The intelligent rebar cage processing follows a detailed, step-by-step method to ensure high-quality construction aligned with design specifications. This process involves precise cutting, threading, welding, and assembly of steel bars to form robust rebar cages.
Detailed Construction Steps
- Inspection and Acceptance of Raw Materials:
- Verify the steel bar factory qualification certificate, raw material quality certificate, and test reports.
- Conduct random inspections of raw materials.
- Prepare the steel cage according to construction drawings.
- Cutting and Preparing Steel Bars:
- Use a CNC sawing machine for precise cutting.
- Ensure the cut ends are flat to avoid re-grinding.
- Straighten the steel bars before processing, ensuring the end face is perpendicular to the bar’s axis.
- Stagger sleeve connections by 35 times the diameter of the steel bar.
- Upsetting the Steel Bars:
- Upset the cut steel bars according to design specifications.
- Ensure no transverse cracks in the upset head.
- Re-upset any unqualified heads, avoiding secondary upsetting.
- Threading the Upset Steel Bars:
- Secure the steel bar on the workbench, adjusting for concentricity.
- Operate slowly at first, then increase speed uniformly to maintain thread integrity.
- Ensure operators are certified and trained.
- Check the thread length, polish the cross-section, and protect threads with caps or sleeves.
- Batching and Placing Steel Bars:
- Sort threaded steel bars by cage section (top, middle, bottom) and reinforcement type (main, additional).
- Position main reinforcements and stirrups on the rolling cage welding machine.
- Insert main reinforcements into fixed and movable plate templates, ensuring uniform spacing and minimal diameter deviation.
- Welding and Reinforcing:
- Pre-bend reinforcements to match the steel cage diameter using an arc bending machine.
- Securely weld reinforcement rings and stirrups to main reinforcements.
- Ensure welds are full, without pores, and clean of slag.
- Installing and Assembling:
- Use a crane to position and weld the completed top cage.
- Attach the sonic detection pipe (outer diameter 57 mm, wall thickness 3.5 mm) using threads.
- Arrange four acoustic detection tubes for cages with a pile diameter > 1.5 meters, and three for ≤ 1.5 meters.
- Inspect the steel cages and hang identification signs.
- Final Assembly and Storage:
- Pre-assemble the steel cages in the order of bottom, middle, and top sections.
- Connect sections using long and short wires with sleeves.
- Ensure proper alignment of sleeves and acoustic detection tubes.
- Move assembled cages to the storage area, ready for construction use.
By meticulously following these steps, the intelligent rebar cage processing ensures the creation of strong, reliable steel cages that meet all construction specifications and standards.
