SYARIKAT LETRIK CHEN GUAN SDN. BHD.

METHOD STATEMENT (MS)

Document No: MS - 10 Effective Date:
Exothermic Welding
Page: 1 of 3

1. GENERAL AND SAFETY INSTRUCTIONS

a) Do not use worn or broken equipment which could cause leakage.

b) When using exothermic welding do not use welding material package if damaged or not fully intact.

c) Welding material is an exothermic mixture and reacts to produce hot molten material with
temperatures in excess of 1400°C (2500°F) and a localized release of smoke. These materials are not
explosive. Ignition temperatures are in excess of 900°C (1650°F) for welding material.

d) Adhering to the exothermic welding procedures will minimize risk of burns and fire caused by hot
molten material spillage. In case of fire, use of CO2 fire extinguisher will aid in control of burning
containers.

e) All governing codes and regulations and those required by the job site must be observed. Always use
appropriate safety equipment such as eye protection, hard hat, and gloves as appropriate to the
application.

2. EXOTHERMIC WELDING PROCESS

a) The exothermic welding process is a method of making electrical connections of copper-to-copper or

copper-to-steel in which no outside source of heat or power is required. In this process, conductors are
prepared, placed in a purpose-designed graphite mold, and exothermically welded to produce a
permanent electrical connection.

b) The steps outlined below are a general demonstration of a typical welded connection. These basic
steps are used for all exothermic welding electrical connections.

Prepared by, Approved by,

 SYARIKAT LETRIK CHEN GUAN SDN. BHD.
METHOD STATEMENT (MS)
Document No: MS - 10 Effective Date:
Exothermic Welding
Page: 2 of 3

3. Exothermic Welding Procedure

a) Always wear protective safety glasses and gloves while working with exothermic welding
product.

b) Gather the proper materials and equipment for the type of connection you are making. The
typical exothermic welding system requires a graphite mold, handle clamp, welding material,
natural bristle brush for mold cleaning, wire brush for cleaning/preparing conductors, flint
igniter, and propane torch.

c) Check to ensure the graphite mold is not worn or broken, which could cause leakage of
molten weld metal during the reaction.

d) Inspect the mold ID tag to ensure that it corresponds to the application, indicated by the:
1. Mold part number.
2. Conductor size.
3. Welding material required.
4. Other materials required.
The mold must be correct for the conductor size and application. DO NOT MODIFY
MOLDS.

e) Remove the small wire bracket which is used to temporarily hold the mold together before
using. Set the bracket aside.

f) Slide the handle clamp into the pre-drilled holes with the proper orientation for the
thumbscrews.

g) Tighten the clamp thumbscrews onto the mold.

h) Close the grips to tightly lock the mold. Check for an appropriate seal on the mold.

i) If the mold does not seal properly, make adjustments to tighten/loosen the handle clamp.

j) Graphite absorbs moisture. Ignite the propane torch and dry out the inside of the mold
thoroughly on both sides, heating the mold to approximately 250 degrees Fahrenheit (120
degrees Celsius).

k) The conductors should be clean and dry before the connection is made. Use a propane torch
to dry wire conductors and remove remaining cleaning residue, solvent, or water before
making the exothermic welding connection.

Prepared by, Approved by,

 SYARIKAT LETRIK CHEN GUAN SDN. BHD.
METHOD STATEMENT (MS)
Document No: MS - 10 Effective Date:
Exothermic Welding
Page: 3of 3

l) Next, use a wire brush to further prepare the surface of the conductors. Scrape the outer surface to
remove dirt and oxidation.

m) Insert the conductors and position them for the connection.

n) Close the clamp tightly once the conductors are properly positioned.

o) Steel disk found inside the packaging box of welding material.

p) Insert the steel disk (concave side up) into the mold. Hold the steel disk on the side of the mold
and let it slide into place.

q) Ensure that the steel disk is properly seated.

r) Next, take a tube of properly sized welding material out of the box.

s) Remove the lid over the mold crucible.

t) Quickly pour the loose welding material powder into the mold.

u) The bottom of the tube contains compressed material (starting material). Tap the bottom of the
tube a couple of times to loosen this material.

v) Pour 1/4 to 1/3 of the starting material over the welding material in the mold crucible.

w) Close the lid and pour the remaining 3/4 to 2/3 of the starting material into the slot on the mold
cover.

x) Aiming the flint igniter from the side, ignite the starting material on the mold cover. Withdraw the
igniter quickly to prevent fouling. Allow approximately 30 seconds for completion of the reaction
and solidification of the molten material.

y) Open the mold and remove the connection. Use care to prevent chipping the mold. Avoid contact
with hot materials.

z) Completed exothermic welding connection.

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