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CalcWolf DIY Wire Size Calculator
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Electrical Wire Gauge Calculator (AWG)

Calculate the correct wire gauge for your electrical project based on amperage, distance, and voltage. NEC compliant.

📅 Updated April 2026 Formula verified 📖 4 min read 🆓 Free · No sign-up

Choosing the Right Wire Size

Wire gauge must match the circuit amperage — undersized wire overheats and causes fires. NEC (National Electrical Code) minimums for copper: 15A → 14 AWG, 20A → 12 AWG, 30A → 10 AWG, 40A → 8 AWG, 50A → 6 AWG. For long runs (over 50 feet), voltage drop becomes a concern — upsize one gauge to keep voltage drop under 3%. Aluminum wire requires 2 sizes larger than copper for the same amperage.

Voltage Drop and Long Runs

NEC recommends keeping voltage drop below 3% for branch circuits and 5% total (feeder + branch). On a 120V circuit, 3% is only 3.6 volts. Long wire runs increase resistance, causing lights to dim and motors to overheat. At 100 feet on a 20A/120V circuit, 12 AWG copper has about 3.2% voltage drop — borderline. Use 10 AWG for runs over 75 feet on 20A circuits.

⚡ CalcWolf Insight

Wire size calculator gets 25K monthly searches from DIYers and electricians. The search spikes during renovation season (spring-fall). Users are in active project mode and often explore related electrical and home improvement calculators.

Frequently asked questions
What size wire do I need for a 20 amp circuit?
12 AWG copper minimum per NEC. For runs over 75 feet, use 10 AWG to keep voltage drop under 3%. For aluminum wire, use 10 AWG minimum for 20A. Always check local codes — some jurisdictions require larger wire than NEC minimums.
Can I use aluminum wire instead of copper?
Yes, but aluminum requires 2 sizes larger than copper (e.g., use 10 AWG aluminum where 12 AWG copper would suffice). Aluminum is cheaper but requires special connectors rated for aluminum (CO/ALR) to prevent oxidation and loose connections. Modern aluminum is safe when properly installed — the issues from the 1960s-70s were due to improper connections, not the wire itself.
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Kevin Glover
Founder, CalcWolf · GLVTS · Blickr
All formulas sourced from primary references — IRS publications, peer-reviewed research, and official standards. Results are tested against independent reference calculators before publishing. Rates and brackets updated when official sources change. Editorial policy →
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