Horizontal Bar Terminal to Ground Rod Joint – BR2

Horizontal Bar Terminal to Ground Rod Joint – BR2

SKU: MDBR2xxx Category: Tag:
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SKU: MDBR2xxx Category: Tag:

Product Information:

Horizontal Bar Terminal to Ground Rod Joint – BR2 is a bar to ground rod exothermic welded connection that requires HCD or HCE Handle Clamp.

Features:

A KingsWeld metal consists of copper oxide, aluminium and flux in a granular (powder) form. Comes in standard sizes.

KingsWeld exothermic mould is manufactured from high-quality graphite. This lends itself to easy machining, as well as being able to withstand the high thermal and mechanical shocks produced during the exothermic welding process. The heat obtained in such reactions is in excess of 2000º C.
Our moulds are designed to have an average lifetime of 50 to 60 connections. But, if treated with care, it is possible to obtain a significantly longer life.
Graphite is both brittle and soft, therefore it is important that the operator takes care while handling the product. Worn-out or damaged moulds should not be used.
Each mould has a nameplate, detailing the connection type, part code, and the correct weld metal size to be used.
If you do not see the connection, configuration or size of conductor that you require, please contact our sales office who will be pleased to assist you.

More Information:

To make a KingsWeld connection certain items might be required such as a KingsWeld mould, Handle Clamp, Weld Metal, and/or Flint Gun.

Mould Care Guide:
KingsWeld moulds are manufactured from high quality graphite which, by nature, is soft and needs to be handled with care in order to get the maximum lifetime.

  • Always clean the mould after every weld
  • Only use KingsWeld cleaning equipment (soft brush) to clean the mould
  • Keep the mould dry and away from moisture
  • Do not hit or drop the mould
  • When not in use, keep the mould in its packaging for protection
  • When not in use, keep the mould in its packaging for protection
  • Try not to hit the edges of the mould with the conductors to be connected • Never use a wire brush to clean the mould
  • Always use the correct weld metal size, tools and handle clamps

Mould Inspection:

  • Handle the mould with care.
  • Mould must be dry with fixed lid.
  • Identification plate must be attached.
  • Mould faces must be smooth,so they seal properly.
  • Mould steel disc seat must not show signs of wear, chips or gouges (steel disc must seal the hole properly to prevent weld metal entering the weld cavity prior to welding).
  • Mould steel disc seat must not show signs of wear, chips or gouges (steel disc must seal the hole properly to prevent weld metal entering the weld cavity prior to welding).
  • Tap hole must be well defined.
  • Weld cavity must not show signs of wear, chips or gouges (conductors must have a 3mm gap between them prior to welding, fit snugly and not be loose in the mould).
  • REGULAR CHECKS HELP KEEP MOULDS IN GOOD CONDITION

Mould Sizes:

A (mm)
PRICE KEY
B (mm)
WELD METAL
HANDLE CLAMP
MOULD
12.7
D
20 x 3
#090
HCD
MDBR212.7203
12.7
D
25 x 3
#090
HCD
MDBR212.7253
12.7
D
25 x 4
#090
HCD
MDBR212.7254
12.7
D
30 x 2
#090
HCD
MDBR212.7302
12.7
D
30 x 3
#090
HCD
MDBR212.7303
12.7
D
38 x 3
#090
HCD
MDBR212.7383
12.7
D
40 x 3
#090
HCD
MDBR212.7403
12.7
D
50 x 3
#115
HCD
MDBR212.7503
12.7
D
50 x 6
#250
HCD
MDBR212.7506
14.2
D
20 x 3
#090
HCD
MDBR214.2203
14.2
D
25 x 3
#090
HCD
MDBR214.2253
14.2
D
25 x 4
#115
HCD
MDBR214.2254
14.2
D
25 x 5
#115
HCD
MDBR214.2255
14.2
D
25 x 6
#150
HCD
MDBR214.2256
14.2
D
30 x 2
#090
HCD
MDBR214.2302
14.2
D
30 x 3
#115
HCD
MDBR214.2303
14.2
D
30 x 4
#150
HCD
MDBR214.2304
14.2
D
30 x 5
#150
HCD
MDBR214.2305
14.2
D
30 x 6
#150
HCD
MDBR214.2306
14.2
D
31 x 3
#115
HCD
MDBR214.2313
14.2
D
31 x 6
#150
HCD
MDBR214.2316
14.2
D
38 x 3
#150
HCD
MDBR214.2383
14.2
D
38 x 5
#150
HCD
MDBR214.2385
14.2
D
38 x 6
#200
HCD
MDBR214.2386
14.2
D
40 x 3
#150
HCD
MDBR214.2403
14.2
D
40 x 4
#150
HCD
MDBR214.2404
14.2
D
40 x 5
#150
HCD
MDBR214.2405
14.2
D
40 x 6
#200
HCD
MDBR214.2406
14.2
D
50 x 3
#200
HCD
MDBR214.2503
14.2
D
50 x 4
#200
HCD
MDBR214.2504
14.2
D
50 x 5
#200
HCD
MDBR214.2505
14.2
D
50 x 6
#250
HCD
MDBR214.2506
17.2
D
20 x 3
#150
HCD
MDBR217.2203
17.2
D
25 x 3
#150
HCD
MDBR217.2253
17.2
D
25 x 4
#200
HCD
MDBR217.2254
17.2
D
25 x 6
#200
HCD
MDBR217.2256
17.2
D
30 x 2
#150
HCD
MDBR217.2302
17.2
D
30 x 3
#150
HCD
MDBR217.2303
17.2
D
30 x 4
#250
HCD
MDBR217.2304
17.2
D
30 x 5
#200
HCD
MDBR217.2305
17.2
D
38 x 3
#200
HCD
MDBR217.2383
17.2
D
38 x 5
#200
HCD
MDBR217.2385
17.2
D
38 x 6
#250
HCD
MDBR217.2386
17.2
D
40 x 3
#200
HCD
MDBR217.2403
17.2
D
40 x 4
#200
HCD
MDBR217.2404
17.2
D
40 x 5
#200
HCD
MDBR217.2405
17.2
D
40 x 6
#250
HCD
MDBR217.2406
17.2
E
50 x 3
2 x #150
HCE
MEBR217.2503
17.2
E
50 x 4
2 x #150
HCE
MEBR217.2504
17.2
E
50 x 5
2 x #150
HCE
MEBR217.2505
17.2
E
50 x 6
2 x #150
HCE
MEBR217.2506
16
D
25 x 3
#090
HCD
MDBR216253
20
D
25 x 3
#200
HCD
MDBR220253

12.7, 14.2 and 17.2 = copperbond / 16 and 20 = solid copper/steel

LEGEND:
Conductor Size:
The size of conductors to be joined are denoted by A and B (where applicable). Bar is denoted by its x and y dimensions. Circular conductors are stranded (cable) or solid (ground rod, rebar). Where both stranded and solid circular conductors can be used these are noted in the relevant table footer. Dimensions are given in mm (diameter) unless otherwise stated.

Price Key:
Moulds are priced in bands according to their size and complexity. These are denoted by the price key.

Weld Metal:
Weld metal is sized specifically for each mould. In most cases a single weld metal carton is required. In cases where multiple cartons are required these are denoted by a multiplier (eg 2 x #150).

Clamp:
Each KingsWeld mould type requires a specific clamp. If ordering multiple moulds that utilize the same clamp you only need to purchase a quantity of clamps suitable for the number of operators for your application.

Mould:
Mould part numbers are compiled in a logical manner-prefix ‘MD’ followed by the mould type then followed by size relevant figures (eg CC2 mould to join a 70mm cable to a 50mm cable = MDCC27050).

Sleeve (rail applications):
A copper sleeve that increases the diameter of a small conductor to make it possible to weld the conductor.

Hammer Die:
A hammer die flattens one side of a conductor giving better contact with the rail. Used in rail applications.

The KingsWeld Process:

The KingsWeld exothermic process is a simple, self-contained, efficient way of welding copper-to-copper or copper-to-steel. Click here to see the KingsWeld Exothermic Process.

Each connection uses a KingsWeld weld metal which, when ignited, creates an exothermic reaction between copper oxide and aluminium powder.

The connections are produced inside a graphite mould, specifically designed to suit the size of conductors to be welded as well as the specific joint configuration.
Each connection requires a specific mould designed to suit the joint configuration and conductors being used. Each mould type requires a specific weld metal size.

Once the correct mould and weld metal have been selected, the process is simple and straightforward.

The conductors are positioned in the graphite mould. A steel retaining disc is then inserted into the mould before any weld metal is added. Only after the disc is in place and properly seated can the main weld metal (under the green cap) be poured into the reaction crucible. The ignition temperature of the main weld metal is approximately 1000°C. This is difficult to achieve and so we use a starter powder to start the exothermic reaction, this is contained under the red cap. The starter powder is similar to the main weld metal, but finer, allowing ignition at around 450°C (through using the spark from a flint ignitor).

The resultant exothermic reaction produces high-temperature molten copper (in excess of 2000°C) and aluminium slag.

The molten copper melts the steel retaining disc and flows down the tap hole into the joint cavity. In doing so, the molten copper melts and welds the conductors into a solid homogenous joint.

The whole process takes no more than a few seconds.

The aluminium oxide produced stays on top of the joint and is easily removed.