The process of exothermic welding is a method of making electrical connections of copper to copper or copper to steel in which no outside source of heat or power is required.
In this process, granular metallic powder is placed into a high temperature mold and ignited. This ignition process of the particles (exothermic reaction) creates high heat in excess of 1400 degrees celsius and produces molten metal slag. The liquid metal copper to flows into the weld cavity, filling any available space and completes the weld. The weld should then be allowed to cool and solidify. The mold is removed and made ready for the next weld. This entire process takes only seconds to complete.

Exothermically welded connections produce a permanent joint (or connection) superior in performance to any known mechanical or pressure type surface-to-surface contact connector.

By virtue of its molecular bond, an exothermically welded connection will not loosen or increase in resistance overthe lifetime of the installation.

As recommended by IEC and IEEE regulations all grounding system connections should be made by exothermic weld. Connections should include, but not be limited to, all cable to cable splices, T's, X's, etc.; all cable to ground rods, ground rod splices, cable to steel and cast iron; and cable lug terminations.
Exothermic welding is applicable to materials other than copper, some of these are listed below.
  • Common steel
  • Stainless steel
  • Steel rail
  • Monel
  • Copper-clad Steel
  • Cast iron
  • Columbium
  • Galvanized Steel
  • Niobium
  • Bronze
  • Brass
  • Commercially pure iron
  • Wrought iron
  • Silicon Bronze
Advantages of Exothermic Welding:
  • Current carrying (fusing) capacity equal to that of the conductor
  • Will not deteriorate with age
  • Permanent molecular bond that cannot loosen or corrode
  • Will withstand repeated faults
  • Low labor costs
  • No special skills required
  • No external power or heat required
  • Can be checked visually for quality
  • Portable

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The TectoWeld® catalog is available in both metric and US system.
Both Chinese (Traditional & Simplified) and English catalogs are available.
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TectoWeld® Slide Show: How to make a TectoWeld