In a high-voltage substation, the integrity of your earthing system is the last line of defence for personnel and equipment, the integrity of your copper conductor is not a detail, it is a fundamental safety requirement.
Global Copper Conductors in Newcastle is one of Australia’s only manufacturers of Oxygen Free High Conductivity (OFHC) copper earthing conductors, supplying utilities, electrical contractors, and substation designers with precision manufactured copper strip, tape, and bare annealed conductors to meet the most demanding project specifications.
From transmission substations operating at 330 kV through to distribution substations at 11 kV, our copper earthing products are engineered to perform reliably over the full design life of the installation, protecting personnel, equipment, and the network itself.
Substation earthing systems serve a single, non-negotiable purpose: to provide a low-impedance fault current path that ensures protective devices operate correctly and that touch and step voltages remain within safe limits for personnel.
Copper is the preferred conductor material for substation earthing grids for several reasons:
With a conductivity of 100–102% IACS, copper offers lower resistivity than any practical alternative, minimising impedance in the fault current path.
Copper forms a stable, protective patina in soil, giving it an exceptional service life without the galvanic corrosion concerns associated with aluminium or steel.
Copper's ductility allows it to withstand the mechanical stresses of fault current events without fracturing or losing contact integrity.
Copper is compatible with a wide range of connectors, clamps, and bonding hardware used in substation construction.
Copper earthing grids have been the global standard in high-voltage substation design for over a century.
Australian standards and international best practice consistently specify copper as the conductor of choice for substation earth grids, earth conductors, and lightning protection bonding.
All earthing conductors and systems supplied by Global Copper Conductors are manufactured in compliance with the relevant Australian and international standards. Engineers and project managers specifying copper earthing for substations should reference the following key standards:
This standard governs the copper material designation C10100 (Oxygen-free Electronic Copper) used in all Global Copper products, setting minimum purity and conductivity requirements.
This is the primary Australian standard for substation design, including requirements for earthing system design, fault current capacity, and touch and step voltage limits.
Provides the broader wiring and earthing framework within which substation earthing must be designed and installed.
This widely referenced industry guide provides detailed methodology for earthing grid design, conductor sizing, and risk assessment in Australian substations and network infrastructure.
Common rules. Increasingly referenced in Australian substation projects, particularly for large transmission assets.
This test method covers the determination of the electrical resistivity of metallic electrical conductor material.
Note: Conductor sizing for substation earthing grids must be calculated by a qualified electrical engineer based on fault current magnitude, fault duration, and the specific requirements of the applicable network standard. Global Copper Conductors can assist with technical data to support your design process, contact our team for assistance.
Global Copper Conductors manufactures a comprehensive range of copper earthing conductors suitable for all elements of a substation earthing system, including earth grids, perimeter conductors, risers, bonding conductors, and lightning protection down conductors. Finished product can be supplied on reels, as pancake coils or cut into bars.
Copper earth strip also referred to as copper tape or copper strap is the primary conductor used in substation earth grid construction. Laid in a grid pattern and buried at a depth typically between 500 mm and 1,000 mm, copper earth strip provides the low-impedance mesh that dissipates fault energy safely into the surrounding soil.
Global Copper manufactures copper earth strip in a wide range of rectangular cross-sections up to 50 mm wide and with a maximum cross-sectional area of 200 mm². Custom dimensions are available upon request with overnight die manufacturing capability, allowing us to match any project specification precisely.
Typical applications:
Bare annealed copper offers the highest flexibility of any copper conductor form, making it ideal for installation in complex substation environments where conductors must be routed around obstacles, through conduit, or terminated in tight spaces.
Our annealed copper is supplied in both round and rectangular profiles, fully softened to maximise flexibility without compromising conductivity. The annealing process is performed in-line during extrusion, ensuring consistent mechanical properties throughout the entire conductor length.
Typical applications:
Global Copper Conductors is Australia’s only manufacturer of copper pancake coils, a compact coil format that delivers significant handling and installation advantages on large substation projects.
Pancake coils are wound flat, keeping the conductor in a consistent, manageable form that unwinds easily without tangling or kinking. This is particularly valuable on active substation sites where safe handling of conductor is a priority.
Standard pancake coil sizes available:
| Metric (mm) | Kg/m (Nominal) | Kg per Coil (Approx.) | Metres per Coil |
|---|---|---|---|
| 2.5 × 16.0 | 0.35 | 35 | 100 |
| 2.5 × 40.0 | 0.90 | 36 | 40 |
| 3.0 × 25.0 | 0.68 | 34 | 50 |
| 3.0 × 40.0 | 1.05 | 36 | 34 |
| 3.0 × 50.0 | 1.30 | 65 | 50 |
| 4.0 × 40.0 | 1.44 | 36 | 25 |
| 4.0 × 50.0 | 1.80 | 36 | 20 |
Other sizes up to 50 mm wide are available on request. Contact us for a free quote.
For major substation projects requiring large quantities of earthing conductor, Global Copper Conductors offers custom drum supply, a packaging solution that delivers significant safety, efficiency, and waste-reduction benefits compared to standard coil or reel supply.
Large conductor on a properly engineered drum can be deployed using a drum stand or cable trailer, eliminating the manual handling of heavy coils on site. This directly reduces the risk of strain injuries and conductor damage during installation.
Custom drum lengths allow earthing conductors to be supplied in the exact lengths required for each grid segment, minimising the number of joints in the earth grid. Every joint is a potential weak point, fewer joints mean a more reliable, lower-impedance earthing system.
Ordering conductor in project-specific drum quantities eliminates offcut waste and reduces the cost of unused material on site.
Conductor supplied on a single drum with a clearly labelled test certificate is simpler to verify and document for project quality records than multiple shorter coils joined together.
Custom drums can be manufactured and delivered to match your construction programme, reducing the need for on-site storage and the associated security and handling risks.
Global Copper Conductors works directly with project engineers and procurement teams to specify the right drum length, conductor size, and delivery schedule for each substation project. Contact us early in your project planning to discuss your requirements.
All copper earthing conductors manufactured by Global Copper Conductors meet the following material specification:
| Property | Specification |
|---|---|
| Copper Designation | C10100 — Oxygen-free Electronic Copper |
| Standard | AS/NZS 1567:1997 |
| Minimum Purity | 99.99% copper |
| Electrical Conductivity | Greater than 100.0% IACS |
| Volume Resistivity | No greater than 17.241 nΩ.m at 20°C |
| Test Standard | ASTM B193 |
| Conductor Form | Bare annealed, round or rectangular |
| Max Cross-sectional Area | 200 mm² |
| Max Width | 50 mm |
This specification ensures our earthing conductors meet or exceed the material requirements of AS 2067 and the ENA Power System Earthing Guide for substation applications.
We manufacture in Gateshead, NSW using Australian-sourced OFHC upcast copper rod. Buying Australian means shorter lead times, simpler quality assurance, and support for local industry.
Our overnight die manufacturing capability means we can produce virtually any copper cross-section to meet your project specification, without the long lead times of imported product.
Our team has deep experience in the electric motor, transformer, and earthing industries. We can assist with conductor selection, sizing data, and compliance documentation to support your project team.
Our copper complies with AS/NZS 1567:1997 and is verified against ASTM B193, giving you the documentation you need for project quality records and network owner approval.
Our location in the Newcastle region provides excellent access to transport networks, with fast delivery available to all Australian capital cities, regional areas, and internationally.
Global Copper Conductors can manufacture rectangular copper strip up to 50 mm wide with a maximum cross-sectional area of 200 mm².
Common substation earthing sizes include 25 × 3 mm, 40 × 3 mm, 50 × 3 mm, and 40 × 4 mm, though we can produce other dimensions to your specification with overnight die manufacturing.
Minimum quantities vary depending on the conductor size and drum configuration. Contact our sales team to discuss your project requirements. We work with projects of all scales from single zone substations through to major transmission infrastructure.
Yes. We can provide material test certificates confirming copper purity, conductivity, and dimensional compliance with AS/NZS 1567:1997 for all earthing conductor orders.
Lead times depend on order size and conductor specification. For standard sizes we maintain stock and can turn around orders quickly. For custom sizes, our overnight die manufacturing capability means production can typically commence within 24–48 hours of order confirmation.
Yes. Bare annealed OFHC copper is specifically suited for direct burial in substation earth grids. Copper’s natural corrosion resistance in soil environments gives it an excellent service life, and it is the material of choice specified in AS 2067 and the ENA Earthing Guide for this application.
Yes. We can supply copper conductors with a range of insulation coverings including Nomex, fibreglass, and other industrial insulations. Insulated conductors are used in certain above-grade earthing applications. Contact us to discuss your specific requirements.
Global Copper Conductors supplies copper earthing conductors to utilities, electrical contractors, and substation project managers across Australia. Whether you are specifying a new substation earth grid or replacing existing earthing infrastructure, our team can assist with conductor selection, custom sizing, and delivery scheduling.
Contact us today to discuss your project requirements
