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Calculate the weight and cost of electrical wire for copper, aluminum, steel, and stainless steel. Supports AWG wire sizes for accurate electrical wiring calculations.
The wire weight calculator helps you determine the weight and cost of electrical wire for different materials including copper, aluminum, steel, and stainless steel. Wire weight calculations are essential for electrical installations, material procurement, shipping logistics, and cost estimation.
This calculator uses the American Wire Gauge (AWG) standard, which is the standardized wire gauge system used in North America for measuring the diameter of round, solid, nonferrous electrical wire. The AWG system is also known as the Brown & Sharpe wire gauge. Lower AWG numbers indicate larger wire diameters and higher current-carrying capacity.
Understanding wire weight is critical for electrical contractors, electricians, engineers, and purchasing departments. Accurate weight calculations help determine shipping costs, verify material deliveries, estimate installation labor, and calculate material costs for electrical projects.
The diameter of AWG wire can be calculated using a mathematical formula based on the geometric progression of wire sizes. The AWG system is designed so that every 6 gauge decrease doubles the wire diameter, and every 3 gauge decrease doubles the wire cross-sectional area.
AWG Diameter Formula:
D = 0.005 × 92^((36 - AWG) / 39) inches
Where D is the diameter in inches and AWG is the wire gauge number. The formula uses the reference point that 36 AWG has a diameter of 0.005 inches, and the ratio between consecutive sizes is the 39th root of 92.
Wire Weight Formula:
Volume = π × (Diameter/2)² × Length
Weight = Volume × Density × Quantity
| AWG Size | Diameter (in) | Diameter (mm) | Area (kcmil) | Copper Weight (lb/1000ft) |
|---|---|---|---|---|
| 0000 (4/0) | 0.4600 | 11.684 | 211.6 | 640.5 |
| 000 (3/0) | 0.4096 | 10.405 | 167.8 | 507.9 |
| 00 (2/0) | 0.3648 | 9.266 | 133.1 | 402.8 |
| 0 (1/0) | 0.3249 | 8.252 | 105.5 | 319.5 |
| 1 | 0.2893 | 7.348 | 83.69 | 253.5 |
| 2 | 0.2576 | 6.544 | 66.37 | 201.0 |
| 4 | 0.2043 | 5.189 | 41.74 | 126.4 |
| 6 | 0.1620 | 4.115 | 26.25 | 79.5 |
| 8 | 0.1285 | 3.264 | 16.51 | 50.0 |
| 10 | 0.1019 | 2.588 | 10.38 | 31.4 |
| 12 | 0.0808 | 2.053 | 6.530 | 19.8 |
| 14 | 0.0641 | 1.628 | 4.107 | 12.4 |
| 16 | 0.0508 | 1.291 | 2.583 | 7.8 |
| 18 | 0.0403 | 1.024 | 1.624 | 4.9 |
| 20 | 0.0320 | 0.812 | 1.022 | 3.1 |
AWG stands for American Wire Gauge, a standardized wire gauge system used predominantly in North America for measuring the diameter of round, solid, nonferrous electrical wire. It is also known as the Brown & Sharpe wire gauge. The system has been used since 1857 and is based on a geometric progression where each 6 gauge decrease doubles the wire diameter.
Copper wire weight varies by AWG size. Common examples: 14 AWG weighs 0.012 lb/ft, 12 AWG weighs 0.020 lb/ft, 10 AWG weighs 0.031 lb/ft, 8 AWG weighs 0.050 lb/ft, and 6 AWG weighs 0.080 lb/ft. Use this calculator to determine the exact weight for any AWG size and wire length.
For copper wire at 75°C insulation: 14 AWG supports 15 amps, 12 AWG supports 20 amps, 10 AWG supports 30 amps, 8 AWG supports 40 amps, 6 AWG supports 55 amps, 4 AWG supports 70 amps, and 2 AWG supports 95 amps. Actual ampacity depends on wire insulation temperature rating, installation conditions, and whether the wire is in conduit or free air.
Yes, aluminum wire is significantly lighter than copper wire. Aluminum has a density of 0.098 lb/in³ compared to copper's 0.324 lb/in³, making aluminum wire approximately 70% lighter than copper wire of the same size. However, aluminum has lower electrical conductivity than copper, so a larger AWG size is needed to carry the same current.
Solid wire consists of a single conductor and is more rigid, commonly used in building wiring and permanent installations. Stranded wire consists of multiple smaller conductors twisted together, making it more flexible and resistant to metal fatigue from vibration or movement. Stranded wire is preferred for applications requiring frequent flexing, such as appliance cords and automotive wiring. Both types have the same overall diameter and current capacity for a given AWG size.
Wire size selection depends on current load, wire length, voltage drop, and installation conditions. Use the National Electrical Code (NEC) ampacity tables as a starting point. For longer runs, you may need to increase wire size to minimize voltage drop (typically limited to 3% for branch circuits). Consider ambient temperature, conduit fill, and future load growth. Always consult local electrical codes and a licensed electrician for specific applications.
For speaker wire, 16 AWG is suitable for short runs up to 50 feet, 14 AWG for runs up to 80 feet, and 12 AWG for longer runs or high-power systems. For subwoofers or amplifiers, 10-12 AWG is recommended. Lower impedance speakers (4 ohms) benefit from heavier gauge wire than higher impedance (8 ohms). The wire gauge affects resistance and can impact sound quality over longer distances.
Steel and stainless steel wire are not typically used for electrical current carrying conductors due to their poor electrical conductivity compared to copper and aluminum. However, they are used for structural support in overhead power lines (steel core in ACSR cables), grounding applications, guy wires, and messenger cables. For electrical applications requiring strength, copper-clad steel or aluminum conductor steel reinforced (ACSR) cables are preferred.
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