nVent ERICO Cadweld Plus

for Rail
The Reliable Connection that is Safe, Fast and Easy,
from the Worldwide Leader in Exothermic Connection Technology

+1 800.447.RAIL | rail@nVent.com
Table of contents
nVent ERICO Cadweld Plus for Rail...............................................................................................................................................................................3

Why Exothermics..............................................................................................................................................................................................................4

Overview of nVent ERICO Cadweld Plus Rail Applications.......................................................................................................................................4

Overview of the nVent ERICO Cadweld Plus System.................................................................................................................................................5

Installation is Easy!...........................................................................................................................................................................................................6

Selecting nVent ERICO Cadweld Plus...........................................................................................................................................................................7

2 | nVent.com/ERICO
nVent ERICO Cadweld Plus for Rail

Since 1939, nVent ERICO Cadweld has been the rail industry Cadweld Plus contains the same core components as
standard for making critical exothermic cable-to-rail welded Cadweld Traditional, including:
bonds for signal, power and grounding applications. With the
launch of Cadweld Plus for Rail, nVent ERICO has upgraded
the weld material and ignition system components, making
the system SAFER, EASIER and MORE CONVENIENT to
use. Upgrading to Cadweld Plus is easy; the enhancements
contained in Cadweld Plus are compatible with the unchanged
core elements of the Cadweld kit, including the molds, welder
frame, hardware and Bondstrand.
Complete Welder Assembly Bonds and Connectors

CADWELD PLUS ENHANCEMENTS

Enhanced Features Benefits

Plus cups make the Cadweld system EASIER AND MORE CONVENIENT TO USE. By virtually eliminating the
Integrated, Self-contained
risk of weld powder contamination through the use of an innovative self-contained weld pack, it is much easier
Weld Material Package
to make the proper weld the first time. This makes training personnel on Cadweld plus easier as well.

• Weld package (cup) is waterproof and tamper-proof with a longer shelf-life

• No loose powder, means no spilling in the field which ensures that every weld contains the right amount
of ignition power to weld material. Cadweld is an engineered solution, and this formulated ratio is key to
achieving the highest quality weld each, and every time.
Upgrade over
Traditional Blue Tube

nVent ERICO Cadweld Plus Impulse Exothermic Welding Ignition System INCREASES SAFETY for the user
Electronic Ignition System
and nearby personnel.

• With the ignition system, the user performs the weld standing back at a distance of either 6' or 15' - both
cable lead sizes are available. This is a significant safety advantage over a flint gun, which requires the user
to be in close proximity to ignite the weld.
• The control unit features an ergonomic grip with built-in trigger guard to prevent an accidental discharge.
• The ignition timing LED Count Up Display to provide positive feedback on the status of the ignition sequence,
and features a visual battery life indicator.
• Ignition system offers battery unit flexibility with included AA Batteries (Lithium) and optional tool battery
adapters for Milwaukee® 18 V and DEWALT® 20 V batteries.
The control unit
- upgrade over • The control unit meets the recommendations of AREMA® (the American Railway Engineering and
Traditional Maintenance-of-Way Association) C&S Manual Recommendations; Part 8.1.34, 2013.
Flint Ignitor

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Why Exothermics

• Establishes a permanent molecular bond that

will not loosen or corrode, perfectly suited to
perform in the harshest rail conditions
• Has a current carrying capacity equal to or
greater than that of the conductor
• Can withstand repeated fault currents
without failing
• Over-time will maintain a lower resistance
compared to a mechanical connections.

Overview of nVent ERICO Cadweld Plus Rail Applications

EXOTHERMIC WELD KITS FOR SIGNAL & POWER CONNECTIONS, GROUNDING

Applications Connection Type Termination Styles Conductors Sizes Rail Sections

Signal and Power • Joint Head Bond Welder • 3/4" Tab • BONSTRAND 3/16" , 5/16" • 85 lb to 141 lb
Connections styles for bonding inside or • CONCENTRIC 1/0, 2/ 0, 4/0 (AREMA) T-Rail
• 1" Tab
outside joint bar • ROPELAY 1/0, 2/ 0, 4/035 mm² • UIC
• 3/4" XS
50 mm² 95 mm² 120 mm² • R160
• Cable-to web-of-rail
• Head Free • KCMIL 250, 300, 350, 500 • Girder Rail
• Special Trackwork
• Third Rail
• Stud to Rail

Grounding • Cable to Cable, Rail • 3/4" Tab • BONSTRAND 3/16" , 5/16" • 84 lb Composite
Applications for • CONCENTRIC 1/0, 2/ 0, 4/0 • 85 lb Composite
• Cable to Rail • 1" Tab
Rail Properties
• ROPELAY 1/0, 2/ 0, 4/035 mm² • 150 lb Bethlehem
• Cable to Ground Rod or • 3/4" XS
50 mm² 95 mm² 120 mm² • 150 lb Bethlehem
Other Rounds, Rail • Head Free • KCMIL 250, 300, 350, 500 (Inverted)
• Cable to Lug or Busbar, Rail • 85 lb to 150 lb
• Cable to Rebar, Rail T-Rail Sections
• RI52
• Cable to Steel, Rail
• RI59 Girder Rail
• Cable to Cable to Cable, Rail
• 30 lb ASCE
• Busbar to Busbar, Rail • 40 lb ASCE
• Lug or Busbar to Steel, Rail • 60 lb ASCE
• Lug to Rail • 171 lb Crane Rail

• Copper or Steel Stud to Rail

• Cable to Cable to Ground
Rod or Other Rounds, Rail

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Overview of the nVent ERICO Cadweld Plus System
The Cadweld system comes in a kit that is portable and easy to use in the field. It is centered around a graphite mold containing a
weld cavity where a cable is inserted to connect to rail, or to other cables. Above the cavity is a crucible containing a pack of weld
material that, once ignited, liquefies causing molten weld metal to flow into the weld cavity. In a matter of seconds a permanent
molecular bond is formed. nVent ERICO Cadweld Plus for Rail meets the recommendations of AREMA® and Institute of Electrical
and Electronics Engineers (IEEE) standards.

nVent ERICO Cadweld Plus Impulse

Exothermic Welding Ignition System

nVent ERICO provides Ignition count

up LED timer
comprehensive training
and ongoing support for
Cadweld rail customers .
Control unit

nVent ERICO Cadweld Plus for Rail Components

Welder frame

Cable lead

Ignitor strip

Color coded cover

Cadweld Plus Welding Material

Tap hole

Weld cavity

Conductor Graphite mold

+1 800.447.RAIL | rail@nVent.com nVent.com/ERICO | 5

Installation is Easy!
Proper rail surface preparation is paramount for any rail bond connection. Lightly grinding the rail surface, removing surface
oxidation on the conductors, and drying and heating the rail and molds are highlighted in the instruction print. Once the
preparation is completed, the four steps below complete the Cadweld Plus process.

1 2

Insert Cadweld Plus cup into mold. Attach control unit termination clip to ignition strip.

3 4

Release the control unit trigger guard, press and hold the switch and wait for the ignition.

5 6

After reaction, open the mold and remove the expended steel cup – no special disposal required.

6 | nVent.com/ERICO +1 800.447.RAIL | rail@nVent.com

Selecting nVent ERICO Cadweld Plus
NVENT ERICO CADWELD KITS AND COMPONENTS
The nVent ERICO Cadweld Plus for Rail components consist of a welder frame, graphite mold (with available hardware and mold
cleaner), grinding wheel and available grinding tools, weld material and electronic ignition system. Cadweld Plus for Rail is sold in
kits that include various combinations of these products, individual items are also sold separately*. With the exception of the weld
cup(s) and bond strand in use, each of these components is designed for a multiple-use service life. To find and select Cadweld
and Cadweld Plus kits and individual components, visit erico.com and view the sections detailing Rail Bonds and Power Bonds.
E-mail rail@nVent.com to request the nVent ERICO Rail Products Catalog.
nVent ERICO
Welder Frame Bonds and Weld Cadweld
and Mold Setup Connectors Material Plus Impulse
Exothermic
Welding

+ + +
Control Unit

*Acetylene torch, approved grinding wheel and tools are also required. nVent ERICO offers all necessary Cadweld accessories.

NVENT ERICO CADWELD PLUS IMPULSE IGNITION SYSTEM

Components Included in the Impulse Ignition Kit

Control Unit Leads AA Batteries (Lithium) 1 2 3
Adaptor included in kit

Battery Adapters
(Sold Separately)

Part Number Description

PLUSCU2BAA AA Battery Adapter (1), also included in kit
System Kits PLUSCU2BM Milwaukee® 18 V Battery Adapter (2)
Part Number Description
PLUSCU2BD DEWALT® 20 V Battery Adapter (3)
PBPLUSCU2L6 Kit w/ 6' / 1.8m Lead
PBPLUSCU2L15 Kit w/ 15' / 4.5m Lead
nVent ERICO Cadweld Plus
Impulse Exothermic Welding
Control Unit for Rail

Replacement Leads
Download the Data Sheet
Our latest innovation, nVent ERICO Cadweld Plus Impulse Exothermic Welding Control Unit for Rail, brings you the highest level of
flexibility and ease of use of any of our ignition systems. Precision engineered, the control unit lets you choose your power source:
from off-the-shelf AA-batteries to the rechargeable Lithium-Ion packs you have on your job site.
Why should you choose our latest ignition system? Safety, power and ease-of-use.

(Sold Separately)
SAFETY
• Self-closing trigger guard prevents accidental ignition, providing
added safety
• LED ignition counter provides instant feedback on the timing of
the ignition and is visibile in sunny outdoor conditions
• Five second delay in ignition is a safety feature to allow the user

For more information on the nVent ERICO

to stop ignition, if necessary

POWER
• Battery life indicator integrated into the unit for real-time updates
on battery life; compatible with both AA and rechargeable batteries
• Includes AA alkaline batteries to power approximately
600 connections

Part Number Description Cadweld Plus Impulse Exothermic Welding

• Rechargeable batteries from Milwaukee® or DEWALT® can be used
to power approximately 1500 connections using a 4Ah battery
• Battery adapters available for use with either Milwaukee® or
DEWALT® rechargeable batteries (sold separately)

EASE-OF-USE
• High temperature lead with single molded insert into the control
unit keeps the most-often replaced component of ignition systems
more securely attached and reliable

Control Unit
• Easy-to-use alligator clip design of the termination clearly shows
a positive connection in the viewing window
• Enhanced power tool style grip is ergonomic and easy to hold

PLUSCU2RLD6 6' / 1.8m Part Number

PBPLUSCU2L6

PBPLUSCU2L15
Cable Length

6'

15'
Batteries

8 Lithium AA Batteries

8 Lithium AA Batteries
Working Temperature

–40 °F – 140 °F

–40 °F – 140 °F

PLUSCU2RLD15 15' / 4.5m

ERICO-DS-H85619-CadweldIMPULSEControlUnit-USEN-2006 nVent.com/ERICO | 1

CADWELD PLUS WELD MATERIAL CADWELD TOOLS

Part Number Color Code Ring Package Quantity nVent ERICO offers a variety of equipment and accessories for
SB25PLUSF80 Red 20 pc use with Cadweld, including rail grinders, hand tools and more.
SB32PLUSF80 White 20 pc
PB45PLUSF80 Light Blue 20 pc
PB65PLUSF80 Dark Green 20 pc SBG100
PB90PLUSF80 Gray 10 pc Portable Rail
PB115PLUSF80 Orange 10 pc Grinder with
PB150PLUSF80 Dark Blue 10 pc organic grinding
PB200PLUSF80 Yellow 10 pc wheels that
PB250PLUSF80 Purple 10 pc does not leave
PB300PLUSF80 Light Green 10 pc resin on bonding
PB400PLUSF80 Brown 10 pc surface.
PB500PLUSF80 Light Brown 10 pc

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Our powerful portfolio of brands:

CADDY ERICO HOFFMAN RAYCHEM SCHROFF TRACER

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©2020 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. DEWALT is a registered trademark of Black & Decker Corporation. Milwaukee is a registered trademark of Milwaukee Electric Tool
Corporation. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.ERICO-SB-H86085-CadweldPlusForRail-USEN-2006
+1 800.447.RAIL | rail@nVent.com