EXOTHERMIC WELDING

• The exothermic process

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 Exothermic Process
• Exothermic is a chemical term
describing a chemical reaction
which gives off heat as the
reaction takes place
• Exothermic welding is a
commercially established
technique for joining
reinforcing bar, copper bus
bars and earth and lightning
conductors
• The process was developed in
1938 for welding copper alloy
signal bonds to rails.

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 Exothermic Process
• The thermOweld® process utilizes an
exothermic reaction in the reduction of
metal oxide by another more reactive
metal.
• A general formula for a thermOweld®
connection is:
Copper oxide + Aluminum = Molten Copper +
Aluminum Oxide +
Heat
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 Exothermic Process
• The exothermic reaction
creates approx. 4000 °F
in less than three
seconds creating a
molten copper that makes
a homogeneous
connection.
• A cut away section of a
thermOweld® connection
will show the conductors
lose their original
definition and become a
solid mass copper
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 Facts
• The thermOweld®
process is used to weld
conductors to conductors,
conductors to ground
rods, conductors to steel
structures, all in various
configurations.
• The thermOweld®
process have also been
used extensively in the
field of lightning
protection with the same
type of connections as
used in grounding.

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 Materials Suitable for Exothermic Welding

Stainless Steel Columbium Brass

Copperweld Plain Steel Bronze

Nichrome V Everdur Niobium

Galvanized Steel* Kama Chromax

Silicon Bronze Steel Rail Cast Iron

Copper Clad Steel Corr-ten Monel

* When welding to galvanized steel it is recommended to resurface exposed bare steel.

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 Features
• The thermOweld® connection produces a joint superior in
performance to mechanical, pressure type surface-to-surface
contact connector or brazed connections.
• Because of it's molecular bond, a thermOweld® connection will not
loosen or corrode, with the resultant increase in resistance, over the
lifetime of the connection - even under the most severe conditions.
• The thermOweld® connections replace several alternative, but
lesser quality and usually higher priced, methods of joining
conductors for electrical purposes.
– Brazing.
– Bolted type connectors.
– Shear type bolted connectors.
– Crimp type connectors
– Circumferential compression connectors.

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 Benefits
There are several advantages to use thermOweld® exothermically welded
connections.
• Current carrying capacity of the thermOweld® connection is typically equal
or greater equal than the conductor.
• ThermOweld® connections can withstand repeated high current surges
without deterioration
• The thermOweld® connections will not deteriorate with age since they are
bonded at a molecular level.
• The thermOweld® connection is a permanent molecular bond that cannot
loosen.
• The thermOweld® connections are unaffected by corrosive products to the
same degree as copper.
• Minimum training is required to make a thermOweld® connection.
• The material to make the thermOweld® connection is light and portable.
• No external power or heat is required to make a thermOweld® connection.
• ThermOweld® connections can be checked for quality by visual inspection.

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 Equipment - Molds
• Molds are made of
graphite, a very soft and
porous materials capable
of withstand the thermal
shock of the
thermOweld® exothermic
reaction
• Each mold is machined
for a specific set of
conductors and a specific
configuration
• When properly cared for,
molds should last at least
50 welds

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 Equipment – Weld Metal
• The weld powder consist
of copper oxide and
aluminum which is
measured into specific
weight in grams
• 97% of the content of the
cartridge is the actual
weld metal
• Remaining part is the
starting powder which is
tamped into the bottom of
each cartridge

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 Equipment - Accessories
• Handle Clamps to
manipulate the mold
• Flint igniter to
generate the energy
to start the
exothermic reaction
• Slag removal spade
and mold cleaning
brush to clean the
mold after connection
is made
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 Making a Connection
• Position cleaned
conductors in mold
after making sure
mold is dry, by pre-
heating or making a
test joint.
• Place metal disc in
bottom of mold
crucible

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 MAKING A CONNECTION
• Dump powder into
crucible, being careful
not to loosen all the
starting powder.

• Close lid and place a

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 MAKING A CONNECTION

• Ignite the starting

• Remove weld and

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Markets served

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 Markets Served
• Cathodic Protection
– Installation of
sacrificial anode beds
– Installation of
impress current
anode beds
– Jumper bonds
– Grounding connection
of rectifiers

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 Markets Served
• Electricity
– Substation grounding
systems
– Power generation
plant grounding
system
– High Voltage
Transmission lines
– Distribution lines
– Pad-Mounted
transformers

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 Markets served
• Telecommunications
– External plant
grounding system
– Fence post grounding
– Tower base grounding
system
– Ground bars
– Computer grounding
– Signal reference grid

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 Market served
• Rail
– Signal bonds
– Power bonds
– Contact rail splices

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 International Standards
• The thermOweld®
exothermic welding
process is covered in
various international
standards:
• IEEE 837 Standard for
qualifying Permanent
Connections Used on
Substation Grounding
• The standard states that
exothermic connections,
properly installed are
equal to the conductor
itself

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 International Standards
• ANSI/ASME B31.4.
“Liquid Petroleum
Transportation piping
Systems” and B31.8 “Gas
Transmission and
Distribution Piping
Systems”
• Both standards allow the
use of exothermic
welding of cathodic
protection leads to the
pipe with limits on the
weld metal size
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 International Standard
• American Association of
Railroads (AAR) Signal
Manual Part 8.1.30
• American Railway
Engineering Association
(AREA) Section 33, Part
7.1.5 and 7.1.6
• Covers the manufacture,
application and testing of
exothermically welded
power and signal bonds

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 International Standards
• ANSI-J-Std-607-A-2002
“Commercial building
Grounding (Earthing) and
Bonding Requirements
for Telecommunications
• The standard states that
connections of the
bonding conductor for
telecommunications and
the different ground bars
shall be exothermically
welded

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 Conclusion
• ThermOweld® exothermic
connections are your best
solution for grounding and
lightning protection systems
• ThermOweld® exothermic
connections fulfills all
international applicable
standards for grounding and
lightning protection systems
connections in power
generation, power
transmission & distribution,
cathodic protection, rail and
telecommunications markets

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