Volume2 Issue6

Knowledge Tree

June2010

From Editors
Dear Readers, We are very thankful to readers for your continued support in making this effort more meaningful by giving the valuable suggestions.

Re-inforce the Rebars

What is rebar? Rebar is another name for reinforcement bars i.e. steel bars used in concrete construction. Why rebar's are used in Concrete construction ? As we are aware that concrete is good in Compression & week in in Tension. As the con-

crete member is subjected to many types of loads other than only compression, it becomes The importance of reinnecessary to reinforce / strengthen the concrete for taking the additional Tensile loads. forcement bars in con Steel being stronger in tensile , Bend properties & economical than other metals, steel in struction is not less than the form of round bars are preferred as reinforce media. concrete , but many a times they get misused or How do the steel serve the purpose & why shape of rebar is round than square ? mis-handled. Steel bars are not connected directly to the load. The load coming on the concrete Low quality of raw materimember is transferred by the bond between the concrete & steel. als , procurement from Steel expands when in tension & with in its yield point, steel returns to normal shape unapproved rerollers / up on load removal. Hence the original shape of the concrete member is preserved. Manufacturers , improper Apart from taking the tensile loads , steel bars transfer the shear force developed in storage , cutting , bending concrete members like beams , slabs Etc. safely. & placing methods leads As the round shape has more surface area than square / or any other shape for the to its woes. given volume , Round shape is preferred.

What kinds of steels are available in market & what is suitable for use in the concrete For the correct function of
construction ?

In the earlier days mild steel , cold twisted deformed bars ( CTD ) were widely used.

Latter with advancement in the technology, apart from the one mentioned Hot processed TMT bars are available in various sizes , properties. We have highlighted the importance of these issues In general Mild steel , CTD , TMT , Corrosion resistant steels ( CRS ) are widely used in in achieving good & duraconstruction. ble construction work. We hope this would create awareness among us for a better construction experiTill the invention of this process the biggest challenge for the reinforcement bar makers is ence. achieving high strength from the steel without loosing the ductile properties it is famous With Best wishes for. TMT broadly stands for Thermo Mechanical Treatment .

rebar's as tensile force carriers , good material with excellent bond with concrete is necessary.

What is TMT process how does it helped the construction industry ?

TMT bars are widely

This was not so easy , as one property or other was lost during heating or treatments. So cold treatments were carried like twisting the rebar's which gave additional strength. This is not enough for the slim , lean structures which required higher strengths.

KSV & TSRBR

used in Concrete Construction.

TMT is a manufacturing process in which the bars are subjected to mechanical forces like pressure & thermal forces like Heating & Cooling. The steel bars are heated to 950oC & rolled to required size & shapes. This is followed by sudden cooling of the surface by using cold water at high pressure for fraction of a Minute. This process creates hard surface on the outer layer around 20 % of the total volume due to quenching process but leaves the inner

Contents : Rebar & its importance Page -1-3 Summary , Puzzle , Your VoicePage 4

Developed by KSV & TSRBR , for Internal circulation of L&T ECC DivisionE&GP OC. For any Suggestions or Queries Please write to ksv@lntecc.com or bangartsr@lntecc.com

core soft & malleable.

Thus the good properties we are looking at i.e. improved strength , bendability , elongation & Corrosion resistance are achieved.

What are the chemical & physical properties of these rebar's ?

All rebar's made in India shall conform to IS 17862008 revision. With further advancement in TMT process, 7 classes of rebar's are produced. They are designated as Fe415 , Fe415D . Fe500 , Fe500 D , Fe550 , Fe550 D , Fe600. All these bars shall satisfy the chemical & physical properties as mention in Table 1 & 2

TMT bar with hard outer & soft inner cores

Sizes varying from 6 , 8 , 10 , 12 ,16 , 20 , 25, 28 , 32 , 36 mm are available with fixed standard length of 12 m.

Table 1

Non standard sizes or lengths can also be obtained on special order.

Table2

How do I know whether the steel is good or bad or rejected ?

The rebar's shall be sourced only from approved manufacturers. Rerolled steel / steel from direct market / from Traders shall be avoided. All bars when received shall bear the identification mark & Tag. Manufacturer identification & grade is embossed on the bar itself at every 1 m interval. The batch Number , Heat Number , Quantity Etc. details are attached to each bundle of bars through Tags. The information on these tags shall be verified with Delivery challan & any discrepancy shall be informed to manufacturer. Samples shall be taken from the bundle after leaving 300mm from the ends. The length of sample shall be min.1m & shall be verified for unit weight , physical & chemical properties.

The unit weight of rebar's shall be as per Bar Dia Table3. the bars shall weigh with in tolerances as stated in Table-4 10-

Per Batch

Individual Sample

Table 3

5%

-6 %

The first batch received shall be allowed for consumption in work Up on confirmation Above 3% -4 % from approved lab only. For routine receipts, 16mm Table-4 the materials may be allowed to be used while the test is in progress if sufficient reliability is achieved in the previous supplies. How ever proper traceability on the batch received & where it is used shall be maintained. While in Storage, the Tags shall be kept intact.

16mm

How to store the rebar's materials ?

As proper storage increases shelf life prevents rust , contamination & gives good return per investment , it is necessary to preserve the rebar's. All rebar's shall be stored in gated open yards. The yard shall be developed by leveling , spreading the quarry dust / stone dust. Minimum slopes shall be maintained for good drainage during rains. Elevated platforms shall be constructed using concrete or brick or wooden sleepers & the bars are stored above ground. In all the cases stop rolling arrangement shall be made at the sides to prevent rolling of the bars. For increased protection from aggressive environments like sea side or rain prone areas , or in summer the rebar's shall be protected by tarpaulin cover. In case of rejection the board shall be displayed & No materials shall be consumed from the lot.

What are the cutting & bending methods to be followed?

Bars shall not be cut with gas / with welding gun. The bars shall be cut using

Shear cutting machine Hack saw cutter Disc cutter Manually

Bar bending schedule shall be made for every structure for determining the cutting length & minimizing wastage. Bars shall be cut to size & bent using bending table up to 16 mm bars & bending machine for big dia bars.

What care shall be taken during cutting & bending of bars ?

Min. bending radius of 4d shall be maintained for all bars up to 25mm & 6d for above 25mm. While bending stirrups, a min. length of 8d shall be left beyond bent portion. For laps in any member , more than 50% of the bars shall not be lapped in one location. The laps shall be staggered by min. of 1.3 times the lap length . Bars in crossing shall be suitably joggled to avoid level difference & Less cover.

I don't have one diameter as given in drawing , can I use another dia ?
Yes , it is possible to change the dia of the bar , However the area of reinforcement shall remain same. This can be achieved by adjusting the spacing of the new dia. But this shall be carried with the consent & approval of the customer & designer.

What can I do for reducing wastage & how to deal with scrap ?

BBS preparation with careful planning of laps is necessary for the reduction of wastages Alternatively for similar type of structures bars of required length can be obtained from manufacturer apart from standard length. This reduces the wastage to Zero. The scrap shall be segregated as usable & Non usable scrap.

All usable scrap above 2m length can be reused by giving laps.

Word Search

How to improve corrosion resis-

tance properties of reinforced bars ? While working in corrosion prone areas , it becomes necessary to protect the rebar's from atmospheric action. Though the cover given to concrete is enough , additional precautions are being taken either by using corrosion resistant steel bars or by providing corrosion resistant coating on the bars. The process called as fusion bonded epoxy coating reduces the chances of bond failure between coating & rebar , concrete & also increases the corrosion properties. This is factory applied process & needs touchup at site if any damages are found during cutting , bending & installations.

I want to weld the rebar's for fixing the inserts / in lap area ,
can I do ?

TMT bars being made through thermo mechanical process , any application of heat at any place lowers the Tensile properties. No welding is recommended for any installation to main bars. You may provide additional bar near the main bar for welding

There are 20 words related to reinforcement. Find out & send the answers to bangartsr@lntecc.com to get word detective Honor.

Rebar's are used to provide Tensile properties to the concrete Summary member.

Your Voice:

A.RevathiE&GP OC wrote :

Dear sir, Knowledge Tree regarding Earth work was really very Good , though I am in electrical part I could get to know about civil also thru this.. Mr.Bala BrahmamaHyderabad Cluster Quality HeadE&GP OC wrote :

For the forces are transferred to steel only by the bond between concrete & bars. Hence the rebar's shall be kept free from all adulterants like soil , oil , grease , cement , concrete debris Etc.

Check the material before receipt for manufacturer , batch & Test Certificates. Conduct the routine tests on the bars for confirmation. Store the material above the ground to prevent contamination. Cover the rebar's with tarpaulin during summer / rainy seasons to decelerate corrosion. Use cutting machines for cutting the bars. Don't use gas cutters / welding rods , these methods alter the physical & chemical properties beyond repair. Don't carry the welding unless the process & procedure & operators are qualified.

Dear Sir, The details you have provided in April2010 Volume-2, Issue-4 about Concreting in Summer is really helpful to us. The Concrete crossword in this issue is really interesting. We are grateful to you for providing this information to us and expecting more and more to learn through KNOWLEDGE TREE.

Keep writing. Your suggestions will improve this effort.

Concrete Quality depends on Rebar Workmanship

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