longer</td>
<td>Shorter</td>
</tr>
<tr>
<td>**Environmental Impact**</td>
<td>High energy consumption</td>
<td>Better with recycling</td>
</tr>
</tbody>
</table>
### Recommended Applications
- **Aluminum** is ideal for **long medium-voltage routes**, where weight and cost are crucial factors.
- **Copper** is the better choice for **grid connections, substations, and critical areas**, where **efficiency and longevity** matter most.

The best solution is often a **combination of both materials** to balance **cost and efficiency** effectively.
### Copper or Aluminum – Which choice pays off?
The decision between copper and aluminum cables depends heavily on the specific requirements of a wind farm project. **Aluminum** offers **lower material costs and reduced weight**, making installation easier. **Copper**, on the other hand, excels with **higher efficiency, lower maintenance costs, and longer lifespan**.
The best approach is often a **strategic combination** of both materials:
- **Aluminum** for **long transmission routes** where cost and weight matter.
- **Copper** for **critical grid connections**, ensuring long-term reliability and efficiency.

This way, **costs can be optimized while maintaining operational security**.
Anyone wishing to purchase cables such as **NA2XS(F)2Y** should consider the installation environment, the load and the project period in addition to the pure material price. For many **onshore wind farms**, aluminum offers a clear cost advantage – for others, the more robust NAYY copper cable is worthwhile.
**Need expert advice on cable selection?**<br />Get in touch with **our specialists at KLZ**—we’ll help you find the perfect cable for your wind farm project!
