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 loaded 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 cables to pipes (steel or cast iron), tanks and many other steel structures 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, which can corrode, resulting in an ineffective connection and 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 aand 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 Welders and Molds When making a CADWELD connection, an accurate control of the CADWELD process is accomplished by using a semi-permanent graphite mold. With the 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 Key "CAA" is a solid graphite block with a hold-down handle used for horizontal welding. If a mold only is needed, (without handle), add an "M" to the end of the part number.  Example:  CAHAA-1G-M Welder Price Keys CAT, CAP and CAN are split molds and use the Mini E-Z handle. All welders uder these price keys includes the handle or "mold frame". Refer to the "Welder Price" column on the charts in the "Welder" tab on this page. When making a CADWELD connection, be sure to use all proper PPE including eye protection, gloves and proper clothing.  The CADWELD process is a "hot process" utilzing a molten compound and safety precautions are very important. CADWELD Exothermic Welding Manual EFFECTIVE AUGUST 1, 2018, THE MODEL T320 FLINT IGNITOR IS SOLD SEPARATELY AND WILL NOT BE INCLUDED WITH ANY CADWELD WELDER OR MOLD. Welder Types  The following Cadweld "welders" are designed to make cable connections to steel pipe or other steel structures.  Each welder is designed to work with a specific cable and pipe size in a horizontal or vertical position.   Type CAHAfor Steel Tap conductor (lead wire) to top of horizontal steel pipe or flat surface.   Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (4" & larger pipe)3/4" to 3-1/2" pipe CAHAA-1GCAHAA-1GA CAA CA15 6 Stranded Flat (4" & larger pipe)3/4" to 3-1/2" pipe CAHAA-1HCAHAA-1HA CAA CA15 4 Solid Flat (6" & larger pipe)3/4" to 3-1/2" pipe4" to 5" pipe CAHAA-1KCAHAA-1KACAHAA-1KB CAA CA15 4 Stranded Flat (6" & larger pipe)3/4" to 3-1/2" pipe4" to 5" pipe CAHAA-1LCAHAA-1LACAHAA-1LB CAA CA15 2 Solid Flat (10" & larger pipe)1" to 3-1/2" pipe4" to 8" pipe CAHAA-1TCAHAA-1TACAHAA-1TB CAA CA25 2 Stranded Flat (16" & larger pipe)1" to 3-1/2" pipe4" to 8" pipe10" to 14" pipe CAHAA-1VCAHAA-1VACAHAA-1VBCAHAA-1VC CAA CA32 1 Stranded Flat (16" & larger pipe)1" to 3-1/2" pipe4" to 8" pipe10" to 18" pipe CAHAA-1YCAHAA-1YACAHAA-1YBCAHAA-1YC CAA CA45 1/0 Stranded Flat (20" & larger pipe)2-1/2" to 3-1/2" pipe4" to 8" pipe10" to 18" pipe CAHAA-2CCAHAA-2CACAHAA-2CBCAHAA-2CC CAA CA65 1/0 Stranded Flat (20" & larger pipe)2-1/2" to 3-1/2" pipe4" to 8" pipe10" to 18" pipe CAHAA-2GCAHAA-2GACAHAA-2GBCAHAA-2GC CAA CA65   Type CAHCfor Steel Through conductor to top of horizontal steel pipe or flat surface.     Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (12" & larger pipe)3/4" to 2" pipe2 1/2" to 5" pipe6" to 10" pipe CAHCA-1GCAHCA-1GACAHCA-1GBCAHCA-1GC CAA CA25 6 Stranded Flat (12" & larger pipe)3/4" to 2" pipe2 1/2" to 5" pipe6" to 10" pipe CAHCA-1HCAHCA-1HACAHCA-1HBCAHCA-1HC CAA CA25 4 Solid Flat (12" & larger pipe)3/4" to 2" pipe2 1/2" to 5" pipe6" to 10" pipe CAHCA-1KCAHCA-1KACAHCA-1KBCAHCA-1KC CAA CA25 4 Stranded Flat (12" & larger pipe)3/4" to 2" pipe2 1/2" to 5" pipe6" to 10" pipe CAHCA-1LCAHCA-1LACAHCA-1LBCAHCA-1LC CAA CA25 2 Solid Flat (14" & larger pipe)2" to 3-1/2" pipe4" to 6" pipe6" to 10" pipe CAHCA-1TCAHCA-1TACAHCA-1TBCAHCA-1TC CAA CA32 2 Stranded Flat (18" & larger pipe)2" to 3-1/2" pipe4" to 8" pipe10" to 16" pipe CAHCA-1VCAHCA-1VACAHCA-1VBCAHCA-1VC CAA CA45 1 Stranded Flat (18" & larger pipe)2" to 3-1/2" pipe4" to 8" pipe10" to 16" pipe CAHCA-1YCAHCA-1YACAHCA-1YBCAHCA-1YC CAA CA45 1/0 Stranded Flat (30" & larger pipe)3" to 4" pipe5" to 6" pipe8" to 10" pipe12" to 28" pipe CAHCA-2CCAHCA-2CACAHCA-2CBCAHCA-2CCCAHCA-2CD CAA CA65 2/0 Stranded Flat (30" & larger pipe)3" to 4" pipe5" to 6" pipe8" to 10" pipe12" to 28" pipe CAHCA-2GCAHCA-2GACAHCA-2GBCAHCA-2GCCAHCA-2GD CAA CA65   Type CAVSfor Steel Tap conductor to vertical steel pipe or flat surface.   Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (12" & larger pipe)3/4" to 3-1/2" pipe4" to 10" pipe CAVST-1GCAVST-1GACAVST-1GB CAT CA15 6 Stranded Flat (12" & larger pipe)3/4" to 3-1/2" pipe4" to 10" pipe CAVST-1HCAVST-1HACAVST-1HB CAT CA15 4 Solid Flat (12" & larger pipe)3/4" to 1-1/2" pipe2" to 4" pipe5" to 10" pipe CAVST-1KCAVST-1KACAVST-1KBCAVST-1KC CAT CA25 4 Stranded Flat (12" & larger pipe)3/4" to 1-1/2" pipe2" to 4" pipe5" to 10" pipe CAVST-1LCAVST-1LACAVST-1LBCAVST-1LC CAT CA25 2 Solid Flat (14" & larger pipe)1" to 1-1/2" pipe2" to 4" pipe5" to 12" pipe CAVST-1TCAVST-1TACAVST-1TBCAVST-1TC CAT CA25 2 Stranded Flat (14" & larger pipe)1" to 1-1/2" pipe2" to 3" pipe4" to 6" pipe8" to 12" pipe CAVST-1VCAVST-1VACAVST-1VBCAVST-1VCCAVST-1VD CAT CA32 1 Stranded Flat (18" & larger pipe)1" to 1-1/2" pipe3" to 4" pipe5 to 10" pipe12" to 16" pipe CAVSP-1YCAVSP-1YACAVSP-1YBCAVSP-1YCCAVSP-1YD CAP CA45 1/0 Stranded Flat (18" & larger pipe)2-1/2" to 4" pipe5" to 10" pipe12" to 16" pipe CAVSP-2CCAVSP-2CACAVSP-2CBCAVSP-2CC CAP CA65 2/0 Stranded Flat (18" & larger pipe)2-1/2" to 4" pipe5" to 10" pipe12" to 16" pipe CAVSP-2GCAVSP-2GACAVSP-2GBCAVSP-2GC CAP CA65   Type CAHBfor Cast Iron Tap conductor to top of horizontal cast iron pipe or flat surface.   Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (30" & larger pipe)4" to 24" pipe CAHBA-1GCAHBA-1G-P.S. CAA CA25XF-19 6 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHBA-1HCAHBA-1H-P.S. CAA CA25XF-19 4 Solid Flat (30" & larger pipe)4" to 24" pipe CAHBA-1KCAHBA-1K-P.S. CAA CA45XF-19 4 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHBA-1LCAHBA-1L-P.S. CAA CA45XF-19 2 Solid Flat (30" & larger pipe)4" to 24" pipe CAHBA-1TCAHBA-1T-P.S. CAA CA45XF-19 2 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHBA-1VCAHBA-1V-P.S. CAA CA45XF-19 1 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHBA-1YCAHBA-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 CAHEfor Cast Iron Through conductor to top of horizontal cast iron pipe or flat surface.   Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (30" & larger pipe)4" to 24" pipe CAHEA-1GCAHEA-1G-P.S. CAA CA32XF-19 6 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHEA-1HCAHEA-1H-P.S. CAA CA32XF-19 4 Solid Flat (30" & larger pipe)4" to 24" pipe CAHEA-1KCAHEA-1K-P.S. CAA CA45XF-19 4 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHEA-1LCAHEA-1L-P.S. CAA CA45XF-19 2 Solid Flat (30" & larger pipe)4" to 24" pipe CAHEA-1TCAHEA-1T-P.S. CAA CA45XF-19 2 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHEA-1VCAHEA-1V-P.S. CAA CA45XF-19 1 Stranded Flat (30" & larger pipe)4" to 24" pipe CAHEA-1YCAHEA-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 CAVHfor Cast Iron Tap conductor to vertical horizontal cast iron pipe or flat surface. Conductor Size Surface Welder Part No. Welder Price Weld Metal #14-10 solid, or #8 solidor stranded, or #6 solid Flat (30" & larger pipe)4" to 24" pipe CAVHT-1GCAVHT-1G-P.S. CAT CA25XF-19 6 Stranded Flat (30" & larger pipe)4" to 24" pipe CAVHT-1HCAVHT-1H-P.S. CAT CA25XF-19 4 Solid Flat (30" & larger pipe)4" to 24" pipe CAVHT-1KCAVHT-1K-P.S. CAT CA32XF-19 4 Stranded Flat (30" & larger pipe)4" to 24" pipe CAVHT-1LCAVHT-1L-P.S. CAT CA32XF-19 2 Solid Flat (30" & larger pipe)4" to 24" pipe CAVHT-1TCAVHT-1T-P.S. CAP CA45XF-19 2 Stranded Flat (30" & larger pipe)4" to 24" pipe CAVHT-1VCAVHT-1V-P.S. CAP CA45XF-19 1 Stranded Flat (36" & larger pipe)4" to 30" pipe CAVHT-1YCAVHT-1Y-P.S. CAP CA65XF-19     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.   Size Packed per Box Std. Pkg. CA15 20 100 CA25 20 100 CA32 20 100 CA45 20 100 CA65 20 100 Ductile Iron Connections 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: Whenever possible, make tests on the ductile iron pipe being used to determine if the material for steel can be used. Or use the material (XF-19 alloy) for cast iron. It will make satisfactory connections on all ductile iron.