Made in Japan

Gas Pressure Welding Equipment

More Economic and More Safe with Gas Pressure Welding

Japan Society of Civil Engineers Japanese Industrial Standards Japan Reinforcing Bar Joints Institute Concrete Steel Reinforcing Institute
 . . . Features and fundamental . . .

Gas pressure welding process

The gas pressure welding method was similarly developed in the United States and Japan in the 1930s. Since then, it has found wide appli-
cation in construction and is commonly used to weld steel reinforcing bars. Among all types of joints in Japan, currently, the welded joints
accounts for approximately 90%, and the majority is excuted by gas pressure welding. The reason is that gas pressure welding is superior
in workability to other joining methods for this application. By exploiting this method, the mechanical properties of rebars joints will be
highly improved. This method has higher mechanical properties and much more cost saving compare with other rebar joining methods like
conventional overlap method or coupling method.

This method is not classified as a fusion welding but a solid state welding one, in which the joining process can be performed without melting
the base metal. Atomic diffiusion and reconfiguration along with the bars’ interface occur by simultaneous processes of heating higher than
recrystallization temperature (at about 1200-1300 degrees centigrade) and exerting external pressure. This method is executed as follows: 1)
butting the end surface of materials against each other, 2) heating the interface by oxyacetylene flame with pressure applied and 3) stopping
the heating and pressure when upsetting length reaches the predetermined value.
 . . . Merits . . .

Merits of rebar gas pressure welding

Whole time of operation: 5 min
Joining time for rebar size 25mm: 90 secs

• Reaction of steel bar under bending test • Reaction of steel rebar under excessive stress

• Eliminating of overlap cause significant savings

Merits of gas pressure welding

Reinforcement of concrete structures due to the higher mechanical properties of joining zone higher than the rebar itself.
Reduction of rebar consumption due to elimination of the overlap and also scraps.
Saving time and cost in compare to other mechanical joining mehods such as coupling.
Saving cost due to elimination of human error and unpredictable working situations.

Savings
1- 30% saving in consumption of rebars by eliminating the overlap zone and wastes.
2- Saving the time of execution.
3- Less work force is required
4- Reduction of transportation on account of reducing material consumption.
5- Joining the wasted rebars and reusing

Retrofitting and better implementation

1- By removing overlaps, structural weight is descended; thereby, the lateral forces of gravity is decreased and the strength of the structure
towards earth quakes will be boosted.
2- Appropriate concreteing up and better vibration of concrete will be provided due to reduction of unnecessary volume of rebars in joining
areas.
3- Better involvement between concrete and rebars because of eliminationg extra rebars.
4- Boosting the mechanical strength at the joining point due to increasing the surface area.
5- Maintaining the integrity of force at the junction.
6- Physical and mechanical propertise of the junction is the same as base material of the bar.
 Qualification methods and standards

Gas pressure welding qulification test

. Visual test (VT) . Tensile test

. Bending test . Ultrasonic test

Standards
1- AS/NZS 1554.3:2014; Structural steel welding , part 3: welding of reinforcing steel,
non-fusion welding processes-flame pressure welding
2- JIS Z 3881:2009; Standard qualification procedure for gas pressure welding technique of steel
bars for concrete reinforcement
3- JIS B 6801:1991; manual blow pipes for oxyacetylene welding
4- JIS Z 3062:2009; Method and acceptance criteria of ultrasonic examination for gas pressure
welds of deformed steel bars for concrete reinforcement
5- KS D 0244:2009; Method of inspection for gas pressure welded joint of steel bars for concrete
reinforcement

Certificates
1- USA,Concrete reinforcement steel institute
2- Japan, Reinforcing bar joints institute
3- Japan, Society of civil engineers
4- Iran, Road,housing & urban development research center
5- Iran, Construction engineering organization
 . . . Riken services . . .

Riken services - Implementation of gas pressure welding

. Column rebars

. Foundation rebars

. Shear wall rebars

. Short length rebars

. Wasted rebars

Services and support

- Repair and maintenance
- One-year warranty
- Ten years after sales service

Riken services - Gas pressure welding equipment sales

Merits
- Easy to operate during execution
- High speed
- ability to work in all cases
- Compatible with the environment
- Portable
 . . . Equipment . . .

Operation switch Hydraulic pump/Electric motor

drive pump
Required pressure on longitudinal axis of rebars for joining them
during gas pressure welding process is provided by hydraulic pump.

Code HP1-R
Hydaulic Pump (700bar) with pressure
Description regulator
Waight(kg) 14.8
Code OS1-PM

Description Operation switch

Used Switch On/Off the hydraulic pump

High pressure oil hose

Code 1B-H

Description High pressure oil hose (700 bar)

Rebar welding base RAM cylinder for

Rebar welding base consists of both fixed and movable jaw. rebar welding
It is used for keeping the rebars aligned and transfering base
the pressure which is exerted on the movablejaw by RAM
cylinder to the rebars.

Code 2R-J

Description RAM cylin

Ratchet wrench

Code F1-PM

Description Rebar welding

used for Bar diameter size (mm) 35-18 Code RW1-B

base 8.4 Kg Description Ratchet wrench

 . . . Equipment . . .

Rebar cutter equipped

with diamond saw
During the process of gas pressure welding, the ends of the
rebars must be cut right-angled. Rebar cutter equipped with
diamond saw can cut the rebars right-angled, cold and clean.

Code used for bar diameter

size (mm)

C35-K 35-18

C41-K 41-18

Ring burner Diamond saw blade

The gas mixture of oxygen and acetylene is burned in this section.
The ring burner is designed for covering all parts of the joining
rebars during the heating up process.

Code used for Bar diameter size (mm)

35M-B 35-18

41K-B 41-18

Code used for Bar diameter Description

size (mm)
25S-RB 35-18 Ring burner Gas mixture tube & super valve
32S-RB 32-18 Ring burner
Gas mixure tube is used for mixing the oxygen and acetylene gases
together and super valve is used for regulating the flame condition.
35S-RB 25-18 Ring burner

Gas Hose
Code used for Bar diameter size (mm) Description

MP32-S 32-18 Gas mixture tube

MP35-S 35-18 Gas mixture tube

Code Description
OAH1-B Acetylene/Oxygen twin gas hose

Toolbox
Regultor for Acetylene gas Regultor for Oxygen gas

Code Description Code Description Code Description

1-OM Gas pressure regultor for 1-AM Gas pressure regulator
Acetylene gas for Oxygen gas 1-BX Tool box
Gas Pressure Welding Equipment

How to contact Riken tools

Iran Office: Second floor, No.528, West Taleghani st., Sarparast st. corner,Tehran, Iran
Tel: +98 21 61948 - Extention: 3
Fax: +98 21 66412844
Email: Info@puyagostar.com
Website: www.puyagostar.com

Japan Office: 1F, Sendai Hokushin building, 1-6-10, Aoba-ku, Sendai, Japan
Tel: +81-22-224-1116 Fax: +81-22-224-1140 (Japanese language only)