The limitations of CCA network cable in long-distance and PoE installations

The demand for affordable networking solutions often leads installers and resellers to consider copper-clad aluminium (CCA) Ethernet cable as a cost-saving alternative to solid copper. While CCA cable may appear similar to standard copper cable, it presents significant limitations, especially in long-distance deployments and Power over Ethernet (PoE) applications.

Electrical performance and signal loss

CCA cable consists of an aluminium core coated with a thin layer of copper. Aluminium has approximately 55% higher electrical resistance than pure copper, which directly affects signal transmission, especially over longer distances. The higher resistance causes increased signal attenuation, reduced bandwidth performance, and greater susceptibility to interference and crosstalk.

According to TIA/EIA-568 and IEEE 802.3 standards, the maximum recommended cable length for Ethernet (100 metres) is based on the use of solid copper conductors. Using CCA instead may result in unreliable data transmission, particularly near the maximum run length.

PoE applications and safety risks

CCA performs poorly in PoE applications due to its higher resistance and lower current-carrying capacity. This leads to increased voltage drop and heat generation when powering devices such as IP cameras, VoIP phones, and wireless access points.

In higher-power PoE standards (IEEE 802.3at and 802.3bt), CCA cables often fail to deliver the required wattage over standard distances. In extreme cases, the cables can overheat or deform, posing a safety hazard. Most CCA cables are also not tested or certified to meet South African fire safety standards (equivalent to UL or IEC flame ratings), increasing the risk of fire in high-density installations.

Maintenance and long-term reliability

CCA cable is mechanically weaker than solid copper. It is more prone to breakage during installation, particularly when bent, pulled, or terminated repeatedly. The aluminium core is also more susceptible to corrosion and oxidation, which leads to poor contact and long-term reliability issues at connectors and punch-down blocks.

This makes CCA cable unsuitable for installations that are expected to last 10 to 15 years, especially in commercial or mission-critical environments.

Legal and warranty considerations

Some South African ISPs, installers, and equipment vendors explicitly state in their terms that CCA cable voids product warranties or service guarantees, especially where PoE is involved. Additionally, reputable structured cabling brands do not support performance warranties on CCA-based installations.

When is CCA acceptable?

CCA may be used in very short runs (under 10 metres) where no power delivery is required and the network is non-critical. However, even in these limited scenarios, the long-term cost and reliability risks often outweigh the initial savings.

Final thoughts

While CCA network cable may seem like an affordable alternative, it carries serious limitations that affect performance, safety, and long-term viability. For any installation involving long distances, PoE, or future-proof networking infrastructure, solid copper cable remains the only reliable and standards-compliant option.

What to expect from CCA

1. Maximum reliable distance for 1Gbps Ethernet

Solid Copper (Cat5e/Cat6): Up to 100 metres (90m horizontal + 10m patch cords) per TIA/EIA-568 standard.
CCA Cable: 35–60 metres is the typical maximum reliable length for 1Gbps before experiencing packet loss and increased bit error rate (BER).