How to Weld Rebar

Rebar is used in construction involving concrete. Iron rods of varying lengths and diameters are constructed in cage formations, and concrete is poured over them. The rebar is used to re-enforce concrete to prevent it from breaking under stress. The rods are tied together with mechanics wire or are welded together in place. The foundation of a structure uses thicker-diameter rebar, and the bars become progressively thinner as the structure is built upward.

Rebar
Arc welder
Electrodes (6010 designation)
Welding helmet
Insulated gloves
Wire brush
Clamps

Instructions

- 1
  Position the two pieces of rebar that are to be welded. Secure the rebar with clamps to ensure they will stay in place while welding.
- 2
  Ground the arc welder with the alligator clip to a surface away from the welding area. Secure the electrode into the electrode holder. Put on the protective helmet and insulated gloves.
- 3
  Hold the electrode over the mating surface of the rebar at a 5 to 15 degree angle. Bring the electrode slowly into position over the surface until the electrical arc appears, which will begin at about an eighth to a quarter inch from the surface. Hold the arc in place until a weld-pool forms. The weld-pool is melted metal from the two materials that have begun to mix.
- 4
  Move the electrode in the direction of the joint that is being welded. Keep it on the leading edge of the weld pool and follow the joint. Slower travel speeds will produce a wide bead with shallow penetration. Faster travel speeds will also cause shallow penetration and possibly undercut the weld.
- 5
  Lift the electrode away from the joint once the welding process is complete. Inspect the weld-seam for imperfections or cracks. Repeat the welding process in steps three and four if needed.
- 6
  Clean the weld-seam with a wire-brush brush to remove splatter or slag.

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