Wind turbines are among the most frequently lightning-struck structures on earth. Standing 100 metres or more above open terrain, they attract both downward and upward-initiated lightning strikes, and an inadequately earthed turbine puts equipment, personnel, and the broader network at risk.
Our pancake coils are purpose-built for the repetitive, turbine-by-turbine installation sequence of wind farm construction. Compact, tangle-free, and easy to handle across rough terrain, they are the practical choice for foundation ring electrodes, perimeter earth loops, and inter-turbine bonding conductors on Australian wind farm projects.
Wind farm sites are typically remote, terrain is rough, and construction crews must work efficiently across large areas – installing identical earthing configurations at each turbine base while managing tight construction programme deadlines.
Global Copper’s pancake coils are wound flat in a stable, self-supporting format that unwinds smoothly and consistently without tangling or kinking. Each coil delivers a continuous conductor length that can be deployed quickly around the turbine foundation ring and along the trench without manual handling difficulties.
The flat-wound format keeps the conductor in a controlled, predictable form from first metre to last – reducing installation time per turbine and eliminating the frustration and safety risk of tangled coil on an active construction site.
Pancake coils are low-profile and stackable, making them straightforward to transport to remote wind farm sites and move between turbine locations on site without heavy lifting equipment.
On a wind farm where the same earthing configuration is repeated at every turbine, the consistency of pancake coil supply – same length, same conductor, same handling characteristics at every location – supports a smooth, predictable installation rhythm across the full turbine fleet.
Our pancake coils are available in lengths up to 100 metres, allowing foundation ring electrodes and perimeter loops to be installed in single continuous runs at most turbine bases – minimising the number of joints in the earthing system and reducing the associated inspection and documentation burden.
Every pancake coil we supply is manufactured from 99.99% pure OFHC upcast copper rod sourced from Australian producers. You receive consistent quality and material traceability with every order – not the variable quality risk of imported product.
Wind turbine earthing systems must simultaneously address two distinct but interconnected design requirements – power system fault current management and lightning protection.
All copper earthing conductors supplied by Global Copper Conductors are manufactured in compliance with the relevant Australian and international standards. The following standards are most referenced in wind turbine and wind farm earthing design:
All coils are manufactured from 99.99% pure OFHC copper to C10100 designation, bare annealed for maximum flexibility and conductivity.
Standard Pancake Coil Sizes:
Other sizes up to 50 mm wide are available on request. Contact us for a free quote.
| 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 | 40 | 30 |
| 4.0 × 40.0 | 1.44 | 36 | 25 |
| 4.0 × 50.0 | 1.80 | 36 | 20 |
Custom sizes up to 50 mm wide are available on request with overnight die manufacturing capability. Contact us for a free quote on non-standard sizes or project-specific quantities.
Global Copper Conductors supplies copper pancake coils to wind farm developers, EPC contractors, and electrical subcontractors across Australia. Whether you are in early design, detailed engineering, or ready to procure, our team can assist with coil selection, custom sizing, test certification, and delivery scheduling.
