aluminothermic welding - 1 file download
TRANSCRIPT
SOLDAL
Copper/ Copper
Copper / Steel
Copper / Stainless Steel
Copper / Brass
...etc.
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C-SOL/I00
Copper
AluminothermicWelding
AluminothermicWelding
AluminothermicWelding
KLK-SOLDAL PROCESS C-SOL/I02
KLK-SOLDAL Connection C-SOL/I02
KLK-SOLDAL mould and cartridges C-SOL/I03
KLK-SOLDAL Euipment C-SOL/I04
Cables, bus bars, steel re-bar and earth rods C-SOL/I05
Instructions for making connections C-SOL/I06
KLK-SOLDAL welding procedure C-SOL/I07
Standard connections C-SOL/I08
Instructions for using cartridges' selection charts C-SOL/I10
CABLE/CABLE connections chart C-SOL/I11
CABLE/EARTH-ROD connections chart C-SOL/I12
CABLE/CONCRETE STEEL RE-BAR connections chart C-SOL/I13
CABLE/STEEL SURFACE connections chart C-SOL/I14
CABLE-STEEL PIPE connections chart C-SOL/I14
CABLE/BUS BAR connections chart C-SOL/I15
connections chartBUS BAR/BUS BAR C-SOL/I16
KLK-SOLDAL dedicated uses C-SOL-I17
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C-SOL/I01
SUMMARY
Copper
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KLK-SOLDAL ConnectionKLK-SOLDAL Connection
The KLK-SOLDAL process utilizes the high temperature of the reaction
between copper oxide and aluminium. The reaction takes place in a
graphite mould-crucible, into which has been introduced the pieces to be
welded, molted metal from the aluminothermic reaction flows over the
pieces, causing them to be melted and fused into a solid homogeneous
mass.
The reaction is so quick that the pieces to be welded get a lower
temperature, on the zone around the welding point, than that arising
when using other process. This is an important fact for protecting
insulated cables or physical characteristics of the pieces to be welded.
The KLK-SOLDAL process may also be used in addition to welding copper
to copper, Eg. connections between copper and the following materials:
Common stell Brass
Stainless steel Bronze
Steel rail Nicrome V
Copper clad steel Durium
Galvanized steel Monel
...etc.
The KLK-SOLDAL connection is a perfect molecular weld:
Connections are not affected by high current surges. Tests
have shown that the electrical conductors will melt before the
connection when subjected to high short-circuit current.
Connection conductivity is at least equal or greater than the
conductors welded.
There is not possibility of corrosion at the point of the weld,
since conductors become an integral part of the connection.
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C-SOL/I02
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C-SOL/I03
KLK-SOLDAL mouldKLK-SOLDAL mould
KLK-SOLDAL cartridges and discsKLK-SOLDAL cartridges and discs
Upper cover, coloured
according to cartridge
size
Upper cover, coloured
according to cartridge
size
Aluminothermic powderAluminothermic powder
Starting powderStarting powder
Lower cover, black
coloured
Lower cover, black
coloured
Mould coverMould cover
Starting powderStarting powder
Aluminothermic powderAluminothermic powder
Metallic discMetallic disc
Tap holeTap hole
Welding cavityWelding cavity
Cables
Each plastic container holds the aluminothermic powder at one end (coloured cover)
and the starting powder at the other one (black cover). Close the tap hole with the
metallic disc before to dump the aluminothermic powder into the crucible.
CARTRIDGE
TYPE
COLOUR
UNITS/BOX
C-15
LIGHT
GRAY
C-25
DARK
GRAY
C-32
VIOLET
C-45
WHITE
C-65
YELLOW
C-90
ORANGE
C-115
RED
C-150
BROWN
C-200
BLUE
C-250
GREEN
20 2020 20 10 10 10 1010 10
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C-SOL/I04
KLK-SOLDAL EquipmentKLK-SOLDAL Equipment
The KLK-SOLDAL equipment is light and portable and requires no outside power
source, thus being useful for field use. It requires very little time or skill to get top quality
connections.
FLINT IGNITER:
It is used for easy ignition of
the starting powder.
Standard replacement flints
are suitables.
CARDCLOTHBRUSH:
MOULD BRUSH:
It is used for cleaning the
conductors before making
the weld.
It is recommended to safely
cleaning the inner part of
the mould after every weld.
MOULD SCRAPERS:
its shape fits the crucible to
easy remove the slag and to
check tap hole clearance after
making every weld.
MOULS:
Moulds are manufactured
from a heat-reistant material
(graphite) block that lasts for
an average of 70-100
connections under normal
conditions of use.
The metallic cover protects
from the reaction
projections.
HANDLE CLAMPS TSC:
They are designed to handle
the moulds allowing to
open and close them safely.
There are two types of
handle clamps depending
on the mould size: TSC- 80
and TSC-100.
HANDLE CLAMP MS:
iIt is designed to fit moulds
manufactured from a solid
piece of graphite, specially
those used to weld cables on
steel pipes.
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C-SOL/I05
Size mm No.of wires x dia. Overall dia. mm.2
Size mm No.of wires x dia. Overall dia. mm.2
10 7 x 1.35 4.05
16 7 x 1.70 5.10
25 7 x 2.14 6.42
35 7 x 2.52 7.56
50 19 x 1.83 9.15
70 19 x 2.17 10.85
95 19 x 2.52 12.60
120 19 x 2.85 14.25
150 37 x 2.25 15.75
185 37 x 2.52 17.64
235 37 x 2.85 19.95
300 61 x 2.62 22.68
400 61 x 2.85 25.65
10 7 x 1.35 4.05
16 7 x 1.70 5.10
25 7 x 2.14 6.42
35 7 x 2.52 7.56
50 19 x 1.83 9.15
70 19 x 2.17 10.85
95 19 x 2.52 12.60
120 19 x 2.85 14.25
150 37 x 2.25 15.75
185 37 x 2.52 17.64
235 37 x 2.85 19.95
300 61 x 2.62 22.68
400 61 x 2.85 25.65
COPPER CONDUCTORS (UNE 21012)
COPPER CLAD EARTH RODS
EARTH ROD Type Overall dia mm.EARTH ROD Type Overall dia mm.
J - ....58 14.3
J - ....34 17.3
....NU 146 14.6
....NU 183 18.3
....ST 143 14.3
J - ....58 14.3
J - ....34 17.3
....NU 146 14.6
....NU 183 18.3
....ST 143 14.3
Nominal size Overall dia. mm.Nominal size Overall dia. mm.
6 7.2
8 9.6
10 12
12 14.4
14 16.8
16 19.2
20 24
25 30
32 38.4
6 7.2
8 9.6
10 12
12 14.4
14 16.8
16 19.2
20 24
25 30
32 38.4
CONCRETE STEEL RE-BARS
Moulds are cut to
fit the type and
size of copper
conductors,
concrete steel re-
bars and earth
rods shown in
these tables. For
any other type
and/or size, it is
necessary to
confirm the
.
actual overall
diametre
Cables, bus bars, steel re-bars and earth rodsCables, bus bars, steel re-bars and earth rods
PREPARATION OF THE GRAPHITE MOULD
Moisture in moulds will cause a porous weld. Moulds must be perfectly dry before
making a weld.
For making proper connections, warm the mould before starting the first weld with
a welding torch or ignite a cartridge to get the mould over 100º C. When using a
cartridge be careful to avoid handle clamp damage due to molten metal leaking.
Generated heat will maintain the mould at the appropriate temperature for the next
weld. If delays among welds cause temperature to fall the mould drying process
must be started again.
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C-SOL/I06
Instructions for making connectionsInstructions for making connections
PREPARATION OF CONDUCTORS
Conductors must be clean, dry and well fitting to get a perfect weld.
Cables treated with oil or grease must be cleaned with a degreaser (preferably
a quick drying and non residual solvent). In extreme cases heat the conductor
with a welding torch to remove grease and oil completely.
Rusty conductors must be polished with a cardclothbrush.
A moist or muddy conductor will cause a porous weld and molten metal
outside the mould. Conductors must be dried with a welding torch and then
all mud removed.
Badly cutted or ill-fitted conductors will prevent closing the mould properly,
causing molten metal to run away. To avoid deformation of cable ends, use a
properly cable cutter.
PREPARATION OF THE STEEL SURFACES
Steel surface must be rust free and perfectly clean and flat.
Rust film, paint, grease or dust must be cleaned off with a grinder.
Remove moisture with a welding torch.
Galvanized surfaces may be cleaned without needing to remove the zinc
coating.
PREPARATION OF THE EARTH RODS
Earth rod end on which the weld is to be done must be perfectly clean, dry and
without any deformation.
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C-SOL/I07
KLK-SOLDAL Welding ProcedureKLK-SOLDAL Welding Procedure
Remove the isolation of theconductor on a length of 15cm when using insulatedcable.
Using the cardclothbrushbrush the cable and the rodend to remove all dust andoxydes.
Before starting the first weldpre-heat the graphite mouldwith a welding torch during atleast 5 minutes.
This operation is veryimportant because moisture inmoulds will cause a porousweld.
Open the mould by separatingthe two arms of the handleclamp.
Cable must sit on top of rod.Support mould to keep it fromsliding down the rod whenwelding. Use lock pliers orclamp on rod below mould.
Close securely the mouldwith the handle clamp toavoid molten metal losses.
Place the metallic disc, conicalside to bottom, on tap hole.
Open coloured cover of thecartridge size shown on themould tag and pour thealuminothermic powder intothe crucible.
Open black cover of thecartridge and spread all thestarting powder on thewelding powder and on thetop edge of the mould, underopen cover, for easy ignition.
Close the mould cover andplacing the flint ignitor fromaside ignite the startingpowder.
It is advisable, once theignition takes place, to pulliaway the flint igniter quicklyto avoid its damage.
Wait one minute and opencompletely the mould handleclamp to remove the weldedconnection.
During this operation takecare of your graphite mould.
Remove slag from thecrucible and tap hole withthe mould scraper. Removedust from the weld cavity, taphole, crucible and mouldcover with the mould brush.
If the mould is still warm, youcan go on the weldingprocess without pre-heatingit again.
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C-SOL/I08
CABLE / CONCRETE
STEEL RE-BAR
CABLE / CONCRETE
STEEL RE-BAR
CR-PHCR-TL
CR-TP
CR-TH
CR-PV
CR-XS
Standard connectionsStandard connections
CABLE /
CABLE
CABLE /
CABLE
CC-L CC-TH
CC-DPH
CC-TV
CC-X CC-XS
EARTH ROD /
EARTH ROD
EARTH ROD /
EARTH ROD
PP-V
CABLE / EARTH RODCABLE / EARTH ROD
CP-ARCP-TS
CP-T
CP-V CP-VS
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C-SOL/I09
CABLE / STEEL
SURFACE
CABLE / STEEL
SURFACE
CABLE / BUS BARCABLE / BUS BAR
BUS BAR / BUS BARBUS BAR / BUS BAR
PL-LVPL-ARI
PL-TVPL-V
PL-TSPL-DPPL-TH
PL-LH
PL-X
Standard connectionsStandard connections
CABLE / STEEL
PIPE
CABLE / STEEL
PIPE
CT-TH
CH-TH
CH-PHH
CH-TF
CH-PVHCH-TVDCH-TVI CH-PVVCH-VS
CH-VI
CPL-LCPL-T
CPL-H
CPL-VS
CPL-VI
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C-SOL/I10
Instructions for using cartridges'
selection charts
Instructions for using cartridges'
selection charts
CABLE / ... ConnectionsCABLE / ... Connections
1st.- Choose the appropriate
column from the
connections row.
3rd.- Choose the tap cable size
from the chart upper right
side.
2nd.- Go down through the
column until to find the
run cable size.
4th.- The cell where the run cable row and the
tap one column come together, shows the
cartridge type needed to carry out the
connection.
In the following sheets we will find the type of aluminthermic welding cartridge for
all the Standard connections shown before, depending on the specific connection
and type/size of the conductor to be welded as well as the suitable mould handle
clamp and mould scraper.
To avoid mistakes when using the charts, it is advisable to follow the steps set out
below.
Supposing we want to guess the cartridge type suitable for the connection:
CC-TH 185/50
KLK reserves the right to make, without previous notice, changes in size and quantitiy of cartridges needed
to make a weld. The correct size and quantity of cartridges will be always those shown in the mould tag.
CC-XCC-DPHCC-THCC-TV
3525 7050 95
C-45
C-45
C-45
C-65
C-65
C-90
C-90
C-115
C-115
C-115
C-150
C-200
C-32
C-45
C-45
C-45
C-65
C-65
C-90
C-90
C-90
C-115
C-115
C-45
C-65
C-90
C-90
C-90
C-90
C-115
C-115
C-150
C-200
C-250
C-200
C-250
C-65
C-90
C-90
C-90
C-90
C-115
C-150
C-150
C-200
C-250
C-250
2xC-150
C-90
C-90
C-115
C-115
C-150
C-150
C-200
C-200
C-250
2xC-150
2xC-150
CC-XS
25
35
50
70
95
120
150
CC-L
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
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C-SOL/11
CA
BLE
/C
AB
LE
Connecti
ons
CA
BLE
/C
AB
LE
Connecti
ons
Cla
mp
TS
C100
Cla
mp
TS
C80
CC
-DP
HP
lace
cabl
esac
cord
ing
to
the
sket
chab
ove.
CC
-XS
Sam
alle
rca
ble
mus
t be
plac
ed
over
the
larg
eron
e.
CC
-TH
For
240
mm
and
larg
erga
pta
p
cabl
e(S
)5-
6m
m. f
rom
the
run
cabl
e.
2
S
CC
-XC
utth
ela
rger
cabl
ean
dbu
t the
ends
agai
nst t
hesa
mal
ler
one.
CC
-LFo
r24
0m
man
dla
rger
gap
cabl
es(S
)5-
6m
m. u
nder
the
cent
reof
the
tap
hole
.
2
S
CC
-TV
Cut
run
cabl
ean
dga
pit
(S)
5-6
mm
.
unde
rth
ece
ntre
ofth
eta
pho
le. B
ut
tap
cabl
eag
ains
t run
cabl
e.
S
Opera
ting
instr
ucti
ons
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
For
any
other
cable
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
CC
-XC
C-D
PH
CC
-TH
CC
-TV
35
25
120
150
185
240
70
50
95
C-4
5
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
15
C-1
50
C-2
00
C-3
2
C-4
5
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-4
5
C-6
5
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
50
C-2
00
C-2
50
C-6
5
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
50
C-1
50
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-200
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
00
C-2
50
2xC
-150
2xC
-150
2xC
-200
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-200
2xC
-250
C-1
15
C-1
50
C-2
00
C-2
00
C-2
00
C-2
50
C-2
50
2xC
-200
2xC
-200
2xC
-250
C-1
50
C-2
00
C-2
00
C-2
50
2xC
-150
C-2
50
2xC
-200
2xC
-200
2xC
-250
C-2
00
C-2
50
2xC
-150
2xC
-200
2xC
-150
2xC
-250
2xC
-250
CC
-XS
25
35
50
70
95
120
150
185
CC
-L
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
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C-SOL/I12
CA
BLE
/R
OD
and
RO
D/R
OD
Connecti
ons
CA
BLE
/R
OD
and
RO
D/R
OD
Connecti
ons
PP
-V
CP-A
R
Pla
ceen
dof
cabl
eat
the
axis
ofth
eta
p
hole
and
r od
butte
dag
ains
t the
cabl
e.
Use
acl
amp
onr o
dbe
low
mou
ld.
CP-T
S
Inse
rtca
ble
into
the
mou
ldan
dse
cur e
it
toro
dw
ithba
ckin
gpl
ate
atta
cmen
t.U
se
anot
her
clam
pon
r od
belo
wm
ould
.
CP-V
Gap
rod
and
cabl
e(S
)5-
6m
m. a
t
the
axis
ofth
eta
pho
le. U
sea
clam
pon
r od
belo
wm
ould
.
S
CP-V
S
Inse
rtca
ble
until
the
axis
of
the
tap
hole
. Use
acl
amp
onro
dbe
low
mou
ld.
Opera
ting
instr
ucti
ons
143
146
58
183
34
C-2
00
C-2
00
C-2
00
2xC
-150
2xC
-150
PP-V
Upp
erpo
inte
dro
dis
butte
dag
ains
t low
erro
d
and
blun
t rod
isga
pped
(S)
10m
m. a
t the
axis
of
the
tap
hole
. Use
acl
amp
onlo
wer
rod
belo
w
mou
ld.
S
CP-T
For
120
mm
and
larg
ercu
t run
cabl
ean
d
gap
it(S
)5-
6m
mun
der
cent
r eof
tap
hole
. Use
acl
amp
onr o
dbe
low
mou
ld.
2
S
Cla
mp
TS
C100
Cla
mp
TS
C80
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
For
any
other
rod
and/o
rca
ble
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
CP-V
35
25
120
150
185
240
70
50
95
C-6
5
C-6
5
C-6
5
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-6
5
C-6
5
C-6
5
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
00
C-2
00
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-1
50
C-1
50
C-1
50
C-2
50
C-2
50
C-2
50
C-2
50
C-2
50
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-2
50
C-2
50
C-2
50
2xC
-150
2xC
-150
2xC
-150
2xC
-150
2xC
-150
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-2
50
C-2
50
C-2
50
C-2
50
C-2
50
2xC
-200
2xC
-200
2xC
-200
2xC
-250
2xC
-250
2xC
-200
2xC
-200
2xC
-200
CP-A
R
143
146
58
183
34
CP-T
143
146
58
183
34
CP-T
S
143
146
58
183
34
CP-V
S
143
146
58
183
34
143
146
58
183
34
Copper
Alu
min
oth
erm
icW
eldin
gCopper
Alu
min
oth
erm
icW
eldin
g
C-SOL/I13
CR
-TL
CR
-TP
Wra
par
ound
stee
l re-
bar
with
mas
tic, l
eavi
ngsp
ace
betw
een
the
mas
ticla
rger
than
wel
d
cavi
ty. P
lace
cabl
een
dat
cent
re
ofta
pho
le.
CR
-XS
Wra
par
ound
stee
l re-
bar
with
mas
tic, l
eavi
ngsp
ace
betw
een
the
mas
ticla
rger
than
wel
dca
vity
.
Pla
ceca
ble
over
top
ofre
-bar
.
CR
-TH
Wra
par
ound
stee
l re-
bar
with
mas
tic, l
eavi
ngsp
ace
betw
een
the
mas
ticla
rger
than
wel
dca
vity
.
But
t tap
cabl
eag
ains
t re-
bar.
Wra
par
ound
stee
l re-
bar
with
mas
tic, b
elow
the
wel
dca
vity
.
But
t tap
cabl
eag
ains
t re-
bar.
Use
acl
amp
onre
-bar
belo
w
mou
ld.
CR
-PV
Opera
ting
instr
ucti
ons
CR
-PH
Wra
par
ound
stee
l re-
bar
with
mas
tic,
belo
wth
ew
eld
cavi
ty. I
nser
t cab
lein
to
the
mou
ldan
dse
cure
itto
re-b
arw
ith
back
ing
plat
eat
tach
men
t.U
sea
clam
p
onre
-bar
belo
wm
ould
.
Wra
par
ound
stee
l re-
bar
with
mas
tic, l
eavi
ng
spac
ebe
twee
nth
em
astic
larg
erth
anw
eld
cavi
ty. I
nser
t cab
lein
toth
em
ould
aand
secu
re
itto
re-b
arw
ithba
ckin
gpl
ate
atta
chm
ent.
Use
acl
amp
onca
ble
belo
wm
ould
.
CA
BLE
/C
ON
CR
ETE
STEEL
RE
-BA
RC
onnecti
ons
CA
BLE
/C
ON
CR
ETE
STEEL
RE
-BA
RC
onnecti
ons
Cla
mp
TS
C100
Cla
mp
TS
C80
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
For
any
other
re-b
ar
and/o
rca
ble
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
CR
-XS
CR
-TL
CR
-PV
CR
-PH
CR
-TP
CR
-TH
35
25
120
150
185
240
70
50
95
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-1
15
C-1
15
C-1
50
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-1
15
C-1
15
C-1
50
C-1
15
C-1
15
C-1
15
C-1
15
C-1
15
C-1
50
C-1
50
C-1
50
C-2
00
C-1
50
C-1
50
C-2
00
C-1
15
C-1
50
C-1
15
C-1
15
C-1
15
C-1
50
C-1
50
C-1
50
C-2
00
C-1
50
C-1
50
C-2
00
C-1
50
C-1
50
C-1
50
C-1
50
C-1
50
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-2
00
C-1
50
C-1
50
C-1
50
C-2
00
C-2
00
C-2
00
C-2
50
C-2
00
C-2
00
C-2
50
C-2
00
C-2
00
C-2
00
C-2
00
C-2
50
C-2
50
C-2
50
C-2
00
C-2
50
C-2
50
C-2
50
C-2
50
C-2
50
2xC
-150
C-2
50
2xC
-150
10
16
20
10
16
20
10
16
20
10
16
20
10
16
20
10
16
20
C-2
50
2xC
-200
2xC
-150
2xC
-200
2xC
-150
2xC
-200
Copper
Alu
min
oth
erm
icW
eldin
gCopper
Alu
min
oth
erm
icW
eldin
g
C-SOL/I14
CA
BLE
/S
TEEL
SU
RFA
CE
Connecti
ons
CA
BLE
/S
TEEL
SU
RFA
CE
Connecti
ons
CA
BLE
/S
TEEL
PIP
E
Connecti
ons
CA
BLE
/S
TEEL
PIP
E
Connecti
ons
CT-
TH
Pla
ceca
ble
end
atce
ntre
of
tap
hole
. Fill
the
gap
betw
een
cabl
ean
dst
eel w
ithm
astic
outs
ide
the
wel
dca
vity
. Hol
d
dow
non
mol
dco
ver
to
prev
ent m
ould
from
tippi
ng.
Opera
ting
instr
ucti
ons
CH
-PV
HC
H-T
VD
/C
H-T
VI
Fill
the
gap
betw
een
cabl
e
and
stee
l with
mas
ticou
tsid
e
the
wel
dca
vity
. Sec
ure
mou
ldto
the
stee
l sur
face
with
acl
amp,
ifpo
ssib
le.
Pla
ceca
ble
end
atce
ntre
ofta
p
hole
. Fill
the
gap
betw
een
cabl
ean
dst
eel w
ithm
astic
outs
ide
the
wel
dca
vity
. Sec
ure
mou
ldto
the
stee
l sur
face
with
acl
amp,
ifpo
ssib
le.
CH
-PH
HC
H-T
HC
utca
ble
and
gap
it(S
)
3-4
mm
unde
rce
ntre
of
tap
hole
. Hol
ddo
wn
on
mou
ldco
ver
topr
even
t
mou
ldfro
mtip
ping
.
Pla
ceca
ble
end
atce
ntre
ofta
pho
le. H
old
dow
non
mou
ldco
ver
topr
even
t
mou
ldfro
mtip
ping
.
CH
-PV
VC
H-V
IC
H-V
SC
utca
ble
and
gap
it(S
)5-
6m
m
assh
own
abov
e.Fi
llth
ega
p
betw
een
cabl
ean
dst
eel w
ith
mas
ticbe
low
the
wel
dca
vity
.
Sec
ure
mou
ldto
the
stee
l
surf
ace
with
acl
amp,
ifpo
ssib
le.
Cab
leen
dm
ust b
epo
sitio
ned
as
show
nab
ove.
Fill
the
gap
betw
een
cabl
ean
dst
eel w
ith
mas
ticbe
low
the
wel
dca
vity
.
Sec
ure
mou
ldto
the
stee
l
surf
ace
with
acl
amp,
ifpo
ssib
le.
Cab
leen
dm
ust b
e
posi
tione
das
show
n
abov
e.S
ecur
em
ould
to
the
stee
l sur
face
with
a
clam
p,if
poss
ible
.
CH
-TF
Cab
leen
dm
ust b
ebu
tted
agai
nst t
hest
eel s
urfa
ce.
Sec
ure
mou
ldto
the
stee
l
surf
ace
with
acl
amp,
if
poss
ible
.
Cla
mp
TS
C100
Cla
mp
MS
Cla
mp
TS
C80
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
NO
TE:
Moul
dm
ustfit
pipe
shap
eso
whe
nord
erst
ate
ove
rall
diam
etre
of
the
stee
l pip
e.
Ss
For
any
other
cable
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
CT-T
H
C-1
5
C-1
5
C-2
5
C-3
2
C-4
5
C-6
5
10
16
25
35
50
70
CH
-TF
CH
-PH
HC
H-P
VH
CH
-VS
CH
-PV
VC
H-V
IC
H-T
HC
H-T
VD
CH
-TV
I
C-4
5
C-4
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
00
C-4
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
00
C-4
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-4
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
00
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
50
2xC
-150
C-6
5
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
50
2xC
-150
C-9
0
C-1
15
C-1
50
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-150
2xC
-200
C-6
5
C-9
0
C-1
15
C-1
50
C-2
00
C-2
00
C-2
50
2xC
-150
2xC
-150
25
35
50
70
95
120
150
185
240
Copper
Alu
min
oth
erm
icW
eldin
gCopper
Alu
min
oth
erm
icW
eldin
g
Copper
Alu
min
oth
erm
icW
eldin
gCopper
Alu
min
oth
erm
icW
eldin
g
C-SOL/I15
CA
BLE
/B
US
BA
RC
onnecti
ons
CA
BLE
/B
US
BA
RC
onnecti
ons
CP
L-H
CP
L-L
CP
L-V
IIn
sert
end
ofta
pca
ble
even
with
uppe
red
geof
run
bus
bar.
Fill
the
gap
betw
een
cabl
ean
dm
ould
with
mas
ticbe
low
wel
dca
vity
.
CP
L-V
SR
unbu
sba
ris
inse
rted
tose
at
inm
ould
. But
t tap
cabl
eag
ains
t
uppe
red
geof
run
bus
bar.
Run
bus
bar
isin
sert
edto
seat
inm
ould
. But
t tap
cabl
eag
ains
t
uppe
red
geof
run
bus
bar.
But
t end
sof
cabl
ean
dbu
sba
r
unde
rce
ntre
ofta
pho
le
Opera
ting
instr
ucti
ons
CP
L-T
But
t tap
bus
bar
agai
nst s
ide
ofru
nca
ble.
Cla
mp
TS
C100
Cla
mp
TS
C80
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
For
mou
lds
CP
L-V
Sand
CP
L-V
Isu
itable
car t
ridge
shall
be
whic
hco
rres
pon
dto
the
less
wid
ebus
bar
am
ong
thos
eof
the
sam
eth
ickn
ess.
For
any
other
cable
and/o
rbus-
bar
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
CP
L-V
IC
PL-
HC
PL-
TC
PL-
LC
PL-
VS
20x2
25x5
20x5
30x5
50x5
20x3
30x3
40x5
25x3
40x3
60x5
C-3
2
C-4
5
C-4
5
C-4
5
C-6
5
C-4
5
C-4
5
C-4
5
C-6
5
C-9
0
C-1
15
C-1
15
C-1
15
C-1
50
C-4
5
C-6
5
C-6
5
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-4
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-9
0
C-1
15
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
00
C-2
50
C-2
50
C-1
15
C-1
15
C-1
15
C-1
50
C-2
00
C-2
00
C-2
00
C-2
50
C-2
50
C-1
15
C-1
15
C-1
50
C-2
00
C-2
00
C-2
00
C-2
50
C-2
50
C-1
15
C-1
15
C-1
50
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-150
C-1
15
C-1
15
C-1
50
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-150
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
25
35
50
70
95
120
150
185
240
2xC
-150
2xC
-150
2xC
-150
2xC
-200
2xC
-200
C-1
50
C-2
00
C-2
50
2xC
-150
2xC
-150
2xC
-150
2xC
-150
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C-SOL/I16
BU
SB
AR
/B
US
BA
RC
onnecti
ons
BU
SB
AR
/B
US
BA
RC
onnecti
ons
Opera
ting
instr
ucti
ons
PL-
LH
Bus
bar
3m
mth
ick
and
thin
ner
isga
pped
(S)
3m
m
unde
rce
ntre
ofta
pho
le. B
us
bar
thic
ker
than
3m
mis
gapp
ed(S
)5-
6m
m.
S
PL-
LV/
PL-
AR
I
Ens
ofbu
sba
rle
ssth
an30
mm
wid
em
ust b
ecu
t as
show
n
abov
eun
der
cent
reta
pho
le(S
)
5-6
mm
.Bus
bar
wid
erth
an30
mm
(S)
10-1
2m
m.
S
PL-
TV
Inse
rten
dof
tap
bus
bar
even
with
uppe
red
geof
run
bus
bar.
PL-
V
End
ofbu
sba
r6
mm
thic
kan
d
thin
ner
are
gapp
edas
show
n
abov
eun
der
cent
reof
tap
hole
(S)
5-6
mm
.Bus
bar
thic
ker
than
6m
m(S
)10
-12
mm
.
S
PL-
TH
Tap
bus
bar
6m
mth
ick
and
thin
ner
isga
pped
(S)
5-6
mm
from
the
edge
ofth
eru
nbu
s
bar.
Bus
bar
thic
ker
than
6m
m
isga
pped
(S)
10m
m.
S
PL-
TS
Tap
bus
bar
isga
pped
(S)
5-6
mm
from
the
uppe
r
edge
ofth
eru
nbu
sba
r.
Sec
ure
them
with
back
ing
plat
eat
tach
emen
t.
S
PL-
XP
L-D
P
Pla
cebu
sba
rin
the
mou
ldsl
ots.
Inse
rten
dof
tap
bus
bar
until
cent
reof
tap
hole
. Tap
bus
bar
mus
t be
atle
ast 7
0m
m
para
llel t
oth
eru
nbu
sba
r .
70
For
any
other
bus
bar
size
,ple
ase
ask
fact
ory
for
furt
her
info
rmati
on.
Cla
mp
TS
C100
Cla
mp
TS
C80
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
Moul
dsc
rape
r
R-4
5
R-9
0
R-1
50
R-7
50
(For
C-4
5&
C-6
5)
For
C-9
0&
C-1
15)
(For
C-1
50to
C-2
50)
(2xC
-150
to3x
C-2
50
and
Cla
mp
TSC
-100
)
PL-T
SP
L-D
PP
L-L
HP
L-T
HP
L-X
PL-A
RI
PL-V
PL-T
VP
L-L
V
20x2
20x3
20x5
25x3
25x5
30x3
30x5
40x3
40x5
50x5
60x5
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
2xC
-150
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
2xC
-150
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
2xC
-150
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
50
2xC
-150
C-1
15
C-1
15
C-1
50
C-1
50
C-2
00
C-2
00
C-2
50
C-2
50
2xC
-150
2xC
-200
2xC
-250
C-9
0
C-9
0
C-9
0
C-9
0
C-9
0
C-1
15
C-1
15
C-1
15
C-2
00
C-2
00
2xC
-200
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
50
C-1
50
C-2
00
2xC
-150
C-4
5
C-4
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
50
C-1
50
C-2
00
2xC
-150
C-4
5
C-6
5
C-6
5
C-6
5
C-9
0
C-9
0
C-1
15
C-1
15
C-1
50
C-2
00
C-2
50
Copper
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C-SOL/I17
Other KLK-SOLDAL
Aluminothermic Welding
dedicated uses
Other KLK-SOLDAL
Aluminothermic Welding
dedicated uses
For further information, ask factory for dedicated catalogs.For further information, ask factory for dedicated catalogs.
KLK-SOLDAL Aluminothermic Welding
for rail track return power current and
signalling circuits.
KLK-SOLDAL Aluminothermic Welding
for rail track return power current and
signalling circuits.
KLK-SOLDAL Aluminothermic Welding
process for soft welding connections to
high grade rails and steel pipes.
KLK-SOLDAL Aluminothermic Welding
process for soft welding connections to
high grade rails and steel pipes.
KLK-SOLDAL Aluminothermic Welding
for earthing connections Cable / Cable
and Cable / Earth rod using disposable
moulds WON 1 WELD
KLK-SOLDAL Aluminothermic Welding
for earthing connections Cable / Cable
and Cable / Earth rod using disposable
moulds WON 1 WELD
KLK-SOLDAL Rail Aluminothermic
Welding.
KLK-SOLDAL Rail Aluminothermic
Welding.
Copper
Alu
min
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Alu
min
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C-SOL/I18
Electro Materiales, s.a.Electro Materiales, s.a.La Juveria - Tremañes - P.O. Box 333 - 33280 GIJON - SPAIN - Tel. + 34 - 985 32 18 50 - Fax + 34 - 985 31 28 20 - E-mail: [email protected]