Exothermic Weld

8/10/2019 Exothermic Weld

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EXOTHER IC WELDING CATALOUEXOTHERMIC WELDING CATALOUGE


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S. no. EXO

01 Exothermic Weld Pro

02 Tools Required for Ex

03 Exothermic Weld Ope

04 General Safety Instru

05 Mould Selection Char

06 Cable to Cable Conne

07 Cable to Ground Rod

08 Cable to Lug / Tape

09 Cable to Steel Conne

10 Steel to Lug / Tape C

11 Steel to Rod / Stud C

12 Ground Rod to Groun

13 Ground Rod to Tape

14 Cable to Re-Bar Conn

15 Tape to Re-Bar Conn

16 Re-Bar to Re-Bar Con

17 Rod to Re-Bar Conne

18 Tape to Tape Connec

HERMIC WELDING INDEX

ess

othermic Weld Process

ration Process

ctions

ctions (CTC)

Connections (CGRC)

onnection (CLTC)

tions (CTS)

nnections (SLTC)

onnections (SRSC)

d Rod Connections (GRGR)

onnections (GRTC)

ection (CREC)

ction (TREC)

nection (RERE)

tion (RORE)

ion (TTC)

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Page no.

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mailto:[email protected]


3/18

EXOTHERMIC WELDI

Exothermic welding, also known as

joining two electrical conductors,

conductors. The process employs a

copper, and requires no external souan aluminothermic reaction between

The reaction reaches very high temp

oxide used. The reactants are usually

with the reaction triggered using a sp

activation energy for this reaction is

initiation requires either the use of a

powdered magnesium metal or a ver

The aluminum oxide slag that it prod

When welding copper conductors, th

semi-permanent graphite crucible m

copper, produced by the reaction, flo

and over and around the conductors

electrically conductive weld between

cools, the mould is either broken off

The advantages of these crucibles

flexibility, especially in field applicati

The weld formed has higher mechresistance. It is also highly stable wh

increased electrical resistance over t

other welding processes, requires a

can be impeded by wet conditions or

FEATURES

It has a superior electrical con

It does not corrode oxide or d

It is able to withstand repeate

It never increases its resistanc

It has higher mechanical and s

It offers a permanent wel

longwearing and trustworthy

It guarantees the most com

tapes and metallic pieces mad

NG PROCESS

exothermic bonding and thermite weldin

that employs superheated copper alloy

exothermic reaction of a copper thermi

rce of heat or current. The chemical reactialuminum powder and a metal oxide.

ratures, depending on the metal

supplied in the form of powders,

ark from a flint lighter. The

ery high however, and

booster material such as

hot flame source.

ces is discarded.

e process employs a

uld, in which the molten

ws through the mould

to be welded, forming an

them. When the copper

or left in place. Alternatively, hand-held gra

include portability, lower cost (because

ns.

anical strength than other forms of welen subject to repeated short-circuit pulse

e lifetime of the installation. However, the

upply of replaceable moulds, suffers from

bad weather (when performed outdoors).

ductivity than the conductors themselves.

egrade with time and is resistant to galvani

d electrical discharges.

e.

queezing resistance than the conductors th

ding and a low resistance connection

results in earthings

on connections not only between copper

e of brass, stainless steel, and copper coate

Page 3 of 18

g is a welding process for

to permanently join the

e composition to heat the

n that produces the heat is

phite crucibles can be used.

they can be reused), and

d, and excellent corrosion s, and does not suffer from

process is costly relative to

a lack of repeatability, and

coupling.

emselves.

, essential for achieving

cables but also for welding

d steel earth rods.


4/18

TOOLS REQUIRED FO

1) Graphite MouldGraphite mould is made of high quality

high quality welding work and can be u

Following are the advantages.

1. A smooth metal connection that will

2. It is not affected by high current sur

3. No need for the external welding ma

4. Use only lightweight and cheap equi

When making a copper wire conn

rod or other metal connection, place th

the graphite mould. Just ignite to star

surface. It is also applicable for other

and Brass. It can be used in various

Lightning and Surge Protection, Groun

connection mould is designed to last f

care given the mould during use.

2) Mould Handle Clamp (UniFor most connections involving lugs, ca

exothermic handle clamps are used.Th

exothermic molds. Normally we recomtwo moulds

3) Steel Metal DiskSteel discs are very important. The disc

the welding powder to heat to proper t

allowing the molten copper to a point

enter the weld gravity before ignition.

4) Exothermic Weld PowderExothermic Weld Powder is the most re

weld metal available with us. Quality v

every lot we produce. Upon final acce

packaged in moisture-resistant plastic

Then the cartridges and required met

moisture-resistant boxes. All sizes of w

Standards Size Packing available are 150 Grams, 200 Grams, 250 Grams, 1

R EXOTHERMIC WELDI

graphite suitable for

sed for several times.

not loosen or corrode.

e or over current.

chine.

ment.

ction of Ground

e weld powder into

the welding process. The result will be cl

etal such as: Iron, Galvanized Steel, Rail

pplications to have the certainly good co

ing in Electrical Work, Railway Constructi

r an average of 60 to 100 connections. Th

ersal) ble or rectangular bus,

se will fit 90% of all standard

mend one Handle for every

acts timing device to allow

emperature, the disc away

here it would weld metal to

ne Metal is must for every shot

liable and consistently-performing

alidation steps ar e ta ke n for

tance, our weld metal isspecially

cartridges with special closure caps.

l discs are packaged in

eld metal are available.

50 Grams, 100 Grams, 125 Grams ilogram

Page 4 of 18

G PROCESS

an and smooth connection

ay track, Cast Iron, Bronze,

nnections in work. Such as

n, Cathodic Protection. The

is will vary according to the


5/18

5) Ignite Powder (Starting PoIgnite Powder also known as Starting P

Starting Powder on the Mould followe

pour it little on the Top Side of Mould.

This resulting exothermic reaction redmelts the retaining disc and flows into

of 5 grams is sufficient for this Process.

6) GlovesGloves is required for safety purpose a

at more than 1400 degree Celcius.

7) Flint GunIt is designed with the advantages of sa

Starting Powder in order to result in ex

We recommend one Flint Gun for ever

8) Brush (Soft and Hard)Two Brush Required:

1) Soft Brush Its used to Clean Mould

is very sensitive and there should not b

so we recommend to use Soft Brush to

2) Hard Brush Its used to clean other

We recommend a Pair of Brush for 50

9) Slag Removal ToolIt is used to remove the metal Scrap fr

10) File CardIt is used to clean the objects to be wel

11) Sealing CompoundSealing Compound is used to fill the ga

wder) wder is required and is must. Pour little

by the Exothermic Weld powder and again

Ignite starting powder with a spark gun.

ces the weld powder to molten copper allthe weld cavity where it partially melts th

the Exothermic Weld Powder melts

fety and convenience. It is used to ignite

othermic reaction.

100 Shots

Weld Cavity because its shape

e any damage while using Brush,

Clean Mould Weld Cavity

section of Mould

onnection

m Mould

ded

on the mould if any.

Page 5 of 18

y. The molten copper alloy conductors. Ignite Powder


6/18

EXOTHERMIC WELD

The Exothermic Weld process is a met

steel in which no outside source of hea

in a purpose designed graphite moul

bonded electrical connection. The ste

connection. These basic steps are u

instructions included with every mold

STEP - 1:

Always wear protective safety glasses a

STEP - 2:

Gather all the proper material and eq

typical Weld system requires a graphit

cleaning, wire brush for cleaning/prep

graphite mold is not worn or broken, w

STEP - 3:

Slide the handle clamp into the pre-d

STEP - 4:Tighten the clamp thumbscrews onto

STEP - 5:

Close the grips to tightly lock the mol

STEP - 6:

The material to be welded (cable, ro

accessories. Thus the oxide layer and

absorbs moisture, this should be r

welding. After the first welding is dowithin 15 minutes as it conserves the

PERATION PROCESS

od of making electrical connections of cop

t or power is required. In this process, cond

d, and exothermically welded to produc

ps outlined below are a general demons

sed for all electrical connections. Be su

efore making a connection.

nd gloves while working with exothermic w

uipment/accessories for the type of conn

e mold, handle clamp, welding material, na

aring conductors, flint igniter, and propane

hich could cause leakage of molten weld m

rilled holes with the proper orientation for

the mold.

d. Make adjustments to tighten/loosen the

d, tape) must be clean and dry using the

superficial impurity is eliminated. Given t

moved by preheating with a gas weldin

e, it is not necessary to re-heat the mouldpreviously generated heat.

Page 6 of 18

per-to-copper or copper-to-

uctors are prepared, placed

a permanent molecularly

tration of a typical welded

e to read and follow the

elding products.

ction you are making. The

tural bristle brush for mold

torch. Check to ensure the

etal.

the thumbscrews.

handle clamp.

rush included in the set of

hat the graphite mould also

g torch to avoid a porous

if the next welding is done


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STEP - 7:

Place the conductors in the mould

reaction.

STEP - 8:

Obstruct the tap hole with the metall

STEP - 9:

Empty the contents of the welding mi

STEP - 10:

Empty 50% of the starting powder o

mixture. Close the mould lid.

STEP - 11:

Ignite the starting powder extended

STEP - 12:

Once started, the reaction will take

mould.

STEP - 13:

After at least 2 minutes of the bondinmould by undoing the handle grip. Re

mould from the joint and clean the jo

slag. Once open, clean the slag stickin

mould with the relevant tool and clea

cavities. The mould will be ready now

without having to reheat it as it is alr

Note:

In Normal case minimum two mould

is cooled and cleaned after firing, thand one should not hurry.

and close the handle clamps to avoid m

ic disk.

ixture package.

n the side of the mould as a fuse, scatteri

n the top/side of the mould using the flint

3-4 seconds during which it is recomme

g, open the move the

int for any

g to the

n the

to use again

ady warm.

should be used on site to keep the proces

other should be used. The task should be

Page 7 of 18

aterial leakages during the

g the rest into the welding

igniters.

nded to stand clear of the

s continue while one mould

undertaken very peacefully


8/18

GENERAL & SAFETY INST

A. Only equipment and materials s

B. Do not connect items except as

may result in improper and unsafe c

property damage.C. Do not use worn or broken equ

in case of fine leakages.

D. When using Weld do not use w

E. Make connections in conforma

F. Personnel should be properly tr

G. Avoid contact with hot materials.

H. Advise nearby personnel to stand

I. Remove or protect the inflammabl

J. Provide adequate ventilation to th

K. Do not smoke when handling star

L. Avoid direct eye contact with fla

F. Welding material is an exothermic

in excess of 1400C (2500F) and

900C (1650F) for welding materi

G. Adhering to the welding procedu

spillage. In case of fire, use of wate

water will aid in controlling a fire

applied from a distance.

H. All governing codes and regulati

appropriate safety equipment sucapplication.

WARNING :1. Products shall be installed and use

2. Products must never be used for

manner that exceeds specified load r

3. All instructions must be completel

4. Improper installation, misuse, mi

may cause bad weld joint, property d

MAINTENANCE & STORAGE1. Mould is usually good for 50 - 60 c

2. The equipment is fragile and shoul

3. Cleaning of moulds should be d

after a weld process. Avoid hot moul

4. Cavity cleaning should be carefully

5. On completion of task, mould sh

should be properly wrapped in Bubbl

6. The moulds and the weld powder7. All tools and accessories must be

RUCTIONS:

ould be used to make connections.

detailed in instruction sheets. Failure to co

onnections, damage to items being welde

ipment which could cause leakage. Sealing

lding material package if damaged or not f

ce with instructions and all governing code

ained and must wear safety glasses and gl

at least 7 to 10 Foot away of welding oper

e material from the operation site to safeg

e work area.

ting material.

h of light from ignition of starting material

mixture and reacts to produce hot molten

localized release of smoke. Ignition tempe

al. These materials are not explosive.

res will minimize risk of burns and fire cau

r or CO2 will aid in control of burning con

hould the exothermic materials become

ons and those required by the job site mu

as eye protection, hard hat, and glo

d only as indicated in product instruction s

purpose other than the purpose for which

tings.

y followed to ensure proper and safe install

sapplication or other failure to comply wit

amage or even serious badly injuries.

INSTRUCTIONS: onnections in field conditions.

ld be handled carefully while in use.

ne using appropriate brush / tool after th

cleaning.

done to avoid damages / chipping.

ould be well cleaned from inside and from

e Plastic Packing while storing it.

should always be stored in cool & dry place leaned before storing to safe reuse.

Page 8 of 18

ply with these instructions

d or even injury to body or

compound should be used

lly intact.

s.

ves.

tions site.

ard against fire hazards.

l.

material with temperatures

ratures are in excess of

sed by hot molten material

tainers. Large quantities of

involved. Water should be

st be observed. Always use

es as appropriate to the

eets.

they were designed or in a

ation and performance.

instructions and warnings

e mould is reasonably cool

outside using soft cloth. It

s.


9/18

1) Cable to Cable Connection

CTC 1 CTC 2

CTC 6 CTC 7

CTC 15 CTC 16

CTC 20 CTC 21

CTC 26 CTC 27

CTC 31 CTC 33

CTC 37 CTC 38

ould Selection Chart

s (CTC)

CTC 3 CTC 4

CTC 11 CTC 13

CTC 17 CTC 18

CTC 23 CTC 24

CTC 28 CTC 29

CTC 34 CTC 35

CTC 39 CTC 40

Page 9 of 18

CTC 5

CTC 14

CTC 19

CTC 25

CTC 30

CTC 36

CTC 41


10/18

2) Cable to Ground Rod Conn

CGRC 1 CGRC 2

CGRC 6 CGRC 7

CGRC 12 CGRC 13

CGRC 17 CGRC 18

CGRC 22 CGRC 23

CGRC 31 CGRC 33

CGRC 37 CGRC 38

ctions (CGRC)

CGRC 3 CGRC 4

CGRC 8 CGRC 9

CGRC 14 CGRC 15

CGRC 19 CGRC 20

CGRC 24 CGRC 25

CGRC 34 CGRC 35

CGRC 39 CGRC 40

Page 10 of 18

CGRC 5

CGRC 11

CGRC 16

CGRC 21

CGRC 26

CGRC 36

CGRC 41


11/18

3) Cable to Lug / Tape Connec

CLTC 1 CLTC 2

CLTC 8 CLTC 9s

CLTC 14 CLTC 15

CLTC 19 CLTC 20

CLTC 24 CLTC 25

CLTC 29 CLTC 30

CLTC 34 CLTC 35

tion (CLTC)

CLTC 3 CLTC 4

CLTC 11 CLTC 12

CLTC 16 CLTC 17

CLTC 21 CLTC 22

CLTC 26 CLTC 27

CLTC 31 CLTC 32

CLTC 36 CLTC 37

Page 11 of 18

CLTC 5

CLTC 13

CLTC 18

CLTC 23

CLTC 28

CLTC 33

CLTC 38


12/18

4) Cable to Steel Connections

CTS 1 CTS 2

CTS 7 CTS 8

CTS 14 CTS 15

CTS 24 CTS 25

CTS 32 CTS 34

CTS 50 CTS 52

(CTS)

CTS 3 CTS 4

CTS 9 CTS 12

CTS 16 CTS 22

CTS 26 CTS 27

CTS 36 CTS 38

Page 12 of 18

CTS 6

CTS 13

CTS 23

CTS 31

CTS 48


13/18

5) Steel to Lug / Tape Connect

SLTC 1 SLTC 2

SLTC 6 SLTC 7

SLTC 12 SLTC 13

SLTC 17 SLTC 18

6) Steel to Rod / Stud Connec

SRSC 1 SRSC 2

SRSC 8 SRSC 9

ions (SLTC)

SLTC 3 SLTC 4

SLTC 8 SLTC 9

SLTC 14 SLTC 15

SLTC 19 SLTC 20

ions (SRSC)

SRSC 5 SRSC 6

SRSC 11 SRSC 23

Page 13 of 18

SLTC 5

SLTC 11

SLTC 16

SRSC 7


14/18

7) Ground Rod to Ground Rod

GRGR 1 GRGR 2

GRGR 6 GRGR 7

GRGR 16

8) Ground Rod to Tape Conne

GRTC 1 GRTC 2

GRTC 6 GRTC 7

GRTC 12 GRTC 13

GRTC 17 GRTC 18

Connections (GRGR)

GRGR 3 GRGR 4

GRGR 13 GRGR 14

ctions (GRTC)

GRTC 3 GRTC 4

GRTC 8 GRTC 9

GRTC 14 GRTC 15

GRTC 19 GRTC 25

Page 14 of 18

GRGR 5

GRGR 15

GRTC 5

GRTC 11

GRTC 16


15/18

9) Cable to Re-Bar Connection

CREC 1 CREC 2

CREC 6 CREC 7

CREC 12 CREC 13

CREC 17 CREC 18

CREC 25 CREC 35

CREC 51 CREC 52

(CREC)

CREC 3 CREC 4

CREC 8 CREC 9

CREC 14 CREC 15

CREC 19 CREC 20

CREC 36 CREC 38

Page 15 of 18

CREC

CREC 11

CREC 16

CREC 21

CREC 48


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10) Tape to Re-Bar Connectio

TREC 3 TREC 4

TREC - 8 TREC 13

TREC 18 TREC 20

11) Re-Bar to Re-Bar Connecti

RERE 3 RERE 4

12) Rod to Re-Bar Connection

RORE 1 RORE 16

(TREC)

TREC 5 TREC 6

TREC 15 TREC 16

n (RERE)

RERE 5 RERE 6

(RORE)

Page 16 of 18

TREC 7

TREC 17


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13) Tape to Tape Connection (

TTC 1 TTC 2

TTC 14 TTC 40

TTC)

TTC 3

TTC 41

Page 17 of 18


18/18

AMIABLE IMPEX E il i f @ i bl i

Regd. Office - A

10

Bo

Ph

Fa

M

Mo

E-

UJJMo

Em

Website:

T l 91 9594899995 URL

MIABLEIIABLE IMPEX.

/A,SuryaDarshan, PaiNagar,

ivali (W), Mumbai 400092. India.

ne: 022-28933996 / 022-2895710

: 022-28957102

ULIK SHAH

b :+ 91- 9594899995

ail: [email protected]

WALSHAH:+ 91- 9820733979

il: [email protected]

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PEX

Website: wwWebsite: www.exothermicweld.com
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Exothermic Weld