Welding rebar question

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Part 2 to my previous burgler bar thread. The burgler bars I'm making are for 5 windows, each 44"x54". The entire thing is made out of rebar. The first one has been approved as the pattern. Each one has about 55 junctions, about 300 total junctions for all. On the first one, like a good boy I wire brushed each joint before welding it.I'm using #4 1/2" rebar from one of the big box stores. Hasn't been stored outside but there's still a little light rust on them and I'm not familiar enough with rebar to know if they're coated with something like maybe the mill scale on regular steel. Wire brushing made the joints very shiny, removed the rust and a greyish color that was on them.I'm using .035" solid wire on my Hobart 210mvp with CO2 gas. I really, really don't like the idea of wire brushing or a wire wheel on a bench grinder for each of those joints. Is that best practices for good joints on rebar and is it really needed with the setup I'm using?
Reply:Is it weldable rebar? Most isn’t.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:Make some test joints and try to destroy them. CO2 will handle light rust and scale just fine. Be sure to use more than a small tack on the intersecting joints to get some heat into them.
Reply:I agree, make test welds and try to break them. Years ago I welded rebar to make chicken ladders for the steel mills. I wanted to burn up various old rod on these. After I welded them I threw them in a pile on the ground and noticed they were breaking. I called the guys at Hobart filler metals and they told me I needed a low hydrogen electrode, being 7018 or ER70S-6. So I started to use the 7018 and every so often I would throw one up in the air as high as I could and now they didn't break."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!

" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
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Reply:OK, I did a test. Two 6" pieces welded into a cross shape. The weld is also underneath (can't see it in the photo) I put the vertical bar in my vise and whaled on the end of the right hand crossbar with a sledge hammer. All that happened was that the vise and my workbench shook. So I guess I'm good to go without wire brushing the joints. Whew!

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Reply:I weld re-bar all the time with just S6. Never had one break.Thermal Arc 320SP ( Lorch )Cobra PythonsThermal Arc 300 AC/DC  ( Sanrex )ESAB 301i AC/DC  ( Lorch )Thermal Arc 161STL  ( WTL )Thermal Arc 190S  ( Sanrex )Cut Master 82, 42. Cut45 ( WTL )Victor Gas Apps.Boxes and boxes of welding crap.
Reply:

Originally Posted by JD1

OK, I did a test. Two 6" pieces welded into a cross shape. The weld is also underneath (can't see it in the photo) I put the vertical bar in my vise and whaled on the end of the right hand crossbar with a sledge hammer. All that happened was that the vise and my workbench shook. So I guess I'm good to go without wire brushing the joints. Whew!
Reply:There's a difference in Rebar types most common is A615 especially at a box store requires pre heating to 500 degrees prior to welding otherwise it is not intended for welding. A706 Rebar is most often used when welding is required and doesn't require pre-heating. Other than that I don't believe any preparation is needed other than to make sure it's clean and free from rust. Sent from my SM-G998U using Tapatalk
Reply:

Originally Posted by ronstruc

There's a difference in Rebar types most common is A615 especially at a box store requires pre heating to 500 degrees prior to welding otherwise it is not intended for welding. A706 Rebar is most often used when welding is required and doesn't require pre-heating. Other than that I don't believe any preparation is needed other than to make sure it's clean and free from rust. Sent from my SM-G998U using Tapatalk
Reply:

Originally Posted by ronstruc

There's a difference in Rebar types most common is A615 especially at a box store requires pre heating to 500 degrees prior to welding otherwise it is not intended for welding. A706 Rebar is most often used when welding is required and doesn't require pre-heating. Other than that I don't believe any preparation is needed other than to make sure it's clean and free from rust. Sent from my SM-G998U using Tapatalk
Reply:Just use a Lincoln AC225 and some 6013 rods!


Reply:I've welded weldable and non-weldable rebar from the bi box stores using my 210 MVP, CO2 and .030 wire.....never a problem.GreggHobart Handler 210 MVPHobart Stickmate 210i