What Size Wire for a 80 Amp Circuit Breaker? (NEC Table 310.16)

Complete Copper vs. Aluminum AWG wire size, continuous load limit (64A max), ground wire gauge, and conduit sizing for 80A circuits (64A Ford Charge Station Pro EV chargers & heavy workshop subpanels).

Direct NEC Table 310.16 Answer for 80 Amps

4 AWG

Minimum Copper Wire (75°C)

THHN / THWN-2 / XHHW in Conduit

2 AWG

Minimum Aluminum Wire (75°C)

SER / XHHW-2 Feeder Cable

64 Amps

Max Continuous Load (80% Rule)

For loads running 3+ hours (EVs, lighting)

1" EMT

Recommended Conduit Size

Fits 3x 4 AWG + Ground under 40% fill

Common Applications for a 80A Circuit

64A Ford Charge Station Pro EV chargers & heavy workshop subpanels. Remember that under the NEC 125% continuous-load rule (NEC 210.19 & 210.20), a standard 80A breaker can only supply up to 64A of continuous load (any load that runs for 3 hours or more without stopping, such as an EV charger or commercial lighting).

When to Upsize for Voltage Drop (Over 100 Feet)

If your one-way wire run exceeds 100 feet at 240V (or 50 feet at 120V), step up one wire gauge from 4 AWG to keep total line voltage drop under the NEC 3% branch-circuit recommendation. Use our Voltage Drop Calculator to check your exact footage.

2. NEC Wire Size & Ampacity Calculator (Table 310.16)

Load Current (Amps)

Conductor Metal

Terminal Temp Rating

Conductors in Raceway

Continuous Load (runs 3+ hours continuously — apply NEC 125% rule)

What Size Wire for a 80 Amp Circuit Breaker? (NEC Table 310.16)

Direct NEC Table 310.16 Answer for 80 Amps

Common Applications for a 80A Circuit

When to Upsize for Voltage Drop (Over 100 Feet)

2. NEC Wire Size & Ampacity Calculator (Table 310.16)

Recommended Wire, Breakers & Termination Tools