This analysis finds that while multiple reconductor options can replace ACSR without structural modification, advanced steel‑core conductors provide the most balanced and scalable performance across capacity, sag, cost, and reliability considerations. Composite‑core options such as ACCC® offer advantages in high‑temperature sag but are significantly more expensive up to 3.5× the cost and fail sag requirements under ice loading, limiting their use to rare, highly constrained cases.
By contrast, advanced steel solutions, particularly ACSS/TW variants using giga‑strength steel, enable smaller core diameters and larger aluminum areas, resulting in higher capacity and lower line losses than composite alternatives, while maintaining acceptable sag performance. Among all candidates, 959.6 kcmil ACSS/TW “Suwannee” stands out as the only option meeting sag criteria under a one‑inch ice load, while also delivering the highest capacity at the lowest cost. Overall, the findings show that next‑generation giga‑strength steel cores represent a practical and sustainable technology path, delivering superior performance and economics for North American grid modernization.