ECN Electrical Forum - Discussion Forums for Electricians, Inspectors and Related Professionals
ECN Shout Chat
Recent Posts
Does NEC 551.71 (F) apply to dwellings?
by BigB - 01/20/23 10:46 AM
by HotLine1 - 01/19/23 09:10 AM
Power submeter connections
by HotLine1 - 01/19/23 09:09 AM
AFDD's coming to the UK
by Texas_Ranger - 01/17/23 07:22 PM
New in the Gallery:
Burger King crown sillyness
Burger King crown sillyness
by wa2ise, December 11
240/208 to a house
240/208 to a house
by wa2ise, October 9
Who's Online Now
0 members (), 117 guests, and 22 robots.
Key: Admin, Global Mod, Mod
Previous Thread
Next Thread
Print Thread
Rate Thread
Page 1 of 3 1 2 3
Joined: Oct 2000
Posts: 2,749
I am interested in hearing about your experiences concerning these two recognized code methods for splicing the GEC, etc..

[Linked Image from]

[Linked Image from]

Joe Tedesco, NEC Consultant
Stay up to Code with the Latest NEC:

2020 NEC & Related Reference & Study Guides
2020 NEC & Related Reference & Study Guides
Pass Your Exam the FIRST TIME with these Exam Prep Combos:

>> Master Electrician Exam Prep     >> JourneyMan Electrician Exam Prep

Joined: Apr 2004
Posts: 201
The biggest downsides of Caddweld are:
  • damp molds where they have been left in a tool box or storage shed over the weekend
  • the process can not be used in rain or drizzle
  • the molds "wear out" after about 50 shots, then you have to be creative by using putty to seal against leakage or old pennies to add more copper to the mix (not listed since it changes the mix and has not been tested)
  • once in a while, if you are not careful, you will burn through instead making a good weld (operator error)

We used to use the Caddweld system for all of our grounding grids in our substations but have gone to the mechanical type because of the above downsides. [Linked Image]

- - - - - - - - - - - - - - - - - - - - - - - - - - -
Charlie Eldridge, Indianapolis, Utility Power Guy

Charlie Eldridge, Indianapolis Utility Power Guy
Joined: Dec 2004
Posts: 86
Is the mold that big metal block?

50 shots, how hot does the thing get, is the steel melting?

Why aren't there replaceable inserts, are you supposed to buy a new one?

Are you an Ideal rep? (couldn't resist)

Sam, San Francisco Bay Area
Joined: Jan 2003
Posts: 4,391
The molds well that is a the costly part.

Each mold is specific, in my cellar I have a 4/0 to 3/4" ground rod mold and a 4/0 run to a 2 AWG tap mold.

You need a mold for each different wire size or application.

The shop has a few dozen molds in stock, some have magnetic holders that hold the mold to building steel in order to cad weld a conductor to building steel.

The process is fairly simple, clean the conductors, dry the mold (and conductors if damp) with a torch, clamp the mold onto the conductors, pour in the appropriate sized 'load', close the cover, with a glove on use a striker tool to light it off.

Bright light, lots of smoke and presto you have a permanent connection if all went well.

Remove mold carefully as the weld will be red hot and the mold is also smoking hot.

I think the molds are made of graphite but I am not sure of that.

Bob Badger
Construction & Maintenance Electrician
Joined: Dec 2004
Posts: 86
Holy explative batman, those things are chemical?

I guess that explains everything but the replaceable inserts.

Sam, San Francisco Bay Area
Joined: Nov 2000
Posts: 2,148
The mold is graphite and being very soft wears out from use. The openings get too larger to contain the molten copper.

Joined: Apr 2004
Posts: 201
50 shots, how hot does the thing get, is the steel melting?

Sam, there is a very thin steel insert put into the bottom of the upper chamber and the reaction gets hot enough to completely melt the steel insert. The powder is copper oxide and aluminum, I believe. It is required to get a hot enough to actually make a weld. In my opinion, if done properly, the Cadweld makes a perfect connection and nothing is better.

Because of the graphite mold getting a little oversized, I have used old pennies (the newer ones are copper plated zinc) to take the place of the steel insert. As I said before, this is not an approved method. [Linked Image]

- - - - - - - - - - - - - - - - - - - - - - - - - - -
Charlie Eldridge, Indianapolis, Utility Power Guy

Charlie Eldridge, Indianapolis Utility Power Guy
Joined: Jan 2004
Posts: 615
I have used old pennies to take the place of the steel insert.

U.S. Treasury may object too. [Linked Image] I think technically they own the penny, you just own the value it represents.

[This message has been edited by Jps1006 (edited 01-02-2005).]

Joined: Jul 2004
Posts: 9,788
Likes: 14
I guess the T men are after me too. I use pennies for shot pin washers.

Greg Fretwell
Joined: Mar 2003
Posts: 849
Used um both cadwelds a pain in the _____
The crimp works Great just the tool is very expensive. There are now premade cadeweld charges made no pennies required that are set off electricaly no flame required.

Page 1 of 3 1 2 3

Link Copied to Clipboard

Tools for Electricians
Tools for Electricians

* * * * * * *
2023 National Electrical Code (NEC)
2023 NEC Now Available!
* * * * * * *

2020 Master Electrician Exam Preparation Combos
2020 NEC Electrician
Exam Prep Combos:
Master / Journeyman


Member Spotlight
Berkley, MA
Posts: 144
Joined: March 2008
Top Posters(30 Days)
BigB 9
triple 3
Popular Topics(Views)
302,373 Are you busy
231,775 Re: Forum
216,398 Need opinion
Powered by UBB.threads™ PHP Forum Software 7.7.5