REINFORCEMENT WORKS

Category of Reinforcements
Carbon steel bars (plain and deformed).
Cold reduced plain and deformed steel wire fabric.
Stainless steel bars and fabric.
Galvanized carbon steel bars and fabric.
Epoxy coated carbon steel bars.
Fiber Reinforced Polymer (FRP) rebar- [Non steel reinforcement]
Reference Indian Standards:
IS 1786 - 2008 - Specification for High Strength Deformed bar and Wires
for Concrete Reinforcement.
IS 432 PART 1- 1982 - Specification for Mild steel and Medium tensile
steel bars and hard drawn steel wire for concrete reinforcement
IS 432 PART 2 -1982-Specification for Mild steel and Medium tensile steel
bars and hard drawn steel wire for concrete reinforcement.
IS 2502 -1963 - Code of practice for Bending and Fixing Bars for Concrete
Reinforcement.
SP 34 -1987 Hand book on Concrete Reinforcement and Detailing

Reference International Standards.

BS 4449 Carbon steel bars for concrete.
BS 7295 Fusion bonded epoxy coated steel
BS6744 Stainless steel
BS 4483 Steel fabric
BS 4482 Hard drawn wire
BS 8666 Scheduling dimensioning, bending and cutting of steel
reinforcement for concrete - Specification
ASTM A 615 for carbon steel rebar.
ASTM A 706 for seismic rebar.
ASTM A 955 for stainless steel rebar.
ACI 440 for FRP bars
DIN 488 Reinforcing steels
How to Calculate Hook & Bend Allowance

Bar Diameter, Bar Diameter,

d ≤ 25mm d > 25mm
REBAR TYPE
k k
Hook Bend Hook Bend
Value Value

Mild Steel 2 9d 5d 3 11d 5.5d

Medium Tensile Steel 3 11d 5.5d 4 13d 6d

Cold Worked Steel 4 13d 6d 6 17d 7d

Note:

• All the Value is to be rounded off to nearest 5mm.

• If the calculated result is<75mm, then take the result as 75mm.
 Calculated Hook & Bend Allowance:

Hook Allowance (H) Bend Allowance (B)

Nom
Medium Cold Medium Cold
inal
Mild Steel Tensile Worked Mild Steel Tensile Worked
Size
Steel Steel Steel Steel
of
Bar Rec Rec Rec Rec Rec Rec
(D) Min om Min om Min om Min om Min om Min om
md. md. md. md. md. md.

5 75 - 75 - 75 - 75 - 75 - 75 -

6 75 - 75 - 75 - 75 - 75 - 75 -

8 75 - 90 - 105 - 75 - 75 - 75 -

10 90 - 110 - 130 - 75 - 75 - 75 -

12 110 - 130 - 155 - 75 - 75 - 75 -

16 145 - 175 - 210 - 80 - 90 - 95 -

20 180 - 220 - 260 - 100 - 110 - 120 -

22 200 - 240 - 285 - 110 - 120 - 130 -

25 225 - 275 - 325 - 125 - 140 - 150 -

28 250 310 310 365 365 475 146 155 155 170 170 195

32 290 350 350 415 415 545 160 175 175 190 190 225

36 325 395 395 470 470 610 180 200 200 215 215 250

40 360 440 440 520 520 680 200 220 220 240 240 280

45 405 495 495 585 585 765 225 250 250 270 270 315

50 450 550 550 650 650 850 250 275 275 300 300 350
 LARSEN & TOUBRO LIMITED -ECC DIVISION

QUALITY FORMAT

BAR BENDING SCHEDULE

PROJECT : DATE :
AREA/BUILDING :
TIME :
DESCRIPTION OF WORK :
DRG.REF . :

TOTAL
BAR DIA. OF NO.PER NO.OF No. OF CUT NET
MEMBER NO. BAR MEMBER MEMBER BARS LENGTH LENGTH SHAPE

TOTAL Wt.

REMARKS :

SITE ENGINEER REINFORCEMENT ENGINEER CLIENT

Minimum Diameter Required for Bending Former

Bending Former
Bending Former
Minimum dia. (mm).
Bar diameter ‘d’ (mm) Minimum dia. (mm).
[As per IS 2502-1963]
[As per BS-8666-2005]
for cold worked steel.

6 48 (8d) 24 (4d)

8 64(8d) 32(4d)

10 80 (8d) 40 (4d)

12 96 (8d) 48 (4d)

16 128 (8d) 64 (4d)

20 160 (8d) 140 (7d)

25 200 (8d) 175 (7d)

28 336 (12d ) 196 ( 7d)

32 384 (12d) 224 (7d)

40 480 (12 d) 280 (7d)

50 600 (12 d) 350 (7d)

 Cross
CROSS-SECTIONAL MASS PER METRE RUN
NOMINAL SIZE( mm) -
AREA (Sq mm) (Kg/m) Secti
4 12.6 0.099 onal
Area
5 19.6 0.154 and
Mass
6 28.3 0.222 of
7 38.5 0.302 Reba
r
8 50.3 0.395

10 78.6 0.617

12 113.1 0.888

16 201.2 1.58

18 254.6 2.00

20 314.3 2.47

22 380.3 2.98

25 491.1 3.85

28 616 4.83

32 804.6 6.31

36 1018.3 7.99

40 1257.2 9.86

45 1591.1 12.50

50 1964.3 15.42
CHECKS
During procurement of Rebar
 Check the brand isapproved or not.
 Check Grade of reinforcement
 Check the Quantity requirement and duration
 If new vendor collect sample and check for conformity

On receipt at site

Collect sample for test

BOQ [black soft annealed wire or GI wire of 16 gauge (1.6mm dia.)]

Rebar Stacking
TESTING OF REBAR
Sample collection
 Samples of 1 m length (quantity as per below table) taken randomly
per lot for each diameter.

Breaking of bars :
If rebars breaks during bending then check the carbon content of the lot.
Ensure bars of 25mm and above are free from cracking while bending 90
deg . If observed then straighten the bars again to know they are not
breaking. Collect samples and send for chemical analysis. Mark and identify
the lot till results available and lot is cleared of doubt.
Sample Testing on receipt at site
Samples of rebars collected from the lots received at site 2 sets of samples ( 3
specimens each) for 100 MT per Lot or Heat number and tested for mechanical
properties as above. If one sample fails to meet the requirement 2 additional samples
to be collected from the same lot and tested for conformity. If one specimen fails to
meet the physical requirement of Table 3 IS 1786 the whole lot is rejected.
Cover blocks
Cover blocks used shall be of same grade of concrete or made up of PVC
 Check Rolling margin ( at site lab)
Weigh the mass (measure to a precision of +0.5%) of the rebar
samples.
Calculate the nominal mass = Mass of the sample

The nominal mass should satisfy the Table 2 of IS1786-2008

Mechanical Properties (To be tested at external Lab).

 0.2% proof stress
 Elongation
 Tensile strength
 Bend and Rebend test

Universal Testing machine (Used for

finding 0.2% proof stress, Elongation
& Tensile strength)
Rebar Mechanical properties should satisfy Table 3 IS 1786 requirements

For Bend and Rebend test there should be not any rupture or cracks visible
in the bent portion.
If any one of the test sample fails then collect 2 more sample of 3 Nos
each.
If any one sample fails – LOT REJECTED.
Nominal Cover for Durability requirement:

Exposure Nominal concrete cover in mm

Mild 20
Moderate 30
Severe 45
Very Severe 50
Extreme 75

nominal cover by +10mm

DESCRIPTION NOMINAL COVER

In no Case Less than Dia of Bar
Column Longitudinal Reinforcing In no Case <40mm (or) Dia of Bar
Bar
COLUMN OF SIZE Up to 200 mm, 25 mm
whose reinforcing bar is <12mm
Dia.
Footings Minimum Cover is 50 mm

+10 mm
ACTUAL COVER = OF NOMINAL COVER
-0mm
Material for Cover

Concrete cover blocks

PVC Cover block

Photographs

Plain Rebars

Deformed Rebars
Stainless Steel Rebar
Hot Dip Galvanised Rebar

FRP Rebar
Pre-fabricated cages

Rebar Tying machine

Splicing Methods
Lap Splicing
Welding
Mechanical Coupler

Precautions:
Splicing should not be done at the area where the max. Bending moment
is more than 50% of moment resistance.
Lap splicing is not permitted for reinforcing bar > 32mm. (Clause
26.2.5.1(A), is 456 -2000 amendment 3).
Bars >32mm shall be welded or mechanically spliced.
When two different dia. Bars is to be spliced, then the lap length calculation
is to be made on basis of smaller dia rod.

SPLICE-STRENGTH:

Description Compression Tension

Welded splice 100% of design strength 80% of design strength
of bar of bar
Mechanical splice 100% of design strength 100% of design strength
of bar of bar

Reinforcment couplers:
Classification according to IS Code (Draft):
Class L +H
Class L.

Different mechanical splicing systems based on type of reinforcment

coupler used:
Threaded couplers
 Parallel threaded couplers
 Tapered threaded couplers
 Upset parallel threaded couplers
Coupler with crimped sleeve
Coupling with injected sleeve
 Molten metal injection
 Grout (or) epoxy resin injection
Butt splices
Welded couplers
Other patented type
Classification of test for reinforcment couplers

Static tensile test

Slip test

Cyclic tensile test

Low cycle fatigue test &

High cycle fatigue test for ‘L+H ‘couplers only.

The above data is based on draft published by Indian Standard.

Reinforcement Binding
Hair Pin Tie:

The hair pin tie, the most secure

tie used on all good work for
fixing key bars and setting the
work securely, before infilling.

A most secure tie used on column,

beams and for tying key bars
before infilling.

Crown Tie:

The crown tie, again a most secure

tie, and is used in much same way
as the hairpin tie.

It has one further use that it can

be used to tighten bars together
that have a tendency to spring.

Splice Tie:

The splice tie, is used exactly as

the name indicates for joining
laps of splices in bars.

It is in fact, exactly the same as the

crown tie. And as the same useful
qualities
Welding of Reinforcments:

References Standards:
IS 9417-1989
SP-34(S&T)-1987

Lap Welding

Rebar Dia. Vs Electrode size

NOMINAL BAR SIZE OF ELECTRODE,

Sl.No.
DIAMETER (mm) MAX (mm)
1 Up to and including 10 mm 2.50
2 Over 10 up to and including 18 mm 3.15
3 Over 18 up to and including 28 mm 4.00
4 Over 28 mm 5.00
Quality Control Test on Welded Rebars
Samples of Lap welded joints to be tested for Mechanical properties like
Tensile. The failure should occur in the bars outside weld area and not on
the weld.
Samples of Butt weld joints to be tested for Tensile and Bend test. The failure
should occur in the bars outside weld area and not on the weld in tensile and
no sign of crack in the weld portion in bend test.
Precautions in Rebar Actvity:

Why is it important to bend the

bar around the correct radius?

The tighter the bend, the greater

the strains that are created in the
bar around the bend. The bend
diameters in IS 2502 -1963 have
been specified as they have been
demonstrated to give a good
balance between the need to
maintain ductility and provide
practical construction solutions.
The bend diameter requirements of
IS 2502-1963 are mandatory .and
they should not be compromised.

Why TMT Rebar should not be

cut with Flame?

If a TMT bar is heated and then

allowed to air cool, the hardened
surface will be lost and the strength
of the bar will approach that of the
core. This loss of strength is the
reason for the restriction on the
Flame /Gas cutting of TMT rebar

Cross-Section of TMT Rebar

Do not position laps in beam column junctions.
Do not position laps in the midspan of the beam at bottom

Ensure sufficient chairs are For the bars greater than 12 dia
added at the right spacing the slope shall not be more than 1
in 6 dia as per the sketch. This is to
maintain the structural integrity.