CADWELD Exothermic Welding Manual

1 CADWELD . Exothermic Welding Manual WARNING. 1. ERICO products shall be installed and used only as indicated in ERICO product instruction sheets and training materials. Instruction sheets are available at and from your ERICO customer service representative. 2. ERICO products must never be used for a purpose other than the purpose for which they were designed or in a manner that exceeds specified load ratings. 3. All instructions must be completely followed to ensure proper and safe installation and performance. 4. 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.

2 GENERAL AND SAFETY INSTRUCTIONS: A. Only ERICO manufactured equipment and materials should be used to make CADWELD connections. B. Do not connect items except as detailed in instruction sheets. Failure to comply with these instructions may result in improper and unsafe connections, damage to items being connected, bodily injury and property damage. C. Do not use worn or broken equipment which could cause leakage. D. Do not alter equipment or material without ERICO authorization. E. When using CADWELD do not use Welding material package if damaged or not fully intact. When using CADWELD PLUS, do not tamper with or disassemble the Welding material unit.

3 F. Make connections in conformance with CADWELD instructions and all governing codes. 1. Personnel should be properly trained in the use of this product and must wear safety glasses and gloves. 2. Avoid contact with hot materials. 3. Advise nearby personnel of Welding operations in the area. 4. Remove or protect fire hazards in the immediate area. 5. Provide adequate ventilation to the work area. 6. Do not smoke when handling starting material. 7. Avoid direct eye contact with flash of light from ignition of starting material. G. Welding material is an Exothermic mixture and reacts to produce hot molten material with temperatures in excess of 1400 C (2500 F) and a localized release of smoke.

4 These materials are not explosive. Ignition temperatures are in excess of 900 C (1650 F) for Welding material. H. Adhering to the CADWELD Welding procedures will minimize risk of burns and fire caused by hot molten material spillage. In case of fire, use of water or CO2 will aid in control of burning containers. Large quantities of water will aid in controlling a fire should the Exothermic materials become involved. Water should be applied from a distance. 1. Make sure there is proper mold fit and assembly of equipment. 2. Avoid moisture and contaminants in mold and materials being welded . Contact between hot molten metal and moisture or contaminants may result in spewing of hot material.

5 3. Base material thickness must be sufficient for the size and type of connection being made to prevent melt-through and leakage of hot molten metal. I. Applications or conditions may exist which require special considerations. The following are examples, but are not intended to be a complete listing of applications/conditions. CONNECTIONS TO PIPE/VESSELS. For use with cast iron pipe or heavy casting meeting ASTM A47-84, A48-83, A126-84, A278-85, or A377-89. DO NOT USE ON CAST IRON SOIL PIPE (ASTM A74-93). Evaluate possible effects of CADWELD . connections to structural members and thin-wall materials; vessels/piping systems that are pressurized, closed or containing (or having contained) flammable/explosive/hazardous materials.

6 Evaluation should be made prior to use, based on conditions of use and applicable codes, and should incorporate as a minimum, effects of melt-through of hot material; structural/metallurgical effects of CADWELD . connections, pressure (temperature) build-up and fire/chemical decomposition hazards. CONNECTIONS TO REBAR. Application of the CADWELD connection may have an effect on the rebar's structural integrity. The rebar's chemistry and the location of the weld should be considered before making any welds to the rebar. For lapped rebar splices, it is recommended that the connections be made near the bar end at an area of minimum stress. If CADWELD Rebar Splices are used, the grounding connection can be made to the splice sleeve with minimal effect on the structural characteristics of the splice.

7 SAFETY INSTRUCTIONS: All governing codes and regulations and those required by the job site must be observed. Always use appropriate safety equipment such as eye protection, hard hat, and gloves as appropriate to the application. 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.

8 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.

9 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.

10 The CADWELD Process The 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 purpose-designed 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.