Copper wire weight calculation determines the mass of copper conductors based on their length, diameter, and material density. Knowing wire weight is essential for shipping costs, structural load planning, material procurement, and electrical installation budgets in construction and manufacturing.

Copper has a density of 8960 kg/m³ (0.324 lb/in³), making it one of the heavier common conductor materials. Wire weight scales with cross-sectional area (diameter squared) and length, so small diameter increases significantly affect total mass. This calculator supports both AWG (American Wire Gauge) standard sizes and custom diameter inputs.

The American Wire Gauge (AWG) system standardizes wire diameters:

• Larger AWG number: Thinner wire (AWG 30 = 0.255 mm, AWG 10 = 2.588 mm).
• Smaller AWG number: Thicker wire (AWG 4/0 = 11.684 mm, higher current capacity).
• Gauge steps: Each 3 AWG reduction approximately doubles cross-sectional area.
• Common sizes: AWG 12-14 for residential wiring, AWG 18-22 for electronics, AWG 4/0-2/0 for service entrance.
• Weight scaling: AWG 10 weighs ~4× more per meter than AWG 16 due to area difference.

1. Enter wire length: Input total length in meters or feet.
2. Select AWG gauge OR enter diameter: Choose standard AWG size or input custom diameter in mm/inches.
3. Choose weight unit: Select kilograms or pounds for output.
4. Click Calculate: Get wire weight, cross-sectional area, and DC resistance.
5. Review results: Use weight for shipping estimates, resistance for voltage drop calculations.

Wire weight calculations are critical in:

• Electrical Contracting: Estimating material costs and shipping weights for large wire orders.
• Building Construction: Calculating structural loads from heavy feeder cables in commercial buildings.
• Aerospace/Automotive: Weight optimization in vehicles where every gram affects fuel efficiency.
• Power Distribution: Planning cable tray and conduit support systems for transmission lines.
• Recycling/Scrap: Valuing copper wire scrap by weight for recycling revenue.
• Manufacturing: Material procurement planning for coil winding, transformers, motors.
• Telecommunications: Network cable weight for tower and pole mounting load calculations.
• Marine/Offshore: Cable weight for underwater installations and buoyancy compensation.

Comparing copper and aluminum conductors:

• Density difference: Copper 8960 kg/m³ vs aluminum 2700 kg/m³ (copper 3.3× heavier).
• Conductivity trade-off: Aluminum requires larger diameter for same current capacity.
• Weight savings: Aluminum wire can be 50% lighter than equivalent copper for same resistance.
• Application choice: Aluminum for overhead power lines (weight reduction), copper for buildings (space/termination).
• Cost consideration: Aluminum cheaper per pound but requires thicker wire; total cost varies by application.
• Mechanical strength: Copper stronger and more flexible; aluminum requires special connectors.

Wire weight correlates inversely with resistance:

• Heavier wire = lower resistance: Larger cross-section reduces voltage drop and power loss.
• Voltage drop: V_drop = I × R, where R depends on length/area ratio.
• Power loss: P_loss = I² × R; doubling current quadruples heat loss in wire.
• NEC requirements: Maximum 3% voltage drop for branch circuits, 5% total from service to outlet.
• Long runs: Increase wire size (weight) to maintain acceptable voltage at load.
• Temperature rise: Resistance increases ~0.4% per °C for copper; heating reduces conductivity.

Scenario: Calculate weight of 100 meters of AWG 10 copper wire.

1. AWG 10 diameter: 2.588 mm = 0.002588 m
2. Radius: 0.002588 / 2 = 0.001294 m
3. Area: π × (0.001294)² = 5.261 × 10⁻⁶ m²
4. Volume: 5.261 × 10⁻⁶ × 100 = 5.261 × 10⁻⁴ m³
5. Weight: 5.261 × 10⁻⁴ × 8960 = 4.714 kg (10.39 lb)
6. Resistance: (1.68 × 10⁻⁸ × 100) / (5.261 × 10⁻⁶) = 0.319 Ω
7. For 1000 ft (305 m): 4.714 × 3.05 = 14.4 kg (31.7 lb)

Approximate copper wire weight per 100 meters (220 lb/1000 ft reference):

• AWG 4/0: ~50 kg/100m (thick service entrance cable)
• AWG 2/0: ~31 kg/100m (sub-panel feeders)
• AWG 4: ~12 kg/100m (heavy appliance circuits)
• AWG 10: ~4.7 kg/100m (30A circuits, electric dryer)
• AWG 12: ~3.0 kg/100m (20A general circuits)
• AWG 14: ~1.9 kg/100m (15A lighting circuits)
• AWG 18: ~0.75 kg/100m (electronics, thermostats)
• AWG 22: ~0.30 kg/100m (communications, control wiring)