Storm Copper's circle shear slowly turns out another perfect copper circle.

No matter what size, shape or physical profile of copper cut you may need, Storm Copper Components can make it happen fast and to exact specifications. This capability now includes a circle shear machine that produces perfect copper circles and rings.

Copper circles are commonly used for a variety of crafts and metal art, including metal spinning of ferrules, bowls, cups or most anything round. Copper circles are also used as fence post caps, heat diffuser plates, pipe-end caps and as round plates used in tube heat exchangers.

For fast-order response for these common uses, Storm stocks a wide range of copper circles from 3-1/2” to 35” in diameter, cut from copper sheet from .002” (20 gauge) to .125” (8 gauge) thick.

For OEM’s, Storm produces made-to-order copper circles that can be used as spacers, or essentially large washers or ring gaskets for high-end Ultra High Vacuum (UHV), where extreme vacuum systems require special seals and gaskets used between components to prevent even trace leakage.

Other industrial uses for copper gaskets include heat exchangers, compressors, condensers, pumps, valves, and general industrial applications in all sizes & shapes.
According to plant industrial engineer, Steve Crumley, “Storm’s circle shear works like a giant can opener, slowly turning a piece of square copper sheet while heavy pressure is applied to the round cutting wheel. For thicker copper sheet, several revolutions may be required to insure a precise, even cut.”

Crumley adds, “by cutting a 35” circle, then readjusting the Circle Shear to cut a 33” circle from the original, you end up with a 35” ring, or washer up to 1/8” in thickness, and that’s a pretty serious washer!”

It’s important to understand how cutting made-to-order circles or ring gaskets is only the final part of a production process based on a set of specifications put forth by the customer and by Storm’s quality engineering team. For example, copper gaskets used in UHV have to meet pre-set vacuum ratings as well as temperature ranges. Gaskets or seals can be produced for single or multiple uses, with precise inner and outer diameters.

The circle shear machine is just one part of the overall capability Storm Copper maintains to provide custom cutting, shaping, punching, milling and plating of copper to meet the most diverse customer requirements and production schedules.

When you need copper, call the experts at Storm Copper Components. They’ll give you a great price on copper circles, without giving you the run around!

All too often electrical parts manufacturers have to send out copper connectors to outside vendors for plating or coating, a lengthy process that requires excess packaging, additional freight costs, lost time and risks that commonly occur in shipping. When the plated copper components are returned for testing before delivery, even the slightest scratch in the plated surface can lead to rejection and delays to the customer.

Storm’s electroplating options for copper electrical connectors include bright tin plating, matte tin, nickel, silver, various tin/lead alloys and pure lead. Storm Copper offers this diverse offering of plating options to meet the many varied requirements dictated by a wide variety of industry applications.

For example, tin is a common plating metal most often specified applications like power sub-stations, tower grounding, and high-voltage connections. Tin plating is fairly inexpensive, protects copper from outside environmental degradation that damages connections, masks copper from thieves by destroying its value to recyclers.

Storm’s electroplating process incorporates an electrolyte bath where electrical connectors such as copper bus bars are fully immersed to produce a uniform coating over edges and the rounded surfaces of bus bar holes and bends. For better-quality, Storm uses a trace amount of lead in its tin plating process to prevent the occurrence of tiny crystalline structures called “whiskers” than are electrically conductive and can be broken off during installation, increasing the potential of electrical hazards.

Silver plating is popular in the switchgear industry because it is very good on surface-to-surface conductivity. Because of its high cost, silver is generally limited to application on contact points where two components are joined together.

In applications where lead-acid or wet cell batteries are used, caustic materials or vapors can degrade electrical battery connectors, lead is the preferred plating because it is impervious to sulfuric acid.

No matter what environment or application, Storm offers a clear edge to OEM’s and systems installers through its cost- and time-saving capability to plate tin, silver, nickel and lead in house.

Storm Copper Components is committed to meeting its customer’s requirements by providing innovative, cost-effective solutions and by focusing on continual improvement of all our products, processes, and services. For 20 years, the company has specialized in the manufacture of custom electrical connectors for the wireless, telecommunications, power and alternative energy markets, serving OEM’s, electrical contractors and system installers.

For more information, or to schedule an interview with Dan Kitts, please call Dave Krikorian at 1-800-334-2177 or email dkrikorian@stormcopper.com.

Now you can recharge your favorite electronics communication devices, thanks to the amazing nature of copper, and the innovative "Juice Bag."

Technology has become such an integral part of our daily lives, it’s hard to remember what life was like without the intrusion of that familiar ring-tone announcing a cell phone call, text message or email needing attention. While some may feel these devices are overwhelming or unnecessary, for today’s active lifestyles personal communications devices are mandatory.

Now that high-tech devices have broken down the barriers which kept us tethered to a physical location, conducting business or checking the latest sports news in a coffee shop, beach side resort or golf course is considered the norm, and those who don’t the “abnormal.” The one challenge all of these savvy communicators face is the dreaded tone or flashing symbol announcing the unthinkable – LOW BATTERY!

Today, thanks to the highly conductive and flexible nature of copper, a low-battery warning doesn’t have to mean the end of your remote connectivity. The Atlanta-based company Reware has developed a portable charging system that uses the innovative copper-based CIGS (Copper-Indium-Gallium Sulfide) solar film. Reware’s introduction of the “Juice Bag,” which is available in several popular styles, has the potential to solve this problem and provide unlimited mobility. The bag gets its name from its ability to “juice up” or recharge your favorite electronic devices. This multifunction bag features a built-in electronic charging station that can recharge small electronic devices, including satellite, cell phones, GPS units, PDAs, iPods, MP3 players and digital cameras.

To accommodate different lifestyles, the Reware Juice Bags are sold as backpacks, totes and messenger bags, convenient for travelers, campers, hikers, fishermen, students and business professionals.

The Reware Juice Bag weighs the same as an average backpack and comes equipped with a built-in universal socket into which a variety of devices can be plugged. A light-weight, copper-based solar panel located on the outside of the bag captures the sun’s energy and charges the system as you go about your daily activities. The time it takes to charge an electronic device is equivalent to the time it takes using a standard electrical outlet— between two and six hours.

Henry Gentenaar, a managing partner at Reware, said they carry the largest selection of solar bags using CIGS technology and, “Thanks to the sturdy composition of the copper-based solar film, Reware bags are high quality and durable.”

The use of CIGS technology in this product not only highlights the progress of solar panel design, but also illustrates the significant role that copper is playing in the advancement of mainstream solar panel usage.

“The great thing about using copper-based panels is that they are very powerful and rugged. We chose copper-based technology because it’s reliable,” Gentenaar added.

For years, copper has been the metal of choice for HVAC, plumbing and building and construction needs because of its durability, recyclability and thermal and electrical conductivity.

“This is really exciting new technology, and it’s no surprise that copper is an enabler in it,” said Bob Weed, vice president of OEM for the Copper Development Association. “In today’s mobile world, a portable electronic charging station is a must have for anyone who wants to stay connected.”

Farhad Moghadam, CEO of Ascent Solar, a Colorado-based company which produces copper-based CIGS solar film, said that the copper solar technology’s efficiency makes it ideal for solar backpacks. Moghadam explained that the use of copper cells carries the benefit of weight reduction, which is a big concern for manufacturers of solar back packs. The thin nature of the copper-based material (only a few microns thick) makes them lightweight and portable, and surprisingly durable for outdoor recreational activities.

“Copper’s electrical and thermal conductivity is what makes it so valuable in increasing the efficiency of CIGS solar technology,” said Moghadam.
The copper film can be manufactured at lower temperatures than other materials, decreasing the manufacturing cost. Solar backpacks for consumers would never have been possible without the decrease in cost of manufacturing attributed to copper.

Several companies, including Sunload and Clear Blue Hawaii, are incorporating copper-based solar panels in their own versions of portable electronic charging stations for the consumer. Along with the solar backpack line, Reware plans to launch portable charging mats that fold to the size of a magazine and can be unfolded to create a charging station. These are popular in military applications, and will soon be available to the public. Gentenaar plans to have the product launched in early 2010.

See the full line of Reware products at their online store: Reware Solar Bags

The book’s research was conducted by the Lightning Protection Institute (LPI), with findings that indicate how well-designed and professionally installed electrical grounding systems can shield buildings, trees, electronic equipment, and then reduce personal injury from lightning. The information in this booklet also reflects an appreciation of lightning protection products, installation, and use derived from consultation with manufacturers, users, inspection authorities, and others having specialized experience.

Published by the LPI, the booklet had been available online for as high as $49.00, Storm now offers the book for $12.99. Copies are available at Storm’s online electrical grounding store.

Much of the book’s content has multiple uses for homeowners involved in household lightning protection, not only as a do-it-yourself guide but as a planner that could lead to creating a more effective electrical grounding design. The booklet would also help a homeowner in hiring a certified installer or electrical contractor.

LPI adopted the latest National Fire Protection Association (NFPA) codes in the booklet, including the NFPA 780 Standards, content of considerable value to lightning protection installers, electrical journeymen and contractors. Contents include System Certification, Inspection and Maintenance, Main and Down-lead Conductors, Electrical Grounding, Interconnection (Bonding), and contents go on to cover specific types of installations.

To get a copy of this information-packed book, go to StormGrounding.com

“Properly grounded” is a term that gets tossed around a lot in electronics conversations, but assumptions on the part of both parties in these discussions can contribute to costly mistakes. For most, the need for a detailed explanation eventually becomes obvious. Ham radio enthusiasts often raise the question of grounding, perhaps prompted by the knowledge that they are often holding onto a microphone cord that is ultimately connected to an electrically charged system and a very tall metal antenna.

The questions most often asked are:
Just what does it mean to be properly grounded?
What makes one ground proper and another improper?
And the most critical question is; what components need to be grounded properly?

For many ham radio enthusiasts, a complete understanding of the proper grounding procedures of a radio station was the last thing on their mind when they un-boxed their new receiver/transmitter and started to set up a ham station. Although it doesn’t have to be a complicated process, there are two critical steps to grounding a ham radio station that will insure your personal safety, the safety of your equipment as well as your home and improved performance of your radio. Maintaining your personal safety and that of your equipment should be a high priority when dealing in ham radio installations. The other aspect of grounding relates to performance, since grounding can affect signal efficiency as well as the clarity of messages that you send and receive.

Types of Radio Grounding
There are two aspects of safety and grounding to consider; RF Grounding and Surge Protection. Although there is no total protection against a direct lightning strike, a grounded system is always best.

Radio Frequency (RF) Grounding is a completely different concept in grounding, compared to surge grounding. A radio frequency is an Alternating Current (AC) signal and it has impedance. An RF ground wire is nothing more than a short antenna. An effective RF ground needs to be no less than a quarter wave-length at the highest frequency used. Ham Radio connections should be made with as few strands as possible and preferably a bare solid wire. This is very important, RF performs best on smooth surfaces, therefore, it is not recommended to use braided cable for RF connections.

Storm's Ham Radio grounding kit w/call letter engraving.

All radios, tuners, meters, etc in a radio system should be grounded in a star ground configuration. The common point should be located at the tuner, if one is used, otherwise use a copper ground bus bar and make all connections on the bar. All Connections to radios should be with either insulated or bare wire with as few strands as possible. Now you need to connect your internal ground run directly to the ground outside where you should have a ground rod driven into the soil for the connection point. This rod will in turn be connected to all your other ground rods if you set up a system of grounding rods. Using numerous ground rod connections with solid, smooth wire or copper sheeting will provide the best grounding. Although copper is the best choice, aluminum can be used above ground; however, you should never use it below ground because aluminum is very susceptible to corrosive elements in the dirt. A ground wire can vary in size from (#4 up to 4/0). Run bare copper between the separate ground rods to form a ground system. Bare copper wire provides added surface contact area for the ground system. It should be laid underground between connecting rods.

Tip: Draw a detailed map of the buried cable runs to avoid hitting or digging up the system in the future. For maximum affect this run must be less than nine feet. Be sure to properly research what size material you need based on your equipment grounding needs.

Surge Grounding protects against an unexpected surge in electricity. This is often times caused by a lightning strike. When lightning strikes a power line some distance away, the massive jolt of electricity will cause a surge or electronic shock wave to travel down the wires to your home and potentially all electrical components inside its walls. Since lightning strikes cannot be predicted, it is imperative that you ground your equipment properly when you first install your equipment. If you take the “install now, ground later” approach, an untimely storm could take your ham radio ambitions back to the starting line.

Storm's Ham Radio grounding kit

An additional benefit to a proper surge ground is protection from static build-up, which can sometimes zap the user or harm equipment. A surge, or safety ground, should have enough surface area contacting the earth to dissipate the surges safely.

Lightning can be a frequent and unwelcome visitor to tall towers. The height of these structures often require a large-area ground with low impedance in addition to a wide, smooth copper flashing or heavy gauge solid wire surrounding critical areas. These critical areas would include a work area or equipment area near the base of the tower. Tall towers need a ground which will spread an electrical charge out over a wide area, rapidly and evenly. The goal is to prevent the voltage in objects near a structure from rising significantly faster than other objects located near the tower. When lightning strikes, very high currents can flow between objects near a tower, therefore, it is important to provide a low-impedance path for these currents.

Lightning grounds should always provide a common low impedance path between everything conductive entering a building. This means power lines, telephone lines, TV antennas, and metallic conduits or pipes should all share a common ground connection buss that has very low impedance. Normally the lowest impedance connection is provided by a wide smooth surface copper flashing, although very heavy round copper can be used. Round copper has lower RF resistance per unit length for a given surface area, but flat wide copper has less reactance and lower overall impedance. This is because fewer magnetic flux lines encircle any given area of wide strip than enclose the surface area of a compact conductor. In effect the magnetic field is “spread out”, reducing inductance.

You can order the Ham Radio Grounding Kit, or the Ham Radio Grounding Kit with Call Letters engraving online at Stormcopperstore.com, or contact our customer service staff at 888-334-2177.

Kits include one .25" thick grounding bar 6" wide of solid cold-drawn copper (110 Electrolytic Tough-Pitch). Standoff Insulators: A Mounting Brackets: B 3/8"-16 x 5/8" Stainless Hex Bolts: C Stainless Spring-Lock Washers: D

While attending the recent National Association of Tower Erectors (NATE) conference, Storm representatives kept getting comments from tower installation professionals, stating they had a serious need for grounding bars with expanded capacity, which could accommodate more cable terminations.

One of the things that Storm Copper prides itself on is the ability to respond to special needs or requests from customers. Very shortly after the conference, Storm introduced a new grounding bar and optional kit that is well on its way to raising the industry standard from what has been historically a 4” bar.

Like the smaller 4” version, these UL-listed 6″ solid cold-drawn copper ground bars divert maximum current associated with lightning strikes common to communication towers and antenna installations, but they have a one major advantage – a significant expansion in available connection space for an increased number of cable attachments. The .25” x 6” x 12” version of this product has a hole configuration that provides 12 – .41″ drilled holes, EIA spaced at 1.5″ and
6 – Slotted Holes, affording greater space for attaching multiple cables with compression lugs. An additional safety feature is that the additional size also increases spacing from the outside edge to 2”, instead of the standard 1-3/4”. This additional margin of safety serves to further isolate connections from accidental contact when service personnel are working on promises.

Storm 6” grounding bars are available in lengths of 12”, 16” and 18”, or custom orders of any size can be accommodated with a quick turnaround time.

Kits are also available, which makes it more convenient for ordering all the necessary components at one time. For example, a kit includes .25″ x 6 ” x 12″ Solid Copper Ground Bar with 2 – UL recognized standoff insulators; 2 – Stainless Mounting Brackets; 4 – Stainless 5/8 – 1 x 1 hex bolts and spring-lock washers. Kits for larger sizes include additional components proportionate to length.

Storm maintains a huge inventory of standard components, but special configurations are not a problem. Storm uses a computerized flexible tooling system designed to reduce set up and production time on special orders and that’s huge according to owner, Dan Kitts. “Our products usually ship in 24 hours, compared to three to eight weeks that are the industry norm. That’s obviously a significant advantage for time critical installations,” he said.

If you haven’t visited the Storm Grounding Web site you’re in for a pleasant surprise. All products are arranged conveniently for a minimum of clicks required to order and the pricing is structured so contractors and journeymen electricians can save money and pass on those savings to their customers to build loyalty and return contracts. With Storm Copper Components, you can expect the best quality products at very competitive prices, exceptionally fast shipping times, free UPS shipping and a satisfaction guaranteed policy that is second to none.

Check out Stormgrounding.com and see what I’m talking about!