THERMO MECHANICALLY TREATED[TMT] BARS

2009-2010

1 INTRODUCTION
1.1 Emergence of steel (Dayarathnam P, 2004)
Concrete has been most extensively used in buildings ever since Joseph Aspdin invented and
patented Portland cement, about one hundred sixty years ago. At its face value, concrete is a
simple material close to the natural one. However, it is lot more complex and can be source of
strength or weakness to the user depending on how well the quality assurance is built into it. It is
robust and reasonably durable one, with compressive strength going up to 150 N/mm 2 under
controlled conditions in suitable combinations of the components. However, its tensile strength is
far below the compressive capacity, so reinforcement is required to resist tensile forces.
Laboratory practices have not been able to device a direct method of evaluating the tensile
capacity, even though indirect tests are available to extrapolate the tensile strength. Many
structures are subjected to bending or combined bending compressive forces. Members such as
ties, pipes and tanks that are subjected to direct tensile forces require reinforcement. Steel bars or
wires are embedded in concrete in the tensile zone, thus reinforcing the tension capacity of the
concrete. The reinforcement is not only used to resist tensile forces but also to resist even
compressive force as in the case of struts, columns etc. Steel is equally good in resisting tension
and compression and its strength is measured by yield or proof strength in uniaxial tension test.
Steel being ductile, it also helps in making the brittle concrete a ductile material to a limited
extent depending on detailing of the reinforcement. The mild steel has a percentage elongation of
the order of 24 percent with yield strength of 250 N/mm 2. The deformed reinforcement bars
either cold twisted or hot rolled do not have a clear yield point like the one in mild steel,
therefore the strength of such high yield steel is specified by proof strength. The proof strength is
the stress that is measured at a preassigned permanent set, normally taken in the range of 0.2
percent. (Most commonly used high yield strength deformed bars have proof strengths of 415
N/mm2 and 500 N/mm2.)
Steel bars of proof strength 550 N/mm2 are also available in the market and used is limited
extent. Even though steel of strength more than 550 N/mm 2 can be produced at reasonable cost,
but not used as reinforcement because of the strain limitations of the concrete. The ultimate
tensile strain in plain concrete is of the order of .00015 and crushing strain is of the order of .

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0035.Where as the tensile strain in commonly used high yield strength steel is of the order of
fifteen percent, corresponding to a strain of 0.15. Even though the high strength steel is ductile,
its ductility and strength can not be totally imparted to the brittle concrete without causing
apparent or real damage to the concrete structure as a whole. To avail the advantage of the high
strength of the steel, higher strains in concrete create wide cracks in tension zone and also lead to
crushing under compression. To make the reinforced concrete behave as reasonable
homogeneous material, the embedded reinforcement must be integrated to act along with the
concrete both in compression and tension. Therefore, the bond between the two materials is
equally important to ensure the achievement of the designed strength. That is how the plain bars
in construction were replaced by the deformed bars during sixties. The high strength or even
medium grade concrete must have the high yield deformed bars to ensure integrated action and
eliminate slip between the concrete and steel. The word deformed bar is a misnomer, because
there is really no deformity in the reinforcement in the real sense. The deformation introduced in
the production of the bars aids to enhance the bonding between the two materials and provides an
integrated reinforced concrete.
There are other important points one must pay attention to, regarding reinforcement besides its
strength and bond. The durability of a structure depends on the quality of steel, surface treatment,
and the exposure conditions. Even though concrete provides an alkaline environmental
protection, but in an aggressive exposure condition, the steel reinforcement must be protected
with proper surface treatment of the bars. The level of protection to the reinforcement depends
on the aggressiveness of the exposure. Surface treatment and galvanizing the bars are commonly
used methods besides using the stainless steel reinforcement bars in the most aggressive
exposure condition.
Detailing of reinforcement is another important parameter in establishing the strength and
durability of a structure. The location of the laps and splices, and curtailment of the bars are
important not only from the point of strength but also from durability and constructability angles.
In framed building construction, the beam-column joints are critical, and bar bender has
tendency to provide bar laps and splices at such locations, the percentage of reinforcement is
high and is on both the faces of the members. Providing laps at joints congests the reinforcement
thus resulting in voids or even honeycombing.

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Reinforcement is necessary in all reinforced construction not only for strength, but also to
minimize the micro-cracking due to secondary effects such as shrinkage, creep, moisture and
thermal variations. The minor discontinuity in concrete at the reinforcement bar level has a
tendency to change the stress distribution pattern from the assumed simple beam, column and
plate theories. The size of the crack in concrete, either due to bending or tension or due to
secondary effects depends on the diameter of the bar and its location with reference to the
surface of the member. Smaller diameter bars spaced at closure workable spacing are preferred
to large diameters. However, one has to balance between the bar size and volume of the
reinforcement. Just because the reinforcement strengthens the concrete, one should not under the
impression that more reinforcement means more strength. There is always a maximum workable
volume of reinforcement for optimal construction, performance and even for cost. For durability
and good performance, design and construction must take precautions of protection and detailing
of reinforcement bars, in addition to the design considerations.
Concrete structures subjected to dynamic loads such as wind, cyclonic weather and earthquake
undergo repeated reversal stresses. Such loads cause micro cracking and increase the brittleness
of the concrete. Reinforcement is required for protection against cracking of concrete and also to
provide ductility to the structure. Lack of proper reinforcement detailing and enforcement of
quality assurance in buildings have lead to disasters in the recent earthquakes. Therefore the
design and detailing of the reinforcement must be looked into a holistic manner rather than
following simple strength consideration.

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2 STEEL AS REINFORCEMENT (Mediratta S.R, 2004)

2.1 INTRODUCTION
The concept of reinforced concrete (RC) was first initiated by Jean Louis Lambot in 1850 and
subsequently, several engineers improvised this to bring about efficient RC members and
structures of today’s standard.
Steel is a versatile material in terms of strength, rigidity, workability, low cost and scope of
application. The per capita consumption of steel is strongly linked with economic development
of a country. The per capita consumption of steel is comparatively low in comparison with that
of the developed world. The average per capita annual consumption of steel is more than 400 kg
in developed countries and about 50 kg in developing countries. But in India, the per capita
consumption is only about 30 kg. Faster infrastructure development will consume more steel as
well as provide sustainable assets. Steel has major application in the areas of construction,
infrastructure building and rural development. Now by realizing the importance of steel
consumption in the national economy, all major countries in the world have been making large
investments for expanding steel capacity and the world steel production has been growing.
Recent statistics shown that in India total steel production is only 3.8 percent of the total world
steel production. However, even this small quantity is difficult to consume and we have to export
2-3 million tones to keep our mills running. It has been estimated that by 2006-07, the total
production of finished steel in India will be 48.7 million tones, whereas the apparent
consumption is expected to be around 42.6 million tones with the need to export excess
production. There is a need to increase steel intensity in structures without increasing the cost so
as to accelerate steel consumption in the country. Steel being the most reliable material, increase
in percentage of steel will increase durability of the structure.
Construction is one of the major steel consuming sectors of steel. There are three common types
of constructions materials-concrete, steel and composite. However, concrete construction uses
two techniques namely reinforced concrete (RC) and prestressed concrete (PSC). In both these

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techniques, steel reinforcements or the so called rebars play a very important role, comparable to
the bones in the human body.
Pain concrete has very poor tensile and bending strength. Steel reinforcements in RC and PSC
make up this deficiency.
In spite of this, reinforced concrete, though not suitable, is used for beams, which are normally
subjected to tensile stresses. Often cold twisted deformed (CTD) bars are used as reinforcement,
which are prone to accelerated corrosion. With a view to improve durability and cost
effectiveness, steel-intensive structures are increasingly being built using load bearing beams of
steel with RC slab/floor for buildings or PSC deck for bridges/flyovers by adopting technology
of steel-concrete composite construction.
2.2 STEEL BARS/ RODS FOR REINFORCEMENT
Concrete has high compressive strength but low tensile strength. Therefore, steel reinforcement
used in these zones of a concrete structure that develop tensile stresses due to bending, shear or
even compressive loads as in beams, slabs and long columns. However reinforcement action is
efficient only to the extent of bond strength between the reinforcing steel bars and the
surrounding concrete as well as the end hook anchorages. Because of difference in modules
elasticity of steel and concrete, the latter develops tensile cracks. Major cracks can be avoided by
using ductile mild steel and by improving the local bond all along the bar. The bond is improved
by ensuring a non smooth surface, that is, by providing ribs of certain profile and depth on the
surface of the bars and by using deformed bars with ribs and ridges. Further, well distributed
steel reinforcements help in reducing temperature and shrinkage effects in the concrete.
2.3 TYPES OF REINFORCING BARS (Vishwanatha C.S, 2004)

Fig.2.1 Fig.2.2

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a. Plain mild steel bars (Fig.2.1): Have yield strength of 250 N/mm 2 and it is used as
reinforcement for the concrete construction industry up to 1965.
b. Square Twisted bars (Fig.2.2): They were brought into market by IRC steels. As these bars
were not efficient enough, they were phased out from the Indian market in very short -period.

Fig.2.3 Fig.2.4
c. Cold twisted bars (Fig.2.3): In 1967, Tor Isteg Steel Corporation of Luxumberg introduced in
India, Cold twisted deformed circular bars of proof stress 420 N/mm 2, which is subsequently
became popular as Tor 40 rebars.
d. Hot rolled bars (Fig.2.4): In this strength of about 420 N/mm 2 from 250 N/mm2 is achieved
by incorporating alloys like nickel and vanadium in the molten metal, while producing the
billets. The billets are subsequently passed through stands resulting in high strength
deformed hot rolled rebars.

Fig.2.5 Fig.2.6
e. Torkari rebars (Fig.2.5): In contrast to the cold twisting, a new procedure for manufacturing
high strength deformed rebars was developed by Germans, branded as Torkari rebars. It is

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possible for production of rebars of proof strength up to 550 N/mm 2. The manufacturing
procedure essentially comprises of simultaneous cold reduction of and cold ribbing of wire
rods. This process restricts diameters up to 11 mm.
f. Special reinforcing bars (Fig.2.6): For durability consideration, there is a corrosion resistant
rebars (CRS) from Tata steel.
g. Coated reinforcing bars: The two main categories of factory produced rebars in the Indian
market are, galvanized and epoxy coated rebars. Ex:The galvanized rebars were used in
Bahai’s temple at New Delhi. Epoxy coated rebars are used in bridge structures in coastal
belt around the country.

Fig.2.7
h. Thermo processed (TMT) rebars (Fig.2.7): Between 1980 and 1985, new type of rebars
termed TMT, a Thermo Mechanically Treated bars were developed around the world, for the
benefit of RC constructions. Notable amongst them were Torsid from France, Tempcore
from Belgium and Thermex from East Germany. The first to produce TMT rebars in India
were Tata steel by about 1992 through Tempcore technology. Later Vizag steel came on line
followed by SAIL through technology. In the initial years, the production was restricted to
bars having diameter higher than about 16mm.

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3 THERMO-MECHANICALLY TREATED BARS

3.1 GENERAL
Thermo mechanically treated steel known as TMT steel can be described as new-generation-
high-strength steel having superior properties such as weldability, strength, ductility and
bendability meeting highest quality standards at international level. TMT bars possess tough
surface providing high yield strength and a soft core providing excellent ductility. Strength,
weldability and ductility are such properties which declare TMT steel highly economical and
safe for use. An additional advantage of TMT steel is that a twisting operation is included in Tor
steel, which subjects the bars to torsional stresses making them less corrosion resistant while
TMT bars are free of such stresses thus having superior corrosion resistance.
3.2 PROPERTIES (SAIL, www.sail.co.in)
Fire resistance
Ability to resist action of high temperature without appreciable deformation or loss of strength is
termed fire resistance. Ideal structural material should be fire resistant. Because of its high
thermal stability TMT bars can withstand high temperature of the range 500ºC-600ºC, ensuring
fire safety and providing its advantage over HSD bars.
Ductility
Ductile materials accommodate large deformations before failure. This quality distinctly
separates them from materials that are brittle which cannot do so and hence fail suddenly.
Ductile failures are gradual. Structures and elements of ductile materials are amenable for
restoration and rehabilitation. High elongation and ductility has given Elegant TMT bar high
seismic resistance which makes it withstand even in earthquake zones 4&5. TMT bars guarantee
elongation well above 15%.
Corrosion resistance
This is a property by virtue, the material possess resistance to corrosion activities which depends
on the composition and the weathering conditions. With chemical composition as per IS 1786,

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Elegant TMT bar is produced by thermo-mechanical treatment and not by cold twisting.
Therefore, there are no torsional residual stresses in the bar.
Bending
TMT Bars exhibit very high bendability and also re-bendability due to lower carbon content and
higher elongation. They can withstand bending and re-bending with internal diameters of 1D and
4D respectively, where D is the diameter of the Bar. It is easier to work with these TMT Bars
due to easy bendability.
Weldability
The materials which do not suffer from loss of strength at the weld joints are said to have
excellent weldabilty. Surprisingly in TMT bars there is no loss of strength due to its low carbon
content and can be easily welded with CTD bars. Further no pre-heating or post-heating is
necessary during welding.
Others
The significance of TMT bars is that it shows a combination of toughness, hardness, excellent
straightness, high strength and high fatigue resistance on dynamic loading.
3.3 INDIAN STANDARD SPECIFICATIONS FOR TMT BARS
The IS-1786 (1985) stipulates the percentages of some of the constituents of TMT bars.
Table3.1 Composition of TMT bars (IS-1786)
Constituent Percent, Maximum TMT(Fe 415/FE
500/Fe 550)
TMT Fe TMT Fe TMT Fe
415 415 500 500 550 550
Carbon 0.25 0.3 0.25 0.3 0.25 0.3 0.2
Sulphur 0.05 0.0 0.05 0.05 0.05 0.055 0.045
6 5
Phosphorus 0.05 0.0 0.05 0.05 0.05 0.05 0.045
0 6 5
Sulphur and Phosphorus 0.1 0.1 0.1 0.10 0.1 0.1 0.09
1 5
Corrosion Resistant - - - - - - 0.75 min
Elements
Carbon Equivalent - - - - - - 0.53 max

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Table3.2 Properties of TMT bars (IS-1786) (Mary land Metrics http.mdmetric.com)

Property Grade
Fe 415 TMT Fe TMT Fe TMT
415 500 500 550 550
0.2 percent proof 415 415 500 500 550 550
stress/yield stress
Min N/mm.sq.
Elongation.percent 14.5 22(Up to 12 20(Up to 8 18(Upto 25
,Min,on gauge 28mm dia) 28mm dia) mm dia)
length 5.65.Square 20 (Above 18 (Above 16(Above
Root(A) where A is 28 mm 26 mm dia) 28 mm dia)
the cross-sectional dia)
area of the test
piece
Tensile 10% 10% more 8% more 8% more 6% more 6% more
Strength,Min more than than the than actual than actual than the than the
the actual actual 0.2% 0.2% proof actual actual
0.2% 0.2% proof stress but 0.2% proof 0.2% proof
proof proof stress but not less stress but stress but
stress but stress but not less than 580 not less not less
not less not less than 545 N/mm.sq than 585 than 630
than 48.5 than 500 N/mm.sq N/mm.sq. N/mm.sq.
N/mm.sq. N/mm.sq (Upto (Upto
28mm dia) (Upto 28mm dia)
560 28mm dia) & 610
N/mm.sq.) & 560 N/mm.sq.
(above 28 N/mm.sq.)
mm dia) (above 28 (above 28
mm dia) mm dia)

Upto
28mm dia)
& 560
N/mm.sq.)
(above 28
mm dia)

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3.4 THERMO-MECHANICAL TREATEMENT PROCESS

In this process advanced heat treatment techniques such as controlled water quenching are
applied on the red hot rebars as they come out of the rolling mill and the end product is known as
thermo mechanically treated (TMT) rebars. Though this is the standard practice in developed
countries, it has recently been introduced in India and TMT bars manufactured by SAIL, TISCO
and the Vizag Steel Plant are commercially available in the country. Thermo-mechanical
treatment has helped to produce reinforcement bars of high strength, superior ductility,
weldability, bendability and thermal resistance creating a virtual revolution in reinforcement
engineering.
The thermo-mechanical treatment process involves rapid quenching of hot bars through a series
of water jets after the bars come out of the last rolling mill stand Fig.3.1. The short residence
time in the water jacket provides intensive cooling of the surface layer, transforming it into a
hardened structure (Fig.9 & 10). The bars are then cooled in the atmosphere so that the
temperature between the core which is still hot and the cooled surface layer is equalized. The
heat extracted from the core tempers the peripheral hardened structure, while the rebar core cools
down slowly to turn into a ferrite-pearlite aggregate. The strength of the bars is carefully
controlled by optimizing the water pressure for their specific alloy chemistry and bar diameter.
The composite structure of the ductile ferrite-pearlitie core and the tough surface rim of tempered
martensite provide an optimum combination of high strength, ductility and toughness. The
absence of any cold worked structural zone and the specific design of steel chemistry in the form
of tempered martensite layer on the rebar surface, imparts high thermal resistance to the rebars,
even at elevated temperatures of up to 600oC. These rebars are ideal for use in places prone to
fire hazards. They possess excellent bendability due to the unique feature of uniform elongation
and can withstand bending and rebending better than conventional CTD bars. These bars have
very good weldability and do not suffer from loss of strength at the weld joints and can be easily
welded with CTD bars. No pre-heating or post-heating is necessary during welding. TMT rebars

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are commercially available in strengths of 415, 500 and 550MPa. Considerable care has to be
exercised in the application of water quenching as improper application can lead to brittle and
hard rebars.

Fig.3.1 Water cooling system

Fig.3.2 Cross-section of a TMT bar

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Fig.3.3 TMT bar showing soft core of ferrite-pearlite with strong and tough case of martensite

3.5 COMPARISON AND MERITS OVER OTHER PROCESSES

3.5.1 PROCESSES (Kaushik,S.K. and Singh,B, 2002)
To decide the percentage of carbon content in steel has been a major challenge for the engineers.
While certain minimum carbon content in steel is essential to achieve the required strength, an
excess of carbon content threatens its property of weldability. In TMT bars, this problem has
been eliminated. In these bars, the carbon content can be restricted to 0.2% to attain weldability
and at the same time no strength is lost on this account. The joints can be welded by ordinary
electrodes and no extra precautions are required. SAIL and RINL (Rastriya Ispat Nigam Limited)
are doing a good job in producing TMT bars.

Table3.3 Relative comparison of processes (Hy-Tuf steels, www.hytuf.com)

Result Achieved by Ductility Weldability
Process
1 Hot rolling Alloying elements Ductility impaired at Reduced due to
used in steel high strengths higher carbon
equivalent
2 Cold Mechanical Cold twisting Greatly reduced due Inconsistent; high
Working Cold drawing to cold working strength affected at
high temperature at
welding

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3 Thermo-processing Utilizing the heat of Excellent. Consistent

bars by controlled Well above
cooling international
standards

Fig.3.4 Stress-strain curve for MS bar

3.5.1.1 Hot rolling
In this process the rolling temperature, ideally should be 900ºC, hence hot rolling, and the
reduction ratio should be a minimum of 1:20 and the rib pattern must be in conformity with the
requirements of IS 1786 so as to provide adequate bond between steel and concrete. The end
result of this process is the production of mild steel (MS) bars with proof strength of 250-MPa.
Nowadays, plain MS bars are less commonly used in reinforced concrete because of their
relatively lower strength, though they cost almost the same as high strength deformed bars.
However, they are frequently employed in practice where nominal reinforcement is called for, as
for example the distribution reinforcement in the case of one way slabs. Low strength is also
preferred in cases where deflections and crack widths need to be controlled or where excessive
ductility is required as in earthquake-resistant design. The bars obtained through this process are
referred to be hot rolled bars (MS bars) and the typical stress-strain diagram of these bars is as
shown in Fig.3.4
3.5.1.2 Cold mechanical working
The process of cold working involves stretching and twisting of mild steel, beyond its yield
plateau, and subsequently releasing the load, as indicated by the thin line in Fig.3.5. The end

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product is the familiar cold twisted deformed (CTD) bars. Although stretching and cold twisting
results in a residual strain in the steel, it also results in an increased proof strength. Upon
reloading, the steel follows a linear elastic path (with the same modulus of elasticity, ES as the
original mild steel) up to the point where the unloading started the new raised yield point.

Fig.3.5 Effect of cold working on MS bars

After the yield point, as can be seen from Fig.3.5, the material enters the strain hardening range,
following the path indicated by the thick line in Fig.3.5. It should be noted that although the
process of cold working effectively increases the proof strength of the steel, it also reduces the
ductility in the material. This is perhaps the price to be paid in exchange for higher strengths. It
will be easily appreciated that higher proof strengths for cold-worked bars can be achieved by
suitably selecting the point of unloading in the mild steel strain hardening range and also by
using higher grades of mild steel to begin with. Cold mechanical working is a simple process
involving minimum costs.

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Fig.3.6 Stress-strain curve for CTD bar

The bars obtained through this process are referred to be hot rolled bars (MS bars) and the
typical stress-strain diagram of these bars is as shown in Fig.3.6.
3.5.1.3 Thermo processing

Fig.3.7 Stress-strain curve for TMT bar

This process has been discussed in the previous clause.

3.5.2 COST SAVING (Hy-Tuf steels, www.hytuf.com)
The replacement of conventional CTD bars by TMT bars results in saving in terms of weight and
thereby cost. However, the percentage savings will depend upon the type of structural member
and grade of steel. For CTD bars, design strength is 0.87 times fy corresponding to 0.002 strain
as there is no definite yield point. The design strength is further lowered by dividing it by 1.15
and 1.1; the respective factors of safety for material (steel) and eccentricity. Therefore, strength
equal to 0.687fy i.e. 0.687x415=285.105 N/sq.mm only is utilized for CTD bars in axial

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compression. In case of TMT grade steel by virtue of definite yield point, design strength in axial
compression is 400 N/sq. mm. This design strength further divided by factors of 1.15 and 1.1,
gives strength of 400/1.15x1.1=316.2 N/sq.mm in place of 285.105 N/sq.mm corresponding to
CTD bars. In other words, an additional strength of 31 N/sq.mm is available if CTD bars are
replaced by TMT bars. This, in turn increases the load carrying capacity of a column of the given
cross-section and concrete grade with TMT bars in place of CTD bars. The following typical
example illustrates that, there are savings of steel by weight in a doubly reinforced beam, as the
definite yield point in TMT bars results in saving of compressed steel as compared to CTD bars.

Table3.4 Economy in using Fe500 & 550 in lieu of Fe 415

Area of % saving
Dimension of the Mu Grade steel No. & dia. of bars with
Fcu
section (mm) (kN-m) steel (mm2) respect
Ast Asc Tension Compr. to Fe415
4-20# +
Fe415 2063 960 9-12# ---
4-16#
300 4-20# +
15 Fe500 1710 788 7-12# 17.3%
3-16#
4-20# +
Fe550 1545 728 7-12# 24.8%
Mu 2-16#
=4 4-20# +
bd 2 Fe415 2130 555 5-12# ---
5-16#
4-20# +
Fe500 1763 465 5-12# 17.0%
20 3-16#
4-20# +
d′ 50 Fe550 1613 420 3-16# 4-12# 24.2%
= = 0.11
d 450

Where Mu = Ultimate moment of the section

Ast = Area of the tension reinforcement\
P = Proportion of tension steel (Ast / bd)
Fcu = Characteristic strength of concrete
Asc = Area of compression reinforcement
P1 = Proportion of compression steel (Asc / bd)

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3.6 TEST TO IDENTIFY A GENUINE TMT BARS (Vishwanatha C.S, 2002)

This test helps us for better understanding of the characteristics of TMT bars. The test initially
involves cutting a TMT bar followed by smoothening of the cross section to a fine polished state
by grinder and emery paper. The smooth end of sample is then pickled in nitrol solution (10%
nitric acid with 90% ethyl alcohol). The result shows a uniform tempered martensite periphery
with a softer core. This is the uniqueness to identify a genuine TMT bars.
The figures below show that has been found in various tests.

Fig.3.8 X-section good Q & T rebar:

Fig.3.8 shows the uniform and concentric hardened periphery and the softer core. Such bars will
have desired tensile strengths coupled with high elongation as required in seismic zone.

Fig.3.9 Typical Thermex Bar

In this, uniform tempered martensite periphery is clearly visible. Depending on the size and
grade, the hardened periphery will be about 30% of the bar cross sectional area for good Q&T
rebars. Ideal rebar for civil construction.

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Fig.3.10 Indian Thermex X-section

Here we can observe the uniform tempered martensite periphery. Elongation measured was 19%.
A good rebar for civil construction.

Fig.3.11 Over quenched Low Ductility bar

Figure illustrates a highly over-quenched rebar. The hardened periphery is about 60% of the total
cross sectional area. Produced by mill personnel who are not fully trained in quenching and
tempering technology. Such bars will have high yield strength and very poor ductility and should
never be used in civil construction.

Fig.3.12 Non-uniform Quenched bar:

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This fig illustrates improper quenching treatment. There is a non-uniform hard periphery
signifying that the quenching has not taken place all round the periphery. Such bars are very
frequently noticed in India in mills that have made their quenching lines. Such bars should be
avoided by civil engineers.

Fig.3.13 Bar by improper Q&T system-Fake TMT

This figure illustrates a bar produced by bad quenching and tempering system. The quenching is
not uniform and the test results will be anybody’s guess. Such bars are produced mainly by ‘hit-
and-trial’ “TMT” technology and system. Such bars should never be used in civil construction as
properties will vary from bar to bar.

Fig.3.14 Typical Thermex Bar-Blue

Figure shows a very uniform cross section of hardened periphery with a soft core. An excellent
rebar for civil construction.

3.7 ADVANTAGES (Mediratta S.R, 2004)

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The main advantages of TMT bars are

i. They contain lower carbon content and thus exhibit better ductility and weldability (can be butt
or lap welded).
ii. TMT bars have better yield strength, tensile strength and percent elongation, when compare
to CTD bars of the same grade.
iii. TMT bars display easy bendability and thus require less energy for bending and rebending
along with superior reverse bending properties.
iv. They possess inbuilt ability to resist loss of strength at higher temperatures.
v. TMT bars also available in higher strength levels than those listed in the Indian standard. Use
of Fe 500 grade TMT bars can result in saving of more than 15 percent in steel consumption
when compared to CTD bars.
vi. They display better corrosion resistance than CTD bars due to the absence of cold twisting
process.
vii. Superior product with consistent properties
viii. Easy manufacture of different strengths of rebars from nearly the same steel grades
ix. Better fatigue resistance
x. Easy and less construction time
xi. It is an ideal choice for seismic zones due to excellent ductility properties.
Lastly and most importantly, the Thermex Cooling System is an in-line process and the high
strength Thermex rebars are ready for dispatch to the customer almost immediately after rolling
is complete – unlike the few days taken in the case of CTD rebars which results in large
inventory levels in the mill.

3.8 APPLICATIONS (Mediratta S.R, 2004)

1. TMT Bars are much superior to conventional TOR Steel by virtue of their various engineering
properties and can be used for Residential Buildings, Bridges, and Industrial Establishment
2. In all types of concrete reinforcement purposes like Steel-concrete composite construction
which involves one or more of steel concrete composite elements, that is, composite beam,
composite slab and composite columns.

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3. Because of corrosion resistance TMT bars are employed in construction exposed to coastal,
marine or underground environment.eering

prope
rties and can be

4 PRODUCTION
4.1 QUALITY
Basically the desired properties of a thermo processed bar are
i. Minimum Yield strength 500 N/mm2 (or more)
ii. Minimum Tensile strength 10% more than yield strength subject to minimum 560 N/mm2.
iii. Stress Ratio (TS/YS) 1.10(generally 1.15 to 1.25)
iv. Minimum A5 Elongation 16 (generally 18 to 22).
v. Weldability
Basically, TMT is a good quality material if it is manufactured properly. (Dr.Vishwanatha,
2002). According to him the concern is the mills, capability to control the temperature of the bar
that gets into the cooling tube .The temperature of the bar that gets into the cooling tube must be
about 850-900 degrees, plus or minus 30-40 degrees. But if any particular mill cannot control the
temperature of the bar that gets into the cooling tube, then we don’t get a good product. Most of
the secondary sector rerolling mills in the country come in the category of cross country mills,
which are not that sophisticated and that refined as the major plants. In most of these mills, they
are not able to control the temperature of reinforcing bars when it gets into the cooling tube, if at
all they have installed that technology. When the temperature can not be controlled properly, the
product that comes out invariably is non uniform, and it can not satisfy the requirements. So, the
market is flooded with substandard material.

4.2 AVAILABILITY
TMT rebars are commercially available in strengths of 500 and 550 MPa. The brands from the
renowned manufactures like SAIL, TISCO, IISCO, RINL, VIZAG STEEL PLANT etc are
within the purview of desired limits on the chemical composition of steel given in IS 1786.
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Various brands of TMT bars available in the market are SAIL TMT, SAIL TMT HCR, and
VIZAG TMT etc. The TMT reinforcing bars are available in almost all sizes: 8mm, 10mm,
12mm, 14mm, 16mm, 18mm, 20mm, 22mm, 25mm, 28mm, 32mm, 36mm, 40mm in standard
lengths & specific lengths up to a length of 20 meters.
As per today’s scenario there is an availability of some international brands namely THERMEX,
TEMPCORE. These bars are being manufactured to have greater strengths and good ductility so
that there is saving in steel coupled with safety. These are by far stiffer than that specified by IS:
1786-1985.

4.3 MARKETING
Production of TMT bars is not simple. It requires huge investments, expertise and stringent
process controls apart from quality inputs. Actual quality of steel gets deteriorated, unless proper
treatments are done. We find untreated re-bars are available in the market and being offered as
TMT bars made by integrated steel plants. These products are having very low physical
properties due to the absence of thermo-mechanical treatment and hence it very dangerous to use
these materials in construction activities.
The main steel plants produce about 1.5 million tones each year of what they strangely call TMT
rebars - this includes the Thermex bar production of SAIL at Durgapur and Bhilai steel plants.
Presumably we are talking Q&T rebars such as Thermex-as explained earlier, every mill in India
is legally making TMT bars. The Q&T rebars will become the preferred choice and it is expected
that by 2010 they will constitute 80 to 85% of the rebars made in the country against the present
50 to 55%. The CTD bars are definitely being phased out.
Some builders because of the lack of knowledge insist on CTD where inconsistency is very high,
because ultimately the strength is imparted by twisting the bar, which is a manual process.
Awareness of TMT bars is the order of the day.

4.4 NEW DEVELOPMENTS

The smaller is the diameter of steel, the greater are the chances of its getting corroded. It is a well
known fact that embedded steel corrodes faster than exposed steel and corrosion occurs mostly
due to chloride ion effect or carbonation. Instead of conventional method of providing metallic

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coatings to steel, a change in the metallurgy of steel itself is finding its way now. A new
development on steel front is production of corrosion resistant steel, called CRS. Carbon content
in this steel is restricted to 0.18%, Manganese is absent, silicon is 0.45% and the percentage of
corrosion resistant elements such as chromium is as high as 1.5%... SAIL and TISCO have taken
great strides in this direction.
Further research towards production of fusion bound epoxy coated reinforcement steel and
corrosion resistant low alloy steel is under way. To meet with the increasing demand of electrical
industry SAIL has intensified its efforts to produce sophisticated silicon steel. Interesting results
in this direction are expected soon.

5 DISCUSSIONS
A versatile material, steel has played a vital role in the construction industry. With its multitude
of features like superior strength, toughness and ductility, high strength to cost ratio, improved
safety in construction and operation and greater flexibility, it has become the preferred material
in construction. However, the non-availability of the right quality, cost effective steel and
absence of corrosion resistance technology has been one of the major hurdles in its growing
popularity.
The Cold Twisted Deformed (CTD) bars did meet the demand for low-cost, high-strength
reinforced steel bars and were cheap alternatives to costly alloying elements such as Cr, Ni, Ti
etc. But these bars sacrificed two essential properties of weldability and elongation. The search
for a process better than CTD led to the development of TMT bars. With their high-strength,
high-ductility properties, TMT bars overtook the popularity of CTD bars.
However, there is a great concern on non-availability of quality TMT bars. The factors, as per
the TMT bars are considered, are raw materials, rolling mill and treatment process. Bar which is
manufactured without sacrificing any one of the above factors undoubtedly ensures a quality
TMT bar. Moreover, there is hardly any difference in appearance between standard and sub-
standard bars. Due to this there is a misguidance and confusion among clients and users. Hence it
is the responsibility of civil engineers to adopt a detailed examination for requisite properties and
verification of source which carries a paramount importance as per today’s scenario.

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REFERENCES
1 C.S.Vishwanatha, “History in prospective- A journey through Indian reinforcing bars”,
The Indian concrete journal, Jan 2004, vol.78, pp14-18
2 S.R.Mediratta, “Steel reinforcement-Demand, quality and new application in India”, The
Indian concrete journal, Jan 2004, vol.78, pp.9-13.
3 P.Dayaratnam, “Guest editorial comments”, The Indian concrete journal, Jan 2004,
vol.78, pp.3-4.
4 C.S.Vishwanatha, “The ABC of TMT bars”, The Master builder, Oct-Nov 2004, vol.6,
pp.41
5 HY-TUF STEELS PVT LTD, www.hytuf.com
6 Jagvir Gaoyal, “Latest Developments on steel front”, www.tribuneindia.com
7 Kaushik.S.K. and Singh.B. “Influence of steel-making processes on the quality of
reinforcement”, The Indian concrete journal, July 2002, vol.76, pp.407-412.
8 Prabir C, Basu, Shylamoni P and Roshan A.D, “Characterization of steel reinforcement
for RC structures, An overview and related issues”, The Indian concrete journal, Jan
2004, vol.78, pp.22
9 Mary Land Metrics, http.mdmetric.com
10 SAIL, www.sail.co.in

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