ERICO CADWELD for Rebar Splicing System User Manual

Instruction Manual

CADWELD®for Rebar Splicing System

IMPORTANT

General and Safety Information

A. Only ERICO®manufactured equipment and materials should be used to make CADWELD®rebar splices.

1. Do not splice except as detailed in the instructions.

2. Do not use worn or broken equipment that could cause leakage.

3. Do not alter equipment or material without factory authorization.

4. Do not substitue for specified ERICO manufactured equipment and materials.
Failure to comply with the above may result in hazards to the individual, improper splices, or damage to items being spliced.

B.

Make splices in accordance with described splicing procedures and in consideration of surrounding conditions and personnel.
Refer to ANSI Z-49.1 SAFETY IN WELDING AND CUTTING and your local safety procedures.

1. Personnel should be properly trained in the use of this product.

2. Avoid breathing concentrations of smoke, as it may be hazardous to health.

3. Avoid contact with hot materials.

4. Advise nearby personnel of splicing operation in the area.

5. Remove or protect fire hazards in the immediate area.

6. Do not smoke when handling starting material.

C. Adhering to the recommended splicing procedures will minimize risk of burns and fire caused by hot molten material

spillage.

1. Make sure there is proper fit and assembly of equipment.

2. Avoid moisture and decomposable contaminants on splicing equipment and rebar.
Contact of hot molten metal with moisture or contaminants may result in spewing of hot material.

D. Unusual applications or conditions may exist which require special considerations.

1. Provide adequate ventilation where natural air flow is not sufficient to prevent personnel breathing concentrations of
smoke.

E. Storage of CADWELD filler material should be in a clean, dry, “No Smoking” area and should be restricted to access by

authorized personnel only.

1. Starting material and filler material are exothermic mixtures and react to produce hot molten materials with
temperatures in excess of 2200°C (4000°F) and a localized release of smoke. These materials are NOT explosive.
Ignition temperatures are in excess of 450°C (850°F) for starting material and 900°C (1650°F) for filler material.

2. In case of fire, water or CO

2

will aid in control of burning containers. Large quantities of water will aid in controlling

a fire should the exothermic materials become involved. Water should be applied from a distance.

F.

CADWELD filler material in the work area should be protected from spatter and hot materials to prevent accidental ignition.
Use a covered wood or metal gang box for storage of materials not for immediate use.

G. Dispose of slag from the CADWELD splicing process in a steel container that has a layer of dry sand in the bottom.

The sand is necessary to prevent burn through.

H. See splicing instructions enclosed for additional information.

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Table Of Contents

General Safety Information...............….............................................................................IFC

Rebar Cleaning Procedure (Preparation) …………............................................................... 2

Instructions for Vertical Splicing (Bar-to-Bar) .................................................................... 3-4

Instructions for Horizontal Splicing …………....................................................................5-6

Filler Material Remixing and Placement Procedures............................................................. 7

Venting CADWELD

®

Horizontal Splices ……….................................................................... 8

Inspection …….................................................................................................................. 9

Eccentricity and Cocking of Rebars ……………................................................................. 9

Rejection of a Splice and Its Causes................…................................................................10

Void Limits.........................................................................................................................11

Additional Instructions for B-Series.................................................................................... 12

Welding of Splice Sleeves to Structural Steel......................................................................12

Care of Finished Assemblies...............................................................................................12

Addenda ...........…........................................................................................................... 13

External Bar Reference Marks ...........….............................................................................13

Bar End Gap ……..............................................................................................................13

B-Series Sleeve Repair........................................................................................................ 13

Tap Hole Relocation...........................................................................................................14

Use of Sleeves Out of Their Normal Position..................................................................... 15

Repair of Bar-to-Bar Production Splice Samples or Rejected Splices....................................15

Traceability....................................................................................................................... 15

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Rebar Cleaning Procedure (Preparation)

1. Rebar ends to be spliced must be dry and free of
excessive rust, loose mill scale, dirt, paint, concrete, etc.
Clean back from bar end at least one-half sleeve length.

2. Cleaning Procedure

2.1 Torch and Power Brushing (See notes)

2.1.1 Flame dry ends to remove moisture and/or
burn away any other foreign contaminants.
Flame should be soot free and not leave any
residue or deposits on bar ends. A “rosebud”
torch tip is recommended.

2.1.2 Remove excessive rust and all loose mill scale,
dirt, paint, concrete, etc. with a power wire
brush.

2.1.2.1 Heavy duty, low speed (200-350 rpm),

reversible drill is recommended for
use with ERICO

®

brand of cleaning
brushes (Series RBW343). See catalog
for additional information.

2.1.2.2 1000 rpm or higher is recommended
for wire wheel and cup brushes

2.1.3 Repeat steps 2.1.1 and 2.1.2 on extremely bad
bar surfaces.

2.2 Torch and Sandblasting

2.2.1 Sandblast bar ends clean.

2.2.2 Flame dry ends to remove moisture.
Flame should be soot free and not leave any
residue or deposits on bar ends. A “rosebud”
torch tip is recommended.

2.3 Torch and Hand Wire Brushing
(See notes)

2.3.1 Flame dry ends to remove moisture and/or

burn away any other foreign contaminants.
Flame should be soot free and not leave any
residue or deposits on bar ends. A “rosebud”
torch tip is recommended.

2.3.2 Should lack of power or clearance restrictions
prevent the use of power-driven equipment,
remove excessive rust and all loose mill scale,
dirt, paint, concrete, etc. with a hand wire brush.

2.3.3 Repeat steps 2.3.1 and 2.3.2 on extremely bad
bar surfaces.

2.3.4 Wipe bar ends with a clean, dry rag to remove
any dust.

3. Badly deformed bar ends may require cutting to assure
easy fit of the sleeve. Bar end shear “drags” may be
flame cut or ground off. Oversize longitudinal ribs
should only be ground as flame cutting may damage the
bar, especially on higher strength steels. The longitudinal
ribs should not be ground below the height of the bar
deformations.

4. Cleaned bar ends that must be left out overnight should
be protected (use empty plastic filler material bags) and
must be re-dried and re-cleaned if necessary.

NOTES:

1. Brushes must be kept free of grease, oil, and/or
other contaminants that could evolve gas and
cause porosity in filler material.

2. Eye protection should be worn when using
power-driven cleaning brushes.

3. Do not reverse the rebar cleaning brush
while it is engaged with the rebar.

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Instructions For Vertical Splicing (Bar-to-Bar)

1. Clean rebar ends as per “Rebar Cleaning Procedure”
on page 2, as required.

2.

Position bottom support clamp and end alignment fitting
so end of rebar will be at tap hole opening of sleeve.

“T” shaped support rod on bottom support clamp
should be in line with the sleeve tap hole so that
support will be directly beneath the pouring basin.

3. Place a double wrap of packing material into position in
the lower end alignment fitting. Using a blunt screwdriver,
place the first wrap around the bar into the space
between the bar and end alignment fitting. The second
wrap around the bar is placed loosely above the first.

4. Place splice sleeve into lower fitting and seat firmly
against the packing to seal lower end of sleeve.

5. Lower top rebar into position. The average gap
between bar ends should not exceed 1/4-in. (6mm).
If a natural gap is not provided by the shape of the
reinforcing bar ends, a spacer can be used.

Spacers are enclosed in an envelope in each carton of
CADWELD

®

ferrous filler material.

Both bar ends should be visible through the sleeve tap
hole.

6. Place a single wrap of packing material loosely around
bar on top of splice sleeve; DO NOT PACK.

7. Place end alignment fitting on top of splice sleeve;
position ceramic insert guide tube assembly firmly into
taphole, making sure it is completely seated inside the
hole.

8. Flame dry pouring basin and crucible before using.
As a check, a drop of water should boil off rapidly.

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Instructions For Vertical Splicing (Bar-to-Bar)

9.

With pouring basin frame handles unlocked and pouring
basin slightly open, place the pouring basin around the
ceramic insert and against the splice sleeve. Close pouring
basin frame handles and lock. Place chain around the
sleeve and finger tighten thumb nut. Be sure to support
the pouring basin while securing chain to prevent
unseating of the sleeve against the bottom packing.

Adjust “T” shaped support rod against bottom of pouring
basin. Support rod should just touch and support levelled
pouring basin DO NOT force pouring basin up.

NOTE: A crucible should not be reused until allowed to

cool for 15 minutes or more. If more frequent use
is desired, several crucibles complete with frames
should be used alternately to allow sufficient cooling
time. Clean crucible thoroughly inside. Empty the
crucible completely, see Note 15 & 16 on this page for
additional information. DO NOT use a wire brush.

10. Place crucible ceramic insert assembly in bottom of
crucible. All crucibles use the same ceramic insert.

11. The crucible ceramic insert assembly is supplied with a
steel disk pre-installed into it as a one-piece assembly.
If the steel disk is not present in the ceramic insert,
place the steel disk on the crucible ceramic insert and
check for proper seating. Remix bag of CADWELD

®

filler

material

and fill crucible according to the instructions on

page 7.

12. Position crucible on the pouring basin and secure the
tiedown chain, keeping it just loose enough to allow
swivelling of the crucible without tipping.

13. Open the starting material container. Evenly distribute
the starting material over the filler material in the crucible,
saving a small amount to be placed on the tab of the
crucible extension. Place the crucible extension on the
crucible and put the remainder of starting material on
the tab. Place the crucible cover on the extension.
Standing off to the side of the opening and up wind,
ignite the starting material on the tab.

14. Keep the tiedown chain secured at all times.
Immediately after the sleeve has filled, slowly swivel
the crucible back and forth to break the slag between
the base of the crucible and top of the pouring basin.
Repeat after 15 or 20 seconds as necessary.

After the slag has solidified, release the tiedown chain
and remove the crucible. All other parts can then be
removed.

15. Clean the crucible by turning upside down and placing
a metal rod (#5 [16mm] rebar) against the ceramic and
lightly tapping the rod end to discharge the slag and
ceramic into a suitable waste container.

16. Break off riser with hammer. Clean slag from crucible
and pouring basin as soon as possible to promote cooling.
Use a whisk broom, rag or wooden wedge for cleaning.
Do not use a wire brush. Cover and crucible extension
need not be cleaned every time.

NOTE: Clean flash or debris from all mating surfaces as debris
can

cause springing of the equipment clamps and hinges.