Renewable Energy Grid Infrastructure Upgrade

Background

A National Power Utility managing over 15,000 km of transmission lines faced a dual challenge: modernizing aging grid infrastructure to integrate growing renewable capacity while combating persistent copper theft that caused millions in annual losses and frequent outages. The utility needed conductors that were both stronger and less attractive to thieves.

The Challenge

The grid upgrade required conductors that could:

• Support longer spans between towers to reduce new tower construction in environmentally sensitive areas
• Maintain adequate fault current capacity to protect substation equipment
• Deter theft — copper grounding conductors were being stolen at an alarming rate, causing outages and safety hazards
• Reduce carbon emissions during installation, aligning with national climate commitments

The Solution: Raytron CCS Grounding Conductors

We supplied our Copper Clad Steel (CCS) strand platform, engineered for grid-scale deployment:

• Material: High-strength steel core with copper cladding, delivering tensile strength 2× that of equivalent copper conductors
• Span capability: Longer spans between towers, enabling up to 10% tower reduction in new construction
• Theft deterrence: Steel core makes conductors unattractive to scrap thieves — the cladding is metallurgically bonded and cannot be separated for resale
• Fault current: Meets IEEE 80 and IEC 60228 fault current capacity requirements for grounding applications

Results

• Tower Reduction: 10% fewer towers needed in new-build sections due to longer span capability
• Carbon Footprint: 40% reduction in installation-phase carbon emissions from fewer tower foundations and shorter construction timelines
• Theft Prevention: Zero copper theft incidents in 2 years of operation across 120 km of upgraded line
• Fault Performance: Full compliance with fault current capacity standards, protecting substation equipment as designed