重庆某化工项目钢筋焊接施工方案(中英文对照).doc

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1、钢筋焊接施工方案文件编号： Approved： 批 准： Audit： 审 核： Fabrication: 编 制： Contents 目录一、 Project overview.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

2、项.16-16一、 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 wa

3、shing 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

4、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

5、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 ensure the construction safety、quality、high efficiency and especially the preparat

6、ion 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 specificationJGJ18-2012钢筋焊接及验收规程JGJ18-2012 Technical specification of reinforcing steel mechanicalJGJ

7、107-2010钢筋机械连接技术规程JGJ107-2010Upsetting straight thread reinforcing steel jointJGJ71-2005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;

8、 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： 4. 1.1.1 Reinforcing steel: the grade and diameter of reinforcing steel shall meet the design require

9、ment, 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 o

10、il.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、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

11、、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：The welding rod brand o

12、f reinforcing steel electric arc welding 钢筋电弧焊使用的焊条牌号Item项次Bar grade钢筋级别Overlap welding、 ligating bud welding搭接焊、帮条焊Groove welding坡口焊1级E4303 E4303E43032级E4303 E4303E50033级E5003 E5003E50034、级与钢板焊接E4303E4303 4.1.1.3.1 The welding rod coating surface shall not crack、pore and irregularity defects, and n

13、ot 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

14、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 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

15、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 regula

16、tion.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

17、及火灾等事故。 4.1.2.5 Familiarity with drawing, do well technical disclosure.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：Determine welding parameter 确定焊接参数Send samples送试Inspect equipment检查设备Select welding parameter选择焊接参数Test welding work, test piece试焊接作业试件Quality inspection 质量检验Star

18、t welding施焊4.22 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

19、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

20、 shall be weld 3 simulated specimens by tension test, after the test, then can be batch production according to the determined welding parameters.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

21、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

22、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

23、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。 4.2.5.5 Multi-layer welding: if reinforcing steel diameter larger, it shall need for multi-la

24、yer 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 suffi

25、cient 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

26、 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 wel

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

28、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6080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 weldi

29、ng: 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7080，防止

30、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 r

31、od inclination of 80 90 with welding direction . The remaining layers electrodes yaw, and a little 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

32、 welding钢筋帮条焊：4.2.5.11.1 Steel bar ligating bud welding is applied to 、grade 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 we

33、lding 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 specif

34、ication. 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、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。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

35、.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 welding seam 焊缝型式Steel bar ligating length帮条长度l1级Welding of one s

36、ide单面焊Welding of double sides双面焊8d4d2级Welding of one side单面焊Welding of double sides双面焊10d5dNotice: d is the diameter of main steel bar.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 25mm b

37、etween two main steel bar termination.两主筋端头之间，应留25mm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 sh

38、all 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

39、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 welding of double sides cannot use, it also adopt welding of

40、 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、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

41、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

42、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 a

43、way from the lap end 20mm or more.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 s

44、eam 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 pa

45、ste 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.钢板厚度不小于0.6d,并不宜小于6mm。4.2.5.13.2 Steel bar shall be used

46、 to grade , . By anchoring bar diameter not less than 8mm, the structure anchoring rebar diameter not less than 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、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625mm以内，可采用贴脚焊；锚固钢筋直径为2032mm时，宜采用穿孔塞焊。4.2.5.13.3 Site installation conditions, each from floors in the same type of conne