FurseWELD Exothermic Welding Systems, Joints & Moulds from ABB Thomas & Betts

By Chris Dodds on 24th February, 2016

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FurseWELD Exothermic Welding Systems, Joints & Moulds from ABB Thomas & Betts

FurseWELD exothermic welding is a cost efficient method of achieving high quality electrical connections.

FurseWELD is a simple, self-contained exothermic welding system that uses the high temperature reaction of powdered copper oxide and aluminium, within a mould, to form permanent electrical connections.

Exothermic welded connections are accepted according to the 11kV and 33kV substation earthing design and construction manuals by most UK DNO's, including UK Power Networks (UKPN) - for instance earth welding copper to copper tape connections and copper tape to stranded cable earthing connections.

Typical applications include:

  • Earthing for power plants and high voltage substations (11kV-33kV)
  • Telecommunications
  • Transmission and power distribution lines
  • Cathodic protection
  • Rail connectionsABB Furseweld



FurseWELD Earth System Benefits

  • Requires no external power or heat source
  • Creates high quality electrical connections
  • Completely portable
  • Can be used safely with minimum training
  • Cost effective exothermic welding 
  • Can be used for over 45 standard connection configurations


FurseWELD Earth Connection AdvantagesFurse FurseWELD

  • Tolerant to repeated fault currents
  • Highly conductive
  • Does not loosen
  • Excellent corrosion resistance


FurseWELD Exothermic Welding - contact T&D for Training & Certification Courses

FurseWeld Furse


FurseWELD connections have at least twice the cross-sectional area of the copper conductors being joined or welded, and an equivalent or greater current carrying capacity. Corrosion resistance is exceptional due to the very high copper content (> 90%) of the alloy.

Typical FurseWELD Applications : Furseweld

  • Bar to Bar
  • Bar to Earth Rod
  • Cable to Bar
  • Cable to Cable 
  • Cable to Earth Rod
  • Exothermic Moulds & Joints


FurseWELD is suitable for connections to copperbond, solid copper and stainless steel earth rods - threaded porttion of copperbond earth rods must be removed prior to FurseWELD application. 


FurseWELD Exothermic Welding Moulds

FurseWELD system of exothermic welding uses moulds to contain the exothermic reaction that creates safe and robust connections. Different types of FurseWELD moulds are available, whose use depends on the requirements of the project.

  • Graphite Moulds - Marketleading FurseWELD graphite moulds are extremely robust and capable of creating over 75 connections each.
  • Mini-Moulds - FurseWELD mini-moulds are a cost effective alternative to full sized moulds, especially where lower numbers of connections are required. They are smaller overall, less robust and therefore lower priced. Care is required in order to achieve similar service lives to full sized moulds.
  • Sureshot - the FurseWELD Sureshot system is a single use ceramic mould supplied complete with retaining disc and powders - It has been designed for use in applications where only a few exothermic welding connections are required. 


FurseWELD - How to make a FurseWELD Joint Connection

1. Locate the copper conductors to be joined in the FurseWELD cavity and close the mould.

2. Locate the steel retaining disc in the base of the crucible, pour in the weld powder followed by the starting powder. Ignite starting powder with a spark gun.

3. The exothermic reaction reduces the weld powder to molten copper alloy which melts the retaining disc and flows into the weld cavity where it partially melts the conductors

4. The molten copper allow cools to leave a fusion weld of great mechanical and electrical integrity.




  • Furse
Established in 1894 as W.J.Furse & Co Ltd by William Joseph Furse when he bought a steeplejacking company, Furse has developed a lot over the last 120 years. 
Today, Furse is the market leader for Earthing & Lightning Protection and for many years has been promoting the concept of a 'Total Solution' for earthing and lightning protection and all Furse connection components have successfully passed the BS EN 50164-1:2000 test procedures.
Furse continues to expand and since 1998 has been part of the Thomas & Betts Corporation and today is part of ABB.


  • Further Reading

Lightning: It’s All About The Bolt : The Essentials Of Lightning Protection + Video 



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FurseWELD Exothermic Welding Systems, Joints & Moulds from ABB Thomas & Betts

Category:  Earthing & Lightning Protection

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