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Horizontal Thru Bar to Horizontal Steel Surface Joint

Horizontal Thru Bar to Horizontal Steel Surface Joint

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Description

Product Information:

Horizontal thru Bar to Horizontal Steel Surface Joint  is a bar-to-surface exothermic welded connection that requires an HCD Handle Clamp with a chain.

The AI Weld Exothermic Connection is a permanent, zero-maintenance weld solution providing up to 50 years of service life. Unlike pressure-type connections – such as bolts or crimps – AI Weld welds do not loosen or degrade with time, providing consistent electrical performance without increased resistance. The granular powder of the AI Weld metal includes copper oxide, aluminium, and flux and is available in standard sizes.

AI Weld Mould Features

  • High-quality graphite that provides ease of machining and resilience to thermal and mechanical shocks during welding, with heat over 2000ºC.
  • Designed for 50-60 weld connections per mould; under proper care, the lifetime can be significantly extended.
  • Due to graphite’s brittleness and rather soft nature, handling requires much care.
  • Moulds come with nameplates specifying connection type, part code, and required weld metal size.
  • In the event no particular connections or configurations of the conductors are present, the sales team is here to provide customized support.

Mould Care Guide:

  • For maximum lifetime and proper working of AI Weld moulds
  • Clean after each weld using only AI Weld cleaning apparatus (soft brush).
  • Keep dry and do not allow the mould to get moist
  • Store in the packaging when out of use to avoid any damage
  • Do not hit or drop the mould or bang its edges with the conductors.
  • Never use a wire brush to clean.
  • Always use the correct weld metal size, tools, and handle clamps.

Mould Inspection Checklist

  • Careful handling. Mould must be dry and in good condition with the lid tight.
  • Label must be fitted
  • Faces of the mould must be smooth for closure
  • Steel disc seat must have no wear, cracks or gouges to prevent weld metal from leaking out.
  • The definition in the tap hole must be distinct.
  • The weld cavity should have no signs of wear, and the conductors should be fitted to suit a 3mm gap in between.
  • Routine checking with care ensures the AI Weld moulds are not damaged.

 

How To Install

The AI Weld Process:

Six basics steps in the AI Weld Process lead to a successful exothermic weld:

  1. Insert the conductors into the mould cleaned while ensuring that the mould is dry with minimal moisture. This can be ensured either by the process of preheating or possibly a test connection.
  2. Fit the provided metal disc at the bottom of the mould crucible.
  3. Pour in the weld metal completely, which you find under its green lid.
  4. Add on top of the weld metal, the starting powder found under its red cap. Only a small quantity shall be applied on the lip of the mould for easy ignition, then close the lid.
  5. Draw a charge from the flint gun to ignite the starting powder, pull the chargeback immediately after firing in order not to foul the gun.

Caution: Have no part of your body over the top or in front of the aperture

  1. When 20 seconds have elapsed open the mould by crank handle. Use the cleaning brush to remove slag and clean the mould and crucible and lid liberally.

Additional information

A(mm)

20*3, 25*4, 25*5, 25*6, 25*3, 30*2, 30*3, 30*4, 30*5, 31*6, 38*3, 38*5, 38*6, 40*4, 40*5, 40*6, 40*3, 50*3, 50*4, 50*5, 50*6, 50*8, 60*6, 60*8
Weld Metal

#025, #032, #045, #065, #090, #115, #150, #200, #250, 2*#0250, 2*#150, 2*#200, 2*#250, 2*200, 25, 3*#200, 3*#250, 3*250, 32
HANDLE CLAMP

HCD, HCE

Product Options

LEGEND:

Conductor Size:

  • A and B denote the sizes of conductors being joined.
  • Bar is specified by its dimensions, x and y.
  • Circular conductors can be either:
    • Stranded (e.g., cable)
    • Solid (e.g., ground rod, rebar).
  • If both stranded and solid conductors are applicable, this will be noted in the relevant table.
  • All conductor dimensions are provided in millimeters (mm) unless specified otherwise.

Price Key:

Moulds are priced according to their size and complexity and are categorized into pricing bands, referred to by a price key.

Weld Metal:

Weld metal is specifically sized for each mould. Normally, this is one carton of weld metal but when more than one is needed it will be indicated by a multiplier; such as 2 x #150.

Clamp:

  • Each type of mold requires a specific clamp.
  • If multiple molds use the same clamp, you only have to order enough clamps for the number of operators you will need for your job.

Sleeve (Rail Applications):

A copper sleeve is used to increase the diameter of smaller conductors to make them weldable.

Hammer Die (Rail Applications):

A hammer die flattens one side of a conductor for better contact with the rail, improving the weld quality.

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