Exothermic welding is a simple self-contained method of making high quality electrical connections for

welding copper to copper, copper alloy such as brass, bronze or copper to steel.

Exothermic welding is a simple self-contained method of making high quality electrical connections for
welding copper to copper, copper alloy such as brass, bronze or copper to steel.

The exothermic welding system uses the high temperature of reaction of powdered copper oxide and
aluminium. The reaction takes place in a graphite mould, which is machined according to the conductor
sizes to be welded and which can be used for approx. 60 welds or more welds if properly cared for. The
reaction last a few seconds only and the process requires no external power or heat source, making it
completely portable and ideal for field use.

Typical applications include earthing of sub-stations and power plant, cathodic protection, rail
connections, lightning protection, telecommunications, etc…

An exothermic welding shows a lot of advantages in comparison to mechanical or crimping systems.

As it is a molecular weld it will not be affected by high current surge. It can be shown by tests that the
electrical conductor will melt before the exothermic weld when subject to high short circuit current.

The weld metal has the same melting point as copper and the cross section of the weld is higher than
the cross section of the conductors to be welded so that the current carrying capacity is greater than
that of the conductors.

In addition to copper material such as brass, bronze, stainless steel, steel rail, etc… may also be welded.
The result will be a connection composed of an alloy without dielectric influence at the exothermic weld
point and totally unaffected by corrosion.
What Is Exothermic Welding And Why Is It Used?
Exothermic welding – also known as thermite welding or exothermic bonding – is a process for
permanently joining earthing (grounding) or lightning protection conductors together.

An exothermic weld can be especially useful for joining dissimilar metals. The process has the advantage
in that it requires no external heat source and works by employing a chemical exothermic reaction of a
thermite composition (weld powder) to heat the conductors to a point where a low resistance,
mechanically sound molecular bond is formed once cooled.

Exothermically Bonded Connections

Although mechanical connections and exothermically welded connections are very similar in their
applications, their performance can differ greatly.

Our “Traditional” and “PLUS” exothermic welding material is suitable for welding these materials
together:

Copper

Mild steel

Bronze

Brass

Specialised applications would also include cast iron and stainless steel materials, please speak to our
Sales Team: 020 8405 6789 or email: sales@etscablecomponents.com.

Exothermic welding is the only reliable means of bonding galvanised mild steel to copper conductors,
e.g. fence earthing or structural steel applications. ETS is the authorised UK re-seller and stockist for
ERICO CADWELD® exothermic welding products

CADWELD®:

Will not deteriorate with age.

Eliminates any risk of loosening or corrosion due to its molecular bonding characteristics.

Will resist repeated faulty currents.

Offers the lowest possible earth path resistance.

By visual inspection can be quality controlled.

Exothermic Welding Training

ETS can provide in-house training at short notice (UK only), either at our training facility or at a
customer’s site for the ERICO CADWELD® exothermic welding system.

These courses are designed to show and teach the correct preparation procedures, use and applications
of the CADWELD® welding system. You can find out more about our exothermic welding training courses
here.
Welding powder
The welding powder is packed in a 10 or 20 box containing also the ignition
powder and a metallic disc to be placed in the mould crucible
Welding powder
Weight (kg) Designation Conditioning Reference
0.03 Welding powder type 25 20 KW25
0.04 Welding powder type 32 20 KW32
0.06 Welding powder type 45 20 KW45
0.08 Welding powder type 65 20 KW65
0.10 Welding powder type 90 20 KW90
0.13 Welding powder type 115 10 KW115

0.17 Welding powder type 150 10 KW150

0.22 Welding powder type 200 10 KW200
0.27 Welding powder type 250 10 KW250

ERICO CADWELD PLUS Welding Material, F20 – 150PLUSF20

Mixture consists mainly of copper oxide and aluminum

• Primarily used in grounding and bonding applications

• Integrated welding material package

• Color coding by size for easy identification

• Electronic ignition

• No starting material required

• Non-explosive

• Not subject to spontaneous ignition

• See specific ERICO CADWELD connection details to determine welding material requirements