U. S.

Department of A g r i c u l t u r e S o i l Conservation S e r v i c e Engineering D i v i s i o n Design Branch

January 12, 1971

DESIGN NOTE.NO. 11* Subject: Welding Reinforcing S t e e l f o r Reinforced Concrete

Welding o f r e i n f o r c i n g b a r s u s u a l l y i s n o t n e c e s s a r y i n SCS c o n s t r u c t i o n and g e n e r a l l y should be avoided, u n l e s s t h e saving i n o t h e r c o n s t r u c t i o n c o s t s i s s u f f i c i e n t t o balance t h e c o s t o f t h e c o n t r o l t h a t must b e e x e r c i s e d t o i n s u r e good welds. I f a s u b s t a n t i a l number of l a r g e b a r s , 1/11 o r l a r g e r , a r e t b b e s p l i c e d and t h e r e i s n o t room f o r t h e r e q u i r e d l a p t o develop t h e b a r s t r e n g t h i n bond, welding may be necessary. However, i t u s u a l l y i s more economical, and b e t t e r s t r u c t u r a l l y , t o i n c r e a s e t h e w a l l t h i c k n e s s and u s e s m a l l e r ' b a r s which can be lapped. Therefore, g e n e r a l l y speaking, t h e u s e of 811 o r l a r g e r b a r s i s n o t recommended.

Tack welding of r e i n f o r c i n g b a r s i n l i e u o f w i r e t y i n g t o hold them i n p l a c e i s n o t p e r m i t t e d by SCS s t a n d a r d s p e c i f i c a t i o n s . Bars can b e s e r i o u s l y weakened by t a c k welding. S t e e l Composition The s t a n d a r d s p e c i f i c a t i o n s f o r r e i n f o r c i n g b a r s r e f e r r e d t o i n M a t e r i a l S p e c i f i c a t i o n 539, (ASTN A 615, A 616, and A 617) a r e based on p h y s i c a l p r o p e r t i e s and do n o t s p e c i f y t h e chemical composition of t h e s t e e l . Since w e l d a b i l i t y i s dependent upon chemical composition, b a r s may conform t o t h e s e s p e c i f i c a t i o n s y e t n o t b e weldable. I f b a r s p l i c e s a r e t o b e welded, M a t e r i a l S p e c i f i c a t i o n 539 s t i l l a p p l i e s , but t h e c o n s t r u c t i o n d e t a i l s must s p e c i f y i n a d d i t i o n t h a t t h e b a r s b e o f weldable s t e e l . The c o n t r a c t o r should be r e q u i r e d t o p r o v i d e a c e r t i f i e d copy of t h e m i l l t e s t r e p o r t showing t h e a c t u a l composition o f t h e s t e e l furnished. Table I shows t h e i d e a l range o f carbon and manganese i n carbon s t e e l f o r good w e l d a b i l i t y . S t e e l s i n t h e range i n d i c a t e d can b e welded s a t i s f a c t o r i l y without s p e c i a l p r e c a u t i o n s . P r e h e a t i n g , low-hydrogen e l e c t r o d e s , o r both, may be r e q u i r e d t o s u c c e s s f u l l y arc-weld steel c o n t a i n i n g more t h a n 0.30 p e r c e n t carbon o r more t h a n 0.60 p e r c e n t manganese. Oxyacetylene welding can be used f o r s t e e l s w i t h somewhat h i g h e r carbon and manganese c o n t e n t s . Thennit welding can b e used f o r s t e e l having up t o 0.80 p e r c e n t carbon and 1.30 p e r c e n t manganese. *by A. S. Payne, A s s i s t a n t Chief, Design Branch

Table I

Chemical A n a l y s i s of Carbon S t e e l f o r Good W e l d a b i l i t y Range, %

.06 .35

Element Carbon Manganese Silicon Sulphur Phosphorus Welding Rods

.30

.60

.10 max.

.035 max.
.030 max.

S p e c i f i c a t i o n s f o r a r c - w e l d i n g e l e c t r o d e s and d e s c r i p t i o n s o f t h e v a r i o u s c l a s s e s and t h e i r i n t e n d e d u s e s a r e g i v e n i n A W S A5.1, " S p e c i f i c a t i o n f o r Mild S t e e l Covered Arc-Welding E l e c t r o d e s " of t h e American Welding S o c i e t y (ASTM D e s i g n a t i o n : A233). S i m i l a r i n f o r m a t i o n f o r gas-welding r o d s i s g i v e n i n A W S A5.2, " S p e c i f i c a t i o n f o r I r o n and S t e e l Gas-Welding Rods," (ASTM D e s i g n a t i o n : AZ5l). Welding Methods The most common method of f i e l d welding i s t h e s h i e l d e d m e t a l - a r c method i n which h e a t t o f u s e t h e m e t a l i s g e n e r a t e d by an e l e c t r i c a r c between t h e welding r o d o r e l e c t r o d e and t h e m e t a l b e i n g welded. The e l e c t r o d e i s a consumable m e t a l rod c o a t e d w i t h a m a t e r i a l t h a t g i v e s o f f an i n e r t gas t o p r e v e n t c o n t a m i n a t i o n o f t h e molten m e t a l by t h e atmosphere. Oxyacetylene gas welding, i n which t h e welding h e a t i s o b t a i n e d by burning a m i x t u r e of a c e t y l e n e and oxygen, a l s o i s used b u t i s s l o w e r t h a n e l e c t r i c - a r c welding. Both o f t h e s e methods, performed b y u a l i f j e d w e l d e r s , c a n produce welds of h i g h q u a l i t y i n s t e e l s t h a t a r e s u i t a b l e f o r welding. Thermit welding i s a p r o c e s s i n which t h e welding h e a t i s g e n e r a t e d by b u r n i n g " t h e r m i t " powder. The e s s e n t i a l i n g r e d i e n t s of t h e powder a r e aluminum, i r o n o x i d e , and a n i g n i t i n g a g e n t which r e a c t a t h i g h t e m p e r a t u r e t o produce molten s t e e l and alumina s l a g . Oxides of o t h e r e l e m e n t s a r e added t o g i v e t h e r e s u l t i q g weld m e t a l t h e d e s i r e d p r o p e r t i e s . I n welding r e i n f o r c i n g b a r s by t h i s p r o c e s s , t h e b a r s a r e clamped i n p o s i t i o n i n a mold t o which is a t t a c h e d a c r u c i b l e c o n t a i n i n g t h e t h e r m i t powder. When t h e powder i s i g n i t e d , t h e molten weld m e t a l flows i n t o t h e mold and between t h e ends of t h e b a r s . The b a r s and t h e weld m e t a l a r e fused t o g e t h e r . The p r o c e s s produces welds of good q u a l i t y and c a n be used on s t e e l s t h a t a r e h a r d t o weld by o t h e r methods.

3
The t h e r m i t p r o c e s s c a n p o s e a s e r i o u s f i r e h a z a r d i f n o t handled c a r e f u l l y . The molds and t h e powder must b e p r o t e c t e d from m o i s t u r e , and t h e b a r ends must b e c l e a n .

A p a t e n t e d p r o c e s s s i m i l a r t o t h e r m i t welding i s "Cadweld" r e b a r s p l i c i n g i n which a m e t a l s l e e v e i s p l a c e d around t h e a b u t t i n g b a r ends and m o l t e n m e t a l i s c a s t i n t o t h e s p a c e between t h e s l e e v e and t h e b a r s . The b a r s a r e n o t f u s e d , however, s o t h i s i s n o t a welded s p l i c e b u t depends upon mechanical i n t e r l o c k i n g o f t h e c a s t m e t a l w i t h t h e d e f o r m a t i o n s on t h e b a r s and w i t h grooves on t h e i n s i d e o f t h e sleeve.
S p l i c e Design The f o l l o w i n g p r o v i s i o n s r e l a t i n g t o welded s p l i c e s i n c o n c r e t e r e i n f o r c e m e n t a r e c o n t a i n e d i n t h e A C I s t a n d a r d " B u i l d i n g Code Requirements f o r Reinforced Concrete" (ACI 318-63), s e c t i o n 805.

1.

S p l i c e s i n r e i n f o r c e m e n t i n which t h e c r i t i c a l d e s i ~ stress is tensile "Lapped s p l i c e s i n t e n s i o n s h a l l n o t b e used f o r b a r s i z e s l a r g e r t h a n 811." " S p l i c e s a t p o i n t s o f maximum t e n s i l e s t r e s s s h a l l b e avoided wherever p o s s i b l e ; such s p l i c e s where used s h a l l b e welded, l a p p e d , o r o t h e r w i s e f u l l y developed."

S p l i c e s i n r e i n f o r c e m e n t i n which t h e c r i t i c a l d e s i g n 2. s t r e s s i s compressive "Welded s p l i c e s o r o t h e r p o s i t i v e c o n n e c t i o n s may b e used i n s t e a d o f lapped s p l i c e s . Where t h e b a r s i z e exceeds 1/11, welded s p l i c e s o r o t h e r p o s i t i v e c o n n e c t i o n s s h a l l p r e f e r a b l y be used. I n b a r s r e q u i r e d f o r compression o n l y , t h e compressive s t r e s s may b e t r a n s m i t t e d by b e a r i n g o f s q u a r e c u t ends h e l d i n c o n c e n t r i c c o n t a c t by a s u i t a b l y welded s l e e v e o r mechanical d e v i c e . " "An approved welded s p l i c e i s one i n which t h e b a r s a r e b u t t e d and welded s o t h a t i t w i l l develop i n t e n s i o n a t l e a s t 125 p e r c e n t of t h e s p e c i f i e d y i e l d s t r e n g t h o f t h e r e i n f o r c i n g bar.'! Welding s h a l l conform t o AWS D 12.1, "Recormended P r a c t i c e s f o r Welding R e i n f o r c i n g S t e e l , Metal I n s e r t s and Connections i n Reinforced C o n c r e t e C o n s t r u c t i o n . " D e t a i l s o f s e v e r a l t y p e s of welded s p l i c e a r e shown i n F i g u r e 1. Welded l a p s p l i c e s should n o t be used because o f t h e e c c e n t r i c i t y o f l o a d t r a n s f e r t h r o u g h them and t h e r e s u l t i n g tendency t o r u p t u r e t h e c o n c r e t e . Double l a p s p l i c e s such a s i l l u s t r a t e d i n F i g u r e 1 may be used f o r s m a l l b a r s i n t e n s i o n o r compression. The s l e e v e s p l i c e i l l u s t r a t e d i n F i g u r e 1 i s d e s i g n e d f o r column b a r s i n compression. B u t t s p l i c e s a r e good f o r e i t h e r t e n s i o n o r compression.

3.

4.

Weld Square -end bearing plice lr S angle

I

Splice bar

Weld

Weld

(a)

SLEEVE SPLICE

(b)

DOUBLE L A P SPLICES

S ing l e -Beve 1

Groove Weld

Double -Beve 1 Groove W e ld

0t i s
Sing1 e-Vee Groove Weld
Horizontal Bars

V e r t i c a l Bars
(c)

BUTT SPLICES

Fig. 1

- Welded

S p l i c e s for Reinforcing S t e e l

Welding P r o c e d u r e s Welding procedures s h o u l d be s p e c i f i e d i n t h e c o n s t r u c t i o n d e t a i l s . They w i l l depend upon t h e k i n d of s p l i c e , t h e s i z e o f t h e b a r s , t h e composition o f t h e s t e e l , t h e p o s i t i o n and a c c e s s i b i l i t y o f t h e welds, t h e a t m o s p h e r i c t e m p e r a t u r e , and other factors. Procedures and workmanship s h o u l d conform t o S e c t i o n 4 of A W S D 12.1, "Welding R e i n f o r c i n g S t e e l , Metal I n s e r t s and Connections i n R e i n f o r c e d Concrete C o n s t r u c t i o n " and S e c t i o n 4 of A W S D 2.0, " S p e c i f i c a t i o n s Lcor Welded Highway and Railway Bridges

I f t h e r m i t welding i s t o be u s e d , procedures s h o u l d conform t o recommendations of t h e manufacturer o f t h e m a t e r i a l s . The t h e r m i t powder must be of a composition t h a t w i l l produce weld metal o f s t r e n g t h and d u c t i l i t y comparable w i t h t h a t of t h e b a r s b e i n g s p l i c e d , and t h e q u a n t i t y used must be s u f f i c i e n t t o f i l l t h e s p l i c e mold and f u s e t h e ends o f t h e b a r s . Q u a l i f i c a t i o n of Welders S i n c e t h e q u a l i t y of each weld depends upon t h e e x p e r i e n c e and s k i l l of t h e w e l d e r , o n l y w e l d e r s who have been q u a l i f i e d by t e s t s a s p r e s c r i b e d i n t h e "Standard Q u a l i f i c a t i o n Procedure" ( A W S B 3.0) o f t h e American Welding s o c i e t y 1 s h o u l d be p e r m i t t e d t o weld r e i n f o r c i n g b a r s . The c o n t r a c t o r s h o u l d . b e r e q u i r e d t o c e r t i f y t h a t each welder i s c u r r e n t l y q u a l i f i e d a c c o r d i n g t o t h e "Standard Q u a l i f i c a t i o n Procedure1' and t o f u r n i s h t h e d a t e s and r e s u l t s of h i s q u a l i f i c a t i o n t e s t s . Inspection The b a r s t o be welded and t h e weld m a t e r i a l s t o be used s h o u l d be i n s p e c t e d f o r comformance t o t h e s p e c i f i c a t i o n s . S p l i c e a s s e m b l i e s s h o u l d be i n s p e c t e d p r i o r t o welding, f o r p r o p e r alignment and s p a c i n g of t h e p a r t s , p r o p e r groove o r b e v e l a n g l e s , and freedom from l o o s e s c a l e , s l a g , r u s t , g r e a s e , m o i s t u r e , and o t h e r contaminants. The welding p r o c e s s s h o u l d be observed p e r i o d i c a l l y by a n experienced i n s p e c t o r t o i n s u r e t h a t t h e s p e c i f i e d procedures a r e b e i n g followed and a r e producing good welds. D e p o s l t i o n o f t h e weld m e t a l s h o u l d be observed, u s i n g a w e l d e r ' s mask.

'~~~licab po l ret i o n s o f t h e "Standard Q u a l i f i c a t i o n Procedure" W S D 2.0, " S p e c i f i c a t i o n f o r Welded a r e g i v e n i n Appendix A o f A Highway and Railway Bridges."

Each completed weld s h o u l d be i n s p e c t e d v i s u a l l y f o r c r a c k s i n t h e weld o r b a s e m e t a l , f o r i n a d e q u a t e s i z e , u n d e r c u t t i n g , o r o t h e r v i s i b l e d e f e c t s . A l l s l a g must be c l e a n e d from t h e s u r f a c e o f t h e weld and s u r r o u n d i n g m e t a l b e f o r e t h e weld can be i n s p e c t e d a d e q u a t e l y . Any weld i n which a c r a c k i s a p p a r e n t must be c o m p l e t e l y removed and rewelded. U n d e r c u t t i n g t h a t r e d u c e s t h e s t r e n g t h of t h e b a r a d j a c e n t t o t h e weld must be r e p a i r e d by c l e a n i n g and a d d i n g more weld metal. References

I.

A W S D 12.1, Recommended P r a c t i c e s f o r Welding R e i n f o r c i n g S t e e l , Metal I n s e r t s and Connections i n R e i n f o r c e d C o n c r e t e ~ o n s t r u c t i o n . ~$1.50 A W S n 2.0, S p e c i f i c a t i o n s f o r Welded Highway and Railway $8.00 ~ r i d ~.2 e s A W S A 5 . 1 , S p e c i f i c a t i o n f o r Mild S t e e l Covered Arc-Welding ~ l e c t r o d e s . " $3.00 A W S A 5 . 2 , S p e c i f i c a t i o n f o r I r o n and S t e e l Gas-Welding ~ o d s . $2.00 ~
A C I 318-63, B u i l d i n g Code Requirements f o r R e i n f o r c e d C o n c r e t e , American Concrete I n s t i t u t e . June 1963. $3.00

2.

3.
.4.

5.

6.

P l a c i n g Reinforcing Bars, Concrete Reinforcing S t e e l I n s t i t u t e , 228 North La S a l l e S t r e e t , Chicago, I l l i n o i s 60601, 1968. $2.00 Omer W. B l o d g e t t , Design o f Welded S t r u c t u r e s , The James F. L i n c o l n Arc Welding Foundation, P. 0. Box 3035, C l e v e l a n d , Ohio 44117. June 1966. $7.00

7.

' ~ m e r i c a n Welding S o c i e t y , I n c . , 345 E a s t 4 7 t h S t r e e t , New York, N. Y. 10017