Picture yourself driving your car on the highway when all the of the sudden you see brake lights and are forced to slow down because of construction. As you come to a stop, you see workers repaving a damaged road. Now, cars begin to line up in front of you and behind you. Where do you go? Nowhere&#;you&#;re stuck.
A ground rod, also known as an electrode, is similar to this highway scenario. It acts as the only electrical path to dissipate static discharge voltage (such as lightning) into the earth. When that path starts to break down, the static discharge has nowhere to go and puts the whole system at risk.
Many times, engineers are given the choice between three types of ground rods: copper-bonded steel, copper clad ground rods or galvanized steel for grounding systems. However, one material reigns supreme when it comes to strength, service life and overall investment. Hint: it&#;s copper bonded steel.
Continue reading below to learn why copper-bonded ground rods are the better choice for grounding systems versus other alternatives.
Engineers should aim for ground rods that have a strong core for the ease of driving into the earth and high corrosion resistance. Copper-bonded ground rods have a high carbon steel core that is suitable for deep driving. A layer of nickel and then a coating of copper is electroplated on the steel core to provide corrosion protection This coating is not subject to the risk of bending or cracking.
Alternatively, copper clad steel ground rods are more likely to develop cracks and creases to the outer sheath. Additionally, galvanized steel ground rods have a higher corrosion rate, which will significantly reduce serviceable life and put the integrity of the entire electrical system at risk.
Ground rods are often selected based on their resistance to corrosion. Corrosion causes deterioration of a metal as a result of chemical reactions between it and the surrounding environment. A corroded ground rod can put the whole installation at risk because it weakens and breaks down the electrical path.
Copper-bonded rods have a high resistance to corrosion. Galvanized steel rods are more susceptible to corrosion than copper-bonded rods because the zinc coating degrades rapidly when placed underground. This causes the inner steel to be exposed and subsequently corrode faster. Additionally, it&#;s difficult to inspect this degradation below ground and as a result, the electrical installation can fail when subjected to a fault condition.
Sometimes, installers or engineers choose a ground rod based on initial cost. However, it&#;s important to also consider the longevity and performance of the entire system&#;a higher initial cost may save money in the long run if the ground rod is more dependable and has a longer service life.
Unfortunately, over the lifetime of the installation, galvanized steel rods are not the most cost-effective option due to their short service life. Copper-bonded ground rods last significantly longer and require less or no maintenance due to their durability.
nVent ERICO offers a variety of copper-bonded ground rods that have a permanent molecular bond for reliable performance, including:
Ground rods are the foundation to every electrical and lightning protection system. Although copper-bonded ground rods are more expensive up-front, they will cost less in the long run and extend the overall life of a grounding system.
nVent ERICO has the ground rod solution that you can depend on. Download the flyer.
Want to learn more about nVent ERICO&#;s copper-bonded ground rods? Check out our ground rod product page, download the nVent ERICO Grounding, Bonding and nVent ERICO Cadweld Solutions Guide or:
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An electrical conductor is a material that allows electricity to flow through it. However choosing between &#;copper-clad steel conductors&#; and &#;pure copper conductors&#; for lightning protection can be confusing, as both serve similar purposes. But, selecting the wrong one can make a significant difference.
Conductors can generally be classified by the metals they are made from, which depends on the intended purpose. In this blog, we will discuss two widely used conductors: copper-clad steel conductors and pure copper conductors. Additionally, there are various other conductors available in the market, including:
Copper-clad steel conductors, also known as copper-covered steel conductors, are composite material conductors. They consist of a uniform low, medium, or high carbon steel core surrounded by a thick layer of copper. The inner carbon steel core gives the conductor its high tensile strength, while the outer copper cladding provides electrical conductivity. In simple terms, this conductor has a steel core that grants it strength and a copper layer on the outside that ensures electrical conductivity.
The production of copper-clad steel conductors begins with a mild steel conductor, which undergoes a series of processes to enhance its physical properties and surface quality. Initially, the conductor is peeled to remove imperfections, straightened and turned for uniformity, and finally polished to achieve a smooth finish.
Next, the conductor enters the electroplating stage, where it is coated with oxygen-free copper at high temperatures, approximately 25-30 degrees Celsius. Following this, the conductor is subjected to hot-dipping in an oxygen-free copper-clad steel bath, maintained at approximately 45-50 degrees Celsius, ensuring a uniform coating.
After the hot-dipping process, the conductor is immediately cooled with water to strengthen the copper layer. To further enhance the conductor, it undergoes cold rolling, allowing for customization of shape and size according to specific needs. If necessary, the conductor then undergoes annealing&#;a heat treatment in nitrogen gas to improve its ductility and relieve internal stresses. This is the process by which a copper-clad steel conductor is manufactured.
Copper-clad steel conductors are widely used in grounding, i.e. connection of earthing rods to metallic structures, plates, and grid meshes, in power installations, substations, and for lightning arresters. Copper-clad steel conductors are also used for power transmission and radio frequency (RF) transmission lines.
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Pure copper conductors are made a bit differently. They are produced by pushing pure copper ingots through an extrusion machine. This machine forces the copper through several moulds in a row to achieve the right size and shape for the conductor.
They are used in power generation, power transmission, power distribution, telecommunications, electronics circuitry, and several types of electrical equipment. They are found to be ideal in permanent applications where the conductors, cables, or wires are unlikely to be replaced or changed (e.g. concealed wiring inside walls). Also, Copper Conductors in the form of cables find ideal use in signal transmission over long distances since minimal current is required to drive the signals on account of the high conductivity of copper (conductors). They excel in transmitting high levels of data over these distances &#; and minimal current is necessary to push signals all the way through.
Your choice should match your needs. For Earthing and Lightning Protection, copper-clad steel is the more cost-effective option. To illustrate the cost difference, if 1 meter of Copper Bonded Steel Conductor costs you X amount, the same length of Pure Copper will cost about 3 to 4X.
However, both conductors do an excellent job of protecting your building from lightning strikes. They safely channel it to the ground without causing dangerous temperature increases, that could damage your structure.
We hope you now have a clear idea about all the 2 conductors. At Axis, we have a team of 40+ engineers who are here to help you in designing, installing and testing your Grounding and lightning Protection Systems. Our products have been used in substations, data centres, factories and even in everyday residential and commercial buildings.
Thank you for reading the blog, Axis is a leading manufacturer and supplier of AB Cable Accessories and other Electrical Components to over 80+ Countries. To get a quote or to talk to our industry expert visit our contact us section. You can also watch our videos by our experts &#; click here.
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