Innovative Technology

MARCONITE® Electrically Conductive Aggregate
An Innovative Earthing Technology
1 INTRODUCTION
In the past, engineers relied on technology, related to generally available minerals, to design
the earthing systems for various applications like power stations, buildings, railways,
industrial complexes, water & gas plants etc. These earthing systems required presence of
water to maintain.
In the late 19th century Marconite® was specifically developed to meet the requirement of all
type of earthing applications but without the need of water it. It is electrically conductive
black granular, used as backfill material to enhance the effectiveness of the earth to achieve
durable, stable and low resistance performing earthing solutions for all types of soil and
difficult ground conditions.
Marconite® conducts electricity much the same way as metals, through the movement of
electrons. It does not require water to conduct electricity and is not affected by dryness like
other ionic based earthing materials such as Bentonite, Charcoal etc. which always require
the presence of an effective electrolyte else they dry out and do not conduct electricity.
Marconite® conductive concrete is one of the most suitable materials for treatment of soil.
Electrical engineers have been using it to tackle the toughest soil conditions so as to achieve
satisfactory earthing solutions throughout the World for over 50 years.
2 SALIENT FEATURES
2.1 Specifications:
a) Fixed Carbon 98.5 %

b) Ash, Volatile and Water 1.5 %
c) Sulphur Content 1.5 % Maximum
d) Size Grading (Approx) 10% below 0.10 mm

5% above 3.15 mm
85% between 0.10 mm and 3.15 mm
e) Thermal Stability Between (–) 10% and (+) 60% ambient temperature
2.2 Ultra Low Resistivity: The resistivity of Marconite® is 0.001 Ω-m and when mixed with
Portland cement it is still 0.040 Ω-m, which is significantly lower than other earthing
materials:-
a) Marconite® Aggregate = 0.001 Ω-m

b) Normal Aggregate = 30 to 90 Ω-m
c) Marconite® conducting concrete (Mix with Cement) = 0.040 Ω-m
d) Bentonite = 3 Ω-m upwards
2.3 Versatile: Marconite® is suitable for all types of soil/ground conditions. It becomes a
permanent solid structure and does not shrink or gets washed away. It does not require
moisture at all. It performs very well in dry soil and hottest climatic conditions.
INTER-TECH - Prime Distributor of Marconite® for India

2.4 Consistent Performance: Once installed, Marconite® based earthing system gives
consistent performance and earth resistance value remains the same year after year or
shows very insignificant variations.
2.5 Contact area: Solid structure provides larger surface area for dissipation, thus
dissipates current faster.
2.6 Chemically Inert: It’s pH value is within the neutral range.
2.7 Non-corrosive: Marconite® does not corrode steel or copper conductor or attacks
cement structures. It may be noted:-
a) That effect of DC current spreads to a radius of 30 to 50 kms from the earth

electrode stations when DC current back flows (Transformer Saturation) or earth
return is used to transmit the power in HVDC, which accelerates the corrosion of
Earth Electrodes, pipe lines and other metallic objects within it’s vicinity.
b) That GIS equipment uses earthed metal screens / enclosures around individual
phase conductors and residual AC current flows continuously via earthing system.
This causes additional corrosion of earth conductor.
Marconite® encapsulated electrodes are the best solution to protect such corrosion.
2.8 Life: Marconite® based earthing systems has a life of more than 50 years.
2.9 Maintenance: Absolutely maintenance free and does not need water for life. No need to
remove, replace or recharge it in order to maintain the desired earth resistance value.
2.10 Environment friendly: Marconite® does not leach and pollute ground water channels
like other earthing systems. Use of Marconite® also saves trees from burning to get
charcoal.
2.11 No environmental hazard: Marconite® does not pose any environmental hazard for
future generations even after the completion of it’s life as it disintegrates with soil like
any other concrete structure.
2.12 Cost effective: Especially in high resistivity soils, sandy or water logged areas.
2.13 Lowest ownership cost: Long and maintenance free life of Marconite® based earthing
Systems makes it’s cost lowest among all other earthing systems.
2.14 Easy to Install: Requires only a bore hole or trench to install.
2.15 No space constraint: Gas insulated substation (GIS) occupies only 15 - 25% of the area
occupied by the equivalent AIS. Hence it becomes difficult to achieve the required level
of Earth resistance in small areas. Marconite® encapsulated deep driven rods are the
best solution to achieve low value of ground resistance in such cases.
2.16 Improvement Factor: In practice, improvement of 40% - 60% is generally obtained

with the use of Marconite® conductive concrete. Refer Para 13 of this document for
case studies.
2.17 Compressive Strength: Marconite® concrete, once it is set, displays a greater

compressive strength than Gr 25 concrete & becomes significantly greater over a period
of time.

2.18 Metal conductor saving: In designing an earth grid, Dia of conductor is designed
oversized to withstand corrosion. Marconite® encapsulated rods solve this problem and
also save steel conductor on two counts:-
a) Provision of over designing of conductor is not required in the absence of corrosion.
b) Increased surface area of Marconite® embedded rods reduces the overall

requirement of grid’s horizontal conductor, which otherwise would be required if
bare rods are used.
3 TECHNICAL REFERENCES
Many standards, technical books & papers and web sites have reference of Marconite®
conductive concrete/ concrete-encased electrodes. Few of them are mentioned below:-
3.1 IS: 3043 (1st Rev Draft ) Cl 9.2.5 for electrode encased in low resistivity material, e.g.
Conducting concrete page 71-73. (Under revision by BIS)
3.2 BS: 7430: 2011 Cl 9.5.7 for electrode encased in low resistivity material, e.g.
Conducting Concrete page 74-76.
3.3 IEEE Std 80 -2000 Clause 14.6 for concrete encased electrodes page 68.
3.4 Engineers Hand Book on Sub Station Engineering design, Concepts and Computer
Applications by R S Dahiya, Kartson books - page 180.
3.5 Mc Graw Hill Material’s handbook by George S. Brandy, Henery R. Clauser & J A.
Vaccaril – page 265.
3.6 Achieving an acceptable Ground in poor soil-Paper by Keith Switzer, ERICO, Inc.
3.7 WALLIS Soil Survey Report of Royal Offices, Oman recommending the use of Electrically
Conductive aggregate Marconite®.
4 TESTS/REPORTS
Marconite® conductive concrete and it’s electrodes were tested at various independent
National and International laboratories besides testing of material resistivity of each batch is
carried out by the manufacturer i.e. M/s Carbon International Limited, UK and test report is
provided with all the consignments. Results of tests are appended below:-
4.1 Resistivity - Aggregate:
Results: “Ultra low resistivity of 0.001 Ohm-m.”
4.2 Resistivity - Concrete: Marconite concrete (2 Parts Marconite + 1 Part Cement) was
tested by one of the overseas laboratory i.e. Fugro Middle East, Dubai for their client
M/s Trade Circle Ltd., and material was used for world famous building in Dubai i.e.
Palm Jumeirah.
Results: “Ultra low resistivity of 0.040 Ohm-m at 20⁰ C degree.”
4.3 Short Current - Electrode: The test was carried out by Central Power Research
Institute, Bangalore on two specimens of different sizes of Marconite concrete earth
electrodes:-

Results:
Current (kA) Duration Ambient temp
Peak RMS (s) Temp. ° C
Specimens
a) Cu rod L 3 m, D 16 mm,
Marconite ® Encapsulation
L 2.9 m, D 75 mm 39.66 22.69 1.10 29
b) MS rod L 3 m, D 40 mm,
Marconite ® Encapsulation
L 2.9 m, D 100 mm 80.52 40.13 1.11 29
4.4 Earth Resistance - Electrode: Central Power Research Institute, Bangalore measured
performance of two specimens of Marconite concrete earth electrodes after 38 days of
installation with soil resistivity of 468.29 Ω-m of trial ground:-
Results:
Specimens
a) Cu rod L 3 m, D 16 mm ,
Marconite® encapsulation L 3 m, D 100 mm = 90.87 Ω
b) MS rod L 3 m, D 40 mm ,
Marconite® encapsulation L 3 m, D 200 mm = 55.43 Ω
4.5 Compressive Strength - Cube: Two specimens of 200mm³ cubes were tested by Central
Midland Laboratories Birmingham, UK for compressive strength after 7 & 28 days:-
Results:
After 7 Days After 28 Days
Specimen
c) One 22.0 N/mm² 27.5 N/mm²
d) Two 23.1 N/mm² 29.5 N/mm²
Conclusion: “It produced a low resistivity and highly conductive material in its
Hardened State”
4.6 Chemical Test – ROH’s: Marconite aggregate was tested by Muscot Laboratory Service,
Bangalore, (DGQA, Ministry of Defense, GOI approved) for various chemicals:-
Results:
Name of Test Value Ω
a) Lead (Pb) <0.10 pp

b) Mercury (Hg) <0.001 ppm
c) Cadmium (Cd) <0.1 ppm
d) Nickel (Ni) <0.1 ppm
e) Arsenic (As) <0.1 ppm
f) Cyanide (CN) <0.1 ppm
g) Hexavlent Chromium (Cr⁺⁶) <0.1 ppm

Conclusion: “On the basis of the observed values of the tested marconite earthing
material is non hazardous, non polluting”
4.7 CBIP Technical Report no 78 1991: Evaluation of Concrete Encased Electrodes & Use of
Structural Steel for Earthing was carried jointly by CBIP & Dept. of Electrical
Engineering, Punjab Engineering College, Chandigarh.
a) Passage of AC current steel electrodes embedded in concrete causes only negligible

corrosion.
b) Normal stray AC current do not cause deterioration in the strength of concrete.
c) Short duration large currents (like Lightning surges) have negligible effect on the
bond between steel and concrete.
Conclusion: Natural steel under such conditions may be safely used as grounding
electrode.
5 PRACTICAL ASPECTS OF USING MARCONITE®
5.1 Methodology: Marconite® conductive aggregate is mixed with cement normally in the
ratio of 2:1 [2 Parts Marconite: 1 Part Cement] and add one litre of water per kg of
total mix to form a fairly dry mix. Normally a bore hole of up to 100 mm Dia may be
used. But if required deeper bore holes may be made rather than increasing the Dia of
bore hole because surface area benefits obtained with larger diameters are usually
negated by the added costs of drilling larger Dia bore holes and increased quantity of
Marconite®.
5.2 Single Electrode: Marconite® concrete is poured around the metal conductor in the
augured borehole and left it to set into a permanent solid structure.
5.3 Earth Grid: Horizontal conductor of the grid is embedded in Marconite® concrete for
larger surface area. It saves over sizing of steel rods, which is used to counter the
effect of corrosion in bare rod designs.
5.4 Earth Grid Joints: Cross, parallel and riser’s joints of earth grid conductor are
embedded in Marconite® conductive concrete to prevent the opening of welded joints
due to corrosion. This keeps connectivity of the grid intact for it’s life.
6 COMPARISION OF MARCONITE® BASED SYSTEMS WITH TRADITIONAL SYSTEMS
Marconite® Traditional GI pipe / Pipe in pipe/strip

Parameters conductive concrete Plate Earthing with systems with back fill
based systems Charcoal and Salt Compounds
Technical
1 Technology Natural grey CI, GI, Cu plate, GI Pipe in pipe/strip with
Electrically Pipe, Charcoal & Salt. back fill materials.
Conductive Concrete
2 Design Consistency in Coal & Salt vary place Backfill materials
Consistency design to place vary.
3 Resistivity of Ultra low resistivity Charcoal offer Resistivity of back fill
material. - 0.001 Ω-m. resistivity of 2.6 X 10-4 materials is 3 -5 Ω-m.
Ω-m and salt consist
15% - 20% impurities

Marconite® Traditional GI pipe / Pipe in pipe/strip
Parameters
conductive concrete Plate Earthing with systems with back fill
based systems Charcoal and Salt Compounds
4 Material’s ph Inert Acidic Acidic
5 Process Electronic. Ionic Ionic
6 Suitability of Good for Granite, Difficult to install in Difficult to install in

Electrode Hilly terrains, Sandy Granite, Rocks, Hilly Granite, Rocks, Hilly
soil, Made up terrains, Water Logged terrains, Water
ground, Water Areas, River beds & Logged Areas, River
Logged Areas, River Sea shores etc. beds & Sea shores
beds, Sea shores & etc.
Salty soils etc.
7 Easy Only a borehole is Wider excavation is Digging is difficult in

Installation required. In rocky difficult in rocky soils. rocky soils. Thus high
soils it works in low Thus high cost of cost of installation.
depth tranches also. installation.
8 Life 50+ years. 8 years. 10 years.
9 Performance Constant Electrical Watering dissolves salt Back fill material

Conductivity Un-affe into soil. Fails to sweeps away in earth
cted by Environment provide safe discharge water channels which
Temp & Moisture. path or do not activate affects performance.
Does not leach or fault protection due to
gets washed away corrosion.
even in wet soils Fluctuations of Ohmic
Performance value results in
permanent & frequent problems.
consistent.
10 Current Impregnated Has single stage Surface of pipe has

Dissipation aggregate greatly current dissipation. smaller area for
increases the dissipation.
conductive surface
area of electrode &
Current dissipation
stages.
11 Maintenance Lifelong Requires watering & Requires watering &

maintenance free recharge of salt on recharge of back fill
and does not require regular basis. material regularly.
water.
12 Corrosion No Corrosion since Corrodes due to Pipe corrodes due to

metal rod is moisture and heat, moisture and heat,
embedded in inert which affects the which affects the
neutral material. performance. performance.
Environmental
14 Environment Conductive concrete Trees cut for charcoal. Back fill materials
friendly does not leach or Salt dissolves and leaches into ground
pollute earth water pollutes the water and pollutes the water
channel. Save trees. channel. channel.

7 COST COMPARISION: MARCONITE® BASED SYSTEMS WITH TRADITIONAL SYSTEM
Marconite Electrode GI pipe D 40 mm, L GI plate L 0.6 m

D 100mm, L 3 m 3m X W 0.6 m
1 Capital Cost
a On a/c of Surface area

Surface area of one 0.958 sq m 0.380 sq m 0.720 sq m
unit [Electrode]
b Surface area equal-
ant to one unit of 1 2.52 times 1.33 times
Marconite electrode
c On a/c of Life
No of unite required 50 yrs / 50 yrs = 50 yrs / 8 yrs = 50 yrs / 10 yrs =
for a life of 50 yrs. 1 Electrode 6.25 Electrodes 5 Electrodes
d Total no of units
2.52 X 6.25=15.75 1.33 X 5 = 6.65
required for a life of One unit
or 16 units or 7 Units
50+ yrs [ b*c]
e As CPWD DSR 2014
Cost of one unit 4.5 m Rs 3,926/- or
As CPWD DSR 2014
Rs 16,500/- each Rs 4,500/-
with installation 3.0 m Rs 2,618/-
f Capital cost of
Rs 16.500/- X 1 = Rs 2,618/- X 16 = Rs 4,500/- X 7 =
electrode’s 50 yrs
Rs 16,500/- Rs 41,888/- Rs 31,500/-
life
2 Maintenance Cost
a
Water or - Water & watering - Water & watering
Cost of Water, Salt
labour labour
and Labor for one recharge is not
unit. required for life.
Water yrly 6 times : Water yrly 6 times :
Rs 10 X 6 = Rs 60/- Rs 10 X 6 = Rs 60/-
labor one year: labor one year:

Rs 50 X 6=Rs 300/- Rs 50 X 6=Rs 300/-
- Yearly Cost Nil
- Recharge yearly - Recharge yearly
Salt Rs 140/- Salt Rs 140/-
Half day Half day

Labor Rs 315/- Labor Rs 315/-
- Yearly Cost Rs 815/- - Yearly Cost Rs 815/-
- Maint. for life 1 unit - Maint. for life 1 unit

Rs 815*7 yrs = Rs 815*9 yrs =
Rs 5,705/- Rs 7,335/-
- Life Cost Nil
- Maint for life 16 unit - Maint for life 7 unit
Rs 5,705*16 Rs 7,335*7
= Rs 91,280/- = Rs 51,345/-
b
Total Capital cost + Rs 16.500/- + Nil Cap Rs 41,888/-, Cap Rs 31,500/-,
Maintenance of one Maintenance = Maint. Rs 91,280/- Maint. Rs 51,345/-
electrode for 50 yrs Rs 16,500/- = Rs 1,33,168/- = Rs 82,845/-

8 THEORETICAL CALCULATIONS OF PERFORMANCE OF VARIOUS EARTHING SYSTEMS
IN DIFFERENT SOIL RESISTIVITY
Expected Earth Resistance Ω Expected Earth Resistance Ω
Resistivity Ω
Resistivity Ω
Marconite Marconite
Driven Rod Pipe Plate Driven Rod Pipe Plate
Embedded Embedded
D.1, L 3 .6 X .6 D.1, L 3 .6 X .6
D.016,L3m D.04,L3m D.016,L3m D.04,L3m
m m m m
1 0.24 0.33 0.29 0.52 110 26.14 36.83 31.48 57.46
2 0.48 0.67 0.57 1.04 115 27.33 38.50 32.91 60.07
3 0.71 1.00 0.86 1.57 120 28.51 40.18 34.34 62.68
4 0.95 1.34 1.14 2.09 125 29.70 41.85 35.78 65.29
5 1.19 1.67 1.43 2.61 130 30.89 43.52 37.21 67.90
6 1.43 2.01 1.72 3.13 135 32.08 45.20 38.64 70.51
8 1.90 2.68 2.29 4.18 140 33.27 46.87 40.07 73.12
10 2.38 3.35 2.86 5.22 145 34.45 48.54 41.50 75.74
12 2.85 4.02 3.43 6.27 150 35.64 50.22 42.93 78.35
14 3.33 4.69 4.01 7.31 155 36.83 51.89 44.36 80.96
16 3.80 5.36 4.58 8.36 160 38.02 53.57 45.79 83.57
18 4.28 6.03 5.15 9.40 165 39.21 55.24 47.22 86.18
20 4.75 6.70 5.72 10.45 170 40.39 56.91 48.65 88.79
22 5.23 7.37 6.30 11.49 180 42.77 60.26 51.52 94.02
24 5.70 8.04 6.87 12.54 185 43.96 61.94 52.95 96.63
26 6.18 8.70 7.44 13.58 190 45.15 63.61 54.38 99.24
28 6.65 9.37 8.01 14.62 195 46.33 65.28 55.81 101.9
30 7.13 10.04 8.59 15.67 200 47.52 66.96 57.24 104.5
32 7.60 10.71 9.16 16.71 210 49.90 70.31 60.10 109.7
34 8.08 11.38 9.73 17.76 220 52.27 73.65 62.96 114.9
36 8.55 12.05 10.30 18.80 230 54.65 77.00 65.83 120.1
38 9.03 12.72 10.88 19.85 240 57.03 80.35 68.69 125.4
40 9.50 13.39 11.45 20.89 250 59.40 83.70 71.55 130.6
42 9.98 14.06 12.02 21.94 260 61.78 87.05 74.41 135.8
44 10.45 14.73 12.59 22.98 270 64.15 90.39 77.27 141.0
46 10.93 15.40 13.17 24.03 280 66.53 93.74 80.14 146.2
48 11.41 16.07 13.74 25.07 290 68.91 97.09 83.00 151.5
50 11.88 16.74 14.31 26.12 300 71.28 100.4 85.86 156.7
52 12.36 17.41 14.88 27.16 325 77.22 108.8 93.02 169.8
54 12.83 18.08 15.45 28.21 350 83.16 117.2 100.2 182.8
56 13.31 18.75 16.03 29.25 375 89.10 125.5 107.3 195.9
58 13.78 19.42 16.60 30.29 400 95.04 133.9 114.5 208.9
60 14.26 20.09 17.17 31.34 175 41.58 58.59 50.09 91.41
62 14.73 20.76 17.74 32.38 425 100.98 142.3 121.6 222.0
64 15.21 21.43 18.32 33.43 450 106.92 150.7 128.8 235.0
66 15.68 22.10 18.89 34.47 475 112.86 159.0 135.9 248.1
68 16.16 22.77 19.46 35.52 500 118.80 167.4 143.1 261.2
70 16.63 23.44 20.03 36.56 550 130.69 184.1 157.4 287.3
72 17.11 24.11 20.61 37.61 600 142.57 200.9 171.7 313.4
74 17.58 24.77 21.18 38.65 650 154.45 217.6 186.0 339.5
76 18.06 25.44 21.75 39.70 700 166.33 234.4 200.3 365.6
78 18.53 26.11 22.32 40.74 750 178.21 251.1 214.7 391.7
80 19.01 26.78 22.90 41.79 800 190.09 267.8 229.0 417.9
82 19.48 27.45 23.47 42.83 850 201.97 284.6 243.3 444.0
84 19.96 28.12 24.04 43.87 900 213.85 301.3 257.6 470.1
86 20.43 28.79 24.61 44.92 950 225.73 318.1 271.9 496.2
88 20.91 29.46 25.19 45.96 1000 237.61 334.8 286.2 522.3
90 21.38 30.13 25.76 47.01 1050 249.49 351.5 300.5 548.4
92 21.86 30.80 26.33 48.05 1100 261.37 368.3 314.8 574.6
94 22.34 31.47 26.90 49.10 1150 273.25 385.0 329.1 600.7
96 22.81 32.14 27.48 50.14 1200 285.13 401.8 343.4 626.8
98 23.29 32.81 28.05 51.19 1250 297.01 418.5 357.8 652.9
100 23.76 33.48 28.62 52.23 1500
105 24.95 35.15 30.05 54.84 2000

9 TECHNICAL ASPECTS OF DESIGNING EARTHING SYSTEM
9.1 General Requirement: Designing of proper grounding is a necessity for any electrical
power system. A good grounding system provides a low-impedance path for electrical
system’s fault & lightning induced currents to enter the mother earth and also provides
safety. Effectiveness of a buried grounding system depends on many factors like:-
Soil characteristics such as moisture content, soil temperature and type; which
determines the resistivity of the earth.
Resistance of the earth (or earth resistivity); which significantly impacts overall
impedance of the buried conductor.
9.2 Typical Soil Conditions and Resistivity: Typical soils across the World clearly show that
a totally homogeneous soil is difficult to find. Layers of soils consist of differing
materials having different resistivity are found in it’s strata, which can also be repeated
at lower depths. It is also possible to even find irregularities such as rocks and other
deposits accumulated over a number of years. In essence it is necessary to first carry
out a thorough soil investigation for designing an appropriate earthing system. Table 3
of IS 3043, reproduced below, illustrates not only the ranges of soil resistivity typical of
different soil types, but also clearly shows that soil resistivity can further vary according
to climatic conditions, particularly in relation to moisture. Hence it is necessary to
obtain a more precise knowledge of local soil conditions.
Table 3: Examples of Soil Resistivity
Climate condition
Low rainfall
Normal and
& desert
high rainfall Underground
Probable conditions
(i.e. greater Waters
Type of soil values (i.e. less than
than 500 mm a (saline)
250 mm a
year)
year)
Range of values encountered
Ω-m Ω-m Ω-m Ω-m
Alluvium and lighter clays 5 * See note *See note 1 to 5
Clays (excluding alluvium) 10 5 to 20 10 to 100
Marls (e.g. Keuper marl) 20 10 to 30 50 to 300
Porous limestone (e.g. chalk) 50 30 to 100
Porous sandstone(e.g. Keuper
100 30 to 300
sandstone and clay shale’s)
Quartzite, compact and
crystalline lime stone (e.g. 300 100 to 1000
carboniferous marble)
Clay slates and slate shale’s 1000 300 to 3000 1000 upwards 30 to 100
Granite 1000
Fissile slates, schist’s, gneiss
2000 1000 upwards
and igneous rocks
Note: * Depends on water level or locality
9.3 Measurement of soil resistivity: Many methods are applied for soil resistivity
measurements but one well documented method of determining soil resistivity is the
Wenner’s Survey – 4 electrodes method as per IS 3043, as reproduced here.

a) Wenner’s Survey: Four electrodes are driven into the ground in a straight line at
equal distance from each other, as shown in Fig 1. Electrode C₁ and C₂ are
connected and current is made to flow through it. The difference in potential values
at P₁ and P₂ is then measured. The difference in potential is then divided by the
applied current value to determine the resistance R (Ω). If the distance between the
electrodes “a” is in m, then soil resistivity ρ shall be also be determined in Ω-m
using the Formula as mentioned below. Generally, as explained earlier, soil is found
in layers and resistivity varies from layer to layer. By changing the spacing “a” of
the electrodes, it is possible to develop a profile of the soil resistivity at various
depths.
Figure 1
~
V
C₁ P₁ P₂ C₂
Ground
_____________ _____________ ____________

a a a
Formula: ρ = 2ΠaR
Where
ρ = Soil Resistivity in Ohms-m
a = Distance between probes
R = Reading of earth tester in ohms
b) One rod test method: This is a simpler test method than the Wennner’s test
method. The resistance of a single rod, which is driven into the ground for a known
depth, is measured. The resistance measurement and rod dimensions may then be
used to calculate the average soil resistivity. The resistance measurement is done
by using the 61.8% method. The formula for calculating the resistance to earth
resistance (R) of a vertical rod given may be used:
 RL
 
8L
{log e ( )  1}
d
Where:
R is the resistance to earth of a vertical rod;

L is the length of the rod in meters (m);
d is the diameter of rod in meters (m);
 is the resistivity of the soil (assumed uniform), in ohm meters (Ω-m);
10 MAXIMUM ACCEPTED EARTH RESISTANCE
A paper by US AID India has addressed this issue and indicated the generally accepted
resistance value for different applications which may be based on prevailing established

practices. Reference of various other standards, documents and books has also been
reproduced here below:-
10.1 US AID | INDIA Earthing Practices by MVS Brinchi,
a) Power stations (generating station) 0.5 ohms

b) EHT Sub-station 1.0 ohms
c) 33 KV Stations 2.0 ohms
d) D/t Structure 5.0 ohms
e) Tower Foot resistance 10.0 ohms
10.2 Modernization of power distributions

Page 92 Same as above.
10.3 IEEE standard 142-2007 - Chapter 4, page 164

Resistance generally found suitable for industrial
Plant Sub-station and buildings and large installations 1 ohm to 5 ohms
10.4 IS 2309: 1989 and BS 7430:1998 - Cl 12.3.1 & 9.4.3

Lightning arrestors ground resistance for
Protection of buildings and allied structures 10 ohms
10.5 Guide for control of Undesirable Static Electricity

10.6 IS 2689:1989 - Table 4 page 28 (Reaffirmed Mar10)

11 EARTHING SYSTEM FOR DIFFERENT CONFIGURATIONS
11.1 Electrodes or Earth matt: Once the soil resistivity has been determined then effective
earthing system can be designed to meet the earth resistance requirement by using
IEEE 80: 2000 Standard - Safety in ac sub-station grounding or such other standards.
Any particular earthing system can be: -
a) A single or array of electrodes

b) An extensive ground grid system or earth mat
Earthing electrodes are often installed in straight lines, but it is not always essential. In
case the space is limited, then a zigzag system can also be installed by ensuring
necessary distance between the electrodes.
11.2 T Piece system: This system combines a borehole of appropriate size with a horizontal
trench. It can be used in areas with limited space and is useful in low resistivity soils.
There is also an option for connecting T piece systems together to achieve the required
earth resistance value. If necessary, a combination of bore holes and T pieces systems
can also be used to further reduce the earth resistance. This system is used at a
minimum depth of 1 meter to minimize the effects of frost.
12 METHOD OF CALCULATION OF RESISTANCE OF VARIOUS EARTHING SYSTEMS
12.1 Plate Earthing

 
Rg  ohms
4 A
Where
ρ = Soil Resistivity in Ohm – Meters
A = Area of the Plate in M2 (Both sides)
12.2 Pipe / Rod Earthing
R=
Where
R = Earth Resistance in ohms,
L = Length of Pipe / Rod in meters.
D = Diameter of Pipe /Rod in meters,
ρ = Soil Resistivity in Ohm – meters
12.3 Strip / Flat Earthing
 2l 2
Rg  log e ohms
2l wt
Where
l = Length of the strip in meters
w = Depth of burial of the electrode in meters
t = Width (in the case of strip) or twice the diameter (for round conductor) in m
12.4 Conducting Concrete Encased Electrodes
RCE= 1/2 ∏Lr (ρC [Ln(DC/d)]+ρ[Ln(8Lr /DC)-1])
Where
RCE = Resistance of Concrete encased earth electrode.
ρ = Soil resistivity Ω-m
PC = Resistivity of concrete – Marconite Ω-m
DC = Diameter of the Marconite shell in mm
d = Diameter of ground rod
Lr = Length of the rod in m
Ln = Log natural
12.5 Mat Earthing
Ohms

Rg = p
Schwarz’s
Where
r = is the radius of a circle with same area or that occupied by grid in meters
ρ = Resistivity of the soil (assumed uniform) in ohm-m
LT = Total effective length of grounding system conductor, including grid & rods m.
h = Depth of grid burial (m)
A = Total area enclosed by ground gird (m2)
R1 = Ground Resistance of gird conductors in Ω
R 2 = Ground Resistance of all ground rod in Ω
R12 = Mutual Ground Resistance between the group of gird conductors R1 & group
of ground Rods R2 in Ω
12.6 Ring Electrode - HVDC Ground Electrode:
Where
ρ = Apparent Resistivity of Soil in Ohm – m
a = Twice the diameter of the Rod (m)
b = Radius of the Ring (m)
13 CASE STUDIES
In order to demonstrate the practical benefits of use of Marconite® many studies were
carried out to compare Marconite® encapsulated electrodes with other earthing systems,
which clearly shows better performance. Few cases are mentioned below:-
13.1 CPRI Campus, Bangalore, India: Marconite® embedded electrode was installed for
measurement of Earth resistance at Central Power Research Institute, Bangalore
a) Parameters:
Size of metal conductor – Cu rod = L 3 m, D 16 mm
Size of Marconite® encapsulation = L 2.9 m, D 100 mm
b) Measurements taken:
Apparent soil resistivity of the trial ground = 468.29 Ω-m
Earth resistance of Marconite encapsulated electrode = 90.87 Ω
c) Theoretical Calculations of Earth Resistance:

Bare Cu rod - L 3 m, D 16 mm = 156.78 Ω
MS Plate - L 0.6 m X W 0.6 m, T 5 mm = 244.60 Ω
GI strip/Flat – W 50 mm x T 5 mm, L 3 m = 163.45 Ω
d) Comparison of performance – % of Improvement :

i) Bare Cu rod - L 3 m, D 16 mm and;
Marconite encapsulation - L 2.9 m, D 100 mm
=42.04 %
Improvement in Ground Resistance by 42%
ii) Plate earthing - L 0.6 m X W 0.6 m, T 5 mm &;

Marconite encapsulation - L 3 m, D 100 mm
=62.84%
Improvement in Ground Resistance by 63 %
iii) GI strip/Flat - W 50 mm x T 5 mm, L 3 m and;

=44.41%
13.2 CPRI Campus, Bangalore (II): Marconite® embedded electrode was installed for
measurement at Central Power Research Institute, Bangalore
a) Parameters:
Size of metal conductor – MS rod = L 3.1 m, D 40 mm
Size of Marconite® encapsulation = L 3 m, D 200 mm
Apparent soil resistivity of the trial ground = 468.29 Ω-m

Bare MS rod - L 3.1 m, D 40 mm = 130.49 Ω

Bare MS rod - L 3.1 m, D 40 mm and;
= 57.52%
13.3 NDMC, New Delhi: Marconite® embedded electrode was installed and connected to
11kV substation at Chanderlok Building, New Delhi:-
a) Parameters:
Apparent soil resistivity = 14.56 Ω-m


Bare Cu rod - L 3 m, D 16 mm and;
= 96.92%

13.4 Indian Air Force, Palam, Delhi: Marconite® embedded electrode was installed and
connected to electronic laboratory of 73 RMU of Indian Air Force, Palam Airport Delhi:-
a) Parameters:
Size of metal conductor – MS rod = L 30.5m, D 16 mm
Size of Marconite® encapsulation = L 30.4m, D 100 mm
= 55.91 %
13.5 Apollo Hospital, New Delhi: Marconite® embedded electrode was installed and
connected to DG set of Indraprastha Apollo Hospital, Sarita Vihar, and New Delhi.
a) Parameters:
Size of Marconite® encapsulation = L 10 m, D 100 mm
Marconite encapsulation – L 10 m, D 100 mm
= 80.45 %
13.6 Indian Oil Corp. Ltd., Panipat: Marconite® embedded electrode was installed and
connected to electrical system of Panipat Refinery of IOL Ltd., Panipat, Haryana
a) Parameters:
Marconite® encapsulation – L 2.9 m, D 100 mm
= 71.82 %

13.7 All India Radio, New Delhi: Marconite® embedded electrode was installed and
connected to electrical system of NBH, All India Radio, New Delhi.
a) Parameters:
Bare Cu rod - L 4.56 m, D 16 mm and;
Marconite encapsulation – L 4.5 m, D 100 mm
= 68.74 %
13.8 Bhushan Steel Ltd., Sahahibabad, UP: Marconite® embedded electrode was installed
and connected to IT system.
a) Parameters:
Size of Marconite® encapsulation = L14.950m, D100
Bare Cu rod – L 15 m, D 16 mm = 2.77 Ω
= 39.05 %
13.9 Bhushan Steel Ltd., Bhikaji Kama Place, New Delhi: Marconite® embedded electrode
was installed and connected to IT system.
a) Parameters:
Size of metal conductor – MS rod = L 25 m, D 16 mm

Bare MS rod – L 25 m, D 16 mm = 1.01 Ω

Bare MS rod - L 25 m, D 16 mm and;
= 21.91 %

13.10 The Kalgidhar Society, Bru Sahib, HP: Marconite® embedded electrode was installed
at their Akal Academy, Cheema, Dist. Sangrur Punjab & connected to DG set Neutral.
a) Parameters:
Size of Marconite® encapsulation = L 5.9m, D 100mm
Bare Cu rod – L 6 m, D 16 mm = 4.32 Ω
= 77.11 %
14 CUSTOMER REFERENCES
Marconite® conductive concrete was first introduced by us in India to Rajasthan Rajya

Prasaran Nigam Limited, Jaipur (RRVPNL) four years back and they immediately incorporated
the same in specifications of their eleven GIS sub stations & Two 765/400 kV sub stations.
Subsequently many other power and other companies have used Marconite for their plants.
Few of them are listed below:-
a) Power Plants
Pune Municipal Corporation, Pune : 10 MW waste to energy plant in Pune
Karnataka Power Corp. Ltd., Bangalore : 700 MW Bellary Thermal Power Plant
NTPC Ltd., New Delhi : Gas power plant in Faridabad
b) Sub Stations - GIS

Rajasthan RVPNL, Jaipur : 2 nos 132 kV ESS at Pratap Nager & Kuri in Jodhpur
Rajasthan RVPNL, Jaipur : 2 nos 220/132 kV ESS at MNIT & NPH in Jaipur
c) Sub Stations - AIS

Rajasthan RVPNL, Jaipur : 2 nos 765 kV ESS at Phagi in Jodhpur & Anta in UP
Tata Power New Delhi : 2 nos 33 kV ESS at Shalimar Bagh, Shakti Ngr Delhi
NDMC, New Delhi : 2 nos 11 kV ESS at Rohit house & Jan path, N Delhi
MES, Delhi Cantt : 11 kV ESS at Kabul Lane, Delhi Cantt.
ZESCO Ltd., Zambia : 330/132/33 kV ESS at Lusaka, Zambia
Torrent Power, Agra : Street Lighting at Agra
d) Signal Applications
Indian Air Force, Palam : 73 RMU at Technical Area , Palam Airport, Dli
HQ 5 Signal Group, India Army : ACON Facility at Delhi Cantt.
Military Collage of Telecom Engg. Mhow : Army Mobile Communications Lorry
Prasar Bhartti, New Delhi : Jam Nagar House, New Delhi
Vodaphone : Facility at Karnal, Haryana
e) Medical
Apollo Hospital, New Delhi : MRI and DG set
Saket City Hospital, Saket : MRI, CT Scanners & x-ray equipment
Sadhu Vaswani Mission Med Ctr : IT applications

Army’s R R Hospital, Dli Cantt : Medical equipment
Venketeshwar Hospital, Delhi : Under Execution
f) Industrial Plants
Indian Oil Corporation : Refinery at Panipat
National Fertilizer Ltd. : Plant at Panipat.
Hindustan Prefab Ltd. : Plant at New Delhi
Bhabha Atomic Research Centre: At Navi Mumbai
Bhushan Steel Ltd. Sahibabad : Plant at Sahibabad
The Kalgidhar Society : More than 50 schools in Punjab & Haryana
Ahuja Radio Ltd. : Factory at Okhla, New Delhi.
Vulcan Industries : Factory at Ph III Okhla, New Delhi.
SUMMARY: This Technical Bulletin documents the significant benefits that can be obtained by
designing and using an earthing system based on Marconite® conductive concrete. We believe
that Marconite® would provide a cost effective solution to your earthing requirements.
Prime Distributor for India

INTER TECH
B 83 Flatted Factory Complex, Tel : +91-9313710964, 9891472130
Near Modi Mills, Okhla, E mail : info@intertech.com.co
New Delhi – 110 020 URL : www.intertech.com.co www.marconite.co.uk
DISCLAMER: The information given in this document is authentic, to the best of our knowledge and belief but neither
James Durrans & Sons Limited, UK, Carbon International Limited UK nor Inter-Tech, New Delhi and their representatives
are responsible for any variations found hitherto.

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MARCONITE® Electrically Conductive Aggregate

An Innovative Earthing Technology

a) Fixed Carbon 98.5 %

d) Size Grading (Approx) 10% below 0.10 mm

a) Marconite® Aggregate = 0.001 Ω-m

INTER-TECH - Prime Distributor of Marconite® for India

2.6 Chemically Inert: It’s pH value is within the neutral range.

a) That effect of DC current spreads to a radius of 30 to 50 kms from the earth

2.14 Easy to Install: Requires only a bore hole or trench to install.

2.16 Improvement Factor: In practice, improvement of 40% - 60% is generally obtained

2.17 Compressive Strength: Marconite® concrete, once it is set, displays a greater

INTER-TECH - Prime Distributor of Marconite® for India

a) Provision of over designing of conductor is not required in the absence of corrosion.

b) Increased surface area of Marconite® embedded rods reduces the overall

4.1 Resistivity - Aggregate:

Results: “Ultra low resistivity of 0.001 Ohm-m.”

Results: “Ultra low resistivity of 0.040 Ohm-m at 20⁰ C degree.”

INTER-TECH - Prime Distributor of Marconite® for India

d) Two 23.1 N/mm² 29.5 N/mm²

Name of Test Value Ω

a) Lead (Pb) <0.10 pp

c) Cadmium (Cd) <0.1 ppm

d) Nickel (Ni) <0.1 ppm

e) Arsenic (As) <0.1 ppm

f) Cyanide (CN) <0.1 ppm

g) Hexavlent Chromium (Cr⁺⁶) <0.1 ppm

INTER-TECH - Prime Distributor of Marconite® for India

a) Passage of AC current steel electrodes embedded in concrete causes only negligible

b) Normal stray AC current do not cause deterioration in the strength of concrete.

5 PRACTICAL ASPECTS OF USING MARCONITE®

6 COMPARISION OF MARCONITE® BASED SYSTEMS WITH TRADITIONAL SYSTEMS

Marconite® Traditional GI pipe / Pipe in pipe/strip

INTER-TECH - Prime Distributor of Marconite® for India

5 Process Electronic. Ionic Ionic

6 Suitability of Good for Granite, Difficult to install in Difficult to install in

7 Easy Only a borehole is Wider excavation is Digging is difficult in

8 Life 50+ years. 8 years. 10 years.

9 Performance Constant Electrical Watering dissolves salt Back fill material

10 Current Impregnated Has single stage Surface of pipe has

11 Maintenance Lifelong Requires watering & Requires watering &

12 Corrosion No Corrosion since Corrodes due to Pipe corrodes due to

INTER-TECH - Prime Distributor of Marconite® for India

Marconite Electrode GI pipe D 40 mm, L GI plate L 0.6 m

a On a/c of Surface area

labor one year: labor one year:

Half day Half day

- Yearly Cost Rs 815/- - Yearly Cost Rs 815/-

- Maint. for life 1 unit - Maint. for life 1 unit

INTER-TECH - Prime Distributor of Marconite® for India

INTER-TECH - Prime Distributor of Marconite® for India

Table 3: Examples of Soil Resistivity

INTER-TECH - Prime Distributor of Marconite® for India

_____________ _____________ ____________

ρ = Soil Resistivity in Ohms-m

a = Distance between probes

R = Reading of earth tester in ohms

R is the resistance to earth of a vertical rod;

10 MAXIMUM ACCEPTED EARTH RESISTANCE

INTER-TECH - Prime Distributor of Marconite® for India

_______ _ ______