Specifications

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he ability of a grounding sys-

tem to protect property and

personnel is dependent upon the

quality and effectiveness of the con-

nections used to form the ground

circuit. That is why the Harger

Ultraweld

exothermic welding

system is the preferred method for

making electrical grounding con-

nections for all the types of conduc-

tors and electrodes used in today’s

modern grounding systems. While

many grounding connection meth-

ods, including compression, bolted,

brazed and welded, will perform

well for the first few years, only

the molecular bond provided by

the Ultraweld exothermic welding

system is permanent and proven

to work better than typical connec-

tors providing only point-to-point

contact. Ultraweld exothermic

connections are more conductive,

more durable and cannot loosen.

That is why exothermic connec-

tions are the premier standard con-

nection chosen by engineers for

utility substations, transmission

and distribution systems, lightning

protection and telecommunication

system grounds. Ultraweld

exothermic connections are UL

listed (Standard 467—Grounding

and Bonding Equipment).

Effective and Safe

The Ultraweld exothermic

welding process is an effective and

safe method of welding copper to

copper or copper to steel for the

purpose of producing permanent

electrical connections. The

exothermic chemical reaction takes

place at a temperature of approxi-

mately 4,600 degrees Fahrenheit

and, as a result, molten copper

alloy is produced and used to melt

the conductors and cast the fin-

ished connection. The exothermic

reaction takes place in a semiper-

manent graphite mold that will last

50 or more welds if cared for prop-

erly. Molds contain a reaction

chamber and weld cavity for the

specific conductors and the

arrangement of the connection

required. The graphite molds have

permanent markings indicating

the mold part number, the type

and size of weld metal, and the

type and size of conductors that are

to be welded. Instructions detailing

general safety information, con-

nection preparation and welding

procedures are provided with each

mold. Ultraweld weld metal is

packaged in containers that are

resistant to moisture, damage or

spillage during shipping. Ultraweld

starting material does not contain

phosphorous or any caustic, toxic

or explosive substances.

Easy to Implement

Ultraweld is a simple and easy

to use process that provides an

on-site method for making

welded electrical connections

without requiring external

power, welding machine or spe-

cial training. The Ultraweld

exothermic welding system uses

lightweight, inexpensive equip-

ment that can be used to join a

variety of different metals,

including copper conductors,

steel-cored ground rods, galva-

nized steel fence posts and tower

members, ductile and cast iron,

and stainless steel. The process

provides a finished connection

that will never corrode, loosen or

increase in resistance. The fin-

ished connection also provides

an ampacity that exceeds that of

the conductors being joined and

the quality is verified simply by

visual inspection.

Intuitive Part

Numbering System

The Ultraweld exothermic

welding system has the industry’s

easiest and most intuitive mold

part-numbering system. Ultraweld

mold part numbers provide infor-

mation on the connection type,

conductor size(s) and the mold

price key. With the Ultraweld sys-

tem, there is no need for cumber-

some conductor codes. For

example, the part number for a

mold that welds a 4/0 wire over

the top of a 5/8-inch ground rod is

GO584/0B. In this example the

price key is “B,” which is the most

common price key for molds used

for electrical grounding connec-

tions. The price key is used to sim-

plify pricing and indicates the

type of the handle clamp required

to actuate the mold.

The Ultraweld line also

includes Uni-shot molds, an

alternative disposable (single-use)

mold that provides convenience

when only a few connections are

required. The Uni-shot system is

available for select cable-to-cable

and cable-to-ground rod connec-

tion configurations. Finally, a

smokeless line of Ultraweld prod-

ucts that is available for indoor

use and confined spaces. Visit

TESSCO.com or call 800-472-7373

for more information.

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Product information and performance claims are provided by manufacturers.

Permanent Exothermic Welding System Will Never Corrode or Loosen