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GHM Machinery REBAR-BINDING-PROCESS

Rebar Binding Process

Scope of Rebar Binding Process Application

This process standard applies to various components of pile foundation in bridge engineering, including:

  • Cap
  • Pier stud
  • Cap beam
  • T beam
  • Other ground reinforcement binding projects
Preparation of Major Rebar Binding Process Application Standards and Specifications
1 Industry Standards
  • Technical Code for Highway Bridge and Culvert Construction: JTJ 041-2000
  • Highway Engineering Quality Inspection and Evaluation Standards: JTG F80/1-2004
2 National Standards
  • Hot-rolled Round Steel Bars for Reinforced Concrete: GB 13013-91
  • Hot-rolled Ribbed Steel Bars for Reinforced Concrete: GB 1499-1998
  • Mild Steel Hot-rolled Disc Rod: GB 701-1997
Preparation for Construction
1 Technical Preparation
  1. Drawings and Design: Familiarize yourself with construction drawings and prepare the organizational design for reinforcement binding.
  2. Steel Bar Cutting: Cut steel bars according to the drawings’ specifications.
  3. Technical Disclosure: Provide a written technical disclosure to each reinforcement team.
2 Preparation of Materials
  1. Reinforcing Bars:
    • Ensure that reinforcing bars have factory certificates and inspection reports.
    • Inspect for rust and oil stains; sample for mechanical properties retest as required.
  2. Iron Wire:
    • Use 20~22 gauge iron wire (for burnt wire) or galvanized iron wire.
    • Cut wire to meet usage requirements.
  3. Cushion Block:
    • Select cushion blocks based on the protective layer thickness. Use cement mortar blocks with a strength grade matching the concrete design strength.
    • For pile foundations, use 3 cm or 5 cm thick plastic cushion blocks, ensuring sufficient compressive strength.
  4. Steel Pipe:
    • Use as an auxiliary material for binding and hoisting steel skeletons. Ensure the frame is erected securely.
3 Preparation of Implements
  • Main Tools: Rebar hooks, crowbar, wrench, wire brushes, handcart, chalk, rulers, etc.
4 Operating Conditions
  1. Site Preparation:
    • Clean and level the steel bar stacking and processing site. Stack bars according to specification and numbering.
  2. Rust Check:
    • Inspect bars for rust and remove it before transporting to the binding site.
  3. Drawing Familiarization:
    • Check specifications, shape, quantity, and size of processed steel bars against design requirements.
  4. Inspection:
    • Ensure bridge deck pavement mesh dimensions and welding quality are verified before use.
  5. Binding Sequence:
    • Determine the sequence of steel bar placement based on design and process standards. Make technical disclosures to the team.
  6. Positioning:
    • Use chalk to mark the position of main reinforcement on the bottom mold and reserve the protective layer thickness using cushion blocks.
Construction Operation Rebar Binding Process Process
1 Pile Foundation Reinforcement Binding Process

1.1 Process Flow

  1. Steel Bar Welding: Continuously weld the main reinforcement.
  2. Stiffener Ring Processing: Mark the position and weld stiffener rings.
  3. Spiral Bars: Winding and lashing.

1.2 How-to

  1. Welding and Stiffener Processing:
    • Use flash butt welding or arc welding for main reinforcement. Ensure stiffener rings are round with no elliptical distortion.
  2. Position Line:
    • Draw stiffener circle positions based on drawing requirements. Ensure 5 cm from the bottom edge of the main reinforcement.
  3. Welding Stiffeners:
    • Spot weld stiffeners ensuring full, uniform welds with no burns or defects.
  4. Spiral Bars Binding:
    • Tighten spiral bars and main bars without gaps. Bind intersections firmly and use figure-eight buckles if needed. Add concrete cushion blocks to the reinforcement cage.
2 Cap Reinforcement Binding Process

2.1 Process Flow

  1. Pile Head Reinforcement: Adjust and clean reinforcement.
  2. Cushion Cap Reinforcement: Process and form parts as per design.
  3. Mark and Bind:
    • Mark and bind main reinforcement on the cushion layer, bottom plate reinforcement, pier column reinforcement, and roof reinforcement.

2.2 How-to

  1. Pile Head Adjustment:
    • Clean sludge and straighten reinforcement. Adjust spacing to meet design requirements, generally bending outward at 15 degrees.
  2. Cap Reinforcement Processing:
    • Process steel bars according to design drawings ensuring cleanliness and straightness.
  3. Mark Main Reinforcement:
    • Mark positions on the cushion based on spacing from the drawings.
  4. Binding:
    • Place cushion blocks according to protective layer thickness. Ensure lap lengths and positions meet specifications. Use figure-eight binding where applicable.
  5. Pier Column Reinforcement:
    • Ensure verticality and positioning of pier studs during hoisting.
  6. Roof Reinforcement:
    • Ensure even spacing and proper binding of horizontal ribs, using full gang binding and figure-eight buckles.
3 Pier Stud Reinforcement Binding Process

3.1 Process Flow

  1. Welding Main Reinforcement: Ensure proper welding connections.
  2. Draw Stirrups: Mark stirrup spacing lines on main reinforcement.
  3. Set Stirrups: Position stirrups according to spacing requirements.
  4. Tie Stirrups: Securely bind stirrups to main reinforcement.

3.2 How-to

  1. Main Reinforcement Connection:
    • Ensure the connection mode meets design requirements.
  2. Stirrup Spacing:
    • Draw and calculate stirrup spacing based on drawings.
  3. Set and Tie Stirrups:
    • Position stirrups and tie securely ensuring no displacement of protective layer hooks.
  4. Circular Pier Stud:
    • Refer to pile foundation reinforcement binding if pier stud is circular.
4 Cap Beam Reinforcement Binding Process

4.1 Process Flow

  1. Weld Main Reinforcement: Continuously.
  2. Draw Stirrups: Mark spacing on the main reinforcement.
  3. Set Stirrups: Position and bind stirrups.
  4. Prestressed Bellows: Thread and seal.
  5. Hoist: Lift into place.

4.2 How-to

  1. Main Reinforcement Welding:
    • Ensure connections meet design requirements.
  2. Draw Stirrups:
    • Mark stirrup positions on the main reinforcement.
  3. Set and Tie Stirrups:
    • Place and bind stirrups ensuring proper length and quantity.
  4. Prestressed Bellows:
    • Locate, weld positioning reinforcement, and thread bellows.
  5. Hoisting:
    • Use cranes to lift and place the cap beam, removing shelf pipes.
5 T Beam and Box Girder Reinforcement Binding Process

5.1 Process Flow

  1. Bottom Plate Binding: First, then web reinforcement, ends, middle beam, and roof reinforcement.

5.2 How-to

  1. Bottom Plate:
    • Draw ground spacing, place and bind main reinforcement with horizontal ribs.
  2. Web Reinforcement:
    • Ensure proper positioning and binding, with a focus on widening sections.
  3. End and Middle Beam:
    • Bind according to drawing requirements ensuring correct angle and length.
  4. Roof Reinforcement:
    • Ensure even spacing, add reinforcement braces, and tie intersection points.
Rebar Binding Process Quality Standards
1 Raw Materials
  1. Steel Bar Inspection:
    • Perform mechanical property inspections and check product certificates and factory reports.
  2. Visual Inspection:
    • Ensure bars are straight, undamaged, and free from rust or oil stains.
  3. Special Inspections:
    • For brittle or poorly welded bars, conduct chemical composition testing or other special inspections.
2 Steel Bar Processing
  1. Hooks and Bends:
    • Ensure compliance with design requirements for hook sizes and bending.
    • Perform inspections based on sample sizes per working shift.

By adhering to these standards, the reinforcement binding process for pile foundations in bridge engineering can achieve high-quality results and ensure structural integrity.

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