Assessment and optimization of a clean and healthier fusion welding procedure for rebar in building structures

Abstract

The welding procedure for reinforcing bars used in reinforced concrete takes place at fixed industrial installations. The welders must ensure that the reinforcing bar positions are maintained throughout all stages leading up to concreting. Fusion welding offers an alternative procedure that entails fewer risks for the workers’ health. In this study, we aimed to determine the minimum parameters for the intensity, pressure, and time necessary to ensure the level of performance required by this assembly welding. A total of 2160 joints were manufactured, comprising the different thicknesses. For each thickness measurement, 45 different combinations of parameters were applied. The joints were evaluated based on the resulting dimensions and on the failure force necessary to break the joint. For different thicknesses, the breaking loads were over 7350 N. In addition, the welding cycle times did not exceed three seconds. Based on the results obtained in this study, we concluded that assembling rebar (manufacturing reinforcing bars) by electrical resistance welding is a viable option. This method is fast, safe, and clean, and reduces the risks to the workers’ health.