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Copper Bonded Earth Rods
Product Overview
Copper Bonded Earth Rods supplied by R V Metal Corporation are engineered for long-term, low-resistance earthing and grounding applications across power, infrastructure, industrial, and commercial projects. These rods are manufactured using a high-strength low-carbon steel core uniformly bonded with a thick layer of high-conductivity electrolytic copper through a molecular bonding process, ensuring superior electrical performance and exceptional corrosion resistance.
Unlike conventional GI or copper-clad rods with thin electroplated layers, R V Metal Corporation’s copper bonded earth rods offer a continuous copper sheath that will not crack, peel, or separate during driving, even in rocky or high-impact soil conditions. The steel core provides mechanical strength, while the copper layer ensures consistent conductivity and a stable earth path over decades of service life.
These earth rods are widely used in substations, transmission towers, solar power plants, data centers, telecom infrastructure, process industries, and lightning protection systems. Designed to comply with international earthing standards, copper bonded earth rods from R V Metal Corporation deliver reliable grounding performance in diverse soil resistivity conditions, including high-moisture, corrosive, and high-salinity environments.
Available in multiple diameters, lengths, and copper coating thicknesses, the rods can be supplied with threaded ends, driving heads, and couplers as per project specifications. Each product is supported with dimensional accuracy, coating integrity, and quality assurance aligned with EPC, consultant, and utility approval requirements.
Technical Specifications
| Parameter | Specification |
|---|---|
| Product | Copper Bonded Earth Rods |
| Base Core Material | High tensile, low carbon steel |
| Copper Coating Material | Electrolytic Copper (≥ 99.9% purity) |
| Bonding Method | Molecular bonding process (not electroplated or sprayed) |
| Copper Coating Thickness | Minimum 250 microns (custom thicknesses available on request) |
| Standard Diameters | 12.7 mm, 14.2 mm, 16 mm, 17.2 mm, 19 mm (½", ⅝", ¾") |
| Standard Lengths | 1 meter, 1.2 meter, 2 meter, 3 meter (custom lengths available) |
| Electrical Conductivity | High conductivity copper surface ensuring low earth resistance |
| Tensile Strength (Core) | ≥ 600 MPa (suitable for deep driving) |
| Corrosion Resistance | Excellent – suitable for high moisture, saline, and aggressive soils |
| Surface Finish | Smooth, uniform copper finish without cracks or pores |
| Threading Options | Threaded ends available for couplers and extension rods |
| Accessories | Driving head, couplers, clamps, inspection pits (optional) |
| Installation Method | Vertical or horizontal driving using mechanical or manual tools |
| Expected Service Life | 30–40 years (soil and environmental conditions dependent) |
| Operating Temperature Range | -40°C to +80°C |
| Compliance Standards | IEC 62561, IEEE 80, IS 3043, BS 7430 |
| Quality Assurance | Dimensional, coating thickness & visual inspection |
| Applications | Substations, solar plants, lightning protection, telecom, data centers, industrial earthing |
Chemical Composition
| Component | Element | Chemical Composition (%) | Remarks |
|---|---|---|---|
| Copper Coating | Copper (Cu) | ≥ 99.90 | Electrolytic grade copper ensuring high conductivity |
| Oxygen (O) | ≤ 0.04 | Low oxygen content to prevent embrittlement | |
| Impurities (Total) | ≤ 0.06 | Includes trace elements such as Ag, S, Pb | |
| Silver (Ag) | ≤ 0.02 | Present as trace impurity, no adverse effect | |
| Steel Core | Iron (Fe) | Balance | High tensile low-carbon steel base |
| Carbon (C) | ≤ 0.25 | Maintains strength and ductility for driving | |
| Manganese (Mn) | ≤ 1.20 | Improves toughness and wear resistance | |
| Silicon (Si) | ≤ 0.40 | Deoxidizer during steelmaking | |
| Phosphorus (P) | ≤ 0.04 | Controlled to avoid brittleness | |
| Sulphur (S) | ≤ 0.05 | Restricted to maintain mechanical integrity |
Note:
Copper bonded earth rods consist of a high-tensile low-carbon steel core
permanently bonded with high-purity electrolytic copper. The copper layer
provides excellent electrical conductivity and corrosion resistance, while
the steel core ensures mechanical strength for deep driving applications.
UNS Codes & Grades
| Component | Material Description | UNS Code | Grade / Specification | Remarks |
|---|---|---|---|---|
| Copper Coating | Electrolytic Tough Pitch Copper | C11000 | ETP Copper (≥ 99.90% Cu) | Most commonly used for copper bonding due to high conductivity |
| Deoxidized High Phosphorus Copper | C12200 | DHP Copper | Used where hydrogen embrittlement resistance is required | |
| Deoxidized Low Phosphorus Copper | C12000 | DLP Copper | Optional grade for specialized grounding applications | |
| Steel Core | Low Carbon Steel | — | IS 2062 / ASTM A36 Equivalent | Provides high tensile strength for deep driving |
| High Tensile Carbon Steel | — | ASTM A108 / SAE 1010–1020 | Commonly used for heavy-duty earth rod applications |
Important: Copper bonded earth rods are composite products.
UNS designations apply individually to the copper coating and steel core,
not to the finished rod as a single material. Selection of copper grade
impacts corrosion resistance and conductivity, while the steel core governs
mechanical strength and driveability.
Mechanical, Physical & Fabrication Properties
| Property Category | Parameter | Typical Value / Range | Test Method / Standard | Engineering Significance |
|---|---|---|---|---|
| Mechanical Properties | Tensile Strength (Steel Core) | ≥ 450 MPa | ASTM A370 / IS 1608 | Prevents bending or breakage during deep driving |
| Yield Strength | ≥ 250 MPa | ASTM A370 | Ensures dimensional stability under hammering | |
| Impact Resistance | No cracking or delamination | IEC 62561-2 | Critical for rocky or compact soil installation | |
| Bend Test | No copper peeling after bending | IEC 62561-2 | Verifies metallurgical bonding integrity | |
| Physical Properties | Copper Coating Purity | ≥ 99.9% Cu | ASTM B152 / IS 191 | Ensures high conductivity and corrosion resistance |
| Copper Bond Thickness | ≥ 250 microns (standard) | IEC 62561-2 | Determines service life in aggressive soil | |
| Electrical Conductivity | ≥ 98% IACS (copper layer) | ASTM B193 | Low earth resistance performance | |
| Thermal Expansion Compatibility | Copper–Steel matched bond | Manufacturer validated | Prevents cracking due to thermal cycling | |
| Fabrication & Installation | Bonding Method | Molecular / Electrolytic Bonding | IEC 62561-2 | No separation between copper and steel |
| Thread Compatibility | Roll-threaded ends (male/female) | IEC 62561-2 | Allows couplers and sectional rods | |
| Cut-End Protection | Maintains copper coverage | Manufacturer process | Prevents corrosion at exposed steel ends | |
| Driving Capability | Suitable for hammer or power driving | Field verified | Fast installation without rod damage |
Note: Copper bonded earth rods combine the high conductivity
and corrosion resistance of copper with the mechanical strength of steel.
Performance depends on copper bond thickness, bond integrity, and steel core
strength—not merely rod diameter.
Common Names & International Identifiers
| Common / Trade Name | International Identifier | Description | Typical Usage Region | Notes for Engineers / Consultants |
|---|---|---|---|---|
| Copper Bonded Earth Rod | CBER | Steel core rod with molecularly bonded copper coating | Global | Preferred worldwide due to strength + conductivity balance |
| Copper Clad Earth Rod | Copper Clad Ground Rod | Electrolytically bonded copper over steel | USA, Europe, Middle East | Must meet IEC 62561-2 for bond integrity |
| Grounding Rod | Ground Rod | Generic term for earthing electrodes | North America | Material must be specified to avoid GI substitution |
| Earthing Rod | Earth Electrode Rod | Vertical electrode for dissipation of fault current | India, UK, Asia | As per IS 3043 / BS 7430 |
| Driven Earth Rod | Driven Ground Electrode | Rod designed for hammer or power driving | Global | Requires high tensile steel core |
| Sectional Earth Rod | Threaded Coupling Rod | Rod supplied in sections with couplers | Global | Allows deep earthing in high resistivity soil |
| Deep Earth Rod | Deep Driven Electrode | Extended-length earthing solution | Utilities & Substations | Used where surface soil resistivity is high |
| Power Earthing Rod | Substation Ground Rod | High-current capable earthing electrode | Power Plants, Switchyards | Often specified with minimum copper thickness |
| Lightning Earth Rod | Lightning Protection Electrode | Dedicated rod for lightning discharge systems | Telecom, Data Centers | Installed as per IEC 62305 |
| Copper Bonded Ground Electrode | CBGE | Formal technical term used in tenders | Global EPC Projects | Common in consultant BOQs and specs |
Important: Terms such as earthing rod, ground rod,
and earth electrode are often used interchangeably in specifications.
Always confirm material type (copper bonded vs GI vs solid copper), copper
thickness, and applicable standards to avoid non-compliant substitutions.
Standards & International Equivalents
| Region / Country | Standard Number | Standard Title | Scope / Coverage | Key Technical Requirements |
|---|---|---|---|---|
| International (IEC) | IEC 62561-2 | Lightning Protection System Components – Earth Electrodes | Earthing & grounding electrodes | Minimum copper thickness, bond integrity, corrosion resistance |
| International (IEC) | IEC 62305 | Protection Against Lightning | Lightning earthing systems | Used for lightning & surge earthing design |
| India | IS 3043 | Code of Practice for Earthing | Electrical earthing installations | Specifies copper bonded rods for long service life |
| India | IS 2683 (Part 1) | Dimensions of Solid Copper Rods | Copper rod dimensional reference | Often referenced for copper layer equivalence |
| USA | UL 467 | Grounding and Bonding Equipment | Ground rods and accessories | Bond adhesion, corrosion, impact resistance |
| USA | IEEE 80 | Guide for Safety in AC Substation Grounding | Substation earthing design | Step & touch potential control |
| USA | NEC (NFPA 70) | National Electrical Code | Electrical installations | Defines grounding electrode requirements |
| United Kingdom | BS 7430 | Code of Practice for Earthing | General earthing systems | Preferred reference for earthing design |
| United Kingdom | BS EN 62561-2 | LPS Components – Earth Electrodes | European adoption of IEC 62561 | Mandatory for CE-marked systems |
| Europe (EU) | EN 62561-2 | Lightning Protection System Components | Earthing electrodes | Equivalent to IEC 62561-2 |
| Germany | DIN EN 62561-2 | Blitzschutz – Erdungskomponenten | Earthing & lightning protection | Strict corrosion & mechanical tests |
| Middle East | DEWA / SEC / ADDC Specs | Utility Earthing Specifications | Utility & infrastructure projects | Typically mandate IEC + UL compliance |
| Australia / NZ | AS/NZS 3000 | Wiring Rules | Electrical earthing systems | Ground electrode material compliance |
Note: Copper bonded earth rods supplied by R V Metal Corporation
conform to IEC 62561-2 requirements for copper thickness, bond adhesion, and
corrosion resistance. Always specify the applicable standard explicitly in
tender documents to prevent substitution with GI or flash-plated rods.
Applications
| Application Sector | Specific Use Case | Purpose of Copper Bonded Earth Rod | Key Performance Requirement |
|---|---|---|---|
| Electrical Power Systems | Substations, switchyards, transformer yards | Primary grounding electrode for fault current dissipation | Low earth resistance, high corrosion resistance |
| Commercial Buildings | IT parks, malls, hospitals, airports | Main earthing for electrical panels & equipment | Long service life, stable conductivity |
| Industrial Plants | Manufacturing units, refineries, chemical plants | Equipment grounding & personnel safety | High mechanical strength, chemical corrosion resistance |
| Renewable Energy | Solar power plants, wind farms | Inverter, module frame & lightning earthing | Consistent earth resistance over time |
| Telecom & Data Centers | Cell towers, BTS sites, data centers | Signal grounding & surge protection | Low impedance path for transient currents |
| Lightning Protection Systems | Air terminals, down conductors, LPS grids | Dissipation of lightning surge currents | IEC 62305 & IEC 62561 compliance |
| Oil & Gas Installations | Petrochemical plants, pipelines, tank farms | Static discharge & fault current grounding | High bond integrity, spark-free performance |
| Railways & Infrastructure | Metro stations, signaling rooms, traction substations | Protect signaling & traction systems | Mechanical robustness, long-term reliability |
| Residential Projects | High-rise apartments, villas, housing societies | Electrical safety earthing | Maintenance-free grounding solution |
| Defense & Critical Facilities | Military bases, radar stations, research labs | System grounding & EMI protection | High conductivity, zero bond failure |
Note: Copper bonded earth rods are preferred over GI rods in
high-corrosion soils, coastal regions, and critical installations due to their
superior conductivity, longer service life, and stable earth resistance.
Standard Copper Bonded Earth Rods Dimensional Chart
| Rod Diameter | Rod Diameter | Standard Length | Copper Coating Thickness | Core Material | Thread Specification | Approx. Weight |
|---|---|---|---|---|---|---|
| (mm) | (inch) | (meters) | (microns) | (kg) | ||
| 14.2 | 5/8" | 1.2 | ≥ 250 | Low Carbon Steel | 1/2" BSW / UNC | 1.4 |
| 14.2 | 5/8" | 2.4 | ≥ 250 | Low Carbon Steel | 1/2" BSW / UNC | 2.8 |
| 16.0 | 5/8" | 3.0 | ≥ 250 | Low Carbon Steel | 1/2" BSW / UNC | 4.1 |
| 17.2 | 3/4" | 1.2 | ≥ 250 | Low Carbon Steel | 5/8" BSW / UNC | 2.1 |
| 17.2 | 3/4" | 2.4 | ≥ 250 | Low Carbon Steel | 5/8" BSW / UNC | 4.2 |
| 17.2 | 3/4" | 3.0 | ≥ 250 | Low Carbon Steel | 5/8" BSW / UNC | 6.5 |
| 19.0 | 3/4" | 3.0 | ≥ 250 | Low Carbon Steel | 5/8" BSW / UNC | 7.0 |
| 20.0 | 7/8" | 3.0 | ≥ 250 | Low Carbon Steel | 3/4" BSW / UNC | 7.8 |
Technical Notes:
- Copper coating is electrolytically bonded to the steel core and will not crack or peel during driving.
- Standard copper coating thickness is ≥ 250 microns; higher thickness (300–500 microns) available on request.
- Threads provided on one or both ends for use with couplers and driving heads.
- Custom lengths, diameters, and thread forms available for EPC and utility projects.
