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Furseweld Introduction FurseWELD Introduction 9 FurseWELD exothermic welding is a cost efficient method of making large or small numbers of high quality electrical connections. The FurseWELD process The FurseWELD connection FurseWELD is a simple, self-contained system that uses FurseWELD connections have several advantages: the high temperature reaction of powdered copper – Tolerant to repeated fault currents oxide and aluminium, within a mould, to form permanent – Highly conductive electrical connections. – Does not loosen – Excellent corrosion resistance Typical applications include: – Earthing for power plants and substations Most FurseWELD connections have at least twice the – Telecommunications cross-sectional area of the conductors being joined, and an – Transmission and power distribution lines equivalent or greater current carrying capacity. Corrosion – Cathodic protection resistance is exceptional because of the very high copper – Rail connections content (> 90%) of the alloy. The FurseWELD system: – Requires no external power or heat source – Creates high quality electrical connections – Completely portable – Can be used safely with minimum training – Cost effective – Can be used for over 45 connection configurations 9/2 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 9 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 9/3 FurseWELD Introduction 1 2 Locate the conductors (A) Locate the steel retaining to be joined in the weld disc in the base of the cavity (B) and close the crucible (D). Pour in the weld mould (C). powder (E) followed by the starting powder (F). F Ignite starting powder with a spark gun. E C D A B A Making a FurseWELD joint is a simple procedure 9 Moulds FurseWELD products The FurseWELD system of exothermic welding uses moulds – A powder cartridge is required for each joint to be made to contain the exothermic reaction that creates safe and – Handle clamps enable the mould to be handled when hot, robust connections. Different types of moulds are available, and the two halves of the mould to be opened and whose use depends on the requirements of the project. clamped together – Packing is required when welding to reinforcing bar Full-sized graphite moulds Market leading FurseWELD graphite moulds are extremely Conductors robust and capable of producing up to 75 connections each, The range of FurseWELD moulds is designed to work with all if not more when properly maintained. common conductor formats. – Flat tape conductor Mini-Moulds – Stranded conductor FurseWELD mini-moulds are a cost effective alternative to – Solid circular conductor full-sized moulds, especially where lower numbers of connections are required. They are smaller overall, less robust Conductors must be in the orientation shown to achieve and therefore lower priced. Care is required in order to the correct connection. Furse offers technical support achieve similar service lives to full-sized moulds. to assist with selection of joint type. Please contact us where unsure, e.g. where you may be using compacted stranded conductor. If connections shown do not meet your requirements, please contact your local sales office. 9/4 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 3 4 The resulting exothermic The molten copper alloy cools to reaction reduces the leave a fusion weld of great mechanical weld powder to molten and electrical integrity. copper alloy which melts the retaining disc and flows into the weld cavity where it partially melts the conductors (G). G SureSHOT 9 The FurseWELD SureSHOT system is a single-use ceramic mould supplied complete with retaining disc and powders. It has been designed for use in applications where only a few connections are required. Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 9/5 FurseWELD Connection selection guide Bar to bar Connection Type Type BB1 Type BB3 Type BB7 Type BB14 Type BB41 Section 9 / Page No. 9/8 9/9 9/10 9/11 9/12 Bar to steel surface Connection Type Type BS1 Type BS2 Type BS3 Section 9 / Page No. 9/13 9/14 9/15 Bar to earth rod Connection Type Type BR1 Type BR2 Type BR7 9 Section 9 / Page No. 9/16 9/18 9/20 Cable to bar Connection Type Type CB1 Type CB4 Type CB5 Section 9 / Page No. 9/22 9/23 9/24 Cable to cable Connection Type Type CC1 Type CC2 Type CC4 Type CC6 Type CC7 Section 9 / Page No. 9/25 9/26 9/27 9/28 9/29 Connection Type Type CC11 Type CC14 Section 9 / Page No. 9/30 9/31 9/6 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 Cable to earth rod Connection Type Type CR1 Type CR2 Type CR3 Type CR17 Type CR24 Section 9 / Page No. 9/32 9/33 9/34 9/35 9/36 Cable to reinforcing bar Connection Type Type CRE1 Type CRE2 Type CRE3 Type CRE6 Type CRE17 Section 9 / Page No. 9/37 9/38 9/39 9/40 9/40 Cable to steel surface & pipe Connection Type Type CS1 Type CS2 Type CS3 Type CS7 Type CS8 Section 9 / Page No. 9/41 9/41 9/42 9/42 9/43 9 Connection Type Type CS9 Type CS25 Type CS27 Type CS32 Type CS34 Section 9 / Page No. 9/43 9/44 9/44 9/45 9/46 Stud to steel surface SureSHOT Connection Type Type RS1 Type RS2 Connection Type Type SS1 Type SS2 Section 9 / Page No. 9/47 9/47 Section 9 / Page No. 9/49 9/49 Conductors must be in the orientation shown to achieve the correct connection Furse offers technical support to assist with selection of joint type. If connections shown do not meet your requirements, please contact your local sales office on +44 (0)115 964 3700 (UK), +971 (0)4 609 1635 (Dubai) or +65 6776 5711 (Singapore) for assistance. Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 9/7 FurseWELD Bar to bar BB1 Bar to bar BB1 - FurseWELD Part no. Flat tape conductor size A Powder Standard Mini (mm) cartridge mould Handle clamp Mini mould handle clamp 20 x 3 45P10 BB1-4-203 HCPK4 BB1-3-203 HCPK3 25 x 3 65P10 BB1-4-253 HCPK4 BB1-3-253 HCPK3 25 x 4 90P10 BB1-4-254 HCPK4 BB1-3-254 HCPK3 25 x 6 150P10 BB1-4-256 HCPK4 – – 30 x 2 65P10 BB1-4-302 HCPK4 BB1-3-302 HCPK3 A 30 x 3 90P10 BB1-4-303 HCPK4 BB1-3-303 HCPK3 30 x 4 115P10 BB1-4-304 HCPK4 BB1-3-304 HCPK3 30 x 5 115P10 BB1-4-305 HCPK4 BB1-3-305 HCPK3 31 x 3 90P10 BB1-4-313 HCPK4 BB1-3-313 HCPK3 31 x 6 150P10 BB1-4-316 HCPK4 – – 38 x 3 115P10 BB1-4-383 HCPK4 – – 38 x 5 150P10 BB1-4-385 HCPK4 – – 38 x 6 200P10 BB1-4-386 HCPK4 – – 40 x 3 115P10 BB1-4-403 HCPK4 – – 40 x 4 150P10 BB1-4-404 HCPK4 – – 40 x 5 150P10 BB1-4-405 HCPK4 – – 40 x 6 200P10 BB1-4-406 HCPK4 – – 50 x 3 150P10 BB1-4-503 HCPK4 – – 50 x 4 200P10 BB1-4-504 HCPK4 – – 50 x 5 200P10 BB1-4-505 HCPK4 – – 9 50 x 6 250P10 BB1-4-506 HCPK4 – – Special moulds for all FurseWELD products can be manufactured to meet specific customer applications on request 9/8 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 FurseWELD Bar to bar BB3 Bar to bar BB3 - FurseWELD Part no. Flat tape Flat tape conductor size A conductor size B Powder Standard Mini (mm) (mm) cartridge mould Handle clamp Mini mould handle clamp 20 x 3 20 x 3 65P10 BB3-4-203203 HCPK4 BB3-3-203203 HCPK3 25 x 3 25 x 3 65P10 BB3-4-253253 HCPK4 BB3-3-253253 HCPK3 25 x 4 25 x 4 90P10 BB3-4-254254 HCPK4 BB3-3-254254 HCPK3 25 x 6 25 x 6 150P10 BB3-4-256256 HCPK4 – – 30 x 2 30 x 2 65P10 BB3-4-302302 HCPK4 BB3-3-302302 HCPK3 A B 30 x 3 30 x 3 90P10 BB3-4-303303 HCPK4 BB3-3-303303 HCPK3 30 x 4 30 x 4 115P10 BB3-4-304304 HCPK4 BB3-3-304304 HCPK3 30 x 5 30 x 5 115P10 BB3-4-305305 HCPK4 BB3-3-305305 HCPK3 31 x 3 31 x 3 115P10 BB3-4-313313 HCPK4 BB3-3-313313 HCPK3 31 x 6 31 x 6 200P10 BB3-4-316316 HCPK4 – – 38 x 3 38 x 3 115P10 BB3-4-383383 HCPK4 – – 38 x 5 38 x 5 150P10 BB3-4-385385 HCPK4 – – 38 x 6 38 x 6 200P10 BB3-4-386386 HCPK4 – – 40 x 3 40 x 3 115P10 BB3-4-403403 HCPK4 – – 40 x 4 40 x 4 150P10 BB3-4-404404 HCPK4 – – 40 x 5 40 x 5 150P10 BB3-4-405405 HCPK4 – – 40 x 6 40 x 6 200P10 BB3-4-406406 HCPK4 – – 50 x 3 50 x 3 200P10 BB3-4-503503 HCPK4 – – 50 x 4 50 x 4 200P10 BB3-4-504504 HCPK4 – – 50 x 5 50 x 5 200P10 BB3-4-505505 HCPK4 – – 50 x 6 50 x 6 250P10 BB3-4-506506 HCPK4 – – 9 Special moulds for all FurseWELD products can be manufactured to meet specific customer applications on request Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 9/9 FurseWELD Bar to bar BB7 Bar to bar BB7 - FurseWELD Part no. Flat tape conductor size A Powder Standard Mini (mm) cartridge mould Handle clamp Mini mould handle clamp 20 x 3 45P10 BB7-4-203 HCPK4 BB7-3-203 HCPK3 25 x 3 65P10 BB7-4-253 HCPK4 BB7-3-253 HCPK3 25 x 4 90P10 BB7-4-254 HCPK4 BB7-3-254 HCPK3 25 x 6 115P10 BB7-4-256 HCPK4 BB7-3-256 HCPK3 30 x 2 65P10 BB7-4-302 HCPK4 BB7-3-302 HCPK3 A 30 x 3 65P10 BB7-4-303 HCPK4 BB7-3-303 HCPK3 30 x 4 90P10 BB7-4-304 HCPK4 BB7-3-304 HCPK3 30 x 5 115P10 BB7-4-305 HCPK4 BB7-3-305 HCPK3 31 x 3 65P10 BB7-4-313 HCPK4 BB7-3-313 HCPK3 31 x 6 150P10 BB7-4-316 HCPK4 – – 38 x 3 90P10 BB7-4-383 HCPK4 – – 38 x 5 150P10 BB7-4-385 HCPK4 – – 38 x 6 200P10 BB7-4-386 HCPK4 – – 40 x 3 90P10 BB7-4-403 HCPK4 – – 40 x 4 115P10 BB7-4-404 HCPK4 – – 40 x 5 150P10 BB7-4-405 HCPK4 – – 40 x 6 200P10 BB7-4-406 HCPK4 – – 50 x 3 150P10 BB7-5-503 HCPK5 – – 50 x 4 200P10 BB7-5-504 HCPK5 – – 50 x 5 200P10 BB7-5-505 HCPK5 – – 9 50 x 6 250P10 BB7-5-506 HCPK5 – – Special moulds for all FurseWELD products can be manufactured to meet specific customer applications on request 9/10 Total Solution to Earthing & Lightning Protection | 9AKK106354A3360 FurseWELD Bar to bar BB14 Bar to bar BB14 - FurseWELD Part no.
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