INSTRUCTIONS

GRADIENT CONTROL MAT

(GCM)
 INTRODUCTION
Most gradient control mats are designed and installed around above ground pipeline appurtenances to limit power
frequency voltages. The Dairyland gradient control mat is designed to also limit potentially hazardous voltages due to
lightning, a much more difficult task. Step potentials are inherently controlled by the design of the mat (grid wire size,
grid spacing, etc.), but the touch potential that a worker may be subject to is determined both by the mat design and the
installation; therefore, these installation guidelines must be followed to provide maximum protection from lightning-caused
voltages.

The reason for this is that conductors inherently have inductance and when a very fast rising current, such as from
lightning, flows through the conductor from the pipeline to the mat a significant voltage per unit of conductor length
is developed. This voltage drop adds directly to the touch potential for a worker standing on the mat. Therefore, keep
conductor connections between the mat and pipeline as short as possible – as described above.

6. A Dairyland Solid State Decoupler if used, typically Model

WARNING
SSD-A/B-C-D where A/B is the blocking voltage, C is
the fault current rating at 30 cycles, and D is the lighting
current rating in kA. The most common rating is the
KEEP THE CONDUCTORS SHORT! SSD-2/2-1.2-100 for gradient control mat decoupling.
Reference the Dairyland technical literature for model SSD
The most significant installation factor is to keep the for ratings and outline drawings.
conductor that connects the mat to the pipeline as short
as possible, preferably 8” (200 mm) or less, whether the
7. Decoupler conductors, 12” (300 mm) or 36” (900 mm) with
mat is direct connected to the pipeline or connected
factory installed terminals (one end only), order MTL-6-12 or
through a Dairyland solid-state decoupler.
MTL-6-36, with each kit containing two #6 AWG conductors.
It is recommended that two conductors per decoupler
terminal are used, but cut off all excess conductor to make
Materials Required for Installation connections as short as possible.

1. Gradient Control Mats (4’ x 8’), GCM4-8 8. Mounting of decoupler:

2. If more than one mat is required, then weld the mats together • By banding: Banding material to be selected/purchased
using the Dairyland mold Mold-6X and an industry standard by user
#25 cartridge that can be purchased from any industry
source. Do not join mats with compression type or bolted
• By mounting to 8 mm pin brazed studs. Equipment/studs/
type connections - thermit weld only.
ceramic ferrules by user. Requires one Hex Coupling Nut
from Dairyland, model #HCN-M8
3. Magnesium anodes per Table 2, Section 2.1 and 2.2 in the
attached Correng Report, and backfill, if not provided with
• By securing to a post adjacent to the pipeline: User
the anode.
furnished.

4. To thermit weld a #6 AWG anode lead or the #6 decoupler

The first two mounting methods are illustrated in sheets 2
leads to the mat (if the mat is decoupled) use Mold-6X and
and 3 of the attached drawing 100103.
a standard #25 CP cartridge/shot. To thermit weld a #10 or
#12 AWG lead, use Mold-6X with a #15 CP cartridge/shot.
9. Sealant for all thermit welds: Denso LT tape (Available from
Do not attach leads with compression type or bolted type
Dairyland in 2”x33’rolls)
connections - thermit weld only.

10. C
 rushed limestone to cover mat 6” (Use clean washed
5. Wire cutters for 0.135” diameter steel wire (If necessary to
stone only if limestone is not available.)
cut out sections of the mat to fit around pipelines.)

DAIRYLAND ELECTRICAL INDUSTRIES | 608.877.9900 | DAIRYLAND.COM

Document ID: 4547 GCM Installation Instructions Published Date: 2021.01.01
INSTALLATION INSTRUCTIONS
1. Remove topsoil to a uniform depth of approximately 6”
(150 mm) in an area that extends beyond the lateral
mat dimensions. At the anode locations, excavate an

WARNING additional 36” (900 mm) depth to the lateral dimensions of

a horizontally oriented anode as depicted in the Correng
Report. Apply backfill material around the anode (if the
During installation, the voltage on the structure may rise
anode is not already bagged with backfill), and refill the hole
to an unsafe level (i.e., due to induced AC, AC fault or
with native soil, leaving the anode wire extended beyond the
lightning on the structure). Sparking and current flow may
soil surface for later attachment to the mat.
occur when making or breaking connections between the
structure and the gradient control mat. Assure that this does
not occur in hazardous locations where gases or vapors 2. Orient adjacent mats as follows: Flip the adjacent mat over
may be present. All necessary safety precautions must so that the top grid wires on one mat are oriented 90° with
be taken by the user to avoid unsafe worker conditions, respect to the top grid wires on the adjacent mat. This will
including arcing, in accordance with applicable industry enable the outer grid wires on adjacent mats to be placed
and/or company-required practices. Dairyland provides directly next to each other, a requirement for the grid wires
suggested procedures for installing and operating this to fit properly in the thermit welding mold.
equipment (See the section on Worker Safety). But the
user must be responsible for and approve the procedures 3. Locate the position of vertical pipe segments or other
to be used by its workers when installing the equipment structures that will protrude through the mat, and using
because Dairyland cannot be familiar with each user’s wire cutters, remove the unneeded portions of the mat so
safety guidelines. that the mat wires are no closer than 3” (75 mm) to the pipe
at any point, which will avoid contact and abrasion to the
pipe coating.

4. Place the mat segments in position around the structure,

WARNING in the excavated area. When multiple mats are required for
a given site, the adjoining mats should be thermit welded
Do not pin braze or weld in hazardous locations where together approximately every 18” using the mold and
explosive gases or vapors may be present. weld charge recommended. Do not substitute or use any
compression or bolted type connection.

Worker Safety 5.) Weld the #6 AWG anode conductors to the mat as illustrated
in the Correng Report using the mold and weld charge.
For worker safety during installation, it is recommended that For anodes with #10 or #12 AWG conductors, use Mold-
the user obtain certain equipment; namely a pair of electrically 6X with a #15 CP cartridge. Do not substitute or use any
insulated gloves, a shorting cable approximately 3 ft (0.91 m) compression or bolted type connection.
long with insulated clamps on each end, and a multi-meter
to measure AC voltage. (Of these items, Dairyland offers a 6. If the mat is to connect to the pipe through a decoupler,
suitable 3 ft long 1/0AWG shorting cable with insulated clamps, mount the decoupler as close to the mat as feasible, taking
Model# BCL-1/0 for all decoupler ratings.) The following into account that the mat is to be covered with 6” of crushed
installation procedure assumes that these items are available. limestone. The mounting method for the decoupler should
It is suggested that a grounding jumper be used as a safety have been pre-determined by the user and may consist of
precaution in the event the lead to the structure rises to an banding to the pipe wall, mounting by using 8 mm studs pin
unsafe potential when it is disconnected during the installation brazed to the pipe, or by mounting to a post adjacent to the
process or if an electrical disturbance occurs while the pipe that is to be connected to the mat. All mounting is to
decoupler is being installed. Be sure to remove the grounding be user furnished, except, if 8 mm studs are pin brazed to
jumper after the decoupler is completely installed. If the the pipe, a hex coupling nut kit is required from Dairyland
structure voltage is not at a safe touch potential (i.e.,>15VAC (#HCN-M8) to make the connection from one decoupler
to ground per NACE SP0177), then insulating gloves should terminal directly to the pipe wall. See the attached figures
be used. for various decoupler mounting methods.

Install mats and anodes as illustrated in the attached Correng

Report. If a decoupler is used, refer to the attached decoupler
drawing 100103.

DAIRYLAND ELECTRICAL INDUSTRIES | 608.877.9900 | DAIRYLAND.COM

Document ID: 4547 GCM Installation Instructions Published Date: 2021.01.01
7. Make conductor connections from the appropriate decoupler
terminal to the closest section of mat with the short-est lead
that will still allow welding of the conductor to the mat using
the Mold-6X for #6 AWG. Two #6 conductor connections are
recommended from each decoupler terminal as this also
helps to minimize lead inductance, with one conductor set to
the pipe and the other set to the mat, each preferably less than
8” (200 mm) long. Of the two Dairy-land decoupler conductor
lengths available, the 36” (900 mm) long conductors are
never recommended when limiting touch potentials due
to lightning is of concern, but this length is acceptable for
power frequency voltages. When connections are made to
adjacent mats as illustrated in Figure 1 (bottom view) of the
Correng Report it is desirable to mount the decoupler so
one conductor goes to each mat with the shortest possible
conductor length.

8. After all welding is complete (i.e., all mat to mat and lead to
mat welds), seal around and beyond the end of each weld
with two or more layers of Denso LT petrolatum tape or other
user approved sealant. When the Denso tape is used, a 4”
long piece of the 2” wide tape is required to seal each weld.

9. Cover the entire gradient control mat with 6” of crushed

limestone (alternatively, use clean washed stone, but only
if crushed limestone is not available). Extend the covering
at least several feet beyond the outer edges of the mat on
all sides.

DAIRYLAND ELECTRICAL INDUSTRIES | 608.877.9900 | DAIRYLAND.COM

Document ID: 4547 GCM Installation Instructions Published Date: 2021.01.01
Note: This drawing to be used in combination with Gradient Control Mat installation instructions

Steel Pipe

Decoupler shown attached to steel

pipe with M8-1.25 pin brazed studs.
See Sheet 3 for mounting details.
Steel Pipe SSD may also be banded to pipe -
see Sheet 2 for mounting details.

Trim GCM wire to

be no closer than
3" from pipe wall.
Mount decoupler as close to
gradient control mat as feasible
to minimize lead inductance
(i.e. to minimize touch potentials)

10.0
254 Make conductor connections to
mat as short as feasible.

6" of crushed limestone

3" x 3" Grid

Gradient
Control Mat

Thermit weld adjacent

mats together every 18".
Seal after welding.

Native Earth

Thermit weld #6 Awg.

decoupler conductors and ANSI Y14.5M 1994 APPLIES
DAIRYLAND DESCRIPTION Decoupling of Gradient Control Mat:
ELECTRICAL
anode conductors to mat. INDUSTRIES, INC. Typical Installation
Seal after welding. UNLESS NOTED 63 P.O. BOX 187
STOUGHTON,
DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
UNITS: INCHES
3-PLACE: .005 WI 53589 100103 A 2017-02-20 B 2017-02-24
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 1:6 DRAWN: JPW SHEET: 1 OF 3 DWG APPROVAL: JVW
Note: This drawing to be used in combination with Gradient Control Mat installation instructions

Station Pipe
SSD Mounting Bracket furnished

SSD

Banding to be provided by user

(+) (-)

#6 AWG conductors with terminals

attached on one end plus nuts, bolts, and
washers available from Dairyland.
Specify #MTL-6-12 for 12" (300mm) or MTL-6-
36 for 36" (900mm) for a set of two
conductors. Two conductors to each SSD
terminal are recommended. Other
conductor ends are unfinished.

For conductor connections to a steel pipe, a DETAIL A

thermit weld is recommended. Make SCALE 1 : 2
conductor lengths between SSD bus and
pipe as short as possible to minimize
inductive voltage drop due to lightning
and switching transients. ANSI Y14.5M 1994 APPLIES
DAIRYLAND
ELECTRICAL
DESCRIPTION Decoupling of Gradient Control Mat:
INDUSTRIES, INC. Banding SSD to Pipe
UNLESS NOTED 63 P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
STOUGHTON,
UNITS: INCHES
3-PLACE: .005 WI 53589 100103 A 2017-02-20 B 2017-02-24
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 1:12 DRAWN: JPW SHEET: 2 OF 3 DWG APPROVAL: JVW
Note: This drawing to be used in combination with Gradient Control Mat installation instructions
Steel Pipe

This installation method requires

pin brazing equipment and M8 -1.25 threaded
studs furnished by others. Install studs to
spacing shown +/- 0.10" or +/- 2.5mm.
Contact Dairyland for further information

SSD
10.0
254

To connect NEGATIVE terminal to pipe via

SSD Bracket the pin brazed stud, specify #HCN-M8 to
obtain the Hex Coupling Nut plus M8 Bolt
and washers required.
Pin Brazed Stud Use with SSD model: SSD-2/2-1.2-75
Hex coupling nut is first tightened onto pin
brazed stud, then M8 bolt (with washers) is
M8 Bolt Pipe Wall tightened into the coupling nut.

Lock #6 Awg conductors with terminals attached on

Washer one end plus nuts, bolts, and washers available
Flat Washer from Dairyland. C
Two conductors are recommended to the SSD
Flat Washer terminal. Other conductor ends are unfinished.
DETAIL B
SCALE 1 : 2
Coupling Nut

DETAIL C ANSI Y14.5M 1994 APPLIES

DAIRYLAND
ELECTRICAL
DESCRIPTION Decoupling of Gradient Control Mat:
SCALE 1 : 1 INDUSTRIES, INC. Pin Brazed Stud Connection to Pipe
UNLESS NOTED 63 P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
STOUGHTON,
UNITS: INCHES
3-PLACE: .005 WI 53589 100103 A 2017-02-20 B 2017-02-24
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 1:12 DRAWN: JPW SHEET: 3 OF 3 DWG APPROVAL: JVW
 CP of Galvanized Steel
Gradient Control Mats

GUIDELINES FOR CATHODIC PROTECTION OF

GALVANIZED STEEL GRADIENT CONTROL MATS

1.0 APPLICABILITY

1.1 These guidelines apply to cathodic protection of galvanized steel gradient control
mats installed at pipeline appurtenances to reduce electrical step and touch potentials
in areas where persons could come into contact with a pipeline appurtenance subject
to hazardous potentials.

1.2 These guidelines do not apply when the gradient mat is connected to other grounding
systems, either directly or indirectly through the pipeline appurtenance. These appli-
cations require consultation with a cathodic protection specialist.

1.3 If the pipeline is not cathodically protected, the galvanized steel mat should be con-
nected only via a decoupling device, or provision should be made to protect both the
pipe and the mat in consultation with a cathodic protection specialist.

2.0 ANODES

2.1 The magnesium anodes used to protect the mats should be either high potential pack-
aged magnesium anodes (Alloy M1C) or H1-Alloy (Standard) packaged magnesium
anodes, as indicated in Table 1.

Table 1. Magnesium Anode Data

Alloy Weight Standard Package

Anode Type
(ASTM B843-93) (Lbs.) Dimensions
H-1 Alloy
17S4 17 6.5" x 19"
Grade A
M1C
17D4 17 6.5" x 19"
(High Potential)
H-1 Alloy
32S5 32 8" x 30"
Grade A
M1C
32D5 32 8" x 30"
(High Potential)

2.2 The packaged anodes should be provided with 10 ft. of AWG 6/7 RWU 90 cable. The
backfill should be a mix of 75% hydrated gypsum, 15% bentonite, and 5% sodium
sulphate.

Guidelines Section 1 Page 1 of 8

 CP of Galvanized Steel
Gradient Control Mats

2.3 The type and quantity of the packaged anodes should be in accordance with Table 2.
Contact DEI if the size of the mat exceeds 16' x 16'.

Table 2. Required Type and Number of Magnesium Anodes

Calculated Anode Service Life

Soil Required
Mat Anode
Resistivity No. of Layout
Size [1] Type Directly
(Ω
Ω-cm) Anodes Decoupled
Connected
GCM [2]
GCM
Low
32S5 1 >20 years >18 years Figure 3
(1000 to 2000)
4' x 8'
Moderate
17S4 1 >20 years >20 years Figure 3
(Over 2000)
Low
32S5 1 >20 years >17 years Figure 1
(1000 to 2000)
8' x 8'
Moderate
17D4 1 >20 years >20 years Figure 1
(Over 2000)
Low
17S4 2 >20 years >19 years Figure 4
(1000 to 2000)
8' x 16'
Moderate
32D5 1 >20 years >20 years Figure 3
(Over 2000)
Low
32S5 2 >20 years >20 years Figure 4
(1000 to 2000)
12' x 16'
Moderate
32D5 2 >20 years >20 years Figure 4
(Over 2000)
Low
32S5 2 >20 years >19 years Figure 2
(1000 to 2000)
16' x 16'
Moderate
32D5 2 >20 years >20 years Figure 2
(Over 2000)
[1]
The cathodic protection system was designed to provide an anode life in excess of 20 years in soil
resistivities as low as 1000 Ω-cm and to provide the required protection current at soil resistivities
up to 15, 000 Ω-cm. Soils with resistivities higher than 15,000 Ω-cm are not considered corrosive.
[2]
If the gradient control mat is directly connected to a pipe appurtenance, then the polarized potential
of the protected structure is expected to drop from -1100mVCSE to -850 mVCSE and the service life
of the anode would be reduced by 28% for high potential anodes and by 36% for H1-Alloy anodes.

Guidelines Section 1 Page 2 of 8

 CP of Galvanized Steel
Gradient Control Mats

3.0 ANODE INSTALLATION

3.1 The anodes should be installed horizontally approximately 3 ft. below the mat, as
indicated in Figures 1 to 4.

3.2 The anode wire should be run to a close mat wire. The radius of bends should be at
least 8".

3.3 The #6 AWG anode wire connections to the 0.135" diameter galvanized steel wire of
the gradient control mat and the mechanical/electrical bonding of the galvanized steel
wires in adjacent gradient control mats should be done by thermit welding. Custom
molds and the weld metal for each case are available from DEI (Dairyland Electrical
Industries, Inc.) All thermit welded connections should be sealed with two or more
layers of Denso LT tape.

Guidelines Section 1 Page 3 of 8

 CP of Galvanized Steel
Gradient Control Mats

3.0 ANODE INSTALLATION CONT’D

3.3 Cont’d

A
1'-0" 7'-0"

4'-0"
Decoupling
Device

Appurtenance
4'-0" Anode

8' x 8' Gradient Control Mat

Plan View
Decoupling Device
Crushed
Limestone Anode Connection to
Gradient Control Mat

Gradient Control Mat

3'-0"
TYP
Appurtenance

3'-0" 1'-0"

Section `A-A' - Typical Anode Installation

FIGURE 1 • Square Gradient Control Mat with One Anode

Guidelines Section 1 Page 4 of 8

 CP of Galvanized Steel
Gradient Control Mats

3.0 ANODE INSTALLATION CONT’D

3.3 Cont’d

8'-0" 8'-0"

2'-0"

Anode

Decoupling
Device
12'-0"

Appurtenance
A

Anode

2'-0"

16' x 16' Gradient Control Mat

Plan View

Decoupling Device
Anode Connection to
Crushed Limestone Gradient Control Mat

Gradient
Control Mat 3'-0"
TYP
Anode
Appurtenance

6'-0" 2'-0"

Section `A-A' - Typical Anode Installation

FIGURE 2 • Square Gradient Control Mat with Two Anodes

Guidelines Section 1 Page 5 of 8

 CP of Galvanized Steel
Gradient Control Mats

3.0 ANODE INSTALLATION CONT’D

3.3 Cont’d

8'-0"

1'-0"

4'-0"

A
8'-0"
6"
Decoupling
Device
A

Decoupling
4'-0" Device
Anode Appurtenance

4'-0" Appurtenance 8'-0"

4' x 8' Gradient

Control Mat
8' x 16' Gradient Control Mat

Plan View
Decoupling Device
Anode Connection to
Crushed Limestone Gradient Control Mat

Gradient Control Mat

3'-0"
TYP

Appurtenance

Anode

Section `A-A' - Typical Anode Installation

FIGURE 3 • Rectangular Gradient Control Mat with One Anode

Guidelines Section 1 Page 6 of 8

 CP of Galvanized Steel
Gradient Control Mats

3.0 ANODE INSTALLATION CONT’D

3.3 Cont’d

8'-0"

1'-0" 1'-0" 1'-0" 1'-6" 9'-0" 1'-6"

A

A
8'-0" 8'-0"
Decoupling Decoupling
Device Device

Anode Anode Anode Anode

Appurtenance Appurtenance
8'-0" 8'-0"

8' x 16' Gradient Control Mat 12' x 16' Gradient Control Mat

Plan View

Decoupling Device
Anode Connection to
Crushed Limestone Gradient Control Mat

Gradient Control Mat

3'-0"
TYP

Appurtenance

Anode

Section `A-A' - Typical Anode Installation

FIGURE 4 • Rectangular Gradient Control Mat with Two Anodes

Guidelines Section 1 Page 7 of 8

 CP of Galvanized Steel
Gradient Control Mats

4.0 ADDITIONAL RECOMMENDATIONS

4.1 It is recommended to use crushed limestone as the high resistivity layer to be installed
on top of the safety mat, in order to minimize the attack of acid rain on the galvanized
steel.

Guidelines Section 1 Page 8 of 8