目录 Contents 1

　目的 Purpose 2

　适用范围 Scope 3

　定义 Definitions 4 参考文件 Reference documents 5 施工方法 Construction method

　1. 目的 Purpose 本程序编写的目的是对惠州乙烯 HDPE、PP 土建基础、钢筋砼建筑物、构筑物的钢筋焊接进行技术指导，保证钢筋施工按国家相关施工验收规范、总承包商和业主项目文件的要求进行施工操作。

　This procedure is prepared to provide technical guidance to rebar welding for civil foundation, reinforced concrete buildings and structures for Huizhou PP/HDPE plant and to ensure rebar construction activities accorded with the state relevant construction acceptance specification and project documents of Contractor and Client. 2. 适用范围 Scope 中国石油天然气第六建设公司所承包工程内所有有关砼工程中的钢筋连接。This procedure applies to all rebar connection related to concrete work used for PP/HDPE Plant by the 6 th

　Construction Company of CNPC. 3. 定义砼工程 Definition 业主：CSPC

　Client: CSPC 总承包商：TCM Contractor: TCM 分承包商：中国石油天然气第六建设公司 Subcontractor: The 6 th

　Construction Company of CNPC 4. 参考文件 Reference documents JGJ18-96

　 钢筋焊接与验收规范

　 Specification for rebar welding and acceptance GB 50204-2002

　混凝土结构工程施工质量验收规范

　Quality Acceptance Specification for Concrete Structure Engineering Construction GB/T 5117

　 碳钢焊条 Carbon steel welding rod 5.施工方法 Construction methods

　5.1 施工一般要求 General requirements 5.1.1 钢筋均应有质量证明书；焊条、焊剂应有产品合格证，且通过验收。Rebar shall be supplied with quality certificate, and welding rods and flux shall have quality certificate and shall be inspected and accepted. 5.1.2 钢筋焊接接头表面应无杂物、锈斑。Welding joints of rebar shall be free from impurities and rust spots on the surface. 5.1.3 焊工必须持有焊工考试合格证。Welders must be qualified issued qualification certificate. 5.1.4 焊接设备状况良好，能满足施工要求。Welding equipment shall be in good condition and meet the construction requirements. 5.1.5 正式焊接之前，参与该项施焊的焊工应进行现场条件下的焊接工艺试验，并经试验合格后，方可正式生产。Prior to production welding, welders engaged in the welding shall perform welding procedure test on site under the site condition. 5.2 电弧搭接焊 Arc overlap welding 适用范围：Ⅰ、Ⅱ、Ⅲ级钢筋均可采用此种施工方法，但应避免在构件上直接进行立焊。

　Applicable scope: this method can be applied to rebar of gradeⅠ,Ⅱ,Ⅲ, but vertical welding should be avoided on components. 5.2.1 Ⅰ 级光圆钢筋，焊条采用 E4303 型；对于 Ⅱ 级螺纹钢筋，焊条采用 E5003型； Ⅲ

　级螺纹钢筋焊条采用 E5503 型。焊条使用前应烘干存放在保温筒中。

　E4303 type electrodes shall be applied to grade Ⅰ

　round bars, E5003 type to grade Ⅱ

　deformed bars, and E5503 type to grade Ⅲ

　deformed bars. The electrodes shall be dried in an oven and kept in quivers before use. 5.2.2 双面搭接焊，搭接长度为 5d；单面搭接焊，搭接长度为 10d 焊缝宽度应大于 0.7d 且不小于 10mm。

　The lap length of double-face and single-face overlap welding is 5d and 10d respectively, and the width of welding seam shall be more than 0.7d and no less than 10mm.

　5.2.3 焊条与焊接电流的选择 Selection of electrode and welding current

　 钢筋直径（mm）

　Rebar Dia. 焊条直径（mm）

　Electrode Dia. 焊接电流(A) Welding current

　平焊 flat welding 10－12 3.2 90－130 14－22 4 130－180 25－32 5 180－230 36－40 5 190－240 5.2.4 焊接地线与钢筋接触良好、牢固。

　Welding ground and rebar shall have a good and firm connection. 5.2.5 钢筋焊接前先预弯，预弯后应保证两根钢筋轴线在同一直线上，施焊时，引弧应在搭接钢筋的一端开始，收弧在搭接钢筋的另一端，弧坑应填满。Pre-bend the bars before welding them. Ensure that the axial lines of the two bars align after pre-bending. When welding, start the arc on one end of the overlap joint bar and end the arc on the other end and the arc pit shall be full filled. 5.2.6 焊接过程中及时清渣，保证焊缝表面光滑平整。

　Remove the slag in time during welding to ensure smooth surface of the welds. 5.2.7 取样检查 Sampling and test 5.2.7.1 取样数量：同一台班内，同一焊工完成的 300 个同牌号、同直径钢筋焊接接头作为一批。一周内累计不足 300 个也作为一批。每批抽查 10%，且不得少于 10 个。

　Sampling quantity:

　 300 rebar welding joints of the same brand and diameter made by the same welder in one shift is taken as a batch, and the accumulative number of joints less than 300 in a week is also taken as a batch. 10% of the joints in each batch shall be taken for test and the minimum number of joints taken for test shall not be less than 10 joints. 5.2.7.3 外观检查要求：焊缝表面应平整，不得有凹陷或焊瘤；焊接接头区域不得有肉眼可见的裂纹；接头处弯折角不得大于 3 度。

　Requirements for appearance inspection: smooth surface of welds without concave or welding beading, no visual crack in the joint area, and the bending angle of the joint shall not be more than 3° 5.2.7.4 力学性能试验：每批切取 6 个试样，3 个进行拉伸试验，3 个进行弯曲试验。

　Mechanical test: 6 samples from every batch shall be taken, 3 for tensile test, and the other 3 for bending test. 5.3 电渣压力焊 Electroslag pressure welding 适用范围：电渣压力焊适用于Ⅰ、Ⅱ、Ⅲ级且直径≤32mm 柱墙的竖向钢筋的现场连接。

　Applicable scope: It is applied to site connection of grade Ⅰ、Ⅱ、Ⅲ vertical rebar with diameter no more than 32mm for column walls. 5.3.1 焊接工艺为引弧、电弧、电渣、挤压四个过程；焊剂采用 HJ431 型。

　The welding procedure includes arc striking, electrical arc, electroslag and pressing. HJ431 type flux shall be used.

　 5.3.2 焊接参数 Welding parameters 钢筋直径 Rebar Dia. （mm）

　焊接电流 Current （A）

　焊接电压 Voltage（V）

　焊接时间 Time（S）

　钢 筋 熔 化 量（mm）

　rebar molten charge (mm) 电弧过程electric arc 电渣过程Electroslag

　电弧过程electric arc 电渣过程Electroslag arc 16 200-250 40-45 22-27 14 4 20-25 18 250-300 40-45 22-27 15 5 20-25

　20 300-350 40-45 22-27 17 5 20-25 22 350-400 40-45 22-27 18 6 20-25 25 400-450 40-45 22-27 21 6 20-25 28 500-550 40-45 22-27 24 6 20-25 32 600-650 40-45 22-27 27 7 25-30 36 700-750 40-45 22-27 30 8 25-30 40 800-850 40-45 22-27 33 9 25-30 5.3.3 引弧前钢筋两端应固定牢固、调直、扶正。

　Prior to arc strike, both ends of the rebar shall be straightened and securely fixed upright. 5.3.4 引弧过程：通电后将上部钢筋迅速提起，使两端头之间的距离为 2－4mm，产生电弧。

　The arc striking process: promptly lift the upper rebar after electrifying, making the distance between two ends at 2-4mm to produce electric arc. 5.3.5 电弧过程：利用电弧所产生的高温作用，将钢筋端头的凸出部分不断烧化，同时将接口周围的焊剂充分熔化。

　Electric arc process: use the high temperature produced by electric arc to burn off the protruding part of the rebar ends continuously and melt the flux around the joints completely. 5.3.6 电渣过程：当渣池形成一定深度后，将上部钢筋缓缓插入渣池，此时钢筋端头在高温作用下迅速而均匀熔化。

　Electroslag process: when the slag basin reaches a certain depth, the upper rebar shall be slowly inserted into it, and the ends of the rebar are molten rapidly and evenly under the high temperature.

　5.3.7 挤压过程：当钢筋端面熔化在呈微凸形时，在停止供电的同时，对钢筋施加挤压力，把焊口部份的金属、熔渣及氧化物等杂物全部挤出结合面。

　Extrusion process: When the ends of the rebar are molten in a slightly protruding shape, exert pressing pressure on the rebar at time the power supply is cut off to extrude all the metal, slag, and oxide, etc. in the joint.

　5.3.8 焊接完成后，先拆机头，待焊接接头保温一段时间后，再拆焊剂盒。

　After completion of welding, dismantling the head of the machine first, and then the flux box after the joint soaks for a period of time. 5.3.9 取样检查 Sampling and test 5.3.9.1 取样数量：同一台班内，同一焊工完成的 300 个同牌号、同直径钢筋焊接接头作为一批。一周内累计不足 300 个也作为一批。

　Sampling quantity: 300 rebar welding joints of the same brand and diameter made by the same welder in one shift is taken as a batch, and the accumulative number of joints less than 300 in a week is also taken as a batch. 10% of the joints in each batch shall be taken for test and the minimum number of joints taken for test shall not be less than 10 joints. 5.3.9.3 外观检查要求：接头处不得有横向裂纹；与电极接触的钢筋表面不得有明显的烧伤；接头处弯折角不得大于 3 度。

　Requirements for appearance inspection:

　no horizontal crack on the joints, no obvious burn on the rebar surface where it contacted with the electrode, and the bending angle of the joint shall not be more than 3°. 5.3.9.4 力学性能试验：每批切取 6 个试样，3 个进行拉伸试验，3 个进行弯曲试验。

　Mechanical test: 6 samples from every batch shall be taken, 3 for tensile test, and the other 3 for bending test. 5.4 闪光对焊 Flash butt welding 适用范围：适用于各级钢筋的焊接，但仅限于钢筋加工厂中的预 Applicable scope: It is applied to welding of every grade bars, but only for prefabrication in rebar processing factory. 5.4.1 焊接工艺包括预热、闪光、和顶锻三个过程。

　Welding procedure includes pre-heat, flash and upset forging. 5.4.2 预热过程：施焊时先闭合电源，然后使两钢筋端面交替接触和分开，使钢筋端面间隙中发出段续的闪光，形成预热过程。

　Pre-heat process: switch on the power supply when welding, then make the two ends of the rebar contact and separate by turns. In this way, flash is produced

　intermittently in the gap to form the pre-heat process. 5.4.3 闪光过程：当钢筋达到预热温度后，进入闪光阶段。移动钢筋，使两钢筋端面保持轻微接触，形成连续闪光。

　Flash process: When the bars reach the pre-heat temperature, flash process begins. The two ends of the bars keep contacting slightly to form continuous flash by moving the bars. 5.4.4 顶锻过程：当闪光到预定的长度，使钢筋端头加热至将近熔点时，就以一定压力迅速进行顶锻。先带电顶锻，再无电顶锻到一定长度焊接接头即告完成。

　Upset forging process: When the flash reaches scheduled length, the ends of the rebar are heated almost to the melting point, upset forging shall be performed promptly with a certain pressure. Upset forging with electricity is done first, and then the same is carried out without electricity to a certain length, and the welding is completed. 5.4.3 焊接注意事项：Notes to welding 5.4.5 焊接前,端头约 150mm 范围内应清除铁锈、污泥等,如有弯曲,应调直或切除。Rust and sludge shall be removed within the length of about 150mm from the end before welding, and the bending parts, if any, shall be straightened or cut off. 5.4.6 钢筋规格、种类变换时,应先制作对焊试样,进行冷弯试验,才能成批焊接。

　In case there is any change in rebar specification and type, production welding in batches shall not be carried out until the butt welding samples are prepared and cold bending test is performed. 5.4.7 焊接钢筋时,应使两钢筋端面的突出部分相接触,以利于均匀加热和保证焊缝与钢筋轴线相垂直。

　When rebar welding is performed, the protruding parts of the bar ends shall be made to contact with each other so that they are heated up evenly to ensure perpendicularity of the weld to the rebar axial line. 5.4.8 焊接结束后，应待钢筋接头由白红色变为黑红色后，才能松开夹具，平稳

　地取出钢筋。

　After welding, the clamping apparatus shall not be removed until the color of the joints changes from white red to black red, and then take out the bar smoothly. 5.4.9 焊接场地应搭设钢筋加工棚等作为防风、防雨措施。

　Rebar fabrication shelter shall be built for welding activities to prevent wind and rain. 5.4.10 取样检查 Sampling and test 5.4.10.1 取样数量：同一台班内，同一焊工完成的 300 个同牌号、同直径钢筋焊接接头作为一批。一周内累计不足 300 个也作为一批。Sampling quantity: 300 rebar welding joints of the same brand and diameter made by the same welder in one shift is taken as a batch, and the accumulative number of joints less than 300 in a week is also taken as a batch. 10% of the joints in each batch shall be taken for test and the minimum number of joints taken for test shall not be less than 10 joints 5.4.10.2外观检查：每批抽查10%，且不得少于10个。Appearance inspection: testing 10% at random and no less than 10 pieces for each batch. 5.4.10.3 外观检查要求：接头处不得有横向裂纹；与电极接触的钢筋表面不得有明显的烧伤；接头处弯折角不得大于 3 度。

　Requirements for appearance inspection:

　no horizontal crack on the joints, no obvious burn on the rebar surface where it contacted with the electrode, and the bending angle of the joint shall not be more than 3°.. 5.4.10.4 力学性能试验：每批切取 6 个试样，3 个进行拉伸试验，3 个进行弯曲试验。

　Mechanical test: 6 samples from every batch shall be taken, 3 for tensile test, and the other 3 for bending test. 5.5 钢筋绑扎搭接 Rebar binding overlap joint 适用范围：各级钢筋的绑扎搭接，尤其适用于柱墙的竖向钢筋搭接。绑扎具体施工方法详见«钢筋绑扎施工程序»

　Applicable scope: It is applied to binding overlap for every grade bars, in

　particular to vertical rebar for column walls. For specific methods, refer to Procedure for Reinforcement Binding Construction. 5.6 柱钢筋连接及施工缝的设置

　Setup of column bar connection and construction joint 5.6.1 柱钢筋连接一般设在施工缝以上部位，本工程高度≥6m 以上的柱子的施工缝在柱脚与基础，地面以上至柱中部位，柱与梁的交界处各设一道施工缝，充分保证砼的振捣密实和砼自由下落时的离析。

　Connection of column rebar is always on the parts above construction joint, and the construction joints of columns with a height of ≥6m are on the parts between

　column footing and foundation, above ground and the middle of columns. A

　 construction joint shall be set up respectively at the boundary of the column and the beam to ensure vibration compaction of the concrete and gravity segregation of the concrete when it falls freely. 5.6.2 施工缝宜设在剪力较小的和便于施工的位置。钢筋接头设在构件的受压区，弯矩较小的部位；施工时接头位置及接头百分率应满足施工规范和施工图纸说明的要求。

　Construction joint shall be set on the place where shearing force is weaker and construction activities are easy to be carried out. Rebar joints shall be in compressive region of the components where bending moment is smaller. Location and percentage of the joints shall meet the requirements of construction specifications and drawings. 5.6.3 施工缝的施工见«砼浇捣搅拌施工程序»脱模后应对接缝处的接痕进行打磨处理。

　For the construction of the construction joints, refer to Procedure for Concrete Pouring and Mixing. Traces on the joints shall be treated by grinding after removal of the forms.