CADWELD® Connections (High Current Busbars)


CADWELD® Connections (High Current Busbars)

The CADWELD process is a method of making welded electrical connections of aluminum to aluminum, copper to copper, and copper to steel in which no external sources of heat, such as electricity or gas, are required.


  • Connections can be made to any size or shape of conductors including:
    • rectangular or round busbar
    • cable
    • laminated conductors
    • braid
    • lugs
  • Current-carrying capacity of the connection is equal or greater than conductor
  • Will not loosen in service – no maintenance required
  • Process develops its own heat to complete the weld
  • Installation and maintenance personnel can be easily trained
  • Welds can be made in a highly magnetic environment


The CADWELD process is ideal for the following process industries in maintaining high current busbars and related connections:

  • Aluminum
  • Copper
  • Zinc
  • Lead
  • Chlorine
  • Plating

More Information

Application Examples

CADWELD Process CADWELD Connection Cross Section
Making a Connection CADWELD Connection Cross Section
CADWELD Connection in Aluminum Smelter Bus Bar Repair
CADWELD Connection in Aluminum Smelter Busbar Repair

How to Make a CADWELD Exothermic Welded Connection

CADWELD Exothermic Welded Connection 1  CADWELD Exothermic Welded Connection 2  CADWELD Exothermic Welded Connection 3
Step 1
Ensure you have all equipment required for the welding process, plus all the safety equipment recommended by ERICO.Prepare the conductor ends for weld.
Step 2
Place the open mold into the conductor ends carefully.
Step 3
Close handles to lock mold halves together.Drop the metal disk into crucible, ensuring it is correctly seated and covering the tap hole.
 CADWELD Exothermic Welded Connection 4  CADWELD Exothermic Welded Connection 5  CADWELD Exothermic Welded Connection 6
Step 4
Pour all weld metal into the crucible.
Step 5
Tap bottom of container to release the starting material. Drop 1/3 of it onto the mold lip.
Step 6
Close the cover. Ignite with spark from flint ignitor.NOTE: DO NOT use a torch or matches.
 CADWELD Exothermic Welded Connection 7 CADWELD Exothermic Welded Connection 8
Step 7
Wait until the reaction is completed (the time taken will depend on the connection type).Open mold and remove from finished connection.
Step 8
Visually inspect the connection to make sure it is good.

NOTE: The above information is a guide only. The detailed instructions and safety precautions provided with each mold should be read prior to making a CADWELD connection.

Engineering Support
With the increasing costs of electric power today, the need for reliable and efficient electrical connections is more critical than ever. ERICO responds with an industry-wise engineering and sales support group.

ERICO engineers provide on-going:

  • System Design
  • Product Specification
  • Product Selection
  • Technical Support
  • Assist in selecting the bonding scheme, which simplifies installation and provides maintenance-free service

Prototype Development
Engineered designs of specific applications, especially large and complex welds, are thoroughly tested. ERICO performs a wide variety of testing. In-house testing capabilities and outside facilities are used to assure connection performance and reliability.