Furseweld | The Furse System of Exothermic Welding

Published 09 Oct 2019

Furseweld | The Furse System of Exothermic Welding

Furseweld | The Furse System of Exothermic Welding

  • uploaded by Chris Dodds | Thorne & Derrick Sales Marketing Manager


The Furse System of Exothermic Welding

Since 1893, Furse has provided world leading Earthing, Lightning and Electronic Systems protection solutions for electrical infrastructure, building services and LV MV HV substations.

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 Exothermic Welding Applications

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

Exothermic Wedling Using the FurseWELD System

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 Advantages

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

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


Furse Earthing

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.

FurseWELD Connections

Typical FurseWELD Applications

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

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

Welding procedure

  1. Position the cleaned conductors in the mould after ensuring the mould is dry by pre-heating or making a test joint.
  2. Lock the mould with the handle clamp; if the mould does not close properly adjust the tension by removing the split pin and turning the eye bolt accordingly. Insert the steel disc into the mould crucible, ensuring it is centred over the tap hole.
  3. Pour the welding powder into the crucible; the starting powder is retained in the underside of the cartridge and identified by a red cap.
  4. Spread the starting powder evenly over the welding powder, placing a small amount on the top edge of the mould for easy ignition.
  5. Close the cover and ignite the starting powder with the flint gun; pull the gun away immediately to prevent fouling the flint. Wait a few seconds to allow the metal to solidify before opening the mould. Remove all slag and dust before making the next weld.

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.





Furseweld Exothermic Welding Tools & Accessories

Furseweld Exothermic Welding Tools & Accessories

  • Handle Clamp
  • Flint Gun
  • Toolkits including cable or tape cleaning brush, mould cleaning brush & mould scraping tool
  • Gas torch (to preheat the mould)
  • Optional toolbox & heat resistant mould jacket

Potential Hazards

As with all forms of welding the potential hazards are:

  1. Accidental contact with hot work.
  2. Spatter of molten metal.
  3. Eye irritation.
  4. Throat/chest irritation.
Frequently Asked Questions About Exothermic Welding

Could you tell me how many welds can be completed  before replacement of the mould is required?

With regards to the Exothermic Welding Mould, the mould should be good for 40-50 joints at a minimum (they could easily do a lot more if they are maintained and used correctly).

Are the earth welding products classed or recognised as “explosives”, and should they be stored in a secure metal box and labelled as explosives?

  • FurseWELD materials must be stored in a dry and secure place
  • Only take onto site, sufficient materials to give continuity of work
  • Fully discuss the operation with the client including site fire precautions. Note: A permit to work system may be required before work can be done
  • Wear all of the above listed personal protective equipment and any other equipment which may be required for the job in hand
  • Do not use flame or heat near flammable substances or atmospheres; this will include the following: paints, solvents, oils, petroleum, diesel, gasses, paper, rags

What are the training and competency assessments requirements and how often should this training be reviewed, refreshed or renewed?

Furse can offer Exothermic Welding Training and will supply a certificate at the end to show that the user has successfully completed a course of instruction and demonstrated competence in the process. This certificate will last for 4 years – contact Thorne & Derrick for further information.

PPE Requirements?

Safety Goggles & Heat Resistant Gloves

Safety Goggles & Heat Resistant Gloves

The following should always be worn:

  1. Safety Goggles
  2. Heat Resistant Gloves (welders gloves)
  3. Safety Boots (for site use)
  4. Safety Helmet (for site use)
  5. Fire Bucket or Extinguisher (if working near flammable materials)

In addition to the above, other equipment may be required dependent upon the location of and the nature of the job. This may include:

  1. Fire bucket/extinguisher (if working near flammable materials).
  2. Heat resistant board (to contain spillage or protect surfaces).

Further Reading


Thorne & Derrick are national distributors of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – servicing businesses involved in cabling, jointing, substation, earthing, overhead line and electrical construction at LV, 11kV, 33kV, 66kV and EHV. Supplying a complete range of power cable accessories to support the installation and maintenance of low/medium and high voltage power systems:

  • Slip-on Cable Terminations
  • Cold-shrink Cable Terminations
  • Heat-shrink Cable Terminations
  • Cable Joints – Heat & Cold-shrink
  • Separable Connectors (Euromold)
  • Surge Arresters & Switchgear/Transformer Bushings

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV 

Thorne & Derrick International

Further Reading