Conducrete Earthing/Grounding Solution - Conducrete Conductive Concrete -  DM100 DM050 - Installation
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Conducrete Earthing/Grounding Solution - Conducrete Conductive Concrete - DM100 DM050 - Installation



Conducrete: Conductive Concrete ...

Conducrete: Conductive Concrete

Earthing Solutions

Conducrete is a very effective earthing/grounding solution which addresses the challenges of any environment in terms of electrical safety, protection of valuable elements from theft and superior earthing performance.

Conducrete is a conductive concrete, which creates safe zones in areas where traditional methods are unsuitable, components stolen, or enhanced safety is required. Conducrete has many applications and a high theft-resistance of material elements.

Conducrete is provided in powder form and easy to install dry or mixed with water in a slurry format and pumped into the trench or hole. Conducrete also provides protection to any system where low impedance earthing/grounding is required.


Part Number




Pack Quantity


Unit Weight

Conducrete DM100 Standard Sized Bag 1 Bag 25kg
Conducrete DM050 Smaller Sized Bag 1 Bag 11.5kg
Conducrete Earthing/Grounding Solution - Wet

Industries Using Conducrete Earthing/Grounding Solution Include:

Electrical Utilities
Wind Farms
Oil and Gas
Industrial and Manufacturing
Institutional and Military

Conducrete Earthing/Grounding Solution Benefits & Features:

Theft Resistant and Maintenance Free
Conducrete protects underlying earthing and grounding systems from theft and sabbotage. Conducrete electrodes are maintenance free over their functional lifetime - no hydration or salt replacement required.

Environmentally Neutral/pH Neutral
Conducrete has no negative impact on the environment. Conducrete is also water impermeable and pH neutral - will not corrode copper conductors.

Long Life Expectancy
Conducrete can extend the life of earthing/grounding systems by 10 - electrodes will last in excess of 25 years.

Compressive Strength and Low Shrinkage
Conducrete has a compressive strength of 21MPa after 28 days - Conducrete electrodes are permanent (will not wash away and will withstand heavy fault currents). Conducrete testing yields shrinkage of 0.015% at 28 days - Conducrete bonds to the surrounding soil resulting in a superior electrode due to the constant contact with the surrounding soil.

High Voltage/Current Test Results
Conducrete electrodes withstood 1682V/688 amp fault for a duration of 500ms. Other earthing/grounding enhancement materials of lower compressive strength have exploded under these test conditions, rendering the protection system useless. Conducrete is the only earthing/grounding backfill that has documented evidence of high fault current withstand.



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Conducrete Earthing/Grounding Solution - Conducrete Conductive Concrete -  DM100 DM050 - Installation Conducrete Earthing/Grounding Solution - Conducrete Conductive Concrete - DM100 DM050 - Installation Document Transcript

  • Tel: +44 (0)191 490 1547 Fax: +44 (0)191 477 5371 Email: Website: ! TBA Civils & Access Engineering ! Cabinet Earthing Trial – Conducrete® Issue status: 01 Owned by: Design & Standards, Telco & Ethernet Engineering & Cabinet Standardisation Team Date of issue: 13/05/2013 Access Network Engineering Authorised by: Nigel Myers Gary Lewis Ken Drew Brian Partridge Find Us On the Intranet: http://sharepoint/sites/customer_ops/accessnetworks/ Engineering/CivilsandAccessEng/default.aspx Company confidential © Virgin Media 2013 ! 1. Document History Issue status Summary of changes from previous versions Draft A Drafted for review Draft B Drafted with more test information Document Change Ref. Date 13/05/2013 05/06/2013 ! * Information sourced from field trial documentation and FM Sudafix (material supplier)* ! 2. Aim To consistently achieve earth impedance values on PME earthed cabinets of 20 ohms or less and on TT earthed cabinets impedance readings of between 80 and 200 ohms. This has not been possible in a reliable, consistent manner using the traditional earth rods or earth plates when installed in bare earth, or encased in Bentonite or Marconite impedance enhancing mediums.
  • ! This document is a record of the cabinet earthing medium Conducrete® trial carried out in Bradford on the 7th May 2013 at NBU 3102 and Leighton Buzzard on 14 May 2013 at NBU5938. Objective To trial and review the recently developed conductive cement Conducrete® in order to assess its suitability as a standardised method of VM cabinet earthing rather than employing the current specified rod or plate. Summary The synopsis below does conclude with a positive resistance test result of 0.416 ohms at Bradford and 4.62 ohms at Leighton Buzzard. However, further testing will be carried out to ensure that the readings achieved are possible in all soil/ground types. The soil at Bradford was gravelly loam and at Leighton Buzzard was heavy clay. A further test at Colchester will be done in a sandy chalk soil. The materials used are cost effective when compared to the current earth rod/plate and Marconite option. 3. Contents • Conducrete® material overview • The Bradford trial installation methodology and results • The Leighton Buzzard trial installation methodology and results • Cabinet Earthing – Traditional current installation methodology • Earth Rods Specification • Earth Plate Specification • Figure 5/1: Positioning of the earth leads on the plate • Figure 5/2: Positioning of the earth ring • Installation Practice • Figure 5/3: Typical Cabinet Earth Plate Layout • Figure 5/4: Typical Cabinets Earth Plate Layout • Installation Procedure • Figure 5/5: Earth Plate Electrode Installation Method • Earth Rod and Plate Resistance Testing • Earth Ring/Conducrete® Resistance Testing ! 4. Conducrete® Conducrete® is a conductive concrete, which can dramatically enhance the performance of earthing/grounding systems for superior electrical protection of assets and can create safe zones in areas where traditional earthing methods are unsuitable,
  • Conducrete® is provided in powder form and is available in 25kg bags (in line with manual handling requirements), or smaller 11.5kg bags. It is easy to install dry directly from the bag, or mixed with water in a slurry format and pumped into the trench or hole. Conducrete® adds protection to any system where low impedance earthing/grounding is required and it has been successfully utilized to enhance and protect earthing/grounding systems across many industries including the following: Electrical Utilities, Telecommunications, Broadcasting, Wind Farms, Mining, Oil and Gas, Industrial and Manufacturing, Municipal and Institutional and Military. ! Summary of Conducrete®’s key features and benefits Protects earthing/grounding systems from theft and sabotage Environmentally neutral Significantly extends the life of earthing/grounding systems, 25 year life cycle. Dramatically enhances the performance of earthing/grounding systems for superior electrical and lightning protection for your assets Cost effective option ! 5a. The Bradford trial methodology and results Location - Opp 144 Wakefield Road, Lightcliffe. ! This cabinet site was chosen due to the inability to gain the required resistance (+100 ohm) from the traditional earth rod method. A second earth rod was installed which reduced the resistance to +30 ohm. ! Attendees - Tim Ingman, Paul Willis (Civils Standards), Gary Lewis (Telco & Ethernet Engineering), Stephen Travers (C&AE Delivery), Fujitsu (VM contractor), John Mayer (FM Sudafix – Supplier) ! Method of operation -16mm earth cable connected to the cabinet earth block, exiting the cabinet via the 56mm black power duct.
  • ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 16mm earth cable coiled within the 500mm deep excavated area ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Dry Conducrete® used as a backfill material, encasing the earth cable !
  • ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Area to be reinstated as per SROH, following the resistance testing. ! ! ! ! ! ! ! ! !
  • ! ! ! ! Earth resistance test carried out – Initial reading was 16 ohm. As the Conducrete® material cured, the resistance reading fell to 0.416 ohm. ! ! ! ! ! ! ! ! ! ! “For comparison purposes” ! ! ! ! ! ! ! ! ! ! 5b. The Leighton Buzzard Trial ! Location: Opposite 36 Kestrel Way, Leighton Buzzard ! This site was chosen as it is a New Build site and the soil is very heavy clay. ! Attendees - Tim Ingman, Gary Lewis (Telco & Ethernet Engineering), John Henry crew (VM Civils Contractor), John Mayer (FM Sudafix – Supplier) !
  • Attached is the FM Sudafix approved method statement and risk assessment. ! Conducrete Method_Statement_JM_17.05.13.doc ! Materials Required: 4 25kg bags of Conducrete 1 16mm CSA earth ring assembly. ! ! ! The Earth Ring Assembly ! Method of Operation: Excavate VMT1 and VMHP1 cabinet site area and Earth Ring area to specified area and depth as per VMNB0022. ! ! • The earth ring excavation should be centred between the VMT1 and VMHP1 cabinet bases under the duct route between the cabinets and chambers. Consult VM Cabinet Standardisation team or the appropriate Engineering team for advice on correct earth ring assembly location. • The earth ring excavation area is 1000 x 600 x 500mm (LWD).
  • ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! • Wear appropriate personnel protective equipment (dust mask and gloves). Read the FM Sudafix method statement. • Lay one unopened 25kg bag of Conducrete® into earth ring excavation. Conducrete® is a very fine, dry powder. Cut open the bag and carefully empty the contents into the excavation with
  • the bag in the excavation. Level the Conducrete® with an appropriate shovel. Install a second25kg bag of Conducrete® into the excavation following the same procedure. • Lay the earth ring on the top of the Conducrete®. ! ! ! • Using same precautions as with the first bag of Conducrete®, install the third and fourth bags into the excavation to cover the earth ring.
  • ! ! • Level the Conducrete® to ensure complete coverage of the earth ring to an overall depth of 100mm. • Carefully place clean excavated native soil over the levelled Conducrete® and manually compact. • Continue backfilling the earth ring excavation and compacting the soil. • No mixture with water is required as the Conducrete® absorbs moisture from the soil surrounding it. !
  • ! • Ensure the 5m insulated earth tail is routed to the VMT1 (left end power compartment) and the 3m insulated earth tail to the VMHP1 (left end power compartment) root areas. ! ! 6. Traditional Cabinet Earthing Techniques General The purpose of the Conducrete® Earth Ring Specification is to consistently achieve earth impedance measurements of less than 20 Ohms for TN-C-S power systems and between 80 & 200 Ohms for TT power systems at all nodes to ensure: (i) A safe environment for Virgin Media employees, Contractors and members of the General Public. (ii) That all VM street cabinets conform to BS 7671:2008 + Amendment No 1: 2011. (iii) That the installation meets the requirements of the local distribution network operator. This applies to all CATV and MUX cabinets erected by VM or any other cabinet to which mains power is connected. ! ! !
  • ! ! ! ! ! ! ! Testing Subject to ground conditions, the earth resistance should be measured as soon as possible after installation. Failure to do so could lead to delay in obtaining Electrical Certification leading to delays in activation. The Contractor shall ensure that all persons engaged to undertake electrical testing and inspection are suitably trained & qualified to be appointed as Competent Persons as defined in BS 7671. ! There are 2 methods available for obtaining resistance readings: (i) Fall of Potential (Using a Fluke 1653B Multi Function Tester (MFT) and Fluke 1630 Earth Clamp kit) - This method can be used immediately after installation of the ring assembly, however it requires suitable ground conditions to enable the earth probes to be driven into the ground, hence it will only be suitable for cabinet sites with soft surrounding such as grass or unmade surfaces. ! (ii) Electrical Measurement - This method requires that the power supply be available into the cabinet(s) and hence can not be made for some time after installation of the ring assembly. A high resistance earth found at this stage will require urgent retrofit work. Measurements (iii) The target measurement for all new earth electrode installations are: _ 20 ohms maximum for TN-C-S power systems _ between 80 - 200 Ohms for TT power systems ! Earth Ring/Conducrete® Method • Connect red test cable to test probe at furthest length from Fluke 1653B/1630 MFT/earth clamp. • Connect yellow test cable to test probe at middle distance from Fluke 1653B/1630 MFT/earth clamp meter. • Connect both test cables to correct test points on Fluke 1653B/ 1630 MFT/earth clamp. • Connect green test cable to Earth Ring insulated tail at VMHP1 root location.
  • ! ! ! ! !
  • ! ! • Turn Fluke 1653B/1630 MFT/earth clamp ON and perform impedance test. • If the DNO has connected their power head in the VMHP1 power compartment, the PME earth impedance test can be done. • Connect the VMHP1 insulated earth tail to the MET at the bottom centre of the power compartment. ! ! ! ! • Perform the PME earth impedance test using the Fluke 1653B MFT. ! ! * Some information sourced from legacy company documentation* ! ! Tel: +44 (0)191 490 1547 Fax: +44 (0)191 477 5371 Email: Website:
  • ! End of Document Tel: +44 (0)191 490 1547 Fax: +44 (0)191 477 5371 Email: Website: