finishing.com -- The Home Page of the Finishing Industry
A website for Serious Education, promoting Aloha,
& the most FUN smiley you can have in metal finishing

HomeFAQsBooksHelpWantedAdvertizeForum
topic 24506

Copper plating steel grounding (earthing) rods



A discussion started in 2003 & continuing through 2017

(2003)

Q. Dear Sir,

We are exploring the possibility of a plant to do copper coating on a mild steel rod. Copper thickness required shall be in range of 20 micron to 125 micron.
Interested to receive electroplating process and how to do equipment sizing.

Regards

Rajan [last name deleted for privacy by Editor]
electric equipment supplier - Dubai , United Arab Emirates


(2003)

A. Hi Rajan.

You might consider hiring a plating consultant, as it could take a long time from your starting point via this forum :-)

... but you need to start with the size and quantity of rods you want to plate. Then you decide how to handle them (general purpose racking either vertically or horizontally, vs. rolling them like in a conduit plater, vs. continuously end-to-end, etc). Then you need to pick a copper plating process; most likely you will need to cyanide copper plate them or nickel strike them as a first step before acid copper plating, and ending with a tarnish preventer. Good luck!

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey


(2003)

A. Hello Mr Rajan,

Firstly you should mention the application of the components which your are going to do copper plating for e.g., its printing roller, or earthing rods? Do you need a hard copper? Such details we need to suggest the right process and equipment.

praveen kumar
Praveen Kumar
    plating process supplier
Mumbai, India




To minimize searching and offer multiple viewpoints, we combined multiple threads into the dialog you're viewing. Please forgive any resultant repetition.



(2005)

Q. I need to copper coat an earth rod (copper bond ground rod). As you may know, to comply with standards the thickness of the coat should be between 0.2-0.3 mm. Does anyone know the cheap easy way for applying this coating?
Is it possible to reach this thickness with electroplating or electroforming? Which one is best suited for this application (quality and financial wise)? Is there any other solution besides these two methods?

Arash Panah
earthing system - UAE


(2005)

A. Actually, Arash, electroforming is the exact same process as electroplating. We just call it electroforming if the substrate is discarded or reused and serves only as a mold for the plating, such that the plating itself constitutes the whole finished object. In your case the steel rod remains in place underneath the copper plating, so it is not an electroforming operation.

Electroplating is how all your competitors make them. I can't say too much more about the exact methods because I was closely involved in the development of a process for one supplier and they used some non-obvious chemistry. But you might want to consider licensing the patented technology from Galvan Industries [Harrisburg, NC] because it is quite slick and very economical.

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey



April 13, 2008

Q. I hope you do answer our question soon. I specifically write to you because I have seen you have a lot of knowledge about grounding rods. The problem we face is that after plating 250 to 300 microns of copper on the steel core we cannot do the threading on the ends of the rods as required. The copper leaves the rod. The bonding is good enough because we have carried out the bonding test. Maybe the copper is not ductile enough? How can the copper be made ductile easily. How are other manufacturers threading these ground rods after the copper plating?

Ajay Balaji
manufacturer - Mumbai, Maharahtra & India


April 14, 2008

A. Hi, Ajay. Unless you are doing an undercoat of nickel plating or cyanide copper, you probably do not have sufficient adhesion. If you are doing so, then the copper is probably too hard. Perhaps you can anneal it if you cannot deposit it in softer form.

Good luck!

Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey


April 16, 2008

A. If my conversion is correct, you are plating about 0.001 inches of copper.
When you thread an end, the copper is not going to stay attached to the core in the threaded area. If it is peeling off beyond the threaded area, then you do have a bond strength problem and your test is not adequate for the use.
One way would be to mask off the end, so you do not have to thread the copper. But why are you threading the rod?

One American chemical company sell proprietary solutions that are made for this purpose and it evidently works. I think that it is an electroless process, so maybe the rod is pre-threaded. Maybe you can overcut the thread by 0.002 per side and truncate the top of the thread more than normal and be able to plate the threads without having to "chase" them after plate.

James Watts
- Navarre, Florida



May 26, 2009

Q. Dear sir
I want to start a earth rod manufacturing industry I am pretty confused about the copper coating process can you please tell me what kind of machine I require. Is it expensive?
Regards gladson

Gladson Anchan
- Bangalore, Karnataka, India


May 28, 2009

A. Hi, Gladson. If you have not yet visited a couple of ground rod or copper plating facilities and read up on it, I'm not sure that you are yet ready to choose which style of machine you need.

The rods can be hung from a rack vertically, or they can be hung from a rack horizontally, or they can be plated while rolling in a machine similar to a conduit plater, or they can be plated continuously, end-to-end. If you have a lot of patience you can probably see sketches of these various approaches in patents. Good luck!

Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey



September 15, 2011

Q. When I copper plated the rods of size 2500- 4500 mm, the deposition of copper is less at the center of the rods...
Can you suggest some remedies for this.. for 250 microns rods.. and as per UL (Underwriters Laboratories Inc.) standard

Abhiraj Naik
engineer - Mumbai, Maharahstra, India


September 15, 2011

A. Hi, Abhiraj

If you are plating these vertically in a conventional tank, the most obvious improvement is to shorten the anodes. This increases the distance from the anodes to the top and bottom of the rods, thereby reducing the buildup on the ends. Please start by telling us what you are currently doing. Thanks!

Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey


September 19, 2011

Q. Hi Sir,
Our tanks are horizontally placed and the rods are placed in the tank parallel to the ground level.
When I copper plated the rods of size 2500- 4500 mm, the deposition of copper is less at the center of the rods.
Can you suggest some remedies for this or 250 microns rods.. and as per UL (Underwriters Laboratories Inc.) standard.
The time limit is 215 minutes.
And still we don't find the perfect finish nor the deposition of copper is very satisfactory.
Please suggest some remedies in this.
Thanking You.

Abhiraj Naik [returning]
Engineer - Mumbai, Maharahstra, India

September 19, 2011

A. Hi, Abhiraj

The plating is thinner near the center and heavier at the ends because there is more electricity flowing at the ends because of the way the electricity bunches up on the ends unless the span of anodes on the anode bar is shorter than the grounding rods.

35151

The easiest fix is to remove the anodes near the end, making sure their span is significantly shorter than the length of the grounding rod. If this isn't enough, you can install "shields" -- vertical PVC or polypropylene sheets that block the shortest current path to the ends of the grounding rods. If the path is longer the resistance will be higher and the excess plating thickness eliminted.

But if you are having multiple problems like "very unsatisfactory deposition", you might wish to retain a finishing consultant; trying to learn satisfactory plating from trial-and-error and books can be a big challenge. Good luck.

Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey


October 5, 2011

Q. The answer you gave me was not satisfactory.
Please suggest some other remedies for this as we copper plate rods of various lengths from 4 feet to 10 feet.

Abhiraj Naik [returning]
Engineer - Mumbai, Maharahstra, India


October 5, 2011

A. Hi, Abhiraj.

Faraday's law tells us that the thickness of metal deposited will be proportional to the current flowing to it. That is, the plating thickness will follow the current distribution. I suppose you could alternately bend the anode rods into a dog-bone shape so that the anodes are closer to the rod you are plating at the center than at the ends; or put plastic shields at the ends of the rods. But if you do not refine the primary current distribution through either the arrangement of anodes or the installation of plastic shields to divert the current, unfortunately you will not ever be able to solve the problem of uneven thickness.

As for whatever other plating problems you are having, if you describe what you are doing in terms of process: sequence, concentrations, temperatures, etc., and in exactly what way the plating is unsatisfactory, people may be able to help you. Best of luck.

Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey



To minimize searching and offer multiple viewpoints, we combined multiple threads into the dialog you're viewing. Please forgive any resultant repetition.



January 3, 2013

Q. We are in search of an electroplating plant where we can produce 100 to 300 micron copper coated MS rod 12-20 mm OD, 10-12 ft.long. We want to rotate the MS Rod at the time of electroplating to get uniform copper coating 100-300 micron. Is it possible?

Amit Sarkar
- Kolkata, West Bengal, India


January 3, 2013

A. Hi Amit.

Try reaching out to Laurens Willard of Galvan Industries, Harrisburg, No. Carolina to see if they are interested in licensing their process and machine design. They copper plate grounding rods. Although there are many companies who can build a plant for you, knowing from experience what works and what doesn't is always a great start, and Galvan developed and patented a really impressive total process and equipment solution :-)

Luck and Regards,

Ted Mooney, finishing.com
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey



July 17, 2017 -- this entry appended to this thread by editor in lieu of spawning a duplicative thread

Q. My name is anandh kumar from chennai


I am doing acid copper plating; I am doing earth rods. For plating these rods we want 250 micron but I need even microns in the rod .

anandh kumar
- chennai tamil nadu,india.


July 2017

A. Hi Anandh. We attached your inquiry to a discussion on exactly that subject. If it does not answer your questions, please tell us what you have been doing and what is happening. Thanks.

Regards,

pic of Ted Mooney
Teds signature
Ted Mooney, P.E. RET
finishing.com
Pine Beach, New Jersey
Striving to live "Aloha"



This public forum has 60,000 threads. If your question seems off topic to this thread, you might prefer to Search the Site

ADD a Q or A to THIS thread START a NEW THREADView This Week's HOT TOPICS

Disclaimer: It's not possible to diagnose a finishing problem or the hazards of an operation via these pages. All information presented is for general reference and does not represent a professional opinion nor the policy of an author's employer. The internet is largely anonymous & unvetted; some names may be fictitious and some recommendations may be deliberately harmful.

  If you need a product/service, please check these Directories:

Jobshops  Capital Equip. & Install'nChemicals & ConsumablesConsult'g, Train'g, SoftwareEnvironmental ComplianceTesting Svcs. & Devices


©1995-2017 finishing.com     -    Privacy Policy
How Google uses data when you visit this site.