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Cadweld Exothermic Welded C.P. Cable Connections

Uses lightweight, inexpensive equipment. Requires no external source of power or heat. Requires no special skills.

Permanent, Welded Connections

CADWELD connections are made with a semi-permanent graphite mold, which holds the conductors to be welded. Weld metal (a mixture of copper oxide and aluminum) is dumped into the top of the mold. The mold is covered and the weld metal ignited. The exothermic reaction produces molten copper, which produces a permanent, high conductivity connection.

Cathodic Protection Connections

  • CADWELD connections are the accepted method of attaching cathodic protection leads to pipes (steel or cast iron), tanks and structures.
  • CADWELD connections weld conductors to the object to be protected. Therefore, no galvanic corrosion can occur at the interface. (With mechanical connections, surface contacts are present, and can corrode, resulting in an ineffective current path.)
  • CADWELD connections for cathodic protection use a special alloy to provide minimum heat effect on the steel, especially important on thin wall, high stress pipes.
  • CADWELD connections are also used for header cable taps, conductor splices and terminations, and ground rod connections.
     

A CADWELD Connection...

  • Has current carrying capacity equal to that of the conductor.
  • Is permanent - cannot loosen or corrode to cause a high resistance connection.
  • Uses lightweight, inexpensive equipment.
  • Requires no external source of power or heat.
  • Requires no special skills.
  • Can be easily checked for quality.

CADWELD Exothermic Welding Manual

 

Type CAHA
for Steel

Tap conductor to top of horizontal steel pipe or flat surface.

 

Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (4" & larger pipe)
3/4" to 3-1/2" pipe
CAHAA-1G
CAHAA-1GA
CAA CA15
6 Stranded Flat (4" & larger pipe)
3/4" to 3-1/2" pipe
CAHAA-1H
CAHAA-1HA
CAA CA15
4 Solid Flat (6" & larger pipe)
3/4" to 3-1/2" pipe
4" to 5" pipe
CAHAA-1K
CAHAA-1KA
CAHAA-1KB
CAA CA15
4 Stranded Flat (6" & larger pipe)
3/4" to 3-1/2" pipe
4" to 5" pipe
CAHAA-1L
CAHAA-1LA
CAHAA-1LB
CAA CA15
2 Solid Flat (10" & larger pipe)
1" to 3-1/2" pipe
4" to 8" pipe
CAHAA-1T
CAHAA-1TA
CAHAA-1TB
CAA CA25
2 Stranded Flat (16" & larger pipe)
1" to 3-1/2" pipe
4" to 8" pipe
10" to 14" pipe
CAHAA-1V
CAHAA-1VA
CAHAA-1VB
CAHAA-1VC
CAA CA32
1 Stranded Flat (16" & larger pipe)
1" to 3-1/2" pipe
4" to 8" pipe
10" to 18" pipe
CAHAA-1Y
CAHAA-1YA
CAHAA-1YB
CAHAA-1YC
CAA CA45
1/0 Stranded Flat (20" & larger pipe)
2-1/2" to 3-1/2" pipe
4" to 8" pipe
10" to 18" pipe
CAHAA-2C
CAHAA-2CA
CAHAA-2CB
CAHAA-2CC
CAA CA65
1/0 Stranded Flat (20" & larger pipe)
2-1/2" to 3-1/2" pipe
4" to 8" pipe
10" to 18" pipe
CAHAA-2G
CAHAA-2GA
CAHAA-2GB
CAHAA-2GC
CAA CA65
 

Type CAHC
for Steel

Through conductor to top of horizontal steel pipe or flat surface.
  

 
Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (12" & larger pipe)
3/4" to 2" pipe
2 1/2" to 5" pipe
6" to 10" pipe
CAHCA-1G
CAHCA-1GA
CAHCA-1GB
CAHCA-1GC
CAA CA25
6 Stranded Flat (12" & larger pipe)
3/4" to 2" pipe
2 1/2" to 5" pipe
6" to 10" pipe
CAHCA-1H
CAHCA-1HA
CAHCA-1HB
CAHCA-1HC
CAA CA25
4 Solid Flat (12" & larger pipe)
3/4" to 2" pipe
2 1/2" to 5" pipe
6" to 10" pipe
CAHCA-1K
CAHCA-1KA
CAHCA-1KB
CAHCA-1KC
CAA CA25
4 Stranded Flat (12" & larger pipe)
3/4" to 2" pipe
2 1/2" to 5" pipe
6" to 10" pipe
CAHCA-1L
CAHCA-1LA
CAHCA-1LB
CAHCA-1LC
CAA CA25
2 Solid Flat (14" & larger pipe)
2" to 3-1/2" pipe
4" to 6" pipe
6" to 10" pipe
CAHCA-1T
CAHCA-1TA
CAHCA-1TB
CAHCA-1TC
CAA CA32
2 Stranded Flat (18" & larger pipe)
2" to 3-1/2" pipe
4" to 8" pipe
10" to 16" pipe
CAHCA-1V
CAHCA-1VA
CAHCA-1VB
CAHCA-1VC
CAA CA45
1 Stranded Flat (18" & larger pipe)
2" to 3-1/2" pipe
4" to 8" pipe
10" to 16" pipe
CAHCA-1Y
CAHCA-1YA
CAHCA-1YB
CAHCA-1YC
CAA CA45
1/0 Stranded Flat (30" & larger pipe)
3" to 4" pipe
5" to 6" pipe
8" to 10" pipe
12" to 28" pipe
CAHCA-2C
CAHCA-2CA
CAHCA-2CB
CAHCA-2CC
CAHCA-2CD
CAA CA65
2/0 Stranded Flat (30" & larger pipe)
3" to 4" pipe
5" to 6" pipe
8" to 10" pipe
12" to 28" pipe
CAHCA-2G
CAHCA-2GA
CAHCA-2GB
CAHCA-2GC
CAHCA-2GD
CAA CA65
 

Type CAVS
for Steel

Tap conductor to vertical steel
pipe or flat surface.

 
Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (12" & larger pipe)
3/4" to 3-1/2" pipe
4" to 10" pipe
CAVST-1G
CAVST-1GA
CAVST-1GB
CAT CA15
6 Stranded Flat (12" & larger pipe)
3/4" to 3-1/2" pipe
4" to 10" pipe
CAVST-1H
CAVST-1HA
CAVST-1HB
CAT CA15
4 Solid Flat (12" & larger pipe)
3/4" to 1-1/2" pipe
2" to 4" pipe
5" to 10" pipe
CAVST-1K
CAVST-1KA
CAVST-1KB
CAVST-1KC
CAT CA25
4 Stranded Flat (12" & larger pipe)
3/4" to 1-1/2" pipe
2" to 4" pipe
5" to 10" pipe
CAVST-1L
CAVST-1LA
CAVST-1LB
CAVST-1LC
CAT CA25
2 Solid Flat (14" & larger pipe)
1" to 1-1/2" pipe
2" to 4" pipe
5" to 12" pipe
CAVST-1T
CAVST-1TA
CAVST-1TB
CAVST-1TC
CAT CA25
2 Stranded Flat (14" & larger pipe)
1" to 1-1/2" pipe
2" to 3" pipe
4" to 6" pipe
8" to 12" pipe
CAVST-1V
CAVST-1VA
CAVST-1VB
CAVST-1VC
CAVST-1VD
CAT CA32
1 Stranded Flat (18" & larger pipe)
1" to 1-1/2" pipe
3" to 4" pipe
5: to 10" pipe
12" to 16" pipe
CAVSP-1Y
CAVSP-1YA
CAVSP-1YB
CAVSP-1YC
CAVSP-1YD
CAP CA45
1/0 Stranded Flat (18" & larger pipe)
2-1/2" to 4" pipe
5" to 10" pipe
12" to 16" pipe
CAVSP-2C
CAVSP-2CA
CAVSP-2CB
CAVSP-2CC
CAP CA65
2/0 Stranded Flat (18" & larger pipe)
2-1/2" to 4" pipe
5" to 10" pipe
12" to 16" pipe
CAVSP-2G
CAVSP-2GA
CAVSP-2GB
CAVSP-2GC
CAP CA65
 

Type CAHB
for Cast Iron

Tap conductor to top of
horizontal cast iron pipe
or flat surface.

 
Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1G
CAHBA-1G-P.S.
CAA CA25XF-19
6 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1H
CAHBA-1H-P.S.
CAA CA25XF-19
4 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1K
CAHBA-1K-P.S.
CAA CA45XF-19
4 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1L
CAHBA-1L-P.S.
CAA CA45XF-19
2 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1T
CAHBA-1T-P.S.
CAA CA45XF-19
2 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1V
CAHBA-1V-P.S.
CAA CA45XF-19
1 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHBA-1Y
CAHBA-1Y-P.S.
CAA CA65XF-19
 
Do not use Type CAHB on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.
 

Type CAHE
for Cast Iron

Through conductor to top of
horizontal cast iron pipe
or flat surface.

 
Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1G
CAHEA-1G-P.S.
CAA CA32XF-19
6 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1H
CAHEA-1H-P.S.
CAA CA32XF-19
4 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1K
CAHEA-1K-P.S.
CAA CA45XF-19
4 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1L
CAHEA-1L-P.S.
CAA CA45XF-19
2 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1T
CAHEA-1T-P.S.
CAA CA45XF-19
2 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1V
CAHEA-1V-P.S.
CAA CA45XF-19
1 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAHEA-1Y
CAHEA-1Y-P.S.
CAA CA65XF-19
 
 
Do not use Type CAHE on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.
 

Type CAVH
for Cast Iron

Tap conductor to vertical
horizontal cast iron pipe
or flat surface.

Conductor
Size
SurfaceWelder
Part No.
Welder
Price
Weld
Metal
#14-10 solid, or #8 solid
or stranded, or #6 solid
Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1G
CAVHT-1G-P.S.
CAA CA25XF-19
6 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1H
CAVHT-1H-P.S.
CAA CA25XF-19
4 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1K
CAVHT-1K-P.S.
CAA CA32XF-19
4 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1L
CAVHT-1L-P.S.
CAA CA32XF-19
2 Solid Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1T
CAVHT-1T-P.S.
CAA CA45XF-19
2 Stranded Flat (30" & larger pipe)
4" to 24" pipe
CAVHT-1V
CAVHT-1V-P.S.
CAA CA45XF-19
1 Stranded Flat (36" & larger pipe)
4" to 30" pipe
CAVHT-1Y
CAVHT-1Y-P.S.
CAA CA65XF-19
 
 
Do not use Type CAVH on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.

CADWELD Formed Terminal Bonds

Factory Made Bonds

Bonds with terminals formed on the ends are often used for bonding pipe joints and fittings. The formed terminal allows a smaller weld metal size to be used.

Field Made Bonds

Formed Terminal Bonds may be made in the field using sleeves (one per conductor end) and forming them in a hammer die.

Cadweld Formed Terminal with Pigtails

Factory Made Bonds with Pigtails for "Dresser Type" Pipe Couplings.
Insulated formed terminal bonds with insulated pigtails are used to bond across the joint and to bond both the middle ring and follower ring of "Dresser Type" couplings.

CADWELD Bonding Straps for Pipe Thawing

In colder climates, water distribution pipes occasionally freeze in the winter. To thaw the ice, a high current (for example, from a welding machine) is applied to heat the pipe and thaw the ice. To accomplish this, each pipe joint must be efficiently bonded to control the electrical path and to prevent burning the pipe gaskets. 1/1 6" x 3/4" copper bonding straps, welded to the pipe with CADWELD connections, provide the necessary bond or current path across the pipe joints. The bonding straps have been tested at over 500 amperes. The straps may also be used to provide continuity for cathodic protection or grounding systems.

Cadweld "Punched Strap" Bond for Steel Pipe

The CADWELD "Punched Strap" Bond allows bonding across joints of steel pipe with a bond of approximately 1 /0 AWG size using a CAl 5 Weld Metal. This allows larger size bonds on steel pressure pipe covered by ANSI/ASME B31. The Punched Strap bond is fabricated from 1/16" x 1-1/4" soft copper, allowing easy hand forming over the pipe coupling.

The 5-hole model is used on "Dresser Type" pipe couplings with two welds to the pipe and three to the coupling, made through the holes. A 2-hole model is used across standard mechanical joints or across "Dresser Type" joints when the coupling does not have to be bonded.


PIPING CODE Applicable to CALDWELD Connections to Pipe Lines

  1. The American Society of Mechanical Engineers* (ASME) publishes codes relating to the design and installation of pressure piping systems:
    • ANSI/ASME B31.8-1992, Gas Transmission and Distribution Piping Systems.
    • ANSI/ASME B31.4-1992, Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols.
  2. In both, under Corrosion Control, the code allows the attachment of electrical leads using exothermic welding but limits the size of the weld metal used to:
    • CA15 for steel pipe.
    • CA32XF1 9 for cast, wrought and Ductile Iron pipe.
  3. These restrictions allow for the welding of #4 AWG and smaller wire to steel pipe using CADWELD Cathodic Type CAHA connections and #6 AWG and smaller to cast, wrought, and ductile iron using Type CAHB connections. When larger sized conductors must be attached to pressure piping systems covered by these codes, several alternative solutions are available:
    • Using a Formed Terminal Bond, a #2 AWG can be welded to cast, wrought and ductile iron with a CA32XF1 9.
    • Using a CADWELD Bonding Strap, a 1/16" x 1" copper strip (equivalent to slightly smaller than a #1 AWG) can be welded to a cast, wrought and ductile iron pipe with a CA32XF19.
    • The "Punched Strap" Bond (1/16" x 1-1/4" copper, equivalent to slightly less than a 1/0 AWG) can be welded to steel pipe using a CAl 5. The 5-hole model is used for "Dresser Type" couplings and the 2-hole model for standard joints.
    • The strands of a larger 7 strand conductor can be spread and each strand welded separately as noted in the following table:
         
Conductor
7 strand
Welder for each strand
for steel pipe
Weld
metal
4/0 CAHAA1H CA15
3/0 to #1 CAHAA1G CA15
#2 to #4 CAHAA1G with sleeve Bl331H CA15

* Available from:

The American Society of Mechanical Engineers
United Engineering Center
345 East 47th St., New York, NY 10017

DUCTILE IRON

Tests by ERICO, Inc. indicate that connections to ductile iron pipe can be made using the CADWELD molds and weld metal designated to be used on steel pipe. However, some reports from the field suggest that all ductile iron is not the same. In some cases, the material for steel will not work. In such cases, the molds and weld material for cast iron do work.

We therefore suggest:

  1. Whenever possible, make tests on the ductile iron pipe being used to determine if the material for steel can be used.
  2. Or use the material for cast iron. It will make satisfactory connections on all ductile iron.

Type CAGR
Ground Rod

Tap conductor to the top
of a ground rod

Please contact Farwest Corrosion Control Company for sizes and ordering information.

Type CAGT
Ground Rod

Through conductor to
the top of a ground rod

Please contact Farwest Corrosion Control Company for sizes and ordering information.  

Type CAPC
Cable-to-Cable Splice

Tap cable to a through cable
   

Please contact Farwest Corrosion Control Company for sizes and ordering information.

Type CASS
Cable Splice

Splice cables end to end
   

Please contact Farwest Corrosion Control Company for sizes and ordering information.

Type CATA
Cable-to-Cable Splice

Concentric strand copper cable
    

Type CATA connections are available for any combination of run and tap conductor sizes. For small size taps, Type CAPC is recommended. Please contact Farwest Corrosion Control Company for sizes and ordering information.

Type CALA
Cable-to-Lug

Cable-to-Lug Connection
     

Please contact Farwest Corrosion Control Company for sizes and ordering information.
 
CADWELD Welders and Molds

When making a CADWELD connection, an accurate control of the CADWELD process is accomplished by using a semi-permanent graphite mold. Control is exercised over the direction and speed of the molten CADWELD weld metal flow and final shape. The graphite used in a CADWELD mold is a high temperature type that lasts for an average of 50 to 100 CADWELD connections under normal usage.

Welder Price CAT, CAP and CAN (to the left) are split and use the new Mini E-Z handle. Welder Part No. includes mold frame. Welder Price CAA (to the right) is a solid block with a hold-down handle. If mold only (less frame) is required, order Welder Part No. "M".



CADWELD Weld Metal

 CADWELD weld metal is a mixture of copper oxide and aluminum, packaged by size in plastic tubes. Each tube contains the starting powder at the bottom of the plastic tube, with the weld metal on top. These containers are packaged, with metal disks, in polyethylene boxes. The welding metal cannot ignite spontaneously. They can be handled and stored without danger and can be shipped with no special packaging or marking.

Two types of CADWELD weld metal are used for cathodic protection connections:

  • F-33 alloy is used for all connections of cable to cable and cable to steel or stainless steel pipe. The F-33 weld metal containers have green caps.
  • XF-19 alloy is used for all connections to cast iron. XF-19 weld metal containers have orange caps.
SizePacked per
BoxStd. Pkg.
CA15 20 100
CA25 20 100
CA32 20 100
CA45 20 100
CA65 20 100

CADWELD Tools and Materials

SHIM STOCK CAB-140-A

Shim Stock is useful to adapt the conductor when a variety of sizes exist and only a few connections of each one are required.

ADAPTER SLEEVES

Small conductors may be built up to fit the opening of larger size welders using either adapter sleeves or shim stock.

Adapter Sleeve
Part Number
Cable Size Use in Mold for Conductor Size
Stranded # Solid # Stranded # Solid #
CAB-133-1H
CAB-133-1K
CAB-133-1L
CAB-112
CAS20F
CAS09F
CAS05F
CAS03F
12, 14
10
8, 10
6
4
2
1/0
2/0
10, 12, 14
8, 10





6

4
2
2
1/0
3/0
4/0
6
4





MOLD CLEANER CAB-136-A

Mold cleaners are useful for removing the slag from CAA molds after making a CADWELD connection.

SHURFIRE CAT-111

Self-igniting propane torch head. Squeeze the control knob for an instant flame. Release, and it's out. No flame adjusting. And the burn tip remains cool during normal use. Operates on its side or upside down. Can withstand 60-MPH winds without flareout. Saves fuel. Safer to use. Fits all standard 14 and 16 oz propane lighters.

EXTENSION FLINT LIGHTER

CAB-321-30. Extension Flint Lighter, 30" long. CAT-320. Replacement Flint Igniter Only. CAT-320-A. Replacement Flints CAB-322. Lead Holding Clip - Fits all CAA Price Welders

CAB-319 VERTICAL PIPE CLAMP

Holds the welder to a vertical pipe while the CADWELD connection is made. Fits all CAN, CAP or CAT price welders and pipes up to 6 inches.

 

CAB-320 HORIZONTAL PIPE CLAMP

Holds the welder to a horizontal pipe while the CADWELD conneciton is made. Fits all CAA price welders and pipes up to 6 inches.

EXTRA CHAINS

 
B323N2 MAGNETIC HOLD-DOWN ASSEMBLY
 

Once attached to the mold handle, the B323N2 securely holds the mold to large flat or slightly curved horizontal steel surfaces during the connection process.

  • Powerful welding magnet (50 lb rating) securely positions mold during connection process.
     

  • Helps with mold stability to reduce the chance of weld metal leakage.
     

  • Quickly and easily attaches to “A” price key hold-down molds (new or retrofit).
     

  • Ideal when used with CADWELD PLUS to allow for full extension of control unit lead.

B323N2 attached to mold frame on
steel pipe during connection process

TOOLS  & ACCESSORIES

ITEMCATALOG #
Tool Boxes Only CAT-396
Complete Kit Box and Tools CAT-343
Complete Kit Box and Tools with Rasp CAT-343-R
RASP (only) CAT-321
Flint Igniter CAT-320
Screwdriver CAT-305
Wire Brush CAT-336
Crimping Tool CAT-335
Disk Container CAT-328
Card Cloth Brush CAT-313
File and Handle CAT-329
Mold Sealer CAT-403
Magnetic hold-down assembly CAT-B323N2

 

 

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