Every time we have run the numbers with the exception of short conductor runs, aluminum has won.
+1 on that. and not by a little.
the last time i did a lot of pulling, i used 250mcm AL instead of 4/0 CU,
and 500mcm AL instead of 500mcm CU, as the current requirements worked out
for that.
the price spread on simpull back then between the two was the aluminum was 24%
of the copper. that included the size difference. i was buying it in 2,500' spools to
save on wastage, and my per foot cost was a quarter of copper.
the spread isn't as large now, based on a quick google.
to make, in my mind, and the AHJ's mind, the installation acceptable, i hypressed
all terminations, and used panduit 600v UL listed heavy shrink tube to cover the
terminations. on breaker terminations, i used finger lugs.
more labor? sure. hypress, with all the dies for copper, al, and grounding was $10k.
panduit heat shrink is slow and expensive, but nowhere near 3M cold shrinks cost,
so i used it.
there was 12,000' of conduit on the job. was it worth it? yeah, just a little bit.
