CADWELD

The CADWELD® ONE SHOT produces a permanent exothermic connection to a ground rod that will not loosen, corrode or increase in resistance for the life of the installation. A convenient, single-use ceramic mold eliminates the need for a mold and handle clamps and/or frames. Ideal for both threaded and plain copper-bonded ground rods. Features

• Easy to use, single-use ceramic mold eliminates need for mold and frame, handle clamp
• Produces permanent connection that will not loosen or corrode
• NEC® compliant, cULus® Listed
• Rural Utilities Service (RUS) accepted

Applications

The CADWELD ONE SHOT is ideal for making permanent reliable connections to ground rods for electrical transmission and distribution, telecommunications and cable television applications.

• http://www.erico.com/products/E1145WB06.asp
• erico_cadweld_one_shot.pdf

• Ideal for field use where reusable molds and tools would be cost-prohibitive

• Probably not approved for air transport

• Approximately $10 per shot

The convenient single-use package makes the connection to the ground rod without a mold or starting material. Thanks to the electronic CADWELD PLUS Control Unit, welds can now be completed up to 6 feet (1.8 meters) away, increasing flexibility in hard-to-reach areas. The new refractory ceramic body utilized with the CADWELD PLUS ONE SHOT system is more durable than conventional ceramic and resists breaking.

Features

• Easy-to-use electronic ignition. No starting material.
• Durable disposable ceramic body eliminates the graphite mold and frame.
• Produces a permanent connection that will not loosen or corrode.
• NEC® compliant.
• cULus® Listed.

Applications

The CADWELD PLUS ONE SHOT is ideal for making permanent reliable connections to ground rods for electrical transmission and distribution, telecommunications and cable television applications.

• http://www.erico.com/products/plusoneshot.asp
• erico_cadweld_plus.pdf
• Demo Video: http://www.erico.com/public/library/fep/AV0002.mov

• Ideal for field use where reusable molds and tools would be cost-prohibitive
• Easy to handle, store and transport – by air, land or sea in unlimited quantities [Cadweld Plus PDF, p.3]

• Requires expensive electrical igniter (Control Unit, $135)
• Specific model required for each size wire of connection
  • Could use “CADWELD Wrap Sleeve B140A” to adapt smaller wire sizes to a larger wire size mold (CADWELD Catalog, p105)
  • Adapter sleeves also available, as well as mold sealer for packing molds (also p105)

• $10 (one connection) to $15 (four connections to ground rod)

Ideal for making ground rod connections for the telecommunications, electric distribution or cable television markets.

• Works on ground rods where the head has been “mushroomed”
• Drive rod to installed depth even after the connection has been made

The GN Connection Kit can be specified for connecting #6 or #4 solid copper ground wire to 1/2“, 5/8”, or 3/4“ ground rods. http://www.erico.com/products/GNkits.asp

Wire connects to side of ground rod in same direction as ground rod.

• Works on mushroomed ground rod heads
• Can drive ground rod after making the connection
• Multiple connections can be made to a single ground rod
• Better for lightning as there is no 90-degree angle at connection

• Requires reusable mold (~$90) & clamp (~$40)
• Large expense for one-time use

• $2/shot

Ideal for connecting ground wires to lugs for termination on a ground bus.

• One CADWELD mold for 7 lug sizes minimizes inventory of molds
• Multiple molds are replaced with ONE versatile mold that utilizes inexpensive conductor sleeves
• No multiple tools or dies required as with crimped connections
• http://www.erico.com/products/TelecomLugs.asp
• erico_cadweld_telecom_lugs.pdf

• Adaptable for multiple sizes of wire (#6, #5, #4, #3, #2)
• Suggests possibility of using this technique for One-Shot molds

• Requires expensive mold
• Only connects to specified lugs, not ground rods

• Sleeves –

• http://www.erico.com/static.asp?id=34

• http://forums.mikeholt.com/showthread.php?t=112161

moisture is a huge safety hazard when doing any type of exothermic welding.

if there is any moisture in the blocks, or in the strands of wire (think 500 mcm
buried in dirt), and you fire the shot, 1/2 second later, there will be a burping
sound like an old coffeemaker, and a **fountain** of molten metal will come
out the top of the block, about three feet up in the air. it's about 3,000
degrees, and will burn thru anything.

any material you are wearing is going to be more material they have to pick
out at the burn center. first and foremost, do not be in the path of weld
material. do not depend on any safety equipment to protect you from weld
material. it's thermite, for all practical purposes, and will smoke thru cast iron,
copper, or my tennis shoes before you can say "oops".

* Use the remote electric control unit/igniter

• http://www.k2ut.org/cadweld.html

I screwed up a few molds, and had a pretty poor success rate at first. I kept bugging the folks at R. F. Connection until they got me in touch with the experts at Erico. Erico has a few products that I would highly recommend to anyone considering this product:

• How to CADWELD, An Easy Connection to Make (videotape)
• CADWELD ONE-SHOT Connections (videotape)
• Booklet: Installers and Inspectors Guide for CADweld Electrical ConnectionsPDF
• Booklet: Contractor Tips for the Use of CADweld Products PDF

I had fouled up a number of one-shots before getting this material, then had a 100% success rate after looking at the data.