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Rebar Processing Solutions

Process & Benefits

EMERGING TRENDS IN CONSTRUCTION PRACTICES IN INDIA

Non-availability of cheap manual labor employed at site for cutting, bending, tying and Fixing of Re-bars. Lack of Space at project sites. Increased awareness about speed, quality & safety of Construction. Cost pressures on Construction Co.s : Find ways & means to reduce pilferage and wastage at site

Ready to use cut & bent Rebars take lead in shaping the Indian Construction market

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REBAR PROCESSING SOLUTIONS TMT COILS STRAIGHT LENGTH


Cutting to required length Bending to required Shapes

Straightening

Mesh

Assembly

Coupler

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PRODUCTS

Shear line

Poly Bender

Single Bender

Radial Bender

Manual Bender

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FINISHED GOOD RANGE

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This Solution will bring a cascading improvement in the way project is executed

1. Reliability of Steel supplies 2. Improvement in Quality

3. Timeliness : Compress project schedules


4. Improvement in Quality of construction

Customer

Customers to focus on their core job CONSTRUCTION


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Advantages of Processed Rebar solutions


Project design Minimize waste Assess steel consumption (5 a 7%), yields (40 a 60 hh/t). Materials procurement Get Steel price quotation. Cut and Bend Service price quotation. Purchase planning at least 5 weeks ahead of requirement. Construction Insure qualified bar benders. Plan adequate equipment plan space for storage and processing (120 m2). Construction Manager High level quality control is necessary. Production capacity is limited by labor and equipment availability. Ensure yields and waste within budget. Possibility to accelerate or slow down the pace of construction by simply reprogramming deliveries. Company's margins Uncertain consumption and yields until completion of work.

Traditional System

Prepare Cut and JSPL Processed Bend Rebar solution Blueprints. Bar forming Shape making Stirrup making Weldmesh welding Weldmesh making
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Price quotation of steel and service.

Program deliveries according to concreting program.

Knowledge of processed steel real cost from the very first day.

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Advantages of Processed Rebar solutions


Lower production costs: The Cut and Bend process, traditionally performed at the construction site, requires between 40 - 60 man hour/t, around 60 % of steel value. By using processed Rebars, the cost of processing decreases by approximately 30 % of steel value, depending on the type of construction and diameters mix. Moreover, lower indirect costs are obtained through shorter construction time. Zero waste: There is usually a certain amount of waste generated, which varies around 5 to10 % (a mean value of 7% can be estimated). With the processed Rebars, customer pays for the theoretical blueprint weight only, and saves on waste, processing or freight.

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Advantages of Processed Rebar solutions


Lower financial cost: Normally the bars are kept in storage for three weeks before using them. Add to this one week for procurement and one additional week for processing at the construction site, Total lead time is 5 weeks. On the other hand, when buying processed Rebars, lead time is considerably shorter as the time required for the delivery of material at construction site is lesser, (5 weeks later than when buying the bars at the plant and bending at construction site.) Elimination of storage: Material is ordered when needed and partial deliveries are programmed according to the concreting schedule. This results in lower financial cost, since the material gets to construction site ready to be assembled. Lesser space is also needed at the site, since no storage space is required for bars (60 m2), nor for the cut and bend process (120m2).

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Advantages of Processed Rebar solutions


Simple, safe and operational: Since the whole cut and bend process is limited to ordering the material according to blueprints, handling of 12 m bars is eliminated, and neatness is improved, thus decreasing the risk of accidents as well as the eternal problem of bar thefts. Greater response capacity and delivery flexibility: You can speed-up the pace of your construction to comply with certification deadlines, or slow it down -e.g. in case of rainsimply by programming delivery dates with our Rebar processing plants at Patratu/ Nalwa. You can also decrease the construction time of the Reinforced Concrete structure.

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Facilities @ plant

JSPL facilities automatic shaping centre

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JSPL Facilities

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JSPL Facilities shear line

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JSPL facilities

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JSPL facilities

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JSPL facilities

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Welded mesh The longitudinal and transverse reinforcement bars are welded into concrete wire mesh. The concrete meshes have a more dense spacing of the steel bar. Concrete wire mesh is also named welded steel fabric. Application: concrete wire mesh is used for coal mine tunnel network protection or reinforcement, concrete pavement, bridge deck pavement, airport runway, tunnel lining, housing floor, roof, wall, floor, concrete pipes and so on. Advantages: concrete wire mesh for a new, efficient and high-quality steel reinforced concrete structures can be reinforced to reduce the installation of a large number of working hours, less than banding employment nearly approached net 50% - 70%. Concrete wire mesh can help to prevent the emergence of concrete cracks and development, roads, floors, Floor welding network configuration can reduce the surface of concrete about 75 percent split.

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Weld mesh plant

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Weld mesh plant

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Weld mesh plant

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JSPL Facilities welded wire mesh


Practical Advantage of Weld Mesh: Greater ability to work to achieve increased output with exact steel areas and spacing. Simplified drawings with easy checking without errors. For Site Supervisors: Simple design enables the placement and checking of steel. Avoid wastage and scrap. For Contractors: Faster work and finish the task within deadline. Reduced steel scrap generation. Easy to read drawings and cross checking. Achieve greater accuracy with less manpower.

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Welded mesh machine


Machine specifications Speed of production Width Length Long. Step Cross step Long. overhang Cross overhang Up to 120 strokes/ min 1200-3200 mm 2000-6000 mm 50-200 mm 50-250 mm 50-200 mm 25-150 mm

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Welded mesh - advantages


Concrete Reinforcement Advantages of Welded Wire Fabric Higher characteristic Design Strength WWF with Fe500 grade results in savings in steel area or steel weight required to the tune of 13.55% vis-a-vis HYSD bars of Fe415 grade Vastly Superior Bonding Behavior As against the peripheral surface area which is responsible for bonding to concrete in the case of individual bars, the right mechanical interconnections by means of welds to cross wires are primarily responsible for stress transfer from concrete to steel and vice-versa in the case of WWF. Each of the rigid welds capable of resisting up to 210 N/mm2 ensure quick and complete stress transfer within 2 welded joints from the critical section. Better and Economic Crack Resistance with Thinner Wires and Closer Spacing WWF usage affords the possibility of using thinner wires at closer spacing. This serves most effectively in countering the non-load phenomena or strain induced stresses due to Shrinkage and Temperature changes. The close spacing of thinner wires and the two way behavior of WWF minimizes the crack widths and preserves structural integrity of the slab. Savings of Labor, Time and Binding Wire The most obvious and clinching advantage in the use of WWF is the immediate and positive savings in labor and time. It is complete freedom from all the mundane filter's jobs. There is no cutting of bars, no marking and spacing them out, and above all no laborious tying of binding wires

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Welded mesh - advantages


The only feasible and Essential Reinforcement for ground slabs WWF usage provides the only practical and easy solution for reinforcing slabs on ground. A plain concrete slab under construction of sub-soil erosion or movements or due to temperature changes coupled with heavy traffic loading will develop cracks which collapse concrete of the surface. The tendency to use extra high strength concrete or extra thickness of concrete to minimize cracking does not solve any problems since the strains induced by the drying shrinkage or temperature contraction do not appreciably change with thickness. Cost of a WWF reinforced slab is also more or less similar to that of a slightly thicker unreinforced slab. Usage of WWF serves to control cracking and crack width in both directions. It ensures that even if a crack develops the cracked faces are held together and the aggregate interlock is maintained. Flexibility of Handling and Placing The usage of thinner wire lends the fabric as extremely flexible in handling. Coupled with the availability in long lengths in roll form, WWF provides the ideal and convenient solution for all kinds of repair work by Re-plastering or Guniting. The same aspect makes WWF indispensable in thin elements such as Precast partitions, shelves, fins, ferro-cements or ferrocate products such as ferrocate water tanks etc. WWF is the only solution for the thin and tough spine of thin and efficient structural elements such as folded plate roofs, folded plate precast roof girders or hyperbolic paraboloid shells

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Thank you

Copyright 2010 Jindal Steel & Power Ltd.