At an altitude of 4800 meters in the Tibetan Plateau transmission lines, the traditional galvanized steel grounding
body three years that rust failure, and the use of 0.25mm electrolytic copper layer of the grounding rod system,
after eight years of wind and snow erosion is still 97% of the conductive properties. This breakthrough in metal
protection technology is redefining the safety standards of modern lightning protection and grounding.
Material revolution: three-layer protection system demystified
A coastal petrochemical base comparison tests show that: electrolytic copper grounding rod in the salt spray
environment life of 25 years, is 3.8 times the conventional materials. Its core technology lies in the innovative
composite structure:
1. Molecular level bonding interface
Through the electroforming metallurgy process, the copper layer and steel core form a 0.02-0.05μm transition
layer of metal intercalation, with a bonding strength of 358MPa, which eliminates the risk of “shelling” of
traditional hot-dip plating.
2. Gradient protection design
Surface layer: 99.9% electrolytic copper, thickness adjustable from 0.25-0.5mm.
Transition layer: copper-iron alloy diffusion tape
Substrate: ASTM A36 low carbon steel
3. Self-healing properties
When the surface copper layer is damaged, the steel core and the copper layer in the electrolyte environment to
form a microcell, the priority corrosion potential of the lower steel substrate, to achieve cathodic protection function.
Engineering Evolution: A New Paradigm for Intelligent Installation
An ultra-high voltage converter station project innovatively applies three-dimensional grounding optimization technology,
which reduces the amount of grounding network materials by 30% while lowering the step voltage to 2.1V:
Three elements of intelligent construction
Geological CT scanning: electromagnetic wave tomography imaging technology is used to establish a three-dimensional
model of soil resistivity.
Dynamic Resistance Reduction Program: Intelligently adjusts the amount of resistor injection according to the soil humidity.
Welding quality monitoring: infrared thermal imaging real-time detection of fusion welding temperature profile
Special environment response strategy
Frozen soil area: Pre-embedded geothermal pipe to maintain a constant temperature around the grounding body.
High corrosion area: superimposed conductive polymer coating protection
Rocky areas: blasting holes with ion mitigation body
Full-cycle management: digitalization from selection to decommissioning
A power grid company's asset management system shows that the operation and maintenance costs of electrolytic copper
grounding facilities decreased by 62% compared with traditional programs, and its management innovations include:
1. Intelligent selection algorithm
Input soil resistivity, lightning days, design life and other parameters, automatically matching the best combination of copper
layer thickness and grounding body length.
2. Corrosion early warning system
Buried electrochemical sensors, real-time monitoring of the remaining thickness of the copper layer, accuracy of ± 0.03mm.
3. Decommissioning assessment model
Based on big data to establish the remaining life prediction formula:
L= [ (C_t -0.1)/v ] × K_s × K_t
(C_t: current copper layer thickness, v: annual corrosion rate, K_s: soil correction factor, K_t: temperature coefficient)
Technology foresight: the next generation of grounding materials
evolution direction
With the new energy power station grounding system for more than 30 years maintenance-free requirements,
the industry is exploring:
Nano-crystalline copper plating: grain size refinement to 50nm, corrosion resistance increased by 5 times
Self-regulating resistance reduction materials: humidity-responsive conductive polymers
Underground Internet of Things (IoT): grounding body with its own wireless sensing network.
Hydrogen protection: hydrogen embrittlement-resistant special steel matrix research and development
Conclusion: When the photovoltaic power plant encountered 12 thunderstorms, data centers face corrosion
failure of the grounding network, electrolytic copper grounding rod system is not only a breakthrough in materials
science, but also a reinterpretation of power safety. This solution, which integrates metallurgical technology,
electrochemical protection and intelligent monitoring, is building a reliable safety barrier for key areas such
as extra-high voltage power grids, offshore wind power and rail transportation. In the wave of new power
system construction, the innovation of grounding technology will become the invisible cornerstone to
safeguard the energy lifeline.