Erico GR1-141GPLUS, GR1-162GPLUS Inspection Guide
The ERICO CADWELD Process
nVent ERICO Cadweld
Installation and
Inspection Guide
WARNING
1. nVent ERICO pr oducts shall be ins talled and used o nly as indicated in nVent E RICO product
instruc tion sheets and tr aining materials . Instruction s heets are availabl e at nVent.com/ERI CO and
from your nVent E RICO customer s ervice repre sentative.
2. nVent ERICO pr oducts must neve r be used for a purpos e other than the pur pose for which they we re
designe d or in a manner that exc eeds specifi ed load ratings.
3. All instru ctions must be co mpletely followe d to ensure proper an d safe installation an d performanc e.
4. Improper i nstallation, mi suse, misapplic ation or other fail ure to completely fol low nVent ERICO’s
instruc tions and warning s may cause produc t malfunction, p roperty dam age, serious bo dily injury
and death.
GENERAL AND SAFETY INSTRUCTIONS:
A. Only nVent ERICO ma nufactured equi pment and materia ls should be used to ma ke nVent ERICO
Cadweld connections.
B. Do not connect i tems except as detai led in instructi on sheets. Failu re to comply with the se
instruc tions may result in i mproper and unsafe c onnections , damage to items bei ng connected,
bodily in jury and
property damage.
C. Do not use worn or bro ken equipment whi ch could cause le akage.
D. D o not alter equipm ent or material wit hout nVent ERICO aut horization.
E. When using C adweld do not use weld ing material pack age if damaged or no t fully intact. Wh en using
Cadweld Pl us, do not tamper wi th or disassembl e the welding mater ial unit.
F. Make connec tions in conform ance with Cadweld i nstructions a nd all governing co des.
1. Personn el should be prop erly trained in th e use of this product a nd must wear safety gl asses
and gloves.
2. Avoid conta ct with hot material s.
3. Advise ne arby personnel o f welding operati ons in the area.
4. Remove or pr otect fire hazard s in the immediate are a.
5. Provide ad equate ventilatio n to the work area.
6. Do not smoke w hen handling sta rting material .
7. Avoid direc t eye contact with “ flash” of light fro m ignition of star ting material.
G. Weld ing material is an exoth ermic mixture a nd reacts to produc e hot molten materia l with
temperat ures in excess of 1400 °C (2500°F) a nd a localized rele ase of smoke. These m aterials are not
explosiv e. Ignition temp eratures are in exces s of 900°C (1650°F ) for welding mater ial.
H. Adhe ring to the Cadweld we lding procedu res will minimize risk o f burns and fire cau sed by hot molten
material sp illage. In case of fi re, use of water or CO
quantiti es of water will aid in con trolling a fire sho uld the exothermi c materials becom e involved.
Water shoul d be applied from a di stance.
1. Make sure the re is proper mold f it and assembly of e quipment.
2. Avoid moistur e and contaminan ts in mold and materia ls being welded. C ontact betwe en hot molten
metal and m oisture or contam inants may result in s pewing of hot materi al.
3. Base materi al thickness mus t be sufficien t for the size and type o f connection be ing made to prevent
melt-th rough and leakag e of hot molten metal.
I. Applicat ions or conditi ons may exist which re quire special co nsiderations . The following are
examples , but are not intende d to be a complete list ing of applicatio ns/conditions.
CONNECTIONS TO PIPE/VESSELS
For use wit h cast iron pipe or he avy casting mee ting ASTM A47- 84, A48 -83, A126-84 , A278-85 , or
A377- 89. DO NOT USE ON CA ST IRON SOIL PI PE (ASTM A74-9 3). Evaluate possibl e effects of Cadwel d
connec tions to structur al members and th in-wall materi als; vessels/pipin g systems that are pre ssurized,
closed or containing (or having contained) flammable/explosive/hazardous materials. Evaluation
should be m ade prior to use, bas ed on condition s of use and applicab le codes, and sho uld incorpora te
as a minimum , effects of melt- through of hot mater ial; structural /metallurgical e ffects of Cadweld
connec tions, pressure ( temperature) build -up and fire/ch emical decom position hazard s.
CONNECTIONS TO REBAR
Applic ation of the Cadweld c onnection may hav e an effect on the reb ar’s structura l integrity. The re bar’s
chemist ry and the locat ion of the weld should b e considered be fore making any welds to t he rebar.
For lappe d rebar splices, i t is recommend ed that the connec tions be made near t he bar end at an area
of minimum s tress. If Cadweld Re bar Splices are us ed, the groundi ng connection c an be made to the
splice sl eeve with minimal ef fect on the struc tural character istics of the splic e.
SAFET Y INSTRUC TIONS:
All gover ning codes and reg ulations and thos e required by the job si te must be observ ed. Always
use appro priate safety equip ment such as eye prote ction, hard hat , and gloves as approp riate to the
application.
WARRANTY
Cadweld pr oducts are warran ted to be free from defe cts in material and wo rkmanship at the ti me of
shipmen t. NO OTHER WARR ANTY, WHE THER EXPRE SS OR IMPLIE D (INCLUDING A NY WARRANT Y
OF MERC HANTABILIT Y OR FITNES S FOR A PARTICUL AR PURPOS E), SHALL E XIST IN CON NECTION
WITH TH E SALE OR USE O F ANY nVent ERICO P RODUCTS. Cla ims for errors, sh ortages, defe cts or
nonconfo rmities ascer tainable upon i nspection mus t be made in writing wi thin 5 days after Bu yer’s
receipt of p roducts. All oth er claims must be ma de in writing to nVent ERI CO within 6 months f rom the
date of shipm ent or transpor t. Products cla imed to be nonconfo rming or defecti ve must, upon nVent
ERICO ’s prior written ap proval in accorda nce with its stand ard terms and proce dures governing r eturns,
promptly b e returned to nVent ERI CO for inspectio n. Claims not made a s provided above and w ithin the
applica ble time period wi ll be barred. nVent ERI CO shall in no event b e responsible if th e products have
not been s tored or used in acco rdance with its sp ecification s and recommend ed procedures . nVent
ERICO wil l, at its option, ei ther repair or rep lace nonconfor ming or defective p roducts for which i t is
responsi ble or return the pu rchase price to the B uyer. THE FOREGO ING STATES BUYER’ S EXCLUSIV E
REMEDY FO R ANY BREAC H OF NVENT ERI CO WARRANT Y AND FOR AN Y CLAIM, WH ETHER
SOUND ING IN CONTR ACT, TORT OR NEGLIGE NCE, FOR LOS S OR INJURY CAU SED BY THE SAL E OR
USE OF A NY PRODUCT.
LIMITATION OF LIABILIT Y
nVent ERICO e xcludes all liabili ty except such lia bility that is dire ctly attribu table to the willful or g ross
neglige nce of nVent ERICO’s em ployees. Shou ld nVent ERICO be hel d liable its liabili ty shall in no
event exce ed the total purchas e price under the c ontract. NVE NT ERICO SHA LL IN NO EVEN T BE
RESPO NSIBLE FOR A NY LOSS OF BUS INESS OR PRO FITS, DOWN TIME OR DELAY, LA BOR, REPAIR OR
MATERIA L COSTS OR AN Y SIMILAR OR D ISSIMIL AR CONSEQU ENTIAL LOS S OR DAMAGE INC URRED
BY BUYE R.
will aid in co ntrol of burning co ntainers. Lar ge
2
The nVent ERICO Cadweld Process
The nVent ERICO Cadweld process is a method of making
electrical connections of copper-to-copper or copper-to-steel in
which no outside source of heat or power is required.
In this process, conductors are prepared, placed in a purposedesigned graphite mold, and exothermically welded to produce a
permanent electrical connection.
The steps outlined below are a general demonstration of a typical
welded connection.These basic steps are used for all Cadweld
electrical connections. Be sure to read and follow the instructions
included with every mold before making a connection.
The Cadweld exothermic process is a system. Materials from
other manufacturers should not be mixed or matched with
Cadweld molds or welding material.
The Cadweld Plus Process ........................................... 11
The Cadweld Exolon Process ......................................19
The Cadweld One Shot Process ................................. 28
The Cadweld Plus One Shot Process ........................ 33
Cadweld Quality Standards ......................................... 38
nVent.com/ERICO | 1
The Cadweld Process
Fig. 1
Always wear protective safety glasses and gloves
while working with Cadweld
exothermic welding products.
Fig. 2
Gather the proper materials and equipment for the type of
connection you are making. The typical Cadweld system requires
a graphite mold, handle clamp, welding material, natural bristle
brush for mold cleaning, wire brush for cleaning/preparing
conductors, flint igniter, and propane torch.
NOTE: Additional materials may be required for your specific
application. Refer to your mold instructions. Advise nearby
personnel of welding operations in the area prior to ignition.
Fig. 3
Check to ensure the graphite mold is not worn or broken, which
could cause leakage of molten weld metal during the reaction.
2 | nVent.com/ERICO
The Cadweld Process
Fig. 4
Inspect the mold ID tag to ensure that it corresponds to the
application, indicated by the:
1. mold part number
2. conductor size
3. welding material required
4. other materials required
The mold must be correct for the conductor size and application.
DO NOT MODIFY MOLDS.
Fig. 5
Remove the small wire bracket which is used to temporarily hold
the mold together before using. Set the bracket aside.
Fig. 6
Slide the handle clamp into the pre-drilled holes with the proper
orientation for the thumbscrews.
nVent.com/ERICO | 3
The Cadweld Process
Fig. 7
Tighten the clamp thumbscrews onto the mold.
Fig. 8
Close the grips to tightly lock the mold. Check for an appropriate
seal on the mold.
Fig. 9
If the mold does not seal properly, make adjustments to tighten/
loosen the handle clamp.
4 | nVent.com/ERICO
The Cadweld Process
Fig. 10
Graphite absorbs moisture. Ignite the propane torch and dry out
the inside of the mold thoroughly on both sides, heating the mold
to approximately 250 degrees Fahrenheit (120 degrees Celsius).
Fi g . 11
The conductors should be clean and dry before the connection
is made. Use a propane torch to dry wire conductors and remove
remaining cleaning residue, solvent, or water before making the
Cadweld connection.
Fig. 12
Next, use a wire brush to further prepare the surface of the
conductors (nVent ERICO T-313 or T-314 brush). Scrape the outer
surface to remove dirt and oxidation. You will notice a slight color
change.
nVent.com/ERICO | 5
The Cadweld Process
Fig. 13
Insert the conductors and position them for the connection.
Fig. 14
Close the clamp tightly once the conductors are properly
positioned.
Fig. 15
Steel disk found inside the packaging box of welding material.
6 | nVent.com/ERICO
The Cadweld Process
Fig. 16
Insert the steel disk (concave side up) into the mold. Hold the
steel disk on the side of the mold and let it slide into place.
Fig. 17
Ensure that the steel disk is properly seated.
Fig. 18
Next, take a tube of properly sized welding material
(as identified on the mold ID tag) out of the box.
nVent.com/ERICO | 7
The Cadweld Process
Fig. 19
Remove the lid over the mold crucible.
Fig. 20
Quickly pour the loose welding material powder into the mold.
Fig. 21
The bottom of the tube contains compressed material
(starting material). Tap the bottom of the tube a couple of times
to loosen this material.
8 | nVent.com/ERICO
The Cadweld Process
Fig. 22
Pour 1/4 to 1/3 of the starting material over the welding material
in the mold crucible.
Fig. 23
Close the lid and pour the remaining 3/4 to 2/3 of the starting
material into the slot on the mold cover.
NOTE: Welding material is an exothermic mixture and reacts
to produce hot molten material with temperatures in excess
of 2500 degrees Fahrenheit (1400 degrees Celsius) and a
localized release of smoke. Avoid looking directly at the “flash”
of light from ignition of starting material. Avoid inhalation of
smoke/fumes.
Fig. 24
Aiming the flint igniter from the side, ignite the starting material
on the mold cover. Withdraw the igniter quickly to prevent fouling.
Allow approximately 30 seconds for completion of the reaction
and solidification of the molten material.
nVent.com/ERICO | 9
The Cadweld Process
Fig. 25
Open the mold and remove the connection. Use care to prevent
chipping the mold. Avoid contact with hot materials. See the
“Cadweld Quality Standards” section to see whether a quality
connection has been made.
Fig. 26
Completed Cadweld connection.
Fig. 27
Cadweld graphite molds will last approximately 50 connections.
Use a soft cotton cloth or a soft bristle brush (nVent ERICO part
#T394) to clean inside the mold cavity and cover.
Fig. 28
Ready to make another Cadweld connection.
10 | nVent.com/ERICO
The Cadweld Plus Process
Fig. 1
Always wear protective safety glasses and gloves
while working with Cadweld Plus exothermic products.
Fig. 2
Prepare the proper materials and equipment for the type of
connection you are making. The Cadweld Plus system requires a
graphite mold, mold clamp, Cadweld Plus welding material cup,
natural bristle brush for mold cleaning, wire brush for cleaning/
preparing conductors, control unit, and propane torch.
NOTE: Additional materials may be required for your specific
application. Refer to your mold instructions. Advise nearby
personnel ofwelding operations in the area prior to ignition.
Fig. 3
Check to ensure the graphite mold is not worn or broken, which
could cause leakage of molten weld metal during the reaction.
nVent.com/ERICO | 11
The Cadweld Plus Process
Fig. 4
Inspect the mold ID tag to ensure that it corresponds to the
application, indicated by the:
1. mold part number
2. conductor size
3. welding material required
4. other materials required
The mold must be correct for the conductor size and application.
DO NOT MODIFY MOLDS.
Fig. 5
Remove the small wire bracket which is used to temporarily hold
the mold together before using. Set the bracket aside.
Fig. 6
Slide the handle clamp into the pre-drilled holes with the proper
orientation for the thumbscrews.
12 | nVent.com/ERICO
The Cadweld Plus Process
Fig. 7
Tighten the clamp thumbscrews onto the mold.
Fig. 8
Close the grips to tightly lock the mold. Check for an appropriate
seal on the mold.
Fig. 9
If the mold does not seal properly, ake adjustments to tighten/
loosen the handle clamp.
nVent.com/ERICO | 13
The Cadweld Plus Process
Fig. 10
Graphite absorbs moisture. Ignite the propane torch and dry out
the inside of the mold thoroughly on both sides, heating the mold
to approximately 250 degrees Fahrenheit (120 degrees Celsius).
Fi g. 11
The conductors should be clean and dry before the connection
is made. Use a propane torch to dry wire conductors and remove
remaining cleaning residue, solvent, or water before making the
Cadweld connection.
Fig. 12
Next, use a wire brush to further prepare the surface of the
conductors (nVent ERICO T-313 or T-314 brush). Scrape the outer
surface to remove dirt and oxidation. You will notice a slight color
change.
14 | nVent.com/ERICO
The Cadweld Plus Process
Fig. 13
Insert the conductors and position them for the connection.
Fig. 14
Close the clamp tightly once the conductors are properly
positioned.
Fig. 15
Remove the proper Cadweld Plus welding material cup from the
plastic container. Inspect the cup to ensure it is tightly sealed and
the ignition strip is securely attached to the seal.
nVent.com/ERICO | 15
Loading...