TerraWeld® Exothermic Welding System
The TerraWeld® Exothermic Welding System provides a superior connection solution via permanent molecular bonding. Because of its inherent molecular-level reliability for conductors and grounding points, exothermic welding is the industry-preferred method for establishing permanent electrical connections.
Welding does not require an external heat or power source
Connections will not loosen or increase in electrical resistance over time
Delivers electrical conductivity equal to or greater than the conductors themselves
Will not corrode, oxidize, or degrade over time
Fully compatible with copper, steel, columbium, bronze, iron, copper-clad steel, stainless steel, Monel, niobium, brass, and silicon bronze
Requires no special skills or heavy machinery to operate
Lightweight and easy to transport to any job site
Significantly reduces labor time and costs
TerraWeld® Applications
The TerraWeld® system is designed to create permanent, high-reliability connections for grounding grids, lightning protection systems, and substation projects. It is widely used to join cables, ground rods, tape, and metal structures across industries like telecommunications, power generation, and commercial construction.
Installation Guide: Locate the number 3 on the application maps to the right to view typical exothermic welding installation points.
How It Works
The TerraWeld® Exothermic Welding System utilizes an exothermic reaction—a chemical reaction that releases energy in the form of intense heat—to permanently fuse metal connections.
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Setup: A lightweight, clamp-on graphite mold is used to safely position and contain the conductors.
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Reaction: The exothermic reaction creates a highly controlled, miniature furnace with temperatures exceeding 2,500°F (1,371°C).
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Fusion: This process instantly produces molten metal that flows into the weld cavity, filling the joint space and molecularly bonding the materials.
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Completion: After allowing the weld to cool for a brief period, the mold is unclamped to reveal a permanent, solid-metal connection.
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