Bar-to-bar exothermic welding molds are purpose-built graphite molds for joining copper bars, busbars, and flat conductors with a permanent molecular bond.

Unlike mechanical clamps or bolted joints, an exothermic bar-to-bar weld creates a low-resistance, corrosion-resistant connection that does not loosen under thermal cycling or fault current.

If you are sourcing exothermic welding molds Bar-to-Bar BB1, BB3, BB7, BB14, BB41, BB44, this category covers the standard connection styles.

1. BB Models
2. Applications
3. Select a model
4. Design & production intro (view videos page)
5. Request a quote or spec sheet

Bar-to-Bar Connections

This range focuses on commonly requested Bar-to-Bar mold codes:

• BB1 / BB3 — compact bar-to-bar joints for lighter grounding bars and smaller bus sections
• BB7 / BB14 — mid-range connections for standard copper bar sizes in substations and equipment bonding
• BB41 / BB44 — heavier bar sections and higher-capacity joints where weld volume and mold cavity size must match larger conductors

Exact mold selection depends on bar width, thickness, and joint type. Share your conductor dimensions and connection sketch, and we will confirm the correct BB mold, welding powder charge, and handle/frame accessories.

Watch a video : 3 benefits for you to use our molds.

Applications

BB bar-to-bar molds are widely specified for:

• Copper grounding grid and mesh bar splices
• Substation busbar and earthing bar extensions
• Lightning protection down-conductor and equipotential bonding bars
• Industrial plant and rail grounding where bolted joints are not preferred

Because the finished weld is permanent, these molds are preferred on projects that prioritize long-term electrical continuity and reduced maintenance.

Choose

To choose among BB1, BB3, BB7, BB14, BB41, and BB44, confirm:

1. Conductor size — bar width × thickness (or equivalent cross-section)
2. Joint orientation — straight splice, tee, or overlapping bar-to-bar layout
3. Powder size — matched weld metal volume for a complete fill

Using the wrong cavity size is the most common cause of incomplete welds. If your bar size sits between two codes, request a size chart before ordering.

What else

1. How we design and manufacture the molds ? > Watch video
2. How our exothermic welding powder works with the molds? > Watch video

Request a Quote

Send your conductor sizes, quantity, and destination port.

We can provide mold recommendations, powder pairing, and a formal quotation for contractors, distributors, and grounding system integrators.

Lucas
Product Manager & Marketing
EarthinGo Team