Beyond traditional grounding: How exothermic welding creates a permanent, highly conductive connection

2025-11-24

The connection point in a grounding network is usually the weakest link. This article introduces exothermic welding, a method of achieving fusion at the molecular level that forms a permanent connection with the same lifetime as the conductor itself, making it ideal for critical applications.

An efficient grounding network relies on the reliability of each connection point. Traditional mechanical connection methods, such as clamps or crimping, can loosen over time, causing increased contact resistance, dangerous hot spots, and potential failure during lightning strikes.

Is there a connection method as reliable as a solid conductor? The answer is yes: exothermic welding.

Exogenous welding is a process that uses high-temperature chemical reactions to melt metals. It works by igniting reactive powder in a graphite mold, creating overheated molten metal, which permanently fuses conductors (such as ground rods and cables) together in the mold.

The advantages of this process are obvious:

Permanent connection: The connection formed is a fusion at the molecular level. It will not loosen, corrode or degrade, and its service life far exceeds that of the mechanical connection and is equivalent to the service life of the conductor itself.

Excellent current carrying capacity: The current carrying capacity of the weld seam is equal to or greater than that of the conductor and can safely withstand strong lightning strikes.

High corrosion resistance: The weld is mainly composed of copper and has excellent soil corrosion resistance.

Exogenous welding is particularly suitable for locations where safety and durability are extremely important, such as grounding systems in substations, wind farms, telecommunications base stations and chemical plants.
Exothermic Welding.png