This document provides an overview of exothermic welding and pin brazing for cathodic protection applications. It describes the benefits of the exothermic welding process such as a rapid reaction that limits heat applied. It reviews components used like graphite molds, weld metals, and electronic ignition options. Pin brazing is described as a quick connection method using low melting point solder. Components of pin brazing units and pins are outlined. Installation instructions are provided for both exothermic welding and pin brazing.

1. Exothermic Welding & Pinning
Brazing for Cathodic Protection
Presented By
Kevin Jones, MBA
NACE CP 1 #16522

2. • The reaction takes place very rapidly limiting the heat
applied to the wire and pipe.
• Will not be affected by a high current surge.
• Current-carrying capacity equal to or greater than
that of the conductors.
Benefits of Exothermic Process

3. Graphite Molds

4. •Made of lightweight graphite
•Capable of handling high repeated temperatures
•Integral handle & cover
Graphite Mold Overview
Wire Size
Pipe
Weld Metal
Mold #
Mold #
Wire Size
Pipe
Weld Metal

5. Weld Footprints
Pipe 4” & Larger
Pipe ¾” – 3 ½”

6. Magnetic Clamps
•Accessory part for both
thermOweld & Cadweld
•Magnetically holds molds In place
•Allows for the installer to remain a
safe distance from the reaction if
used with electronic ignition.
•Works on both steel and iron pipe

7. Chain Clamps
•Holds mold in place on horizontal & vertical
pipe.
•Allows installer to stay a safe distance from the
reaction when using electronic ignition.
•thermOweld version bolts to mold.
•Cadweld version clips onto preinstalled chain
clips.

8. Typical Cathodic Protection Welds

9. Weld Metal

10. • Steel pipe (CP or F-33) – anode leads, test leads and
jumper bonds to steel pipes
• Cast iron pipe (CI or XF-19) - anodes leads, test
leads and jumper bonds to cast & ductile iron pipe
• Electrical Grounding Industry – All non cathodic
protection applications
* ASME B31.8 862.115 Para (B)1 (Steel Pipe) 15 gram maximum weld metal cartridge
* ASME B31.8 826.223 Para (A) (iron type pipe) 32 gram maximum weld metal cartridge
Weld Metal Types

11. • Aluminum & powder copper oxide formula
• Comes tightly packed in moisture resistant tubes.
• Packaged with steel welding disks for holding weld
metal.
• Starting powder packed in the bottom of the tube
• Flint Igniter Required
Traditional Weld Metal Overview

12. Traditional Tube Weld Metal Ignition
Starting Powder Starting Powder
thermOweld Cadweld

13. Cadweld Electronic Ignition
•Requires Ignition Control Unit
•Weld metal comes pre-packaged in convenient “drop in cup”
•Ignition unit has delayed ignition for added safety
•Ignition unit has weather proof sealing gaskets
•Banana plug wire jacks for easy replacement
•Lead wire lengths of 6’ & 15’
•Uses 8 “AA” cell batteries

14. thermOweld Electronic Ignition
•Reaction ignited by electronic igniter sticks
•Electronic ignition stick is placed in starting powder hole of
standard molds
•Ignition unit has flip switch for safety
•Works with traditional tube style weld metal
•Backwards Compatible
•Customizable lead lengths
• Battery Charge Gauge
•Uses 4 “D” Cell Batteries

15. Catalog Part #
Catalog Part #
Lot ID #
Lot ID #
Weld Metal Size
Weld Metal Size
Application Type
Typical Weld Metal Tags

16. Copper Sleeves for
Exothermic Welding

17. Copper Sleeves
•Protects smaller gauge wire from burn through
•Recommended for wires #10STR and smaller
•Acts as a wire alignment gauge
•Allows molds to accommodate several wire sizes

18. Exothermic Weld
Installation & Inspection

19. 1.) Clean pipe 2.) Position conductor 3.) Place metal disc in
bottom of mold crucible
4.) Empty weld metal into
crucible
5.) Close lid & place starting
powder
6.) Remove Slag & clean mold
Traditional Installation Instructions

20. thermOweld Electronic Ignition Instructions
1.) Clean pipe 2.) Position conductor 3.) Place metal disc in
bottom of mold crucible
4.) Empty weld metal
into crucible
8.) Remove Slag &
clean mold
5.) Insert Igniter Stick
Into Remote
6.) Insert Igniter
Into Top of Mold
7.) Press & Hold
Ignition Button

21. Cadweld Electronic Ignition Instructions
1.) Clean pipe 2.) Insert Weld
Metal Container
3.) Attach Control
Unit
4.) Press and Hold
Control Button
5.) Dispose of Cup
8.) Remove Slag &
clean mold

22. Pin Brazing

23. Benefits of Pin Brazing
•Speed of Connection – Quick & Easy
•Low Install Temperature – Low melting point of solder and short
brazing time keeps thermal effects at a minimum
•All weather installation – Application not affected by wind or
rain
•Easy to use – Operators can be trained to use and maintain
equipment in under an hour.

24. Pin Brazer Unit

25. Pin Brazer Facts
•One complete charge will perform about 50 brazed
connections before recharge is needed
•Complete battery charge takes 4-5 hours but unit can be
operated on partial charge
•Versatile connection ability
•No wasted time for clean up

26. Manufacturers of Pin Brazing Units
BAC Safetrack
Two Manufacturers
1.) BAC
2.) Safetrack

27. Important Parts of a Pin Brazer Battery
Grounding Post
Recharge Indicator
Accessory
Plug in Port
Service
Indicator
Charging Port

28. Important Parts of a Pin Brazer Gun
Trigger
Plug
Ferrule
Holder

29. Pin Brazer Pins

30. Pin Brazer Pin Facts
•Silver solder tip creates bonding application
•Multiple pin options
•Only one solder material to choose from to minimize errors
•Silver solder application is safer for the pipe
•Ability to weld larger wire to the pipe without changing heat
applied to the pipe
•Three components: Brazing Pin, Ceramic Ferrule and Wire Terminal

31. Important Parts of a Brazer Pin
Silver Solder
Welding Pin
Threaded Stud (other options available)

32. Proper Installation of Pin Components

33. Typical Connections
Threaded Stud Dead End/Button Connection

34. Accessories

35. Grinder
•Plugs into accessory port on the front of the battery box
•Puts desired surface profile on the welding surface
•Moves at lower RPM’s to lower risk of pipe damage
•Small grinding neck allows for more precise grinding

36. Keyhole Tools
•Works like standard pin brazing gun
•Plugs into accessory port on front of battery box
•Ability to make connections in key hole applications
•Telescoping handle adjusts from 5’ – 8’

37. Installation Instructions
1) Clean Pipe Surface 2) Apply Flux to pipe
and wire
3) Insert braze, electrode &
ferrule in gun
4) Hold gun against
cable lug and pie
5) Pull Trigger

38. Questions?

39. Thank You!