Instructions for making a cast resin socket

In order to connect electric component or cable connections current-free and waterproof, a cast resin sleeve is ideal. Open-ended cable ends, cable lugs and connectors can be cast in and permanently protected and connected. With instructions in four steps, the sleeves are ready for use.

Match processing factors

The art of casting cast resin is the right combination of resin, hardener and additives in quantity, order and time. In addition comes the suitable processing temperature. The technical suitability of the casting resin is specified by the manufacturers in data sheets. For outdoor use, for example underground, previously insurance-related questions should be clarified.

Relevant properties of the casting resin

Unlike decorative cast resin inserts, the characteristics of the resin used must be considered in more detail for joints. In order to use casting resin technically, the following properties must be suitable for the place of use and the stress after hardening:

  • breaking strength
  • elasticity
  • material hardness
  • expansion
  • Heat resistance and fire behavior
  • heat conduction
  • Power line capacity
  • insulating effect
  • Chemical resistance

To pour a cast resin sleeve

  • Two-component casting resin
  • Mold (for example, wet room junction box)
  • If necessary, suitable luster terminals
  • Entisolierer (knife, pliers)
  • Sandpaper 120 grit
  • Screw or clamping tool according to wiring or connections
  • Adhesive tape or PE film

1. Prepare the cable

Isolate the cables according to the intended connection points. Roughen the still sheathed cable strands with abrasive paper as far as they protrude or run through into the later casting resin.

2. Fix connections

Finish the electrical design and installation. Try to place the cable runs so that the liquid resin can spread well on all sides when pouring.

3. Seal the mold

Seal all cable exits with PE foil and / or adhesive tape. Make sure that PE film and adhesive tape are resistant to resin.

4. Pour

Pour the mixed resin slowly and evenly into the mold according to the manufacturer's instructions. It should spread as evenly as possible, so that a pouring in circular movements is recommended.

Tips & Tricks

The more you place the conductive components in the resin sleeve, the more resin surrounds them and the better they are protected. To gain vertical height, it often helps to insert a resin-resistant spacer. In principle, you can clamp or lay a pebble or other inorganic support under the connection installation.

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