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Nelson Fastener Systems d6l Rebar Studs
Nelson Fastener Systems d6l Rebar Studs
Nelson Fastener Systems d6l Rebar Studs
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Questions and Answers
What is weldable rebar?
When welding of steel concrete reinforcement or rebar is needed the most common type of rebar used for these
applications meets the requirements of ASTM A706 (A706).
What are difficulties in hand welding rebar? What are some selling points to stud welding vs. hand welding rebar?
Traditional rebar welding includes but is not limited to; costs of using an AWS certified welder, preparation of written
welding procedure specifications, preheat when required, cutting bars to correct lengths in the field and welding
consumables required.
It can be difficult for the welder to hand weld around the base of a #4 or #5 weldable rebar because of the size of rebar
compared to the required bead of weld.
What is the required fillet weld (bead) size?
o AWS D1.1 Table 7.2 has minimum fillet weld sizes per stud diameter, #4 requires 1/4” and #5 and #6 require 5/16”
minimum. Weld sizes should be designed or verified by the engineer of record and dependent on the application
and loading requirements.
See Stud Welding vs. Hand Welding ROI below.
What is available, what is the lead time and how much does it cost?
#4 #5 and #6 in various configurations are available upon request. Any stud length required is available.
A706 / A706M - 15
Deformed Bar Designation Numbers, Nominal Weights (Masses), and Nominal Dimensions
Nominal Dimensionsª
Nominal Weight, lb/ft Cross-Sectional Area Perimeter
Bar Designation Diameter, in. (mm) 2 2
(Nominal Mass, kg/m) in. (mm ) in. (mm)
4 (13) 0.668 (0.994) 0.500 (12.7) .020 (129) 1.571 (39.9)
ª The nominal dimensions of a deformed bar are equivalent to those of a plain round bar having the same weight (mass) for foot (meter) as the deformed bar
Tensile Requirements
Grade 60 (420)
Tensile strength, min, psi (MPa) 80 000 (550*)
Yield strength, min, psi (MPa) 60 000 (420)
Yield strength, max, psi (MPa) 78 000 (540)
Elongation in 8 in. (200mm), min % - Bar Designation #’s 3, 4, 5, 6, (10, 13, 16, 19) 14
*Tensile strength shall not be less than 1.25 times the actual yield strength
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Physical Properties of D6L Anchors
AS AS fy AS fu fu - Ultimate strength (tensile) 80,000 psi Short Form Specification
ASTM min.
Dia. Nominal Yield fy Tensile To insure that certified Nelson products
Designation fy - Yield strength 60,000 psi min.
Area Lbs. (min.) Lbs. (min.) are used, the following specification is
AS - Area of stud shank suggested: "(Welded Concrete
3/8 0.11 3 6,600 8,800
Reinforcement / Deformed Bar Anchors
/ Concrete anchors) shall be Nelson,
1/2 0.2 4 12,000 16,000 Cold finished low carbon steel, rebar anchors, type D6L, full
ASTM A706: C – 0.33% max penetration, automatic machine
5/8 0.31 5 18,600 24,800 Mn – 1.56% max welded, as shown on the drawings.
P – 0.043% max Studs shall be made from cold-worked,
S – 0.053% max deformed wire per ASTM A-706 and
shall be welded pursuant to the
3/4 0.44 6 26,400 35,200 manufacturer’s commendations.”
Minimum Embedment Length for Full Anchor Capacity Development, After Welding (inches)
Normal Weight Concrete Bar Diameter, db
Compressive Strength, f'c (psi) 0.375 0.500 0.625 0.750
2500 18.00 24.00 30.00 36.00
3000 16.43 21.91 27.39 32.86
3500 15.21 20.28 25.35 30.43
4000 14.23 18.97 23.72 28.46
4500 13.42 17.89 22.36 26.83
5000 12.73 16.97 21.21 25.46
Note: Embedment lengths are calculated from ACI Standard ACI 318, Section 25. ACI minimum embedment length requirement is 12".
Minimum Embedment Length for Full Anchor Capacity Development, After Welding (inches)
Light Weight Concrete Bar Diameter, db
Compressive Strength, f'c (psi) 0.375 0.500 0.625 0.750
2500 24.00 32.00 40.00 48.00
3000 21.91 29.21 36.51 43.82
3500 20.28 27.04 33.81 40.57
4000 18.97 25.30 31.62 37.95
4500 17.89 23.85 29.81 35.78
5000 16.97 22.63 28.28 33.94
Note: Embedment lengths are calculated from ACI Standard ACI 318, Section 25. ACI minimum embedment length requirement is 12".
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ROI: D6L Rebar Stud vs. ASTM A706 Rebar
COST COMPARISON CALCULATOR
Stud Type 1/2 x 18 3/16 Rebar Stud #4 Rebar 18" Long
Fabrication Time
Labor Costs
Material Cost
*Preparation of rebar (measuring, cutting, cleaning, etc.) for welding, this work is typically performed by someone with a different
labor rate than the welder.
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Stud Welding Setup Parameters:
Full strength stud welding results can be obtained by understanding the following settings or adjustments, and how they relate to
weld quality.
Plunge is the amount of stud that protrudes beyond the ferrule. This portion of the stud length is available to be “burned off”,
or melted, to develop the weld flash. Long or excessive plunge may cause excessive splatter and high or uneven fillet formation.
Plunge is a physical measurement set and measured with the stud and ceramic ferrule in place on the stud gun.
Lift is the distance the gun pulls the stud away from the base material. Lift is essential to the stud weld process since is creates
an air gap which the current must bridge. The current flow across the resistance of this gap creates the heat to melt the stud
and base material. If no gap exists, the current will not create sufficient heat to melt the metal. Short lift may allow molten
metal to bridge the arc-gap, resulting in cold welds. Excessively long lift increases the chance of having arc blow and welds that
are bonded on only one side of the stud base. Lift is set on the stud gun and is measured physically when the weld cycle is
initiated. Note that this should be set and measured by placing the stud and ferrule on a non-conductive surface and initiating
the weld cycle so that an actual molten weld is not made while lift is being measured.
Time is the normal duration of the weld. On thin base material, shorter than normal time and higher amperage can be used to
achieve sufficient heat, and still prevent melting through the base material. On some base materials, longer times and reduced
amperage improves the ductility of the weld zone.
Amperage is the current from the power source that flows through the weld arc. Increasing the amperage increases the weld
heat. As with the time setting, a higher amperage setting is needed for larger stud sizes. Amperage is set on the stud welding
control system current setting indicator.
Alignment is centering the stud in the ceramic ferrule so that the stud does not contact the ceramic ferrule during the lift and
plunge, which may cause friction or binding between the stud and ferrule. Binding can slow the stud plunge so that there is less
than full penetration of the stud into the molten weld pool resulting in less than full weld strength.
Electric Arc Stud Welding Parameter / Setup for D6L Rebar Studs
ASTM Diameter Area Downhand Welding Vertical Welding Overhead Welding
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Designation (in) (mm) (in ) Amp Sec Lift Plunge Amp Sec Lift Plunge Amp Sec Lift Plunge
#4 1/2 12.7 0.20 975 0.525 0.093 0.187
#5 5/8 15.9 0.31 1333 0.860 0.093 0.187
#6 3/4 19.1 0.44 1700 1.03 0.125 0.250 1800 0.800 0.125 0.250 1650 0.800 0.125 0.250
> These welding setup parameters produce satisfactory results, in our welding laboratory here in Elyria, Ohio. They should not be considered so restrictive, however,
that they prevent modification by authorized personnel to meet specific application or jobsite conditions. Refer to American Welding Society's (AWS) requirements
regarding production control, application qualification and manufacturer's stud base qualification for further clarification.
> The settings shown are for welding directly to the base metal, in the downhand position. For welding through metal deck or welding in other positions consult your
Nelson representative.
> Stud welding, as with any welding process, should be done safely with properly maintained equipment and according to recommended practices. For additional
information contact your Nelson Representative or see: ANSI/AWS C5.4 "Recommended Practices for Stud Welding", ANSI/ASC z49.1 "Safety in Welding and
Cutting." Both available from American Welding Society...
> Plunge is the distance from the face of ferrule to end of stud, not including the flux load. Lift is the distance the stud retreats when the gun is triggered. Compress
the stud against a non-conductive surface to make the lift measurement.
> Using a set of drill bits is a convenient way to properly gage the necessary lift and plunge during set up, note 1/16" = 0.0625", 1/8" = 0.125", 3/32" = 0.09375.
> For detailed installation and maintenance data refer to the Operation and Service Manuals for the stud welding system and gun being used.
> Special ferrules are required for vertical welding, overhead welding and specialized welding application, e.g. welding into the corner of a steel angle.
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#6 100101140 500011546 501006028 502002042 100109035 500011546 501006028 502002042 100101140 500011546 501006028 502002042
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Notes: