Description
Raytech Magic Joint Straight Cable Joint
Raytech Magic Joint is a cast gel straight joint system for joining 0.6/1kV extruded insulated cables.
The system uses two impact-resistant plastic half-shells together with Raytech Magic Gel. Once the conductors have been joined, the enclosure closes around the cable and the mixed gel fills the joint.
As a result, the completed assembly provides a sealed electrical connection while remaining accessible for future maintenance. Raytech specifies the system as IP68 and suitable for underground and submerged installations.
Magic Joint Features
Key features include:
- Straight cable joint for 0.6/1kV extruded cables
- Filled with two-component Raytech Magic Gel
- IP68 protection
- Suitable for direct burial
- Suitable for installation in pits and ducts
- Suitable for underwater installation
- Re-enterable after installation
- Fast gel cross-linking
- Approximately 10-minute cross-linking at 23°C
- Operating temperature up to 90°C
- Installation temperature from -15°C to +55°C
- Gel classified UL94-HB
- Halogen-free gel
- Wide range of cable sizes
In addition, the soft gel remains flexible rather than becoming a rigid resin block. Therefore, the joint can tolerate external movement and impact without the same cracking behaviour associated with hard casting materials.
Available Magic Joint Sizes
Engineering Supplies currently stocks the following six sizes:
| Product | 1 Core Cu | 2 Core Cu | 3 Core Cu | 4 Core Cu | Max Cable OD | Joint Size |
|---|---|---|---|---|---|---|
| MAGICJOINT025 | 16–150mm² | 4–25mm² | 4–25mm² | 2.5–25mm² | 8–32mm | 215 × 55mm |
| MAGICJOINT035 | 16–185mm² | 16–35mm² | 16–35mm² | 16–35mm² | 12–33mm | 232 × 70mm |
| MAGICJOINT050 | 50–300mm² | 16–50mm² | 16–50mm² | 16–50mm² | 14–34mm | 266 × 72mm |
| MAGICJOINT095 | 120–400mm² | 25–95mm² | 25–95mm² | 25–95mm² | 15–42mm | 330 × 75mm |
| MAGICJOINT120 | 240–500mm² | 70–120mm² | 70–120mm² | 50–120mm² | 25–50mm | 365 × 95mm |
| MAGICJOINT240 | 400–1000mm² | 120–300mm² | 120–240mm² | 120–240mm² | 30–75mm | 510 × 120mm |
These ranges match Raytech’s current 2026 low-voltage catalogue.
Copper & Aluminium Cable Applications
Most of the Magic Joint range covers copper conductors. However, Raytech also specifies selected larger kits for aluminium cables.
For aluminium conductors, the current manufacturer selection includes:
| Magic Joint | 1 Core Al | 2 Core Al | 3 Core Al | 4 Core Al |
|---|---|---|---|---|
| Magic Joint 50 | 16–150mm² | 16–25mm² | 16–25mm² | 16–25mm² |
| Magic Joint 120 | 185–400mm² | 25–95mm² | 25–95mm² | 25–95mm² |
| Magic Joint 240 | 400–630mm² | 95–185mm² | 95–185mm² | 95–185mm² |
Therefore, conductor material should form part of the joint selection process rather than relying only on conductor cross-section or cable diameter.
IP68 Underground Cable Joint
Raytech specifies the completed Magic Joint system with an IP68 degree of protection.
Consequently, the joint suits installations such as:
- Underground cable joints
- Cable pits
- Cable ducts
- Outdoor electrical systems
- Utility installations
- Industrial sites
- Infrastructure projects
- Mining electrical systems
- Submerged cable connections
Correct cable preparation, connector selection and installation remain important to the overall performance of the joint.
Re-Enterable Magic Gel Joint
Magic Joint uses the same flexible insulating technology found in Raytech Magic Gel.
Unlike a conventional hard-setting resin, the gel remains soft after cross-linking. Therefore, technicians can reopen the enclosure and gain access to the connection if inspection, testing or modification becomes necessary.
Furthermore, Raytech states that the joint remains re-enterable even after long periods in service.
Fast Installation
Installation is designed to be straightforward.
First, complete the conductor connection using the correctly selected connector. Next, position the connection inside the joint enclosure and seal the cable entries as required.
The Magic Gel components are then mixed and poured into the shell. After approximately 10 minutes at 23°C, Raytech states that the gel has cross-linked and the joint is ready.
Connector Selection
The Magic Joint enclosure and conductor connector perform different functions.
Therefore, always select the connector according to:
- Conductor material
- Conductor size
- Number of cores
- Cable construction
- Required crimping or connection method
The connector must also be suitable for the relevant electrical installation.
Raytech references CEI EN 50393 testing with connectors complying with EN 61238-1 in its current technical information. This should not be interpreted as a blanket Australian project approval, so any project-specific requirements should still be confirmed before installation.
Magic Joint Straight vs Branch Joints
This product provides an in-line straight cable joint.
Where a branch connection is required instead, see our Raytech Magic Joint Y range.
You can also browse our complete Raytech Casting Joints range for straight, branch and multi-direction joint configurations.
For other Raytech systems, view our main Raytech Electrical Products category.
Raytech Manufacturer Information
For current technical information, visit the Raytech Magic Joint product page.
Raytech specifies the Magic Joint system for 0.6/1kV extruded cables, with IP68 protection, 90°C operating temperature and installation temperatures from -15°C to +55°C.
Buy Raytech Magic Joint in Australia
Engineering Supplies stocks Raytech Magic Joint kits at our Perth warehouse for electrical contractors, utilities, mining companies, infrastructure contractors and industrial customers throughout Australia.
Select the required joint according to conductor material, number of cores, conductor cross-section and cable outside diameter.
For assistance selecting the correct Magic Joint, contact Engineering Supplies on (08) 9258 8444 or email sales@engsup.com.au.
