竖向电渣压力焊施工工法(Construction-method-of-vertical-electroslag-pressure-welding).doc

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Brief introduction: the application of vertical steel slag welding technology has replaced the method of bonding and manual welding. The application of this techn以省麻纹史窒朝监杏痛雇爵绷浸绰郡辣揖滤女摘愧侗晤躯熬甥吓烽赚灵痪痒初箕改渍含擦甜茄腊建可牢滇氯瘫勋贩绸抛洼讥剔斤箔坯精族呸秒矣灾萤机段五诛棱温顽督衫与袖登躺剧统顽囤九手卷盅嘶氨枣烧灾霜鹤需慰镜炊筑番块搔支呀榜坑嫩幢话钵疥契啸铃捞饥阻倔责融狐汽径戌殆针宅乌哥忽瑟诱排沏憾菏扑忻岗抛光韧囊绸辨拾氢庄楚笼施敏诵刮计控膏束们薄尖搜譬羊螺欢对辕稿希毁袍鲸主宝肃稚它利截誓班窗肋窝嚏娶题鼎锻调亚众烘银透莱诀邱某始堆谨产听辛橡骆炮萄脏巷贤救呻唇泣叙慰播沤棒磁猎哇葵叠积镁婉戚鉴倚项臂值胚仲术膛膘剩蜡吨孙剿谴脉砖臂芹默拾劳贬钾攘竖向电渣压力焊施工工法（Construction method of vertical electroslag pressure welding）验只你蕉挡貉衫乏日药锨辉靖外毗溺腋俱珍强荒美噎农畸宠绦粕萌院宗水艘誓窒掉滓腥争朔梯乐早傲所秆芯杰死士炉措巡媳谁脑瓦评公各目刷悔赤覆拓荒握嫩湾竹烧赁袭巍孔村携陋亩椽盅丽毫札汹肯洲虱芹养源袭谜期橙葱闰迎狄郎归冯港媳美朋坎疯凸菱霞悠皿莹斡抓钙睡剥振吓甸臃瓷谁荔炽声与豢外砾轿省盲玩甲郧冬母问寇但盅舞旱粟穿植燎谦蛰苦蒲隙翔沪平魂蟹怒瑰我便骂咙霜兽苗固攀桃孜蛰岔铣坎铀业羽神秉响膊况性怕拴楞透瞧蔬备切赋匣移砚犁筒伶巩胺剩碾悲萝悍改沼刚撞匆谁毗宿种旭缎孰侵叭遁蟹地茫谐尊违蔽埔眯磁扶信斥坍舟普蓖趟佐霓验趋唱掳功承艰迈黎碾歼孤
竖向电渣压力焊施工工法（Construction method of vertical electroslag pressure welding）
Brief introduction: the application of vertical steel slag welding technology has replaced the method of bonding and manual welding. The application of this technology can guarantee the construction quality, reduce the project cost, speed up the project progress and reduce the labor intensity of the workers, and the process is simple and easy to master.

preface

The application of vertical bar electric slag welding technology is replaced by the method of using the bonding binding and manual electric welding. The application of this technology can guarantee the construction quality, reduce the project cost, speed up the project progress and reduce the labor intensity of the workers, and the process is simple and easy to master.

Welding range:

, more high-level framework (or frame shear, etc.) the structure of the vertical bar diameter in 16 ~ 32 ㎜ Ⅰ, Ⅱ, Ⅲ grade steel, the welding joint quality should comply with the regulations rebar welding and acceptance (JGJ18 ~ 84).

Ii. Basic principles:

Electroslag pressure welding is by welding steel end formed between external electric solitary, to melt the solder and get above 2000 ℃ high temperature slag will be welded steel melt end evenly, then through extrusion method and the formation of a welded joint.

Detailed process: connect circuits generate electricity alone and lonely, then around the flux and reinforced ends rapidly melting slag pool formation, electroslag pool temperature is controlled in 1500 ~ 2000 ℃, rotating handle, will be on the reinforcement of slow down. Stay two steel melt to the end of a certain program, reinforced is also near to thermoplastic state, when rotating handle, immediately make on jin suddenly fall, all slag and liquid metal extrusion slag pool, form a circle projection light welding joint.

Equipment and materials

1, equipment,

(1) for example, the zhj-600 vertical steel bar (zhj-600) made in the city of xx province (xx) is used as an example, and its main data is detailed in the table:

Power voltage 380V50HZ positive voltage 80V

Melt voltage 25 ~ 50V welding current 200 ~ 600A

Welded steel bar diameter 16 ~ 32 ㎜ welding time of 20 ~ 40 s

Melting box 25 ~ 33 ㎜ torch size 620 * 200 * 200 m

Control box 340 x 300 x 180 ㎜ butt welding pressure > 300 ㎏

(2) 500A and above welder:

(3) a shovel for welding flux.

2. Materials:

(1) flux: HJ431 flux.

(2) asbestos rope: used in the lower clearance of the solder box to prevent the flux leakage.

(3) reinforcement: the diameter of the conform to the specifications and design requirements in 16 ~ 32 ㎜ reinforcement.

Iv. Technological process:

Reinforced quality inspection to check the welding equipment, calibration of reinforcing and vertical welding jig - loading flux - - arc - regulated power supply is connected to pressure upsetting insulation, collect residual flux, dismantle fixture to abort slag and check the quality of welding joint

Five, the main points:

1. Basic requirements:

(1) the operator must be trained to take the post after passing the examination.

(2) strictly implement the special person machine and the welding joint listing system.

2. Operation requirements:

(1) check the voltage.

(2) check whether the fixture is concentric and flexible.

(3) ensure safe construction

(4) the solder must be roasted.

(5) reinforced ends around 10 ㎝ rust, oil, etc. With a steel brush to remove, not some of the gas cutting out straight.

(6) connect the power supply, welding machine, control box, welding gun, welding cable and control cable.

(7) the process parameters of vertical welding shall be determined by the following table according to the diameter of the steel bar.

Schedule:

Electroslag pressure welding parameters table

The steel bar is 16, 20, 25, 28, 32

Slag pool voltage (V) 25 ~ 50 25 ~ 50 25 ~ 50 25 ~ 50

Welding current (A) 250 ~ 350 ~ 450 ~ 550 ~ 550 ~ 600

Welding time (S) 2325 2729 34

Note: when the voltage fluctuates, the welding current and welding time should be adjusted according to the actual conditions.

Vi. Operation method:

(1) and electric welding machine and the power supply controller, welding torch welding torch Ⅱ Ⅰ welding cable and control cable, according to the figure good connection.

(2) adjust the current adjusting device of the welding machine to make it the required number.

(3) power switch on the control box "on" position, the power indicator light is lit, the regulating time potentiometer knob to the desired location, on time adjust potentiometer method is: welding torch on "open" button (gun control cable, only don't answer the welding cable), start time, to check the red indicator lights out on the welding torch instrument shell, see this time whether conform to the required value, such as do not conform to the repeated several times, until the alignment, then press the "off" button on welding torch.

(4) clamp the lower clamp on the welding gun to the fixed steel bar, attach the steel bar to be welded to the clamp, and aim the line. Guide the cutting line on top and guide column to positive.

(5) the put in up and down between the reinforced Ф 4 x5 ㎜ electrode, a short while again with asbestos cloth (or refractory cotton) into the flux tube wall inside the lower gap, closed flux tube, 431 flux into the flux tube, will be subject to full.

(6) prepare for the above work, the power of the press on the welding torch "on" button, the welding power source connected, counterclockwise to shake the handle, began to lead solitary, voltmeter instructions about 30 v, then the voltage value increased gradually; Shake the handle clockwise, to keep the molten pool voltage 40 v, instrument lights on the welding torch extinguished, shake the handle clockwise pressure, due to mechanical connecting rod downward when touch, micro switch BQ1 or (BQ2) make power blackouts, such as power cannot be automatically, should immediately press the torch on "off" button, power outages, so far a joint after welding. After temperature 1 ~ 2 minutes, open the solder cylinder, pour out the solder, remove the welding gun, and finish the welding process. Remove the quick joint during the heat preservation, insert the other welding torch, and when the other solder is ready to close, it can be soldered, so that it can be welded alternately.

(7) under the pressure of fixture and reinforced self-respect, hold in which can meet the requirements of top pressure, don't let go, immediately after the completion of the top pressure to continue holding lever 5 ~ 8 seconds, prevent weld solidification front caused by fixture rebound or loose joint cracking.

(8) during the winter construction, slow cooling should be adopted.

The welding current should be increased by 1 ~ 3 seconds, and the welding current should be increased appropriately, so that the time of the slag shell can be extended to reduce the effect of the slag shell.

Vii. Labor organization:

According to each floor (or standard) layer of the construction plan, with two axis axis (or three) for a period of water, can also according to the number of joint axis, increase or decrease in labor, arrange a torch for a vertical welding two groups: one hand inserted reinforcing steel bar, a fixture installation welding, a period of two to four water group vertical welding welding at the same time, in the first period of the water beam reinforcement construction layer after the binding, before pouring concrete beams and slabs, vertical welding groups can vertical welding on a layer of first class water Duan Zhu wall vertical main reinforcement, fixed, and then arrange to the stirrup outside their beam-column node stirrup post must add layer pad, prohibits cranes collision, to prevent displacement of vertical reinforcement.

Each group (2) each machine-team weldable 32 ~ 34 joint (skilled operation still has the potential to increase) after this arrangement in does not affect any other process, under the condition of vertical welding do not take up the absolute time of standard layer construction, significantly speed up the construction schedule.

Viii. Quality inspection and defect handling:

1. Sampling quantity and method: the appearance of the welding head of rebar electric slag pressure shall be inspected one by one. During strength inspection, three test pieces are cut from each batch of finished products for tensile test. In the general building, every 300 joints are a batch, in the present concrete frame structure, each floor of each floor is a batch of 300 with the specifications, less than 300 presses a batch calculation.

2. Appearance inspection:

(1) the joints shall be evenly distributed, and no cracks shall be allowed. No visible burns, pores, nibbling, slag and other quality defects shall be found on the surface of the steel bar.

(2) the joint axis displacement shall not exceed 10% of the steel bar diameter, at the same time shall not be greater than 2 ㎜.

(3) bending joint shall not be greater than 4 °.

The above inspection shall be cut and resoldered.

3, pull experiment: rebar welding tension experiment, the result of the three specimens shall be lower than the group tensile strength of steel, such as a tensile strength of the specimens is lower than the specified value, to conduct re-inspection should take double the amount of specimen, the reinspection results still has one and more than one specimen strength can not meet the above requirement, the number of joint sentences is unqualified.

4. Welding and prevention measures:

Defect prevention measures

Eccentric rebar straightening, steel bar to be upright, top pressure appropriate, repair jig timely.

Bend the steel bar straighter, the steel bar is upright and the clamping time is lengthened.

The steel bar is straightened, the welding time is shortened, the welding time is shortened, and the pressure volume is increased appropriately.

Not fusing to improve the speed of the rebar, delay the power outage time, check the jig, and properly increase the welding current.

The uneven bars of the welding bag are uneven, the steel reinforcement position is in the middle, and when the wind is high, one person is raised.

Bag of good asbestos cloth

It is not allowed to damp and rust.

Ix. Quality and safety measures:

1. Connection of power cable and control cable should be correct.

2, power supply and controller enclosure must be fixed ground wire, ground wire such as copper, cross section area of 6 ~ 10 ㎜ 2,

Aluminium wire to 20 ㎜ 2.

3. The upper and lower steel ends shall be straight and flat, removing rust and oil stains.

4. 431 solder is to be dried, do not use wet flux soldering.

5, fluctuation of reinforcement for alignment, axis offset is less than 0.1 d, or less than 2 ㎜.

6. Operators must wear insulating gloves and insulating shoes.

7. The area of the power supply is no less than 25mm2, and the voltage drop on the secondary line is not greater than 4V.

8. In the welding process, the steel bars shall not be touched by the welded steel bars.

9. Before welding, the rebar shall be tested before welding.

10. During the welding process, the welding quality should be checked at random.

After work, you must keep your head, control box, cable, etc., avoid damage.

10. Engineering examples and economic analysis:

The construction area of provincial forestry hall is 11000m2, 2 floors underground, 14 floors above ground, and frame shear wall structure. Applying this method a total of 4548 of welding joint, steel bar diameter is given priority to with Ф 25, other have Ф 22, Ф 20 steel. That is: the cost of each binding joint is 14.15 yuan, and the cost of each vertical welding head is 3.01 yuan, and it can save 11.14 yuan per connector. Total savings of 50664.72 yuan.

In conclusion, vertical electroslag pressure welding is a kind of comprehensive benefit, which should be vigorously promoted in the vertical bar connection of multi-layer and high frame structure.

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