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Email Address: aretepowertech@gmail.com
Exothermic Welding – Permanent Electrical Connections for Earthing & Grounding
In modern electrical and grounding systems, ensuring permanent, reliable, and maintenance-free connections is a top priority. One of the most effective technologies to achieve this is Exothermic Welding (also called thermite welding or molecular bonding).
Exothermic welding creates a molecular bond between conductors, ensuring a connection that is superior to mechanical clamps, compression joints, or bolted connections. It is widely used in earthing, lightning protection, power transmission, telecom, and railways, where system reliability is critical.
👉 For high-quality exothermic welding kits, molds, and accessories, visit www.aretepowertech.co.in
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Exothermic welding is a process of joining two or more conductors (such as copper rods, strips, cables, or GI electrodes) using a high-temperature chemical reaction between aluminum and copper oxide.
The reaction produces molten copper, which flows into a graphite mold around the joint.
The molten copper fuses the conductors together at a molecular level.
The resulting joint is permanent, highly conductive, and corrosion-resistant.
This process is also called:
Thermite Welding
Cadweld (a popular brand name)
Molecular Welding
A graphite mold is placed around the joint.
Exothermic powder (aluminum + copper oxide) is poured into the mold.
The powder is ignited using a flint igniter or spark.
The chemical reaction generates heat (~2500°C).
The molten copper flows into the mold cavity, surrounding the conductors.
The conductors fuse together, creating a permanent joint.
👉 Unlike soldering, no external heat source is required – the reaction is self-sustained.
Permanent Connection: Joints last as long as the conductors.
High Conductivity: Equal or greater than the conductor itself.
Corrosion Resistance: Molecular bond resists oxidation and soil chemicals.
High Current Carrying Capacity: Withstands fault currents and lightning surges.
Low Resistance: Stable electrical properties throughout its life.
No Maintenance: Unlike mechanical clamps, joints never loosen.
Durability: Can withstand extreme weather, vibrations, and soil conditions.
Exothermic welding is used in earthing and electrical connections across multiple sectors:
Earthing/Grounding Systems – Connecting copper rods, GI electrodes, copper strips, etc.
Lightning Protection – Bonding air terminals, down conductors, and ground systems.
Power Plants & Substations – Permanent bonding of busbars and ground grids.
Railway Signaling – Reliable grounding for track circuits.
Telecom Towers & Data Centers – Protection against surges and grounding of sensitive systems.
Oil & Gas Industry – Corrosion-proof grounding in hazardous environments.
Renewable Energy Projects – Solar and wind farm grounding.
Strength
Conductivity
Durability
Maintenance
Resistance
Permanent molecular bond
Excellent
30–50 years
None
Very Low
Weakens over time
Moderate
Needs maintenance
Frequent
Higher
May melt under fault current
Good but unstable
Low (can corrode)
Yes
Low
Can loosen under vibrations
Moderate
Needs tightening
Periodic
Moderate
👉 Exothermic Welding is clearly the most reliable solution for long-term, maintenance-free grounding.
Portable and easy-to-use system
No need for external power or heat source
Produces uniform, repeatable results
Wide range of molds for different joint types
Works with copper, copper-bonded steel, and galvanized steel
Exothermic welding can be used to create various types of joints, such as:
Cable to Cable (T-joint, parallel, cross)
Cable to Rod
Cable to Busbar/Strip
Rod to Rod
Rod to Plate
Ground Mesh Connections
Reaction Temperature: ~2500°C
Conductivity: ≥ 98% of pure copper
Mechanical Strength: Exceeds tensile strength of conductor
Lifespan: 30–50 years (same as conductor)
Standards: IEEE 80, IEC 62561, IS 3043
Graphite Mold (reusable)
Exothermic Welding Powder (available in different grades)
Handle Clamp
Igniter / Flint Gun
Protective Gear (gloves, goggles, apron)
Preparation: Clean conductors of dirt, oil, and oxide.
Mold Placement: Place conductors inside the graphite mold.
Powder Loading: Pour exothermic powder into the mold.
Ignition: Ignite powder using flint igniter.
Reaction: Chemical reaction generates molten copper (~2500°C).
Fusion: Molten copper fuses conductors at molecular level.
Cooling: Allow 30–60 seconds for solidification.
Inspection: Open mold and check joint quality.
Always wear gloves, safety glasses, and flame-resistant clothing.
Keep mold dry (moisture can cause splattering).
Do not inhale fumes. Work in a ventilated area.
Keep fire extinguisher nearby.
Follow manufacturer’s handling instructions.
Exothermic Welding is the most reliable, long-lasting, and maintenance-free method for creating electrical connections in earthing and grounding systems. Unlike mechanical or compression methods, exothermic welding forms a molecular bond, ensuring superior conductivity, corrosion resistance, and durability.
