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1、钢筋电渣压力焊施工工艺标准1. 总则1.1 适用范围本工艺适用于工业与民用建筑现浇钢筋混凝土结构中直径1440mm的HPB235HRB400级(级)竖向或斜向(倾斜度4:1范围内)钢筋的连接。1.2 编制参考标准及规范(1)建筑工程施工质量验收统一标准(GH 503002001)： (2)混凝土结构工程施工质量验收规范(GB 502042002)； (3)钢筋焊接及验收规程(JGJ 182003)。2. 术语钢筋电渣压力焊： 将钢筋安装成竖向对接形式，利用焊接电流通过两钢筋端面间隙，在焊剂层下形成电弧过程和电渣过程，产生电弧热和电阻热，熔化钢筋并加压完成的一种压焊方法。 3. 基本规定在每批钢
2、筋正式焊接之前，应进行现场条件下的焊接性能试验，合格后方可正式生产。电渣压力焊接头应逐个进行外观检查。电渣压力焊接头拉伸试验结果，3个试件的抗拉强度均不得小于该级别钢筋规定的抗拉强度。4. 施工准备4.1 技术准备编写焊接工艺，通过焊接试验选定焊接参数，对焊工进行技术、安全交底。4.2 材料要求(1) 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，并应有可焊性试验。 (2) 焊剂 1) 焊剂的性能应符合GB 5293碳素钢埋弧焊用焊剂的规定。焊剂型号为HJ 401，常用的为熔炼型高锰高硅低氟焊剂或中锰高硅低氟焊剂。 2)
3、焊剂应存放在干燥的库房内，防止受潮。如受潮，使用前须经250300烘焙2h。 3) 使用中回收的焊剂，应除去熔渣和杂物，并应与新焊剂混合均匀后使用。 4) 焊剂应有出厂合格证。4.3 主要机具(1) 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。 (2) 自动电渣压力焊设备(应优先采用)包括：焊接电源、控制箱、操作箱、焊接机头等。 (3) 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100A的焊接电源)。当焊机容量较小时，也可
4、以采用较小容量的同型号，同性能的两台焊机并联使用。4.3 作业条件4.3.1 焊工必须持有有效的焊工考试合格证。4.3.2 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。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。电压表、时间显示器应配备齐全，以便操作者准备掌握各项焊接参数。4.3.3 电源应符合要求。当电源电压下降大于5%，则不宜进行焊接。4.3.4 作业场地应有安全防护措施，制订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。4.3.5 注意接头位置，注意同一连接区段内，纵向受力钢筋的接头面积百分率应符合
5、设计要求。当设计无具体求时应符合在受拉区不宜大于50%的规定，要调整接头位置后才能施焊。5. 材料和质量要点5.1 材料的关键要求焊剂的性能应符合GB 5293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。焊剂应存放在干燥的库房内，当受潮时，在使用前应经250300烘焙2h。使用中回收的焊剂应清除熔渣和杂物，并应与新焊剂混合均匀后使用。 施焊的各种钢筋应有材质证明书或试验报告单。焊剂应有合格证。5.2 技术关键要求电渣压力焊焊接前应针对不同的直径钢筋确定焊接参数(焊接参数包括焊接电流、电压和通电时间)，不同直径钢筋焊接时，应按较小直径钢筋选择
6、参数，焊接时间可延长。对焊工要进行焊接参数的详细交底。5.3 质量关键要求电渣压力焊接头不得出现偏心、弯折、烧伤等焊接缺陷，四周焊包应均匀，凸出钢筋表面的高度应大于或等4mm，钢筋与电极接触处，应无烧伤缺陷，接头处的弯折角不得大4，接头处的轴线偏移不得大于钢筋直径的0.1倍，且不得大于2mm，外观检查不合格的接头应切除重焊，或采取补强焊接措施。5.4 职业健康安全关键要求(1) 焊工操作时应穿电焊工作服、绝缘鞋和戴电焊手套、防护面罩等安全防护用品，高处作业时系安全带。 (2) 电焊作业现场周围10m范围内不得堆放易燃易爆物品。 (3) 操作前应首先检查焊机和工具，如焊钳和焊接电缆的绝缘、焊机外
7、壳保护接地和焊机的各接线点等，确认安全合格方可作业。5.5 环境关键要求严禁在易燃易爆气体或液体扩散区域内进行焊接作业。6. 施工工艺6.1 工艺流程(1)工艺流程：6.2 操作工艺(1) 检查设备、电源 确保随时处于正常状态，严禁超负荷工作。 (2) 钢筋端头制备 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。 (3) 选择焊接参数 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，参见表6.2。采用HJ 431焊剂时，宜符合表6.2的规定。采用专用焊剂或自动
8、电渣压力焊机时，应根据焊剂或焊机使用说明书中推荐数据，通过试验确定。 不同直径钢筋焊接时，上下两钢筋轴线在同一线上。(4) 安装焊接夹具和钢筋 夹具的下钳口应夹紧于下钢筋端部的适当位置，一般为1/2 焊剂罐高度偏下510mm ，以确保焊接处的焊剂有足够的掩埋深度。 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。 钢筋一经夹紧，严防晃动，以免上下钢筋错位和夹具变形。 (5) 安放引弧用的钢丝球(也可省去) 安放焊剂罐、填装焊剂。 (6) 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并作试件送试，以便确定合理的
9、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。 (7) 施焊操作要点 1) 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。 2) 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。 3) 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。 4) 挤压断电：电渣过程结束，迅速下送上钢筋，使其端面与下钢
10、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。 5) 接头焊毕，应停歇2030s后(在寒冷地区施焊时，停歇时间应适当延长)，才可回收焊剂和卸下焊接夹具。 (8) 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。 6.3 应注意的质量问题 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
11、渣过程，短而稳定；挤压过程，压力适当。若出现异常现象，应参照表6.3 查找原因,及时清除。 7. 质量标准7.1 主控项目(1) 钢筋的牌号和质量，必须符合设计要求和有关标准的规定。 进口钢筋需先经过化学成分检验和焊接试验，符合有关规定后方可焊接。 检验方法：检查出厂质量证明书和试验报告单。 (2) 钢筋的规格，焊接接头的位置，同一区段内有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。 检验方法：观察或尺量检查。 (3) 电渣压力焊接头的质量检验，应分批进行外观检查和力学性能检验，并应按下列规定作为一个检验批。 在现浇钢筋混凝土结构中，应以300个同牌号钢筋接头作为一批；在房屋结构中
12、，应在不超过二楼层中300个同牌号钢筋接头作为一批；当不足300个接头时，仍应作为一批。每批随机切取3个接头做拉伸试验，其结果应符合下列要求： 1) 3个热轧钢筋接头试件的抗拉强度均不得小于该牌号钢筋规定的抗拉强度； 2) 至少应有2个试件断于焊缝之外，并应呈延性断裂； 3) 当达到上述2项要求时，应评定该批接头为抗拉强度合格。 当试验结果有2个试件抗拉强度小于钢筋规定的抗接强度，或3个试件均在焊缝或热影响区发生脆性断裂时，则一次判定该批接头为不合格品。 当试验结果有1个试件的抗拉强度小于规定值，或2个试件在焊缝或热影响区发生脆性断裂，其抗拉强度均小于钢筋规定抗拉强度的1.10倍时，应进行复验
13、。 复验时应切取6个试件。复验结果，当仍有1个试件的抗拉强度小于规定值，或有3个试件断于焊缝或热影响区，呈脆性断裂，其抗拉强度小于钢筋规定抗拉强度的1.10倍时，应判定该批接头为不合格品。 检验方法：检查焊接试件试验报告单。7.2 一般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： (1) 四周焊包，凸出钢筋表面的高度不得小于4mm 。 (2) 钢筋与电极接触处，应无烧伤缺陷。 (3) 接头处的弯折角不大于3。 (4) 接头处的轴线偏移不得大于钢筋直径0.1 倍，且不得大于2mm。 检验方法：目测或量测。 8. 成品保护接头焊毕，应停歇2030s后才能卸下夹具，以免接头弯折。
14、9. 安全环保措施9.1 焊工操作时应穿电焊工作服、绝缘鞋和戴电焊手套、防护面罩等安全防护用品，高处作业时系安全带。 9.2 电焊作业现场周围10m范围内不得堆放易燃易爆物品。 9.3 操作前应首先检查焊机和工具，如焊钳和焊接电缆的绝缘、焊机外壳保护接地和焊机的各接线点等，确认安全合格方可作业。 9.4 焊接时二次线必须双线到位，严禁借用金属管道、金属脚手架、轨道及结构钢筋作回路地线。 9.5 雨、雪、风力六级以上（含六级）天气不得露天作业。雨雪后应清除积水、积雪后方可作业。 9.6 严禁在易燃易爆气体或液体扩散区域内进行焊接作业。 10. 质量记录10.1 钢筋出厂质量证明文件。 10.2
15、钢筋原材复试报告。 10.3 钢筋连接试验报告。 （英文版 ） Two regulations promulgated for implementation is in the party in power for a long time and the rule of law conditions, the implementation of comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengt
16、hen inner-party supervision of major initiatives. The two regulations supporting each other, the adhere to a positive advocate, focusing on morality is of Party members and Party leading cadres can see, enough to get a high standard; around the party discipline, disciplinary ruler requirements, list
17、ed as negative list, focusing on vertical gauge, draw the party organizations and Party members do not touch the bottom line . Here, the main from four square face two party rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the s
18、econd part is the interpretation of the two fundamental principles of the revision of laws and regulations in the party; the third part introduces two party regulations modified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two re
19、gulations of the party. and revised the necessity and revised history of the CPC Central Committee the amendment to the Chinese Communist Party members and leading cadres honest politics several guidelines and column 1 by 2015 to strengthen party laws and regulations focus. Two party regulations rev
20、ision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respect for the wisdom of our predecessors, which reflects the unity of inheritance and innovation; follow the correct direction, grasp the limited goals, adhere to the partys leaders
21、hip, to solve the masses of the people reflect a focus on the problem. The new revision of the and , reflects the partys 18 and the eighth session of the third, the spirit of the fourth plenary session, reflecting the experience of studying and implementing the General Secretary Xi Jinping series of
22、 important speech, reflects the partys eighteen years comprehensive strictly practice. (a) revised two regulations of the party need of in based on revised, the promulgation and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play an important role.
23、 But with the party to manage the party strictly administering the deepening, has not been able to fully meet the actual needs. Content is too complicated, eight prohibition, 52 are not allowed to hard to remember, and also difficult to put into practice; the second is concisely positive advocated b
24、y the lack of prohibited provisions excessive, no autonomy requirements; the third is banned terms and discipline law, both with the party discipline, disciplinary regulations repeat and Criminal law and other laws and regulations repeat; the fourth is to clean the theme is not prominent, not for th
25、e existing problems, and is narrow, only needle of county-level leading cadres above. is in 1997 based on revision, in December 2003 the promulgation and implementation, to strengthen the construction of the party play very important role. Along with the development of the situation, which many prov
26、isions have been unable to fully meet the comprehensive strictly administering the practice needs. One is Ji law, more than half of the provisions and criminal law and other countries laws and regulations Repetition; two is the political discipline regulations is not prominent, not specific, for vio
27、lation of the party constitution, damage the authority of Party Constitution of misconduct lack necessary and serious responsibility to pursue; third is the main discipline for the leading cadres, does not cover all Party members. Based on the above situation, need to and the two is likely to be mor
28、e relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the party tree and call up the majority of Party members and cadres of the party constitution of party compasses party consciousness. (II) two party regulations revision process the
29、Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, general books recorded in the Fifth Plenary Session of the eighth session of the Central Commission for Discipline Inspection, on the revised regulations made clear instructions. Acc
30、ording to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study two regulations revision. The Standing Committee of the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14 times held a special meeting to stud
31、y two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively held a forum will listen to part of the province (area) secretary of the Party committee, Secretary of the Discipline Inspection Commission, part of the central ministries and stat
32、e organs Department The first party committee is mainly responsible for people, views of experts and scholars and grassroots party organizations and Party members. Approved by the Central Committee of the Communist Party of China, on 7 September 2015, the general office of the Central Committee of t
33、he Party issued a notice to solicit the provinces (autonomous regions, municipalities) Party, the central ministries and commissions, state ministries and commissions of the Party (party), the General Political Department of the military, every 3 people organization of Party of two regulations revis
34、ion opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting, formed a revised sent reviewers. In October 8 and October 12, Central Committee Political Bureau Standing Committee and the Political Bureau of the Central Committee After cons
35、ideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formally issued two regulations. Can say, two laws amendment concentrated the wisdom of the whole party, embodies the party. Second, and revision of the basic principles of two party
36、regulations revision work and implement the partys eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of the Eleventh Central Committee and General Secretary Xi Jinping important instructions on the revised and , highlighting the ruling party characteristics, serious discipline, t
37、he discipline quite in front of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent and . Main principle is: first, adhere to the party constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constituti
38、on of party compasses party consciousness, maintaining the authority of the constitution. General Secretary Xi Jinping pointed out that no rules, no side round. Party constitution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Co
39、mmission for Discipline Inspection Fifth Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that constitution is the party must follow the general rules, but also the general rules. the revision of the and is Method in adhere to the regulations established for the purpose of
40、 combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set up, wake up the party constitution and party rules the sense of discipline, the party constitution about discipline and self-discipline specific requirements. 4 second is to ad
41、here to in accordance with the regulations governing the party and the party. The Party of rule of virtue de, mainly refers to the partys ideals and beliefs, excellent traditional style. The revised the closely linked to the self-discipline, insisting on the positive initiative, for all members, hig
42、hlight the vital few, emphasized self-discipline, focusing on the morality, and the majority of Party members and the ideological and moral standards. The revised Ji method separately, Ji, Ji Yan to Method, as a negative list, emphasizing the heteronomy, focusing on vertical gauge. Is this one high
43、and one low, a positive reaction, the strict party discipline and practice results transformation for the integration of the whole party to observe moral and discipline requirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the pro
44、blems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-discipline and abide by the discipline to make clearly defined, especially the partys eighteen years strict political discipline and political rules, organization and discipline and
45、to implement the central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions. Not one pace reachs the designated position, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the and mo
46、dified and needs to grasp several key problems (a) adhere to according to regulations governing the party and party with morals in combination, for at the present stage, the leadership of the party members and cadres and Party members in existing main problems of self-discipline, put forward princip
47、les, requirements and specifications, showing Communists noble moral pursuit, reflected at all times and in all over the world ethics from high from low 5 common requirements. One is closely linked to the self-discipline, removal and no direct relation to the provisions of . the second is adhere to a positive advocate