AS Wire
Aluminum-Clad Steel Wire

Development of Aluminum-clad Steel (AS) Wire

Conex Cable, LLC, under the original name of Conex, started production of Aluminum-clad Steel wire (AS wire) in 1988. In 1990 Hitachi Cable Ltd., a worldwide wire and cable manufacturer, became a joint venture partner and inaugurated a new era of growth and development. Then in 2004, Conex became an independent, 100% U.S. owned company and moved its manufacturing facilities from Dublin, California to DeKalb, Illinois.

Aluminum-clad steel wire was originally developed by Hitachi Cable, Ltd in 1956 based on a new technology of the time known as the continuous extrusion method. Even though AS wire has since achieved worldwide acceptance, engineering continues in an effort to improve and refine the process and product.

Conex Cable, LLC has utilized the vast knowledge of Hitachi Cable in many areas including technology, engineering, and production, in the efforts to become a leading manufacturer of electrical wire and cable.

Applications, Products, and Manufacturing Process

Using this technology, Conex Cable, LLC supplies high quality aluminum-clad steel wire and cable products to electric utilities, cable manufacturers, and accessory manufacturers. Conex Cable, LLC manufactures overhead transmission line ground wire; guy wire; guy grip wire; AS wire for optical ground wire (OPGW) applications; and Aluminum-clad Steel (AS) core wire for various overhead conductors.

Our AS wire is manufactured by the continuous extrusion method which bonds high purity aluminum to high strength steel wire. The thick aluminum cladding provides AS wire with superior corrosion resistance as well as high conductivity. AS wire incorporates the capability to vary the aluminum thickness as required for the higher conductivity described in the latest ASTM and IEC standards.

Features of CONEX AS Wire


Thick aluminum cladding— standard ratio of aluminum area in cross section: 25%

Lighter weight, utilizes high carbon steel for strength

Superior corrosion resistance, coating is 1350 EC grade aluminum with a purity of 99.95%

High electrical conductivity, 20.3% is standard

Excellent thermal stability for high temperature operation

Made in DeKalb, IL U.S.A.

Types of AS Wire

AS wire has been used in a great variety of applications such as conductors, ground wires and guy wires in over-head transmissions and distribution line, messenger wires, guard rope, mooring rope, trellis, barbed wires and net fencing. Various applications and cross-sectional views of AS wire are shown below.

All AS Strand



(For telecommunications)


Small loss ACSR/AS





Non-conductor Use

Characteristics of AS Wire

  1. Wider variety of properties and size of steel wire, thickness of aluminum cladding and quality of aluminum. (Cross sectional area ratio of the aluminum in AS wire covers approximately 13% to 85%, while that designated in ASTM B415 is fixed at 25%.)
  2. Wider range of combinations of tensile strength and conductivity.
  3. High corrosion resistance due to thick EC-grade aluminum covering.
  4. Sufficiently strong bonding strength at the boundary between aluminum layer and steel core.
  5. Lighter in weight than galvanized and aluminized steel wire.
  6. Excellent thermal stability for continuous operation in high temperature.
  7. Availability of wider variety of products as follows:
    • AS wires of complex cross section.
    • AS wires of approximately 2.05mm to 8mm in diameter.

Corrosion Resistance

The corrosion resistance of bare aluminum conductors for overhead transmission and distribution line is very important when installed in high risk areas such as near the sea, industrial areas, deserts, etc

The thick, high corrosion resistant EC-grade aluminum covering of AS wire will protect the steel core by its advantageous galvanic action, even if the steel core is partially exposed.

AS Wire Thickness

AS Stranded Wire

Corrosion Resistance

Standard Abbreviation Minimum
Tensile Strength
Conductivity at 20°C
Modulus of Elasticity
Coefficient of Linear
Expansion (x 10-6/°C)
IEC 61232 AS/IEC 1,070-1,340 MPa 20.3 162 GPa 13.0 x 10-6K-1
ASTM B-415
ASTM B-502
AS/ASTM 109-137 20.3 162 GPa 12.6
DIN 48200-Teil 8 AD/DIN 1,080 ~ 1,370 N/mm² 20.3 162 GPa 12.6
ONORM E4031 AS/ONORM 1,080 ~ 1,370 N/mm² 20.3 162 GPa 12.6
UNE 21-059 / 21-060
AS/UNE 1,080 ~ 1,370 N/mm² 20.3 162 GPa 12.6
Australian Standard
1220-part 3 / 1222 part 2
AS/ASTM 1.19 ~ 1.34 GPa 20.3 162 GPa 12.6
Japan Federation of Electric Power Co.
A241, A220
AS/JFEPC 130 ~ 135 20.3 ~ 23.0 14,600 ~ 14,700 12.9
IEC 61232 14% Conductivity 14 AS 160 14 17,300 12>
20% Conductivity 20 AS 135 20.3 15,800 12.6
23% Conductivity 23AS/130 130 23 15,200 12.9
23AS/125 125 15,200 12.9
27% Conductivity 27 AS 110 27 14,300 13.4
30% Conductivity 30 AS 90 30 13,500 13.8
35% Conductivity 35 AS 70 35 12,400 14.5
40% Conductivity 40 AS 70 40 11,100 15.5
JCS: Japanese Cable Markers Association Standard All weights, measurements, and values are nominal.
All ASTM specifications are per the latest addition.
Made in U.S.A.