钢筋焊接施工方案

Reinforcing steel welding construction

scheme

钢筋焊接施工方案

Document No.:文件编号：CNI23-CM-018

Approved：

批 准： Audit：

审 核： Fabrication:

编 制：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

Contents 目录

一、Project overview工程概况......................................1-3 二、Fabrication basis编制依据.....................................3-3 三、Application scope适用范围.....................................3-3 四、Manual electric arc welding手工电弧焊..........................4-9 五、Flash butt welding闪光对焊...................................9-13 六、Reinforcing steel electroslag pressure welding钢筋电渣压力焊„14-15 七、Safety attentions安全注意事项................................16-16

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

一、Project overview工程综述：

This project is Linde Huayi(Chongqing) Gases Co., Ltd 1 Billion Nm3/year Syngas CO/H2 project, located in Chongqing(Changshou) Chemical Industry Park, and the main work contains substation、office、parts stock、pressure swing adsorption unit, MDEA washing unit 1， MEDA washing unit 2, high temperature shift unit, feed gas compression unit 1，feed gas compression unit 2，DEOXO unit 1，DEOXO unit 2， temperature swing adsorption unit 1， temperature swing adsorption unit 2， cold box 1， cold box 2， compression unit 1，compression unit 2， compression unit. The foundation bed is C15 concrete; the unit foundation is using C30 concrete. Together with concrete roads, a total of about 20000 party site concrete.

本项目为林德化医（重庆）气体有限公司10 亿Nm3/年合成气制备CO/H2 项目，位于重庆（长寿）化工园区内， 其中主体工作包括变电所、办公楼、备件仓库、变压吸附单元、MDEA洗涤单元1、 MEDA洗涤单元2、高温变换单元、原料气压缩单元1、原料气压缩单元2、DEOXO单元1、DEOXO单元2、变温吸附单元1、变温吸附单元2、冷箱单元1、冷箱单元2、压缩单元1、压缩单元2、压缩单元。基础垫层C15混凝土，单元基础采用C30混凝土。加之混凝土道路等，现场混凝土总量约20000方。

The unit equipment district covers an area of, equipment foundation, on the welding requirement of reinforcing steel joint is high. In order to

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

ensure the construction safety、quality、high efficiency and especially the preparation of the scheme.

本单元设备装置区占地面积大，设备基础多，对钢筋接头焊接要求高。为保证施工安全、优质、高效完成，特编制本方案。 二、Fabrication basis编制依据：

Related construction drawing and design requirement

相关施工图纸及设计要求

《Reinforcing steel welding and acceptance specification》JGJ18-2012 《钢筋焊接及验收规程》JGJ18-2012

《Technical specification of reinforcing steel mechanical》JGJ107-2010 《钢筋机械连接技术规程》JGJ107-2010

《Upsetting straight thread reinforcing steel joint》JGJ71-2005 《镦粗直螺纹钢筋接头》JGJ71-2005

三、Application scope适用范围：

Reinforcing steel connection shall adopt binding、mechanical and welding. Foundation raft board and beam steel shall adopt manual electric arc welding、flash butt welding; And the column and bar shall adopt electroslag pressure welding.

本工程钢筋连接采用绑扎连接、机械连接和焊接。基础筏板、梁钢筋采用手工电弧焊、闪光对焊；柱筋采用电渣压力焊。 四、手工电弧焊：

4.1、Construction preparation施工准备： 4.1.1、Material and main tools材料及主要机具：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

4. 1.1.1 Reinforcing steel: the grade and diameter of reinforcing steel shall meet the design requirement, and have merchandise certification and retest report. The imported bar also shall have chemistry retest report, chemical composition shall meet welding requirement, and the solderability test. The anchor fluke of embedded parts shall adopt I、II grade bar, which shall not old rusty and greasy oil.

钢筋：钢筋的级别、直径必须符合设计要求，有出厂证明书及复试报告单。进口钢筋还应有化学复试单，其化学成分应满足焊接要求，并应有可焊性实验。预埋件的锚爪应用Ⅰ、Ⅱ级钢筋。钢筋应无老锈和油污。

4. 1.1.2 Steel products: the steel products of embedded parts shall not crack、corrosion、cicatrix、deformation, and its cross dimensions and mechanical properties shall meet design requirement.

钢材：预埋件的钢材不得有裂缝、锈蚀、瘢痕、变形，其断面尺寸和机械性能应符合设计要求。

4. 1.1.3 Welding rod: welding rod brand shall meet design regulation. If no regulation in design, it shall meet following requirement and the quality of welding rod also shall meet following requirement: 焊条：焊条的牌号应符合设计规定。如设计无规定时，应符合下表的要求，焊条质量应符合以下要求：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

The welding rod brand of reinforcing steel electric arc welding

钢筋电弧焊使用的焊条牌号

Overlap welding、 ligating bud welding

Groove welding ItemBar grade

项次 1 2 3 4 钢筋级别 Ⅰ级 Ⅱ级 Ⅲ级 Ⅰ、Ⅱ级与钢板焊接 搭接焊、帮条焊 坡口焊 E4303 E4303 E4303 E4303 E4303 E5003 E5003 E5003 E5003 E4303 E4303 4.1.1.3.1 The welding rod coating surface shall not crack、pore and irregularity defects, and not with the naked eye can see that the eccentricity.

焊条药皮表面应无裂缝、气孔、凹凸不平等缺陷，并不得有肉眼看得出的偏心度。

4.1.1.3.2 During welding, the electric arc shall combustion stability, coating uniform melting and without blocking drop phenomenon. 焊接过程中，电弧应燃烧稳定，药皮熔化均匀，无成块脱落现象。 4.1.1.3.3 Welding rod must accord to requirement of welding rod instructions to stoving, and then using.

焊条必须根据焊条说明书的要求烘干后才能使用。

4.1.1.3.4 Welding rod must have merchandise certification and

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

batch number.

焊条必须有出厂合格证、批号。

4.1.1.4 Arc welding machine、welding cable tray、electric welding pliers、helmet、chipper、wire brush、file、hammer and angle grinder etc.

弧焊机、焊接电缆、电焊钳、面罩、堑子、钢丝刷、锉刀、榔头、角磨机等。

4.1.2、Work conditions作业条件：

4.1.2.1 Welder must have welder certification (original copy).

焊工必须持有焊工证(原件)。

4.1.2.2 The steel bar ligating bud welding size、crevasse angle、reinforcing steel termination clearance、joint position and reinforcing steel axis shall meet regulation.

帮条尺寸、破口角度、钢筋端头间隙、接头位置以及钢筋轴线应符合规定。

4.1.2.3 Power source shall meet requirement.电源应符合要求。 4.1.2.4 Working site shall have safety protection facilities、fireproof and necessary ventilation system, to avoid the occurrence of burn、shock、poisoning and fire accidents.

作业场地要有安全防护设施、防火和必要的通风措施，防止发生烧伤、触电、中毒及火灾等事故。

4.1.2.5 Familiarity with drawing, do well technical disclosure.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

熟悉图纸，做好技术交底。 4.2、Operation process操作工艺： 4.2.1 Process procedure工艺流程：

检查设备 Select welding parameter 施焊 选择焊接 参数 Test welding work, test 质量检验 Start welding 试焊接作业 试件 Quality inspection Send samples送试 Determine welding parameter 确定焊接 参数

4.2．2 Check power source、welding machine and tools. Welding machine grounding wire shall reinforce with good contact, to prevent arcing and burn reinforcing steel.

检查电源、焊机及工具。焊机地线应与钢筋接触良好，防止因起弧而烧伤钢筋。

4.2.3 Select welding parameters. According to the rebar grade、diameter、 joint type and weld location, select the appropriate electrode diameter、welding layer and welding power source, ensure the welding seam and the steel has good fusion.

选择焊接参数。根据钢筋级别、直径、接头型式和焊接位置，选择适宜的焊条直径、焊接层数和焊接电源，保证焊缝与钢筋熔合良好。 4.2.4 Welding test、simulation test. Before each batch of reinforcing steel formally welding, it shall be weld 3 simulated specimens by tension test, after the test, then can be batch production according to the determined welding parameters.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

试焊、做模拟试件。在每批钢筋正式焊接前，应焊接3个模拟试件做拉力试验，经试验合格后，方可按确定的焊接参数成批生产。 4.2.5 Start welding operation施焊操作：

4.2.5.1 Arc strike: with shim plate or steel bar ligating bud welding joints, arc shall be on the steel plate or steel bar ligating bud welding to carry out. Without reinforcing steel shim plate or steel bar ligating bud welding of the joint, arc strike shall be at position that formed welding seam, to prevent burns main reinforcement.

引弧：带有垫板或帮条的接头，引弧应在钢板或帮条上进行。无钢筋垫板或无帮条的接头，引弧应在形成焊缝的部位，防止烧伤主筋。 4.2.5.2 Location: when welding, it shall first weld anchor point then start welding.

定位：焊接时应先焊定位点再施焊。

4.2.5.3 Arc manipulation: when arc manipulation, the straight forward、lateral run out and feeding welding rod three action shall coordinate smooth.

运条：运条时的直线前进、横向摆动和送进焊条三个动作要协调平稳。

4.2.5.4 Put out arc: when put out electric arc and pull out, molten pool shall be filled with, pay attention not on the work surface by arc scratch.

收弧：收弧时，应将熔池填满，拉灭电弧时，应将熔池填满，注意不要在工作表面造成电弧擦伤。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

4.2.5.5 Multi-layer welding: if reinforcing steel diameter larger, it shall need for multi-layer welding, and shall be stratified discontinuous welding, after welding each layer shall be scarfing cinder, then do next layer welding. It shall ensure the height and length of welding seam. 多层焊：如钢筋直径较大，需要进行多层施焊时，应分层间断施焊，每焊一层后，应清渣再焊接下一层。应保证焊缝的高度和长度。 4.2.5.6 Fusion: Welding process shall have sufficient penetration. Main welding seam and location welding seam shall be combined with good, avoid the blowhole、 slag inclusion and burn defect, and to prevent cracks.

熔合：焊接过程中应有足够的熔深。主焊缝与定位焊缝应结合良好，避免气孔、夹渣和烧伤缺陷，并防止产生裂缝。

4.2.5.7 Flat welding: When flat welding, it shall pay attention to molten slag and hot metal mixed unclear phenomenon, to avoid molten slag flow to the molten iron front. Molten pool also shall control into oval, generally use the rightward welding, welding rod with work surface at an angle of 70°.

平焊：平焊时要注意熔渣和铁水混合不清的现象，防止熔渣流到铁水前面。熔池也应控制成椭圆形，一般采用右焊法，焊条与工作表面成70°。

4.2.5.8 Vertical welding: When vertical welding, hot metal and slag separation. It shall avoid To prevent the molten pool temperature is too

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

high, iron drop formation overlaps, operation rod and vertical surface forms a 60 ° ~80 ° c. Make the arc slightly upward, blown into the molten pool center. Welding the first, should press the arc to operation, at the same time as the smaller lateral swing, the remaining layers semicircular lateral sway and pick up welding arc method.

立焊：立焊时，铁水与熔渣易分离。要防止熔池温度过高，铁水下坠形成焊瘤，操作时焊条与垂直面形成60°~80°角。使电弧略向上，吹向熔池中心。焊第一道时，应压住电弧向上运条，同时作较小的横向摆动，其余各层半圆形横向摆动加挑弧法向上焊接。 4.2.5.9 Horizontal position welding: Welding rod inclination of 70 ° ~80 °, preventing molten iron by gravity to the factory on the sinker groove. When the mouth to uphill, it shall without arc travel quickly to pause, downhill to the roots of the mouth with tiny transverse pulling arc action, followed by uniform welding.

横焊：焊条倾斜70°~80°，防止铁水受自重作用坠到厂坡口上。运条到上坡口处不作运弧停顿，迅速带到下坡口根部作微小横拉稳弧动作，依次匀速进行焊接。

4.2.5.10 Overhead: When overhead, it shall use low current, the fusion place shall thin and keep combine with base material perfectly. Before and after the first layer of welding shall be pushed –pulled action with short arc, and keep welding rod inclination of 80° ~90 ° with welding direction . The remaining layers electrodes yaw, and a little

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

pause in the elbow side arc stability and to ensure the both sides of fusion.

仰焊：仰焊时宜用小电流短弧焊接，溶地宜薄，里应确保与母材熔合良好。第一层焊缝用短电弧作前后推拉动作，焊条与焊接方向成80°~ 90°角。其余各层焊条横摆，并在坡口侧略停顿稳弧，保证两侧熔合。

4.2.5.11 Steel bar ligating bud welding钢筋帮条焊：

4.2.5.11.1 Steel bar ligating bud welding is applied to Ⅰ、Ⅱ、Ⅲgrade steel bar. Welding of double sides shall be used by steel bar ligating bud welding, and if not used welding of double sides, it can use welding of one side, but it shall ensure have enough spacing. Steel car ligating bud welding shall adopt the steel bar that same grade and diameter to fabricate, the length of steel bar ligating bud see the following table. As for the steel bar ligating grade and the main steel bar is at the same time, the diameter of steel bar diameter shall smaller than main steel bar for one specification. As for the steel bar ligating diameter and the main steel bar is at the same time, the grade of steel bar ligating shall lower than the main bar.

钢筋帮条焊适用于Ⅰ、Ⅱ、Ⅲ级钢筋。钢筋帮条焊宜采用双面焊；不能进行双面焊时，也可采用单面焊，但必须保证有足够的间隙。 帮条宜采用与主筋同级别、同直径的钢筋制作，其帮条长度见下表。如帮条级别与主筋相同时，帮条的直径可以比主筋直径小一个规格。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

如帮条直径与主筋相同时，帮条钢筋可比主筋低一个级别。 4.2.5.11.2 The welding seam thickness (h) of steel bar ligating joint shall not less than 0.3d, and the width shall not less than 0.7d.

钢筋帮条接头的焊缝厚度h应不小于0.3d，焊缝宽度b不小于0.7d.

The length of steel bar ligating

钢筋帮条长度

Item 项次 Grade 钢筋级别 Specification of Steel bar ligating welding seam 焊缝型式 Welding of one side 单面焊 1 Ⅰ级 Welding of double sides 双面焊 Welding of one side 单面焊 2 Ⅱ级 Welding of double sides 双面焊 Notice: d is the diameter of main steel bar.

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length 帮条长度l ≥8d ≥4d ≥10d ≥5d 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

注:d为主筋直径。

4.2.5.11.3 When steel bar ligating, the assembly and welding of steel bar shall meet following requirements:

钢筋帮条焊时，钢筋的装配和焊接应符合下列要求： a. It shall remain 2~5mm between two main steel bar termination. 两主筋端头之间，应留2～5mm的间隙。

b. It shall use 4 points positioning method to firm steel bar ligating and main steel bar, and the distance from location welding seam to steel bar ligating shall more than 20mm.

帮条与主筋之间用四点定位固定，定位焊缝应离帮条端部20mm以上。

c. When welding, the arc strike shall start in steel bar ligating end, and finish shall in termination, and filling in arc strike. The first welding seam shall have sufficient penetration, main welding seam and weld positioning, especially in the beginning and terminal welding seam positioning, shall be good fusion. 焊接时，引弧应在帮条的一端开始，收弧应在帮条钢筋端头上，弧坑应填满。第一层焊缝应有足够的熔深，主焊缝与定位焊缝，特别是在定位焊缝的始端与终端，应熔合良好。 4.2.5.12 Steel bar overlap welding钢筋搭接焊：

4.2.5.12.1 Steel bar overlap welding: it apply for the I、II、III grade steel bar. When welding, it shall use welding of double sides. If the

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

welding of double sides cannot use, it also adopt welding of one side. The overlap and steel bar ligating shall associate with same length; see the table 4-15.

钢筋搭接焊：适用于Ⅰ、Ⅱ、Ⅲ级钢筋。焊接时，宜采用双面焊。不能进行双面焊时，也可以采用单面焊。搭接长度l应与帮条长度相同，见表4-15。

4.2.5.12.2The welding seam height of overlap joint shall not less than 0.3d, and the welding seam width shall not less than 0.7d.

搭接接头的焊缝高度h应不小于0.3d,焊缝宽度b不小于0.7d。 4.2.5.12.3When overlap welding, the assembly and welding of steel bar shall meet the following requirements: 搭接焊时，钢筋的装配和焊接应符合下列要求：

a. When overlap welding, the main steel shall pre-springing to ensure axis of two steel bars at the same axis. Under the field fabrication member installation conditions, the overlap welding of steel bar shall in the panel point, and if there have problems in steel bar pre-springing, it shall appropriate pre-springing.

搭接焊时，钢筋应预弯，以保证两钢筋的轴线在一轴线上。 在现场预制构件安装条件下，节点处钢筋进行搭接焊时，如钢筋预弯确有困难，可适当预弯。

b. Lap welding with two fixed positioning welds shall be away from the lap end 20mm or more.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

搭接焊时，用两点固定，定位焊缝应离搭接端部20mm以上。 c. Welding arc shall be at one end of the starter bars start closing arc shall be in the lap of the head of the reinforcement end, shall fill the crater. The first layer of the weld shall have a sufficient depth of penetration, the main seam and positioning weld, especially in the positioning the weld starting end and the terminal shall be good fusion.

焊接时，引弧应在搭接钢筋的一端开始，收弧应在搭接钢筋端头上，弧坑应填满。第一层焊缝应有足够的熔深，主焊缝与定位焊缝，特别是在定位焊缝的始端与终端，应熔合良好。

4.2.5.13 The embedded parts arc welding of T-joints: the embedded parts T-joint arc welding joint form paste fillet weld and perforation plug welding two points.

预埋件T形接头电弧焊：预埋件T形接头电弧焊的接头形式分贴角焊和穿孔塞焊两种。

When welding, it shall meet the following requirements: 焊接时，应符合下列要求：

4.2.5.13.1 The steel plate thickness shall not less than0.6d, and not less than 6mm.

钢板厚度δ不小于0.6d,并不宜小于6mm。 4.2.5.13.2

Steel bar shall be used to grade Ⅰ, Ⅱ. By anchoring bar diameter not less than 8mm, the structure anchoring rebar diameter not less than

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

6mm. Anchor bars within 6 ~ 25mm in diameter, can be affixed to the foot welding; anchor bars diameter of 20 ~ 32mm, the appropriate use perforated plug welding.

钢筋应采用Ⅰ、Ⅱ级。受力锚固钢筋直径不宜小于8mm，构造锚固钢筋直径不宜小于6mm。锚固钢筋直径在6～25mm以内，可采用贴脚焊；锚固钢筋直径为20～32mm时，宜采用穿孔塞焊。 4.2.5.13.3 Site installation conditions, each from floors in the same type of connector 300 (with rebar level, the same type of connector, welding position) as a group, less than 300, still as a group.

在现场安装条件下，每一至二楼层中以300个同类型接头（同钢筋级别、同接头型式、同焊接位置）作为一批，不足300个时，仍作为一批。

Inspection method: inspect welding test-pieces and test report. 检验方法：检查焊接试件试验报告单。 4.3Quality standard质量标准：

4.3.1

Basis item: The operator shall examine individual joints after

cleaning residue weldment appearance quality inspection results should meet the following requirements:

基本项目：操作者应在接头清渣后逐个检查焊件的外观质量，其检查结果应符合下列要求：

4.3.1.1 Welding

surface is smooth, without a large depression, welding

tumor.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

焊接表面平整，不得有较大的凹陷、焊瘤。

4.3.1.2It shall not have crack in joints.接头处不得有裂纹。 4.3.1.3 Undercut depth, porosity, and the number and size of the slag, and connector size deviation, the following table shall not exceed the values specified.

咬边深度、气孔、夹渣的数量和大小，以及接头尺寸偏差，不得超过下表所规定的数值。

The size deviation of steel bar electric arc joint and allowance of

defects

钢筋电弧接头尺寸偏差及缺陷允许值（mm）

Allowance Item Project项目 项次 允许偏差 Vertical offset of steel bar ligating along Measuring tap1 the joint centerline 帮条沿接头中心线的纵向偏移 Joints bend 4° 2 T-joint steel bar 不大于10 spacing embedded parts 尺量 Measuring tap 0.5d 尺量 检验方法 deviation method Inspection - 18 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

接头弯折 预埋件T形接头钢筋间距 The axis offset of steel 3 bar in joints 0.1d and not Measuring tapless than 3 尺量 接头处钢筋轴线的偏移 0.1d且不大于3 Welding seam undercut +0.05d 4 depth 0 焊缝咬边深度 Welding seam width 5 焊缝宽度 Welding seam length 6 焊缝长度 Lateral undercut depth 7 横向咬边深度 The number and size of 2 pieces、6mm² weld porosity and slag in for 3, diameter the long 2d weld surface 8 embedded parts of the 2个、6mm²3个，T-shaped porosity connector 直径不大于1.5 not less than 1.5 目测 Visual 0.5 目测 Visual -0.5d 0 Measuring tap尺量 0.1d 尺量 Measuring tap - 19 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

焊缝气孔及夹渣的数量和大小在长2d的焊缝表面上预埋件T形接头气孔 Notice: 注：1. d is the steel bar diameter.

d为钢筋直径。

2. Negative temperature undercut depth not greater than 0.2mm.

负温下，咬边深度不大于0.2mm。

Visual inspection of the failed joint, trimmed or reinforcing submit secondary acceptance.

外观检查不合格的接头，经修整或补强后可提交二次验收。 Inspection method: visual observation or measurement. 检验方法：目测或量测。 4.4Finished product protect成品保护：

Note banding has good protection of the steel skeleton, the improper step indiscriminate demolition, non-stick oil, construction, demolition of the chaos of the skeleton to be seriously repair the steel skeleton reinforced the correct position.

注意对已绑扎好的钢筋骨架的保护，不乱踩乱拆，不粘油污，在施工中拆乱的骨架要认真修复，保证钢筋骨架中各种钢筋位置正确。 4.5The quality problems shall pay attention to应注意的质量问题：

4.5.1 Check for the dimension, groove angle, steel bar termination

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

gap, reinforced axis offset, and the surface quality of steel material, when not meet the requirements, it shall not be welded.

检查帮条尺寸、坡口角度、钢筋端头间隙、钢筋轴线偏移，以及钢材表面质量情况，不符合要求时不得焊接。

4.5.2 Take the wiring shall be in good contact with the steel bar, and it must not indiscriminate to take, prevent arcing.

搭接线应与钢筋接触良好，不得随意乱搭，防止打弧。

4.5.3 Joints with steel plate or steel bar ligating, arc strike shall carry out on steel plate or steel bar ligating. Without steel plate or steel bar ligating joints, arc strike shall in the form position of welding seam, not free to arc strike, to prevent burns main steel bar.

带有钢板或帮条的接头，引弧应在钢板或帮条上进行。无钢板或无帮条的接头，引弧应在形成焊缝部位，不得随意引弧，防止烧伤主筋。

4.5.4 According to the rebar grade, diameter, joint type and weld location, select the appropriate diameter of electrode and welding current, weld reinforcement and ensure good fusion.

根据钢筋级别、直径、接头型式和焊接位置，选择适宜的焊条直径和焊接电流，保证焊缝与钢筋熔合良好。

4.5.5 Slag welding process in a timely manner, the surface of the welding seam shall smooth and weld appearance, to strengthen the welds smooth transition, shall fill the crater.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

焊接过程中及时清渣，焊缝表面光滑平整，焊缝美观，加强焊缝应平缓过渡，弧坑应填满。 4.6、Quality record质量记录

This process standard shall have following quality record: 本工艺标准应具备以下质量记录：

4.6.1 Steel bar ex-factory certificate or test report. 钢筋出厂质量证明书或试验报告单。

4.6.2 Steel bar mechanical performance test report. 钢筋机械性能试验报告。

4.6.3 Homemade steel bar in the process of brittle fracture, welding performance bad and mechanical performance was not bad normal, it shall have chemical composition inspection report.

国产钢筋在加工过程中发生脆断、焊接性能不良和机械性能显著不正常的，应有化学成分检验报告。

4.6.4 Steel bar joint stretching test report. 钢筋接头拉伸试验报告。

4.6.5Embedded parts T type joint stretching test report. 预埋件钢筋T形接头拉伸试验报告。 4.6.6 Welding rod ex-factory certificate. 焊条出厂合格证。

五、Flash butt welding闪光对焊

5.1、Construction preparation 施工准备

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

5.1.1 Material and main tools材料及主要机具：

5.1.1.1 Steel bar: the grade、diameter of steel bar shall meet the design requirement, and have ex-factory certificate and retest report.

钢筋：钢筋的级别、直径必须符合设计要求，有出厂证明书及复试报告单。

5.1.1.2 Main tools: Butt welder and supporting platform, protective dark glasses, welding gloves, insulated shoes, steel bar cutting machine, air compressors, water, rust remover or a wire brush, and cold drawn straightening job line.

主要机具：对焊机及配套的对焊平台、防护深色眼镜、电焊手套、绝缘鞋、钢筋切断机、空压机、水源、除锈机或钢丝刷、冷拉调直作业线。

Commonly butt-welder main technical data see following table 常用对焊机主要技术数据见下表

Commonly butt-welder main technical data

常用对焊机主要技术数据

Welding machine model 焊机型号 Dynamic fixture Transmission 动夹具传动方式

UN1-50 UN1-75 UN1-100 UN2-150 UN17-150-1 Leverage compression spring(manpower control) 杠杆挤压弹簧 - 23 -

Motor Gas---hydraulic cam 电动pressure 气—液压 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

（人力操纵） 机 凸轮 Rated capacitykVA 额定容量 Cyclic duration factor 负载持续率 Power source 、V voltage 电源电压 Secondary voltage 次级电压 V The range of adjust 调节范围 Secondary voltage 次级电压 6 Adjust series 调节级数 8 8 16 16 2.9～5.0 3.52～7.04 4.5～7.6 4.05～8.10 3.8～7.6 50 75 100 150 150 % 25 20 20 20 50 220/38220/380 0 380 380 380 - 24 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

Continuous flash welding 连续闪光焊 20～The maximum mm 10～12 12～16 16～20 25 diameter of steel bar 钢筋最大直径 Preheating flash welding 预热闪光焊 20～22 32～36 The maximum diameter of steel bar 钢筋最大直径 The maximum number of weldment 50 for an hour 每小时最大焊接件数 Consumption of cooling water 冷却水消耗量 Compressed air MP/ / / 0.55 0.6 L/h 200 200 200 200 600 75 20～30 80 120 40 40 40 20～25 - 25 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

pressure 压缩空气压力 Consumption of compressed air 压缩空气消耗量 a m³/ /h / / 15 5

5.2Working conditions作业条件：

5.2.1 Welder shall have effective test certificate. 焊工必须持有有效的考试合格证。

5.2.2 The welding machine and supporting device、cooling water、compressed air shall meet the requirement.

对焊机及配套装置、冷却水、压缩空气等应符合要求。 5.2.3 Power supply shall meet the requirement, when the supply voltage drops greater than 5% and less than 8%, shall take appropriate measures to improve the welding transformer series; more than 8%, shall not for welding.

电源应符合要求，当电源电压下降大于5%，小于8%时，应采取适当提高焊接变压器级数的措施；大于8%时，不得进行焊接。

5.2.4 The jobsite shall have safety protection facilities, fire and necessary ventilation measures to prevent burns、electric shock and fire accidents.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

作业场地应有安全防护设施，防火和必要的通风措施，防止发生烧伤、触电及火灾等事故。

5.2.5 Familiar with the material bill, and clarify the joint position, do well the technical disclosure.

熟悉料单，弄清接头位置，做好技术交底。 5.3、Operation process操作工艺 Process 工艺流程：

检查 设备 选择焊接工艺及 参数 试焊、作模拟 试件 送试 确定焊接 参数 焊接 质量 检验

5.3.1.1Continuous flash butt welding process:

连续闪光对焊工艺过程：

闭合 电路 闪光（两钢筋端面轻微接触） 连续闪光加热到将近熔点（两钢筋端面徐徐移动接触） 带电 顶锻 无电 顶锻

5.3.1.2 Preheating flash butt welding process:

预热闪光对焊工艺过程：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

闭合 电路 断续闪光预热（两钢筋端面交替接触和分开） 连续闪光加热到将近熔点（两钢筋端面徐徐移动接触） 带电 顶锻 无电 顶锻

5.3.1.3Flash---preheating flash butt welding process:

闪光一预热闪光对焊工艺过程：

闭合 电路 一次闪光闪平端面（两钢筋端面轻微徐徐接触） 连续闪光预热（两钢筋端面交替接触和分开） 二次连续闪光加热到将近熔点（两钢筋端面徐徐移动接触） 带电 顶锻 无电 顶锻

5.3.1.4 Welding process method selection: When the smaller diameter rebar reinforced lower-level, to be used continuous flash welding. The maximum bar diameter continuous flash welding that can be welded shall conform to the provisions in the following table. When the bar diameter end face is relatively flat, appropriate preheating flash butt welding; flash welding flash a warm-up should be used when the end face is not flat.

焊接工艺方法选择：当钢筋直径较小，钢筋级别较低，可采用连续闪光焊。采用连续闪光焊所能焊接的最大钢筋直径应符合下表内的规定。当钢筋直径较大，端面较平整，宜采用预热闪光焊；当端面不够平整，则应采用闪光一预热闪光焊。

Continuous flash welding steel bar caps diameter

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

连续闪光焊钢筋上限直径

Welding machine volume 焊机容量（kVA） Ⅰ级 150 Ⅱ级 Ⅲ级 Ⅰ级 100 Ⅱ级 Ⅰ级 75 Ⅱ级 Ⅲ级

5.3.1.5 Welding parameter selection: Flash butt welding, tune elongation burnt allowance, the upsetting to stay as well as welding transformer series parameters should be a reasonable choice.

焊接参数选择：闪光对焊时，应合理选择调伸长度、烧化留量、顶锻留量以及变压器级数等焊接参数。

5.3.1.6 Check power, welding machine and welding platform, underground laying insulation rubber cushion, cooling water, compressed air, everything must be in a safe and reliable state.

检查电源、对焊机及对焊平台、地下铺放的绝缘橡胶垫、冷却水、压

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钢筋级别 钢筋直径(mm) 25 22 20 20 18 16 14 12 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

缩空气等，一切必须处于安全可靠的状态。

5.3.1.7 Test welding, do the classes before the specimen; six specimens in each class before welding parameters shall choose three of them do tensile testing, 3 to do cold bending test. After passing the test, before batch production welding parameters determined.

试焊、做班前试件；在每班正式焊接前，应按选择的焊接参数焊接6个试件，其中3个做拉力试验，3个做冷弯试验。经试验合格后，方可按确定的焊接参数成批生产。

5.4、Butt welding operation 对焊焊接操作：

5.4.1 Continuous flash welding: After electrifying, with the operating lever so that both ends of the reinforcement surface slight contact to generate Joule heat, and the steel bar termination of the projecting portion mutually melted, and the molten metal particles outwardly ejecting the formation of flames flash, and then slowly moves continuously steel bar the formation of a continuous flash, quickly upset to be scheduled burnt allowance disappear after an appropriate pressure to complete the entire continuous flash welding.

连续闪光焊：通电后，应借助操作杆使两端钢筋面轻微接触，使其产生电阻热，并使钢筋端面的凸出部分互相熔化，并将熔化的金属微粒向外喷射形成火光闪光，再徐徐不断地移动钢筋形成连续闪光，待预定的烧化留量消失后，以适当压力迅速进行顶锻，即完成整个连续闪光焊接。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

5.4.2 Preheating flash welding: After electrifying, so that the two steel bar termination to alternately contact and separate steel bar between the terminations of the intermittent flash, forming melted preheating process. When the warm-up process is completed, it shall be immediately transferred continuous flash and upsetting.

预热闪光焊：通电后，应使两根钢筋端面交替接触和分开，是钢筋端面之间发生断续闪光，形成烧化预热过程。当预热过程完成，应立即转入连续闪光和顶锻。

5.4.3 Flash-----preheating flash welding: After electrifying, shall be first flash, when the termination of the steel bar has been leveled, shall immediately proceed to the preheating, flashing and upsetting process.

闪光——预热闪光焊：通电后，应首先进行闪光，当钢筋端面已平整时，应立即进行预热、闪光及顶锻过程。

5.4.4 Guarantee welding joint position and operation requirement: 保证焊接接头位置和操作要求：

5.4.4.1 Before welding and the welding process, shall check and adjust the electrode position, tighten the fixture screw. Steel bar in the electrode must be clamped, the electrode jaws deformation shall immediate replacement and repair.

焊接前和施焊过程中，应检查和调整电极位置，拧紧夹具丝杆。钢筋在电极内必须夹紧、电极钳口变形应立即调换和修理。

5.4.4.2 Steel bar termination, such as bending or into a \"horseshoe\"

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

shape is not to be welded, must Wei straight or resection.

钢筋端头如起弯或成“马蹄”形则不得焊接，必须炜直或切除。 5.4.4.3 Within the scope of steel bar termination 120mm, the rust, oil, must be clean.

钢筋端头120mm范围内的铁锈、油污，必须清除干净。 5.4.4.4 In the process of welding, adhesion in the electrode on the oxide shall always clean.

焊接过程中，粘附在电极上的氧化铁要随时清除干净。

5.4.4.5 Close to the welding joint section shall have appropriate uniform thick plastic deformation and termination shall not be oxidized.

接近焊接接头区段应有适当均匀的墩粗塑性变形，端面不应氧化。 5.4.4.6 After welding to loosen electrode cooling slightly out of jaw, steel bar must be smooth, in order to avoid joint bending.

焊接后稍冷却才能松开电极钳口，取出钢筋时必须平稳，以免接头弯折。

5.5 Quality inspection质量检查：

In the steel bar butt welding production, the welder shall carefully conducted self-inspection, if eccentric, bending, burn, cracks and other defects, shall be excised with heavy welding joint, and find out reasons, timely elimination.

在钢筋对焊生产中，焊工应认真进行自检，若发现偏心、弯折、烧伤、裂缝等缺陷，应切除接头重焊，并查找原因，及时消除。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

5.6、Quality standard质量标准：

5.6.1 Guarantee item保证项目：

5.6.1.1 The variety and quality of steel bar shall meet the design requirement and related specifications.

钢筋的品种和质量必须符合设计要求和有关标准的规定。 5.6.1.2 Steel bar specification、welded joint position、the same section of inner joint percentage, must conform the design requirement and construction specifications.

钢筋的规格、焊接接头的位置、同一截面内接头的百分比，必须符合设计要求和施工规范的规定。

Inspection method；Observe or measurement inspection. 检验方法：观察或尺量检查。

5.7 Mechanical property tests of butt welded joint must be qualified. 对焊接头的力学性能检验必须合格。

5.7.1 Mechanical properties test, from each batch joint random cut six test pieces, three of which the tensile test, 3 do bending test.

力学性能检验时，应从每批接头中随机切取6个试件，其中3个做拉伸试验，3个做弯曲试验。

5.7.2 Within the same machine-team, the same welder finished 3 of 300 completed by the same welder, the same diameter steel welded joints as a batch. If the small number of welded joints within the same station classes, it can be accumulated within a week. If cumulative is still less

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

than the 300 connector, you should be a number of calculations.

在同一台班内，由同一焊工完成的300个同级别、同直径钢筋焊接接头作为一批。若同一台班内焊接的接头数量较少，可在一周之内累计计算。若累计仍不足300个接头，则应按一批计算。

Inspection method: inspect test report of welding test-pieces. 检验方法：检查焊接试件试验报告单。 5.8、Basis item基本项目：

The appearance inspection result of steel bar flash butt welding joint shall meet the following requirements:

钢筋闪光对焊接头外观检查结果，应符合下列要求:

5.8.1 It shall not have transversal crack in joint position. 接头部位不得有横向裂纹。

5.8.2 Steel bar surface that contact with electrode shall not have obvious burn, and it shall not have burning when IV grade steel bar welding.

与电极接触的钢筋表面不得有明显烧伤，Ⅳ级钢筋焊接时不得有烧伤。

Inspection method: observe inspection. 检验方法：观察检查。

5.9、The allowance item允许偏差项目：

5.9.1 Bending angle of joint shall not more than 4°. 接头处的弯折角不大于4°。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

5.9.2 The axis offset of joints shall not more than 0.1 times the steel bar diameter, at same time not more than 2mm.

接头处的轴线偏移，不大于0.1倍钢筋直径，同时不大于2mm。 Inspection method: visual observation or measurement. 检验方法：目测或量测。

5.10Finshed product protection成品保护：

After welding, the electrode jaws shall cooled then to loosen slightly, must remove the steel bar smooth to avoid joints bend.

焊接后稍冷却才能松开电极钳口，取出钢筋时必须平稳，以免接头弯折。

5.11The quality problem shall pay attention to应注意的质量问题： 5.12 Emphasis on welding any aspect of the entire process of steel bar butt production, so as to ensure the quality of the welding abnormal phenomenon shall refer to the following table to find out the reasons, timely elimination.

在钢筋对焊生产中，应重视焊接全过程中的任何一个环节，以确保焊接质量，若出现异常现象，应参照下表查找原因，及时消除。 Steel bar butt welding abnormal phenomena、welding defect and prevention measures

钢筋对焊异常现象、焊接缺陷及预防措施 Item 项次

Variety type of abnormal phenomena and defection - 35 -

Prevention measures 防止措施 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

异常现象和缺陷种类 1. Reduce transformer seriesBurn too severe, and produces 降低变压器级数 the sound of strong explosion 1 烧化过分剧烈，并产生强烈的speed 爆炸声 减慢烧化速度 1. Clear the oxide in bottom and surface of the 2. Slowing the burning electrical grade 清除电级底部和表面的Flash instability 2 闪光不稳定 2. Increase series 提高变压器级数 3. Accelerate burning speed 加快烧化速度 1. Increase Joints in the oxide film, the lack procedure of penetration or slag 3 接头中有氧化膜、未焊透或夹1. Accelerate the burn speed 渣 of approaching upset 增加预热程度 preheating transformer 氧化物 - 36 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

加快临近顶锻时的烧化速度 2. Ensure electric upsetting process 确保带电顶锻过程 3. Accelerate upset speed 加快顶锻速度 4. Increased upsetting force增大顶锻压力 1. Reduce transformer series 降低变压器级数 2. Avoid incinerating process too strong Shrinkage in joints 4 接头中有缩孔 3. 避免烧化过程过分强烈 Properly increasing the upset allowance and upsetting pressure 适当增大顶锻留量及顶锻压力 Overheating of the weld burnt 5 metal or heat-affected area procedure 2. Decrease preheating - 37 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

焊缝金属过烧或热影响区过热 减小预热程度 3. Accelerate the burning speed, shorten the welding time 加快烧速度，缩短焊接时间 4. To avoid excessive charged upsetting 避免过多带电顶锻

Continued table续表：

Item Variety type of abnormal 项次 phenomena and defection 异常现象和缺陷种类 1. Inspect the carbon、sulphur、phosphorus content of steel bar; if not in conformity with the Welding seam have crack6 焊缝出现裂纹 检验钢筋的碳、硫、磷含量；若不符合规定时，应更换钢筋 2. It shall adopt low frequency provisions, shall replace steel barPrevention measures 防止措施 - 38 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

preheat method to increase preheat degree 采用低频预热方法，增加预热程度 1. Remove the rust and pollution in steel bar clamping parts 清除钢筋被夹紧部位的铁锈和油污 Welding seam single side 2. Remove surface oxide within incomplete fusion or electrodes 7 fusion not sufficient 清除电极内表面的氧化物 焊缝单边未熔或者溶合3. Improved electrode notch shape, 不好 increase the contact area 改进电极槽口形状，增大接触面积 4. Clamping steel bar夹紧钢筋 1. Correct adjust electrode Joint bending or axis 8 deviation 接头弯折或轴线偏移 position 正确调整电极位置 2. Trimming electrode jaw or replace the deformed - 39 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

electrode 修整电极钳口或更换已变形的电极 3. Excision or straightening steel elbow 切除或矫直钢筋的弯头 六、Steel bar electroslag pressure welding钢筋电渣压力焊： 6.1 Construction preparation施工准备

6.1.1Material and main tools材料及主要机具：

6.1.2 Steel bar: the grade and diameter of steel bar shall meet the design requirement, and have ex-factory certification and retest report.

钢筋：钢筋的级别、直径必须符合设计要求，有出厂证明书及复试报告单。

6.1.3 Welding flux焊剂

6.1.3.1 The flux function shall consistent with the specification of GB5293 carbon fluxes for submerged arc welding. Flux model HJ401, commonly used for the smelting of high manganese and high silicon low fluoride flux or in manganese and high silicon low fluoride flux.

焊剂的性能符合GB5293碳素钢埋弧焊用焊剂的规定。焊剂型号为HJ401，常用的为熔炼型高锰高硅低氟焊剂或中锰高硅低氟焊剂。

6.1.3.2 Flux shall keep in dry warehouse, to prevent damp. If damp, it shall by 250 - 300 ℃bake for 2h prior to use.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

焊剂应存放在干燥的库房内，防止受潮。如受潮，使用前须经250—300℃烘焙2h。

6.1.3.3 After using, the recovery welding flux shall remove slag and debris, and shall mix new flux then to use.

使用后回收的焊剂，应除去熔渣和杂物，并应与新焊剂混合均匀后使用。

6.1.3.4 Welding flux shall have ex-factory certification. 焊剂应有出厂合格证。 6.2 Main tools主要机具

6.2.1 Manual electroslag pressure welding equipment including: welding power supply、control box、welding clamp、 welding flux tank.

手工电渣压力焊设备包括：焊接电源、控制箱、焊接夹具、焊剂罐等。

6.2.2 Automatic electroslag pressure welding equipment (priority shall be used) include: welding power supply、 control box、operation box、welding head.

自动电渣压力焊接设备（应优先采用）包括：焊接电源、控制箱、操作箱、焊接机头等。

6.2.3 Welding power source: Steel bar electroslag pressure welding shall be adopted secondary load voltage is higher (more than TSV) AC or DC welding power source.(32mm diameter and in and the following welding reinforcing steel, the capacity of 600A welding power source; the

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

diameter of 32mm and above the welded steel, should use the capacity of 1000A welding power source).When the welding machine capacity is small, it can used smaller capacity that same model and isotropic, two welding machine parallel operation.

焊接电源。钢筋电渣压力焊宜采用次级空载电压较高（TSV以上）的交流或直流焊接电源。（一般32mm直径及以下的钢筋焊接时，可采用容量为600A的焊接电源；32mm直径及以上的钢筋焊接时，应采用容量为1000A的焊接电源）。当焊机容量较小时，也可以采用较小容量的同型号，同性能的两台焊机并联使用。 6.3 Working condition作业条件：

6.3.1 Welder shall have effective welder certification. 焊工必须持有效的焊工证。

6.3.2 Equipment shall meet the requirements. Welding fixture shall have enough stiffness, and the maximum allowable load shall be flexible movement, convenient operation.

设备应符合要求。焊接夹具应有足够的刚度，在最大允许荷载下应移动灵活，操作方便。

The diameter of welding flux tank and the welded steel bar diameter shall compatible, so that not to burn in the welding process. Voltmeter、 time display shall be equipped, so that the operator can accurately master the welding parameters.

焊剂罐的直径与所焊钢筋直径相适应，不致在焊接过程中烧坏。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

电压表、时间显示器应配备齐全，以便操作者准确掌握各项焊接参数。 6.3.3 Power source shall meet the requirement, when the power source voltage drops greater than 5%, it would be inappropriate for welding. 电源应符合要求，当电源电压下降大于5%，则不宜进行焊接。 6.3.4 Working site shall have safety protection measures, formulate and implement safety technical measures, strengthen welder's labor protection, prevent the occurrence of burns、 electric shock、 fire、explosion and burn machine accident.

作业场地应有安全防护措施，制定和执行安全技术措施，加强焊工的劳动保护，防止发生烧伤、触电、火灾、爆炸以及烧坏机器等事故。

6.3.5 Note the joint position, pay attention to the cross sectional area percentage of joint steel bar in the same segment, if cannot conform the requirements of relevant provisions in《code for construction and acceptance of concrete structure engineering》, it shall adjust the joint position before welding.

注意接头位置，注意同一区段内有接头钢筋截面面积的百分比，不符合《混凝土结构工程施工及验收规范》有关条款的规定时，要调整接头位置后才能施焊。 6.4、Operation process操作工艺：

6.4.1 Process procedure工艺流程：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

检查设备、电源 钢筋端头制备 选择焊接参安装焊接夹具和钢筋 安放铁丝球(也可省去) 安放焊剂罐、填装焊剂 试焊、作试件 确定焊接参数 施焊 回收焊剂 卸下夹具 质量检查

6.4.2The process procedure of electroalag pressure welding

电渣压力焊的工艺过程：

闭合电路 引弧 电弧过程 电渣过程 挤压断电

6.4.3Inspet equipment、power source, to ensure that at any time in a normal state, and it is strictly prohibited to work overload.

检查设备、电源、确保随时处于正常状态，严禁超负荷工作。 6.4.4The treatment of steel bar termination钢筋端头处理：

Before steel bar installation, steel surface rust、greasy dirt and other debris shall be cleaned which in welding position and contacts with electrode jaw (150mm section), if the steel bar termination bend、twist, shall be straightened or resection, but not with hammer straightening. 钢筋安装之前，焊接部位和电极钳口接触的（150mm区段内）钢筋表面上的锈斑、油污、杂物等，应清除干净，钢筋端部若有弯折、扭曲，应予以矫直或切除，但不得用锤击矫直。 6.4.5Select welding parameters选择焊接参数：

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

The welding parameters of steel bar electroslag pressure welding main including: welding current、welding voltage and welding current “on” time, see the following table.

钢筋电渣压力焊的焊接参数主要包括：焊接电流、焊接电压和焊接通电时间，参见下表。

When different diameter steel bar welded, it shall by smaller diameter steel bar to select parameters, and the welding current “on” time extended about 10%.

不同直径钢筋焊接时，按较小直径钢筋选择参数，焊接通电时间延长约10%。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

The welding parameters of steel bar electroslag pressure welding

钢筋电渣压力焊焊接参数

Welding current“on”Welding voltage time 焊接电压(V) 焊接通电时间(S) Steel bar Welding diametercurrent 钢筋直径焊接电流(A) process(mm) 电弧过程 U2-1 16 18 20 22 25 28 32 36 40 200—250 250—300 300—350 350—400 400—450 500—550 600—650 700—750 850—900 40—45 40—45 40—45 40—45 40—45 40—45 40—45 40—45 40—45

6.4.6 The installation of welding clamp and steel bar: the lower jaw of

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Electric arc Electroslag process 电渣过程 U2-2 Electric arc process电弧过程 t1 22—27 22—27 22—27 22—27 22—27 22—27 22—27 22—27 22—27 14 15 17 18 21 24 27 30 33 4 5 5 6 6 6 7 8 9 Electroslag process 电渣过程 t2 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

clamp shall fasten motion to the steel bar termination in place, usually 1/2 welding flux tank height offset 5--10mm, to ensure that the weld has enough buried depth.

安装焊接夹具和钢筋：夹具的下钳口应加紧于下钢筋端部的适当位置，一般为1/2焊剂罐高度偏下5—10mm，以确保焊接处有足够的淹埋深度。

After upper steel bar put into the clamp jaw, aligning starting point of pneumatic chuck, so that the upper and lower steel bar welding position is located coaxially state, can clamp the steel bar

上钢筋放入夹具钳口后，调准动夹头的起始点，使上下钢筋的焊接部位位于同轴状态，方可夹紧钢筋。

Steel bar by clamping, prevent sloshing, avoid the upper and bottom steel bar bottom displacement and clamp deformation. 钢筋一经夹紧，严防晃动，以免上下钢筋错位和夹具变形。 6.4.7 Place wire ball that used in arc (also can be omitted). Placing welding flux tank, and filling in flux.

安放引弧用的铁丝球（也可以省去）。安放焊剂罐、填装焊剂。 6.4.8 Test welding、test-piece、determining the welding parameters: Before steel bar electroslag pressure formal welding, it must be in accordance with the choice of welding parameters for welding test for specimens to send samples, in order to determine the reasonable welding parameters. After qualification, the formal production shall carry out.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

When using semi-automatic、 automatic welding equipment, shall be determined according to the parameter setting equipment control data, to ensure the quality reliability of welding joint.

试焊、作试件、确定焊接参数：在正式进行钢筋电渣压力焊之前，必须按照选择的焊接参数进行试焊作试件送试，以便确定合理的焊接参数。合格后，方可正式生产。当采用半自动、自动控制焊接设备时，应按照确定的参数设定好设备的各项控制数据，以确保焊接接头质量可靠。

6.4.9 Operation key point of start welding 施焊操作要点：

6.4.9.1 Closed loop、arc strike: Through operating lever or switch on the control box, successively through welding current loop and power input circuit, between terminations of the steel bar ignition arc, starting welding.

闭合回路、引弧：通过操纵杆或操纵盒上的开关，先后接通焊机的焊接电流回路和电源的输入回路，在钢筋端面之间引燃电弧，开始焊接。

6.4.9.2Electric arc process: After the ignition of electric arc, shall control the voltage value. With the operating lever to make the upper and lower steel bar termination to keep certain distance, the arc process delay, making the welding flux continuous melting and form necessary depth slag pool.

电弧过程：引燃电弧后，应控制电压值。借助操纵杆使上下钢筋端面

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

之间保持一定的间距，进行电弧过程的延时，使焊剂不断熔化而形成必要深度的渣池。

6.4.9.3Slag process: Then gradually under feed steel bar, so that the upper steel bar termiantion is inserted into the slag pool, the arc is extinguished, enter the electroslag process time delay, so that the whole section accelerated melting of steel.

电渣过程：随后逐渐下送钢筋，使上钢筋端部插入渣池，电弧熄灭，进入电渣过程的延时，使钢筋全断面加速熔化。

6.4.9.4 Extrusion and interrupt of power: After electroslag process complete, quickly from down to top send steel bar, which termination with steel bar termination contact with each other, while removing slag and molten metal before it gets cold. At the same time shall cut welding power source.

挤压断电：电渣过程结束，迅速下送上钢筋，使其端面与下钢筋端面相互接触，趁热排除熔渣和熔化金属。同时切断焊接电源。 6.4.9.5 Joint welding completed, shall stop 20 - 30S (when welding in the winter, the idle time shall be extended), then welding flux recovery and unloading clamp.

接头焊毕，应停歇20—30S后（在冬季施焊时，停歇时间应适当延长），才可回收焊剂和卸下焊接夹具。

6.5 Quality inspection: In the steel bar electroslag pressure welding production, the welder shall carefully conducted self-inspection, if find

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

eccentric、 bending、burn、welding package is not full weld defects and so on, shall resects joint and re-weld, and find out reasons, timely elimination. Excision of joint, it shall resects the steel bar in heat affected area, namely from the welding seam center was about 1.1 times length of steel bar diameter (within this segment) shall be resected.

质量检查：在钢筋电渣压力焊的焊接生产中，焊工应认真进行自检，若发现偏心、弯折、烧伤、焊包不饱满等焊接缺陷，应切除接头重焊，并查找原因，及时消除。切除接头时，应切除热影响区的钢筋，即离焊缝中心约为1.1倍钢筋直径的长度范围内的部分应切除。 6.5.1 、Quality standard质量标准： 6.5.2 Guarantee project保证项目：

6.5.2.1 The variety and quality of steel bar must be conform design requirement and related standard、specifications. 钢筋的品种和质量，必须符合设计要求和有关标准的规定。 Inspection method: inspect ex-factory quality certificate and test report.

检验方法：检查出厂质量证明书和试验报告单。

6.5.2.2 The steel bar specification and welding joint position, the percentage of joints steel bar area in same section shall be conform the design requirement and construction specifications.

钢筋的规格，焊接接头的位置，同一区段内的接头钢筋面积的百分比，必须符合设计要求和施工规范的规定。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

Inspection method: observation or measurement inspection. 检验方法：观察或尺量检测。

6.6 The mechanical property inspection of electroslag pressure welding joint shall qualify.

电渣压力焊接头的力学性能检验必须合格。

Mechanical properties test, from each batch of joint random cut 3 joints for tensile test.

力学性能检验时，从每批接头中随机切取3个接头作拉伸试验。 6.7 In cast-in-place steel bar concrete multi layer structure, with each floor or same grade of steel bar joint in construction section as a number, and less than 300 still as a group.

在现浇钢筋混凝土多层结构中，以每一楼层或施工区段的同级别钢筋接头作为一批，不足300个接头仍作为一批。

Inspection method: inspect the welding test-piece experiment report.

检验方法：检查焊接试件实验报告单。

6.8Basic item: steel bar electroslag pressure welding head shall be obtained by visual inspection; the result shall meet the following requirements:

基本项目：钢筋电渣压力焊接头应逐个进行外观检查，结果应符合下列要求：

6.8.1 Welding package is uniform, prominent section at least high

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

steel bar surface 4mm.

焊包较均匀，突出部分最少高出钢筋表面4mm。

6.8.2 It shall no obvious burn defect of electrode and reinforced contact point.

电极与钢筋接触处，无明显的烧伤缺陷。

6.8.3 The bending angle of joints shall not more than 4°. 接头处的弯折角不大于4度。

6.8.4 Joint axis displacement shall be not more than 0.1 times steel bar diameter; at the same time is not more than 2mm.

接头处的轴线位移应不超过0.1倍钢筋直径，同时不大于2mm。 Appearance inspection unqualified joints shall be excision and resurfacing welding, or take remedial measures.

外观检查不合格的接头应切除重焊、或采取补救措施。

Inspection method: visualization or measurement

检验方法：目测或量测。

6.9.、Protect finished product 成品保护：

After welding joint, it shall stop 20-30s then unloading clamp, to avoid joint bending.

接头焊毕，应停歇20—30S后才能卸下夹具，以免接头弯折。 6.10、Pay attention to the quality problems应注意的质量问题： 6.10.1 The steel bar electroslag pressure welding in welding production shall pay attention to the whole process in any one part. Joints

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

shall be clean; the steel bar installation shall be in unison; clamp shall fastening to prevent shaking; arc process, strive to reliable; arc process, delay full; Electroslag process, short and stable; the extrusion process, proper pressure. If there is any abnormal phenomenon, shall refer to the following table to find the reasons, it shall remove on time.

在钢筋电渣压力焊生产中，应重视焊接全过程中的任何一个环节。接头部位应清理干净；钢筋安装应上下同心；夹具紧固，严防晃动；引弧过程，力求可靠；电弧过程，延时充分；电渣过程，短而稳定；挤压过程，压力适当。若出现异常现象，应参照下表查找原因，及时清除。

The welding defects and prevention measures of steel bar electroslag

pressure welding joint

钢筋电渣压力焊接头焊接缺陷与防止措施

Item 项次 Welding defects 焊接缺陷 Prevention measures 防止措施 1. Straightening steel bar termination 矫直钢筋端部 Axis deviation 1 轴线偏移 正确安装夹具和钢筋 3. To avoid excessive pressure 避免过大的挤压力

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2. Correct installation clamp and steel bar 中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

4. Repair or change clamp in time 及时修理或更换夹具 1. Straightening steel bar termination 矫直钢筋端部 2. To avoid too fast unloading clamp after 2 Bending 弯折 welding 避免焊后过快卸夹具 3. Repair or change clamp 修理或更换夹具 1. Reduce the top pressure speed 减低顶压速度 Welding packet thin 2. Decrease the welding current 3 and large 减小焊接电流 焊包薄而大 3. Reduce the welding time 减少焊接时间 1. Decrease welding current 减小焊接电流 2. Shorten the welding time 4 Undercut 咬边 缩短焊接时间 3. Notice the starting point of upper jaw, to ensure steel bar extrusion in place - 54 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

注意上钳口的起始点，确保上钢筋挤压到位 1. Increase welding current Incomplete 5 penetration 未焊合 增大焊接电流 2. To avoid the time of welding short 避免焊接时间过短 3. 检修夹具，确保上钢筋下送自如 1. Steel bar termination shall smooth 钢筋端面力求平整 2. Filling the welding flux as uniform as Welding packet 6 irregular 焊包不匀 possible 填装焊剂尽量均匀 3. Extend the welding time and appropriate increase the melting quantity 延长焊接时间，适当增加熔化量 1. Baked flux according to specification按规定要求烘焙焊剂 7 Porosity气孔 2. Cleaning the rust in steel bar welding position 清除钢筋焊接部位的铁锈 - 55 -

中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

3. Ensure the welded position within the burial depth of welding flux 确保被焊处在焊剂中的埋入深度 1. Steel bar conductive parts cleaning rust 钢筋导电部位除净铁锈 8 Burn烧伤 2. Try to clump steel bar尽量夹紧钢筋 1. Completely block the leak of solder tank Welding packet 9 flow焊包下淌 2. 彻底封堵焊剂罐的漏孔 To avoid rapid recovery after welding 避免焊后过快回收焊接

6.10.2、Electroslag pressure welding in the negative temperature conditions to start, but when the environment temperature is lower than -20 ℃, it would be inappropriate to carry out welding.

电渣压力焊可在负温条件下进行，但当环境温度低于-20℃时，则不宜进行施焊。

Rain、 snow is not suitable for welding, if it must start welding, shall take effective shielding measures. The weld joints without cooling, shall avoid encountered snow.

雨天、雪天不宜进行施焊，必须施焊时，应采取有效的遮蔽措施。焊后未冷却的接头，应避免碰到冰雪。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

6.11、Quality record质量记录：

The project shall have following quality record:

本工程应具备以下质量记录：

6.11.1 The ex-factory quality certificate and inspection report of steel bar.

钢筋出厂质量证明书或试验报告单。

6.11.2Welding flux certification.焊剂合格证。

6.11.3 The retest report of steel bar mechanical properties.

钢筋机械性能复试报告。

6.11.4 During steel bar processing, if have brittle fracture、welding of bad performance and mechanical properties were not normal, it shall have chemical composition inspection report.

钢筋在加工过程中发生脆断、焊接性能不良和机械性能明显不正常的，应有化学成分检验报告。

6.11.5 The stretching testing report of steel bar joint.

钢筋接头的拉伸试验报告。 七、Safety attentions 安全注意事项

7.1 All personnel must wear a good approach of individual PPE. 进入施工现场必须穿戴PPE。

7.2 The construction field shall establish full-time HSE supervisor, responsible for HSE management and supervision. Based on full

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

participation, highlight the people-oriented thought; full risk analysis and evaluation, making feasible prevention or mitigation measures.

施工现场设立专职HSE监督员，负责HSE工作的管理和监督。立足全员参与，突出以人为本的思想；充分进行风险分析与评价，制定切实可行的预防或消减措施。

7.3 Field electrical equipment and the activities of the board shall have good grounding; hand-held electric tools shall leakage protector, accomplish“one machine one gate of a protection”; “Tri-proof”socket used and wiring by electricians.

现场用焊机设备应有良好的接地；手持电动工具应有漏电保护器，做到“一机一闸一保护”；插座全部采用“三防”插座，接线由电工负责。

7.4 The welding machine electric equipment must be checked regularly, if found problems, it shall to eliminate hidden dangers in a timely manner; the cable conductor of hand-held electric tool shall periodical inspection, and the damaged cable conductor shall take effective measures, then can be used.

必须定期检查焊机等用电设备，发现问题及时消除隐患；定期检查手持电动工具的电缆线，对已损坏的电缆线采取可靠有效措施方可使用。

7.5 Clear the weld field combustible objects and equipped with fire extinguisher and other necessary fire equipment.

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

清楚焊接现场的可燃物体并配备干粉灭火器等必要的消防器材。 7.5 Welding construction, welders must use the light shield, in order to avoid arc light hurting person.

进行焊接施工时，焊工必须使用挡光板，以免弧光伤人。 7.6 Welding work place shall keep good ventilation and clean sanitation. The use of discard electrode and the welding wire head must be put in the recycling bin, after working, shall clean the construction field in time.

焊接作业场所应保持通风良好，清洁卫生。使用的焊条头和焊丝头必须放在回收桶内，作业结束后，应及时清理施工现场。

7.7 Welding workers shall be the proper use of personal protective equipment; when construction, it must wear work clothes、gloves、welding mask and dustproof mask (virus).

焊接作业人员应正确使用个人防护用品，施工时必须穿戴工作服、手套、佩戴焊接面罩和防尘（毒）口罩。

7.8 The construction site shall be equipped with dry powder fire extinguishers and other necessary fire equipment, roads shall be kept clear. Fire-fighting device shall be able to spare, construction workers shall be able to skillfully use, and receive training.

施工现场应配备干粉灭火器等必要的消防器材，道路应保持畅通。消防器具应能随时备用，施工作业人员应能熟练使用，并得到训练。

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中国核工业二三建设有限公司苏州分公司 China Nuclear Industry 23 Construction Co., Ltd Suzhou Branch

7.9 When clean steel bar weld bond and rust removing work, it must wear protective mask, so as to avoid the wire out of physical injury.

清理钢筋焊口除锈作业时，必须戴好防护面罩，以免钢丝飞出发生身体伤害。

7.9 Before construction team in daily operation, it shall do security speech that based on the construction tasks, and arrangement corresponding safety measures.

施工班组在每天作业前安全讲话，针对当日施工任务，布置相应的安全防护措施。

7.10 Personal injury accident shall be in safe state active rescue and emergency phone call 120; maintain the scene of the accident, take measures to prevent the accident further expansion.

发生人身伤害事故，应在安全状态下积极抢救，并拨打急救电话120；维护好事故现场，采取措施防止事故进一步扩大。

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