ECN Electrical Forum - Discussion Forums for Electricians, Inspectors and Related Professionals
ECN Shout Chat
Top Posters(30 Days)
Trumpy 5
Recent Posts
What do you do?
by ghost307. 09/22/17 08:26 AM
Another generator question
by gfretwell. 09/21/17 02:41 PM
Supporting conduit bodies
by ghost307. 09/18/17 12:12 PM
Thermal Imaging Camera upgrade
by Potseal. 09/18/17 11:57 AM
Linear Power Supply Quits Under Load
by JoeTestingEngr. 09/15/17 11:37 PM
New in the Gallery:
Gallery Test
Popular Topics(Views)
240,878 Are you busy
176,631 Re: Forum
168,540 Need opinion
Who's Online Now
0 registered members (), 47 guests, and 12 spiders.
Key: Admin, Global Mod, Mod
Previous Thread
Next Thread
Print Thread
Rate This Thread
Page 1 of 3 1 2 3
#91168 - 01/02/05 11:09 AM Exothermic Welding or Irreversible Connections, Comments?  
Joe Tedesco  Offline
Member
Joined: Oct 2000
Posts: 2,749
Boston, Massachusetts USA
I am interested in hearing about your experiences concerning these two recognized code methods for splicing the GEC, etc..

[Linked Image]

[Linked Image]


Joe Tedesco, NEC Consultant

2017 / 2014 NEC & Related Books and Study Guides

#91169 - 01/02/05 02:48 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
CharlieE  Offline
Member
Joined: Apr 2004
Posts: 200
Indianapolis
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

#91170 - 01/02/05 04:23 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
Physis  Offline
Member
Joined: Dec 2004
Posts: 86
Burlingame, Ca. USA
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

#91171 - 01/02/05 04:52 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
iwire  Offline
Moderator
Joined: Jan 2003
Posts: 4,391
North Attleboro, MA USA
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
Massachusetts

#91172 - 01/02/05 05:50 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
Physis  Offline
Member
Joined: Dec 2004
Posts: 86
Burlingame, Ca. USA
Holy explative batman, those things are chemical?

I guess that explains everything but the replaceable inserts.


Sam, San Francisco Bay Area

#91173 - 01/02/05 06:00 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
resqcapt19  Offline
Member
Joined: Nov 2000
Posts: 2,148
IL
Sam,
The mold is graphite and being very soft wears out from use. The openings get too larger to contain the molten copper.
Don


Don(resqcapt19)

#91174 - 01/02/05 07:17 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
CharlieE  Offline
Member
Joined: Apr 2004
Posts: 200
Indianapolis
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

#91175 - 01/02/05 10:45 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
Jps1006  Offline
Member
Joined: Jan 2004
Posts: 615
Northern IL
Quote
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).]


#91176 - 01/03/05 03:02 AM Re: Exothermic Welding or Irreversible Connections, Comments?  
gfretwell  Offline


Member
Joined: Jul 2004
Posts: 9,115
Estero,Fl,usa
I guess the T men are after me too. I use pennies for shot pin washers.


Greg Fretwell

#91177 - 01/03/05 12:47 PM Re: Exothermic Welding or Irreversible Connections, Comments?  
Yoopersup  Offline
Member
Joined: Mar 2003
Posts: 826
Michigan
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

Member Spotlight
electure
electure
Fullerton, CA USA
Posts: 4,261
Joined: December 2000
Show All Member Profiles 
Featured:

2017 Master Electrician Exam Preparation Combos
2017 NEC Electrician
Exam Prep Combos:
Master / Journeyman

 

Shout Box
Powered by UBB.threads™ PHP Forum Software 7.6.0
Page Time: 0.020s Queries: 15 (0.002s) Memory: 0.8205 MB (Peak: 0.9989 MB) Zlib enabled. Server Time: 2017-09-23 02:08:52 UTC