Heating concrete with a welding machine – connection diagram with a PNSV cable

It is essential to heat concrete, particularly in colder climates where low temperatures can prevent proper curing. To guarantee the concrete sets properly and reaches its maximum strength, one creative technique combines a welding machine with a PNSV cable.

On construction sites, where conventional heating methods might not be practical or efficient, this technique is especially helpful. The PNSV cable is heated with a welding machine, which also heats the concrete from the inside out, distributing heat evenly throughout the structure.

For concrete heating to be both efficient and safe, it is essential to comprehend the connection diagram and correct equipment setup. This technique reduces problems brought on by incorrect curing, which improves the final product’s durability while also saving time.

What is needed to heat concrete

All the necessary preparations must be made before you can connect a welding machine and use it to heat concrete. Consumables and tools are typically easy to locate; anyone who frequently uses a welding machine for its intended purpose can obtain them.

• Transformer – a suitable device with a maximum limit of about 200-250 A.
• PNSV cable – a couple of pieces of the same length.
• Single aluminum wire with a diameter of 2.5-4 square millimeters.
• Cotton tapes for insulation.
• Pliers.
• Current clamps.

• It is necessary to correctly calculate the heating time of the concrete structure – it depends on the average ambient temperature and the thickness of the material layer.
• It is prohibited to overheat the structure excessively – this will affect the quality as detrimentally as freezing of water.
• The poured concrete solution must be covered with a thin layer of sawdust to eliminate the possibility of strong evaporation of water from the mixture and with heat-insulating material to eliminate heat loss.
• Only cables and electrodes suitable for the work may be connected to the welding device.
• A control incandescent lamp is installed to check the voltage.
• The welding circuit should not be short-circuited to the internal concrete reinforcement, as this is too energy-consuming.

Heating with a welding machine – PNSV cable

By attaching PNSV cables to the concrete, a welding machine can be used to heat it. A pre-drawn diagram, a certain level of knowledge, and consideration of several subtleties are needed for this process.

• The device must be powered from a 200-volt household electrical network.
• The design is relatively simple and effective if everything is done correctly.
• This option assumes economy.
• It is possible to significantly reduce the setting time of the concrete mixture.
• The temperature in the monolithic structure can be maintained in automatic mode.

Although the computations are done differently, the working principle is the same as when using oil transformers. Therefore, in order to heat concrete using a welding transformer and PNSV cable, the following items are required: a 150–250 A welding machine; a specific length of PNSV wire; pliers or a common ammeter; an aluminum cold end cable; and regular electrical tape made of fabric.

You can use a 250 A welding machine and a 3.8 cubic meter plate that measures 4x5x0.19 meters at -12 degrees Celsius as an example of how to perform calculations. The PNSV cable is divided into eighteen-meter segments (the length may vary depending on the specific situation; in this case, it was determined empirically).

Up to 25 A of current can be handled by each piece of cable. You can therefore take 10 segments for 250 A. However, it’s wise to leave a little buffer, which is why they take 8 wires in the example. You must screw an aluminum wire long enough to allow the twist to be in the concrete’s thickness onto each of the PNSV pieces on both sides. The ends of the wire, which should be cold, should be connected to the transformer. Electrical tape needs to be used to insulate the twist.

In order to lay the wire sections, they are tied to the reinforcement with insulated wires or plastic fasteners (to prevent short circuits). The wire can be secured beneath the upper reinforcement if the plate is heated.

The ends of the wire outlets are spread out in various directions within the structure, or they are marked with a (-/+). On a surface that has already been terminally insulated, you can also connect the phases (separate minuses and pluses) to one another.

The terminals are then connected to the welding transformer’s direct and reverse outputs and set to the lowest current value before concrete is poured. The current is measured on the segments (up to 20 A) and on the welding wires (up to 240 A should pass through the wires). The device’s current will gradually drop during the heating process, necessitating an increase.

In less than 40 hours, the slabs with the required dimensions finally acquired the necessary strength indicator. After pouring, it is best to cover the concrete with a protective film to keep it from drying too quickly. It is possible to mount a heat-insulating layer on the film if the temperatures are too low.

In cold weather, heating concrete with a welding machine and a PNSV cable is a useful way to speed up the curing process. This technique involves connecting the PNSV cable, a type of heating wire, to a welding machine, which then delivers controlled heat directly to the concrete. By doing this, you can avoid delays and guarantee structural integrity even in cold weather by keeping the concrete at the ideal temperature for curing.

Heating with a welding machine and electrodes

Heating concrete can be accomplished without a welding machine and cable. If you have the right diagram drawn up and have considered every step, you can also use electrodes.

• There is through heating, which is used for concrete structures of complex shape or impressive thickness. This method involves installing electrodes at a distance of at least 3 centimeters from the formwork.
• The peripheral heating method involves the installation of electrodes on the surface of the concrete. This makes it possible to remove all the heating elements after the concrete has hardened.
• The current supplied to the electrodes must be constantly adjusted, since moisture evaporates and this process requires attention.
• The heating surface should be covered with a special heat-insulating material, this will help reduce heat losses while simultaneously increasing the efficiency of the electrodes.
• If rod heating is used, the electrodes must be mounted at the same distance to eliminate the risk of overheating of individual zones.
• Electrode heating is not effective for small products/structures.
• The current temperature of the concrete must be constantly measured at short intervals.
• The correct electrode connection diagram must be created individually for each case.

Electrodes that are inserted into the concrete’s thickness serve as the heating elements in this instance. The method’s primary drawback, the risk of electric shock to those in close proximity, is highlighted by the fact that the current passes straight through the solution. It is crucial to make sure that neither people nor animals are permitted on the property because the safe voltage level is up to 36 V, if not higher. Although it hasn’t been confirmed, some experts believe that using this method can quickly wear down the welding transformer.

In order to create two sections that are isolated from one another, electrodes (reinforcement bars) are inserted into a concrete structure and connected sequentially. One section is wired with a direct wire, and the other with a return wire. It is recommended, though not required, to connect an incandescent lamp to guarantee control of the current between the two electrodes.

To rule out the chance of the hardening solution drying out and cracking, it’s critical to take regular temperature readings of the concrete. To stop moisture and heat loss, a film covering and insulation must be placed on top of the poured structure.

In order to ensure proper curing in cold weather, it is practical to heat concrete with a welding machine using a PNSV cable. By keeping the temperature at the right level, this technique helps to avoid delays and structural problems when the concrete sets properly.

The connection diagram is simple enough that even someone with rudimentary electrical knowledge can understand it. You can successfully use a welding machine to heat the concrete via the PNSV cable if you carefully follow the instructions and make sure all connections are secure.

It’s critical to keep an eye on the temperature and make any necessary adjustments to prevent overheating, which could harm the concrete. Prioritizing safety measures like appropriate insulation and cautious handling of electrical components is always important.

In general, this technique is a productive and economical means of addressing the difficulties associated with concrete curing in cold climates. It is possible to maintain the caliber of your concrete structures and get dependable results with meticulous planning and attention to detail.

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