Safetrack® Pin Brazing is a patented cable bonding method developed for cathodic protection and railway signalling systems where reliable electrical continuity and long-term corrosion protection are essential. It enables fast, safe and durable cable connections to pipelines, tanks, ships, offshore structures and reinforcement steel.
Using a precisely controlled electronic process powered by 36 VDC, Safetrack® Pin Brazing delivers consistent, high-quality electrical connections in all weather conditions while helping preserve coatings and the integrity of the steel.
What is Pin Brazing?
Pin Brazing is a low-temperature (approximately 650°C) cable bonding process that uses a specially developed silver-based alloy and a controlled electrical discharge to create a molecular silver bond between the cable and the steel. The connection provides an ultra-low transition resistance of approximately 5 µΩ without melting or metallurgically affecting the parent material.
Unlike fusion welding and thermite welding, Pin Brazing minimizes heat transfer, helping preserve protective coatings while delivering a reliable, long-lasting electrical connection.
Why choose Pin Brazing for Cathodic Protection?
Cathodic protection systems depend on secure, low-resistance and long-lasting electrical connections to ensure effective corrosion prevention. Pin Brazing provides a reliable bonding method for connecting cables to pipelines, tanks, ships, offshore structures and reinforcement steel.
Because the process generates significantly less heat than traditional welding methods, the risk of damaging coatings and protective layers is minimized.
Pin Brazing vs. Thermite Welding
Both Pin Brazing and Thermite Welding are used to create permanent electrical cable connections for cathodic protection systems. However, Pin Brazing offers a low-temperature, non-destructive process that preserves the integrity of the steel while providing a reliable, low-resistance connection.
| Feature |
Pin Brazing |
Thermite Welding |
| Working temperature |
Approx. 650°C |
Approx. 2,500–3,000°C |
| Impact on steel |
No metallurgical impact |
Parent material is partially melted |
| Connection method |
Silver-based molecular bond |
Exothermic fusion weld |
| Heat affected zone |
Very small |
Large |
| Installation |
Fast, electronically controlled |
Slower, operator- and mold-dependent |
| Safety |
Low-temperature process |
Molten metal and extreme heat |
| Equipment |
Compact electronic unit |
Molds, welding powder and ignition materials |
| Result |
Consistent, low-resistance connection |
Reliable fusion connection but with higher thermal impact |
Key Benefits of Pin Brazing
- Instant process: Each Pin Brazing connection takes just one second, and the entire procedure is done in minutes.
- Low heat input: The controlled 650°C process helps preserve coatings and surface integrity.
- Material-safe: The parent material remains unaffected.
- All-weather performance: Reliable in rain, snow and windy conditions.
- Ideal for offshore applications: Fast bonding of bracelet anodes on horizontal and vertical pipelines.
- Safe operation: Battery-powered 36 VDC system with no molten metal or open flames.
- Superior conductivity: Molecular silver bonding delivers a transition resistance of approximately 5 µΩ.
- Fully automated: Just pull the trigger – the precision-controlled, 1-second automatic process delivers a perfect bond every time.
Typical Applications
- Cathodic protection systems
- Pipelines and pipeline joints
- Offshore installations
- Ships and marine structures
- Storage tanks
- Reinforcement bars (rebar)
- Steel structures
- Industrial grounding systems
Download the Brochure - Pin Brazing for Cathodic Protection
Offshore Applications
Pin Brazing is widely used on pipe-laying vessels for bonding bracelet anodes to offshore pipelines. The one-second process enables fast installation on both horizontal and vertical surfaces without molds, curing or cooling time.
Pipeline Jumper Bonds
Pin Brazing is an ideal solution for installing jumper bonds across insulated or mechanical pipeline joints, ensuring reliable electrical continuity throughout the cathodic protection system.
Trusted Worldwide
Safetrack Pin Brazing systems are used in more than 85 countries across the pipeline, offshore, marine and railway industries. The technology is used by leading contractors, corrosion specialists and infrastructure owners, including Shell, Saipem, Corrpro, Gazprom and Savcor.
Equipment
Explore our Pin Brazing equipment designed for fast, reliable and repeatable field installation.
Consumables
Learn more about the Pin Brazing consumables used to create reliable electrical connections.
Cable Connection Systems
Pin Brazing is part of Safetrack's complete range of cable connection systems for railway, cathodic protection and industrial applications.