CADWELD® Connections (High Current Busbars)

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The CADWELD® process is a method of making welded electrical connections of aluminum to aluminum, copper to copper, and copper to steel in which no external sources of heat, such as electricity or gas, are required.

Features

Connections can be made to any size or shape of conductors including:
- rectangular or round busbar
- cable
- laminated conductors
- braid
- lugs
Current-carrying capacity of the connection is equal or greater than conductor
Will not loosen in service - no maintenance required
Process develops its own heat to complete the weld
Installation and maintenance personnel can be easily trained
Welds can be made in a highly magnetic environment

Applications

The CADWELD process is ideal for the following process industries in maintaining high current busbars and related connections:

Aluminum
Copper
Zinc
Lead
Chlorine
Plating

More Information

Application Examples

Making a Connection CADWELD Connection Cross Section

CADWELD Connection in Aluminum Smelter Busbar Repair

How to Make a CADWELD Exothermic Welded Connection

Step 1
Ensure you have all equipment required for the welding process, plus all the safety equipment recommended by ERICO.
Prepare the conductor ends for weld.
Step 2
Place the open mold into the conductor ends carefully. Step 3
Close handles to lock mold halves together.
Drop the metal disk into crucible, ensuring it is correctly seated and covering the tap hole.

Step 4
Pour all weld metal into the crucible. Step 5
Tap bottom of container to release the starting material. Drop 1/3 of it onto the mold lip.
Step 6
Close the cover. Ignite with spark from flint ignitor.

NOTE: DO NOT use a torch or matches.

Step 7
Wait until the reaction is completed (the time taken will depend on the connection type).
Open mold and remove from finished connection.
Step 8
Visually inspect the connection to make sure it is good.

NOTE: The above information is a guide only. The detailed instructions and safety precautions provided with each mold should be read prior to making a CADWELD connection.

Engineering Support
With the increasing costs of electric power today, the need for reliable and efficient electrical connections is more critical than ever. ERICO responds with an industry-wise engineering and sales support group.

ERICO engineers provide on-going:

System Design
Product Specification
Product Selection
Technical Support
Assist in selecting the bonding scheme, which simplifies installation and provides maintenance-free service

Prototype Development
Engineered designs of specific applications, especially large and complex welds, are thoroughly tested. ERICO performs a wide variety of testing. In-house testing capabilities and outside facilities are used to assure connection performance and reliability.

Warning, Warranty and Limitation of Liability

WARNING
ERICO products shall be installed and used only as indicated in ERICO's product instruction sheets and training materials. Instruction sheets are available at www.erico.com and from your ERICO customer service representative. Improper installation, misuse, misapplication or other failure to completely follow ERICO's instructions and warnings may cause product malfunction, property damage, serious bodily injury and death.

WARRANTY
ERICO products are warranted to be free from defects in material and workmanship at the time of shipment. NO OTHER WARRANTY, WHETHER EXPRESS OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), SHALL EXIST IN CONNECTION WITH THE SALE OR USE OF ANY ERICO PRODUCTS. Claims for errors, shortages, defects or nonconformities ascertainable upon inspection must be made in writing within 5 days after Buyer's receipt of products. All other claims must be made in writing to ERICO within 6 months from the date of shipment or transport. Products claimed to be nonconforming or defective must, upon ERICO's prior written approval in accordance with its standard terms and procedures governing returns, promptly be returned to ERICO for inspection. Claims not made as provided above and within the applicable time period will be barred. ERICO shall in no event be responsible if the products have not been stored or used in accordance with its specifications and recommended procedures. ERICO will, at its option, either repair or replace nonconforming or defective products for which it is responsible or return the purchase price to the Buyer. THE FOREGOING STATES BUYER'S EXCLUSIVE REMEDY FOR ANY BREACH OF ERICO WARRANTY AND FOR ANY CLAIM, WHETHER SOUNDING IN CONTRACT, TORT OR NEGLIGENCE, FOR LOSS OR INJURY CAUSED BY THE SALE OR USE OF ANY PRODUCT.

LIMITATION OF LIABILITY
ERICO excludes all liability except such liability that is directly attributable to the willful or gross negligence of ERICO's employees. Should ERICO be held liable its liability shall in no event exceed the total purchase price under the contract. ERICO SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS OF BUSINESS OR PROFITS, DOWNTIME OR DELAY, LABOR, REPAIR OR MATERIAL COSTS OR ANY SIMILAR OR DISSIMILAR CONSEQUENTIAL LOSS OR DAMAGE INCURRED BY BUYER.

Due to a policy of continued product development, specifications are subject to change without notice.
CADDY, CADWELD, CRITEC, ERICO, ERIFLEX, ERITECH, and LENTON are registered trademarks of ERICO International Corporation.