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CADWELD Exothermic Welding Solutions
nVent ERICO’s CADWELD exothermic welding system is the industry standard for forming high-quality, permanent, and low-resistance electrical connections. It creates a molecular bond that will not loosen, corrode, or degrade with time — outperforming mechanical or compression-type connections in critical grounding, bonding, and lightning protection applications.
Why Choose CADWELD?
- Molecular Bond Strength — Stronger than mechanical joints and resistant to loosening over time
- Superior Conductivity — Connection has equal or greater conductivity than the conductor
- Corrosion Resistant — Ideal for long-term use in corrosive soils and aggressive environments
- Quick & Reliable Installation — Reduces labour time by 20%, suitable for large-scale installations
- Compliant with Global Standards:
- IEEE Std 837 (Permanent Grounding Connections)
- UL 467 (Grounding and Bonding Equipment)
- IEC 62561-1 and IEC 62305 (Lightning Protection)
- ISO 9001 (Manufacturing Quality)
Why Choose CADWELD?
- Molecular Bond Strength — Stronger than mechanical joints and resistant to loosening over time
- Superior Conductivity — Connection has equal or greater conductivity than the conductor
- Corrosion Resistant — Ideal for long-term use in corrosive soils and aggressive environments
- Quick & Reliable Installation — Reduces labour time by 20%, suitable for large-scale installations
- Compliant with Global Standards:
- IEEE Std 837 (Permanent Grounding Connections)
- UL 467 (Grounding and Bonding Equipment)
- IEC 62561-1 and IEC 62305 (Lightning Protection)
- ISO 9001 (Manufacturing Quality)
CADWELD PLUS System – Simplified, Safer, Smarter
CADWELD PLUS features an integrated welding material and ignition system. No separate starting powder or disk is required.
- Electronic ignition with Plus Impulse Control Unit
- No external power required – operates with standard AA batteries
- Consistent results – even in harsh site conditions
- Safer distance operation – ignite from up to 15 feet away
CADWELD PLUS connections are made with a semi-permanent Graphite mould, which holds the conductors to be welded. Weld metal used are a mixture of Copper oxide and Aluminum. The exothermic reaction produces molten copper, which results in a permanent high conductivity connection as per IEEE Std 837.
Key performance attributes:
- Equal or greater current capacity than the conductor
- Permanent molecular bond; will not loosen or corrode
- Melting point exceeds 1084°C (copper)
- Operates in corrosive, humid, and chemically aggressive environments
- CE/UL electronic ignition controller — 600+ connections per battery set
- Approved under UL 506, ANSI / UL 467, IEEE Std. 80, and IEEE Std. 837-2014
Types of CADWELD Connections
CADWELD offers a wide range of connection configurations tailored to various grounding scenarios:
- Cable-to-Cable (butt splice, parallel, tee)
- Cable-to-Ground Rod
- Cable-to-Flat Surface or Steel Plate
- Cable-to-Rebar
- Ground Rod to Mesh
- Cable-to-Lug and Cable-to-Equipment
Each connection uses a dedicated mold type and weld metal size to ensure strength and conductivity.
Composition and Weld Properties:
- Exothermic Mix: Copper oxide + aluminum powder
- Reaction Temp: >1400°C (generates molten copper)
- Connection Conductivity: Maintains 98% of original copper conductivity
- Mechanical Strength: Withstands high fault currents without degradation
Industry Applications
CADWELD is deployed across a broad range of industries:
- Power substations and utilities
- Oil & gas facilities
- Railways and metro infrastructure
- Industrial grounding grids
- Data centers & control systems
- Renewable energy plants
Step-by-Step Installation Guide
- Clean the conductor to remove corrosion, dirt, and oils
- Place the conductors in the reusable graphite mold
- Insert the CADWELD welding material cartridge
- Connect the electronic ignition system or standard flint ignitor
- Ignite and allow the exothermic reaction to complete (~5 seconds)
- Cool and Inspect — Remove slag and visually confirm a solid bond
Test Methods
Note: The life of an earth electrode can be reduced by corrosive soil environments. CADWELD bonding provides enhanced performance through permanent molecular-level fusion that resists environmental degradation.