Good Construction Practices with TMT

Bars

Shiladitya Chanda
Institute for Steel Development & Growth
Kolkata
A bar bender & fixer should be able to indentify types of
reinforcement bars, read drawings and prepare schedules,
fabricate using hand and power tools, store, transport and fix
reinforcement in position in formwork in readiness for
concrete pours and should strictly practice safety norms and
precautions.
Specific Duties
• Read drawings and bending schedules.

• Identifies the types and grades of reinforcement bars available.

• Indentifies the common defects, delivery conditions and remedial measures, if any.

• Measurement and setting out works.

• Calculate the cut lengths and weights of bars from codes and standards and also calculate the total weight invo
in the job.

• Computes the quantity of material used in day to day work

• Estimates the time requirement of a particular job

• Programmes and maintains progress of material and labour

Specific Duties
• Plans necessary workforce for the job.

• Plans cutting schedule so as to minimize scrap.

• Operates and maintains hand tools and power tools.

• Cuts and bends reinforcement exactly as per the requirement of the schedule.

• Ties and fastens bundled bars to ensure they remain in position whether horizontal or vertical

• Stacks and stores steel tidily and safely to ensure correct utilization based on size and type.

• Keeps accurate and uniform spacing of bars, staggers laps and maintains correct cover

Contd.
Specific Duties

• Recognizes main bars and distribution bars

• Correlates the sequence of reinforcement placing with fixing of inserts, sleeves, conduits

and anchors.

• Prefabricates mesh and cages including additional bars for lifting safely

• Protects the steel from corrosion and weathering action

• Understands the basic terms commonly used in building trade

• Works safely at heights using ladders, scaffolds and safely belts.

Various Types of Reinforcing Bars

• Mild Steel Bars – Not used for Structural

Purposes, nowadays

• High Yield Strength Deformed Bars ( HYSD

Bars) – Commonly Used
Further classification of HYSD Bars
Code Producers
Type Nomenclature Grades Size Availability Application Qualities
Conformity (Major)
High Strength but Low
Elongation, Poor Unorganized
General Construction.
Cold Twisted CTD Bars or TOR Weldability and Poor sectors.
Fe415 IS 1786 8-40 mm Preferably Non
Deformed Bars Steel Bendability, Mostly re-
Critical.
Vulnerable to rollers.
corrosion.
Thermo TMT Bars Fe415/500/550/ IS 1786 8-40 mm High Rise Buildings, Excellent Bendability SAIL, Tata,
Mechanically 600 Bridges, General and Weldability. High RINL, JSW,
Treated Construction (Critical) Fatigue resistant. High JSPL, ESSAR
(Quenched Elongation.
and
Tempered-
QST)
TMT Super TMT-SD Fe415D / Fe500D IS 1786 8-40 mm High Rise Buildings, Higher elongation TATA
Ductile Bridges, General than normal TMT
Construction (Critical)
Corrosion TMT-CRS Fe500 / Fe550 IS 1786 8-40 mm Coastal, Marine or High Corrosion TATA
Resistant TMT underground resistance properties.
construction.
TMT-HCR Fe500 / Fe550 IS 1786 8-40 mm Coastal, Marine or High Corrosion SAIL
underground resistance properties.
construction.
Earthquake TMT-EQR Fe500S / Fe550S IS 1786 - 8-40 mm All general High Ductility SAIL
Resistant TMT Proposed construction in
Earthquake prone
areas
As per Mandatory Certification of Steel Products order of Govt

of India (jointly by Ministry of Steel and Ministry of Consumer

Affairs’) dated 12th September 2012, all steel producers and

steel products (each sizes) are to be licensed with Bureau of

Indian Standards (BIS) and should conform to IS 1786 : 2008

Hence, Cold Twisted Bars – CTD or TOR Steel have
following characteristics,

 High Strength

 Low Elongation

 Poor Weldability

 Poor Bendability

 Vulnerable to corrosion.
Thermo Mechanically Treated Bars (TMT) – Improved
Manufacturing Process by modifying Micro-Structure,

 High Strength – Tensile and Bond Strength

 Higher Elongation – High Ductility

 Good Weldability

 Better Bendability and Rebendability

 Higher Corrosion resistance

 Higher Fatigue resistance

Identification of TMT Bars
CTD Bars / Tor Steel – Helical Ribs

TMT Bars

It is very difficult to distinguish TMT bars

and Plain Ribbed Bars and Sub standard

TMT bars by Visual inspection.

Types of Sub Standard TMT bars

 Low Carbon TMT

 TMT bars with water quenched in Tank

 TMT bars with no quenching

 TMT bars with inadequate quenching

 Hot twisted CTD bars

 CTD bars with high carbon

Identifying TMT bars Contd.

 Try to ensure the producer that has supplied the Rebars has a genuine
‘TMT’ technology. Generally all major steel producers have this
technology.
 Check the BIS license for each diameter.

 Always test the rebars for properties instead of merely relying on the
name ‘TMT’.
 Check the elongation value from the test results. Good TMT bars will
have elongation ranges from 16-28%.
Identifying TMT bars
 Field test the rebars at random. FILING the surface of the rebars with the help
of a ‘rough’ hand file. A site worker will easily recognise if the surface is hard
or soft. All TMT bars will have a harder surface than unquenched bars.
 Try to ascertain visually that TMT bars have a uniform cross section of
hardened periphery with a soft core.
 The cross-section shall be fine polished by grinder and emery paper. The
smooth end of sample is then pickled in nitrol solution (5 to10% nitric acid
with balance ethyl alcohol). The result should show a uniform tempered
martensite periphery with a softer core. (Optional)
Concrete Types
Minimum Concrete grade as per IS 456 : 2000 is M20

 Nominal Mix of M20 – 1:1.5:3

(Cement : Sand : Coarse Aggregates)
 Nominal Mix of M25 = 1:1:2

Clear Covers - For protection against corrosion and fire

 Slab = 20 mm
(for 8/10 mm dia main bars 15mm clear cover may be provided)

 Beam = 25 mm
 Column = 40 mm
(for Column size 200 mm and main rebar dia 12 mm, 25 mm clear cover may
Corrosion and Rusting
Rust

Controlled rust improves bond strength.

Rusting has no effect on rebar strength.

IS 1786:2008 indicates rust as

phenomenon on rebar and not a cause for

concern. Rust, seams, surface irregularities

or mill scale shall not be the cause for

Corrosion
rejection.

Uneven erosion of metal surface and is harmful to the intended service

performance of rebar.
Caution

Intense surface rusting can eventually lead to pitting

or corrosion. Never use severely rusted or pitted
rebars.

Check
Use a wire brush to clean the rebar surface and observe for pit
formation due to corrosion or over rusting.

Do not store rebars in direct contact with ground. Place wooden logs /
sleepers below the rebars.
Good Construction Practice
Weight Table
Formula : (3.1416 x d x d x 7.85) / 4000

Diameter (mm) Weight (kg/m) Tolerance

6 0.22 +7%
8 0.39 +7%
10 0.62 +7%
12 0.89 +5%
16 1.58 +5%
20 2.47 +3%
25 3.85 +3%
28 4.83 +3%
32 6.31 +3%
36 7.99 +3%
40 9.86 +3%
Tolerance : as per IS 1786 : 2008
Symbols relating to shape of the Symbols relating to position and
bar along its length direction
• Alt Alternate Bar EW / BW Each Way / Both Way
• Bt Bent Bar @ Spacing (Centre to Centre)
• B Bottom Bar Limit of area covered by bars
• min Minimum Direction in which bars extend
• max Maximum Symbols related to various
• St Straight Bar structural members
• Stp Stirrups • Bm or B Beam (s)
• Sp Spiral • Col Column (s)
• Ct Column Tie • Fg Footing (s)
• T Top Bar • GR Girders
• JT Joint (s)
• LL Lintel (s)
• LB Lintel Beam (s)
• Sb or S Slab (s)
• WL Wall
• CL Centre Line
Drawings Symbols
Drawings Symbols
Drawings Symbols
 Good Construction Practices as per Codal Provision
1. Reinforcement bars should not be re-bent or straightened

2. Use of same quality rebars throughout the construction is advisable.

3. While concreting in batches, do not break the concreting sequence during consumption of a single batch
mix. Consume the single batch mix at one go only.

4. Crossing bars should not be tack welded

5. Do not place the rebars too close. Reinforcement placing should allow compaction by immersion vibrator.

6. Adequate care should be taken to avoid displacement of reinforcement or movement of formwork. As a

general guidance, the maximum permissible free fall of concrete may be taken as 1.5 m (5’-0”)

7. Concrete should be thoroughly compacted around the embedment and corners of formworks by suitable
means.
 Good Construction Practices as per Codal Provision
Lapping:

• Lap splices shall necessarily be staggered.

• Laps in the bends or hooks shall be minimum 30D (D – diameter of the rebar)

• Laps in straight portion shall be 15D (D – diameter of the rebar)

• When bars of two different diameters are to be spliced, the lap length shall be calculated on the basis of diameter of the smaller bar.
 Checklist for Drawings
• Drawings must be clearly readable and rebar shapes, dia and
numbers are understandable.

• Check for commonly available sizes

• Preparation of Bar Bending Schedule (BBS) is possible.

• For any discrepancy or missing information or confusion, please

contact Engineer-in-Charge.

• Please DO NOT consider anything as standard practice. Follow

written instruction carefully.
Isolated Footings
Foundation
Combined Footings

Pile Foundation

Strip Footings
Isolated footing is the
most common type of
foundation
Good Construction Practices as per Codal Provision
 Minimum depth of footing from Existing ground level is 600 mm (2’-0”).

 The diameter of main reinforcement bars should not be less than 10 mm.

 Thickness at the end of sloped footings shall not be less than 150 mm (6
inches)

 Depth of the Grade Beams shall not be less than 150 mm (6 inches).

 The main reinforcement shall be minimum 3 nos bars of 10 mm dia (top

and bottom). Stirrups spacing 300 mm (12 inches) maximum.
Columns
Good Construction Practices as per Codal Provision
 For Columns, main rebars shall not be less than 12 mm.

 Columns - Minimum bars for Rectangular section is 4 nos and for Circular section
is 6

 Spacing of longitudinal bars measured along the periphery of the column shall not
exceed 300 mm (12 inches).

 Lateral Ties: Spacing shall not exceed 16 x d (d = smallest diameter longitudinal

bars). Ex: A column has 4 nos – 16 mm dia and 2 nos – 12 mm dia. Then minimum
tie spacing shall be 16 x 12 = 192 mm

 Lateral Ties: shall not be less than 5 mm

 Beams
 When different diameter bars are used in a single row, the larger diameter bars shall be placed on the outer

side.

 Stirrups shall be bent in the following ways,

 Spacing of stirrups shall not exceed

0.65 x D (D = Depth of Beam)

 Width of Beam shall be minimum 200 mm.

 Intersection of Beams - Top Steel: Secondary

beam top steel should pass OVER the main

steel beam top steel

 Slabs
 In no case the maximum distance of main bars in slabs shall exceed 300 mm (12 inches).

 Optimum diameter of rebars in slabs shall be one size below of one eighth of Depth of Slab. Like,

for 100 mm (4 inches) slab, optimum diameter would be, < 100/8

or < 12.5 mm or 12/ 10 mm.

One Directional Slab

Condition 1. A slab resting on two opposite side only

2. If L1 / L > 2 (L1 = Length of Slab and L = Width of Slab)

Two Directional Slab

Condition 1. If Ly / Lx  2 (Ly = Length of Slab and Lx = Width of Slab)

Typical Rebar details of One Directional Slabs
Typical Rebar details of Two Directional Slabs
Stairs
Stairs
Stairs
Stairs
Ductility requirement of Earthquake Resistant Buildings
Seismic Map of India
(IS : 13920 )

These stipulations shall be

adopted strictly in Zone IV and

V. In Zone III, if the structure is

an important building like

hospital, school etc or an

industrial structure or more than

5 storeyed, then also following

1. All 135o Hook or Stirrups, minimum extension shall be 10xd, Minimum 75 mm.

2. For beam, the width to depth ratio shall be more than 0.3

3. Wherever main bars are spliced, stirrups spacing shall not be more than 150 mm (for beam and column both).

4. Minimum diameter of stirrups shall be 6 mm, however if the clear span of beams is more than 5.0m, stirrups shall be 8 mm
minimum.

5. Spacing of stirrups at either end of beam (1000 mm) shall not be less than 100 mm (4 inches).

6. The first stirrups from the joint face shall be placed within 50 mm.

7. Minimum dimension of columns shall not less than 200 mm.

8. If the frame is more than 5.0m c/c or column height more than 4.0 m, minimum dimension shall be 300 mm.

9. In the Beam to Column junction, minimum one tie for column reinforcement is necessary. If it is not possible, then hook type
ties may be provided connecting opposite corners.
 Cutting
Small sizes (upto 16 mm diameters) bars can be cut by
Hacksaw blades. Bigger sizes (> 16 mm) bars can be cut by
any abrasive saw. However, flame cutting with oxy-
acetylene torch shall not be practiced. Upto 25 mm (1 inch)
tolerances are permissible while cutting. Cut lengths shall
be measured on a measuring table, so that flatness and
straightness are also checked during measuring.
 Bending
Bending of rebars shall be done either by improvised means
or by hand operated machines or by power operated bender.

Care shall be taken to ensure that bent bars are remaining at

the same plane. Orthogonality check may also done if
required.
 Fixing
Adequate care shall be taken to prevent displacement of
reinforcement bars during shuttering and concreting. In case of
delay occurring between fixing of reinforcement and concreting,
the positioning of rebars shall be checked before concreting.
Distances between parallel rebars shall be maintained with help
of various shapes of CHAIRS, Spacers or cover blocks etc.
Verticality shall be maintained with help of PLUMB device.
 Binding

Rebars crossing each other shall be secured by mild steel

binding wire of size not less than 0.90 mm, in such a
manner that they will not slip over each other while fixing
and concreting. Bottom of shuttering must be cleared of
any wire waste before concreting.
 Placing
Concrete cover blocks shall be used to ensure proper clear cover and required spacing for
rebars.

Beam – After cleaning and alignment (cross and verticality check) of shuttering, proper
cover blocks shall placed at bottom. For side cover, cover blocks shall be tied with
main rebars (top and bottom) at a interval to avoid displacement during concreting.

Column – Cover blocks shall be tied with main rebars from all four sides in a
staggered fashion.

Slabs – Cover blocks shall be placed at regular interval below the main rebars to
ensure uniform clear cover.
 Storing / Stacking
Rebars should not be left with direct contact with the
ground and should be arranged on wooden sleeper or
blocks. Suitable racking system may also be adopted.
Vertical stacking is permissible where stacking place is
extremely limited.

Certain amount of hard rust is desirable on the rebars.

However, adequate care shall be taken to avoid undue
rusting or loose scaling to take place during the storing.
For longer storing, rebar stacks shall preferably be
sheltered with tarpaulin.
 Safety Measures
Rebar can be sharp and is heavy, and can create sparks when
being cut and cause injury while handling. Following
precautions shall be followed,

 Cordon off the work area and erect appropriate warning signs
as far as practicable.

 Ensure that workers are trained and are competent in the jobs
that they have to do.

 Always wear eye protection, sleeved shirts, long pants, gloves,

and fully covered footwear when handling rebars.
 Bar Bending Schedule
It is a compact summary of reinforcement bars with diagrams,
numbers, sizes etc from which fabrication details can be easily
Bend and Hook Allowance (as per IS 2502 – reaffirmed 1999)
worked out. Size of Rebar Bend Allowance Hook Allowance
(mm) (B) (mm) (H) (mm)
6 75 75
8 75 105
10 75 130
12 75 155
16 95 210
20 120 260
25 150 325
28 170 475
32 190 545
36 215 610
40 240 520
For normal bends upto 12 mm diameter, no deduction is required. Bar diameter from 16 mm onwards, a
BBS - Guidelines
BBS - Guidelines
BBS - Guidelines
BBS - Guidelines
BBS - Guidelines
BBS - Guidelines
BBS - Guidelines

Thumb Rules= 160
Rebars for Column ofkgEstimation
/ m3

Rebars for Slabs = 80 kg / m3

Rebars for Beams = 110 kg / m3

Rebars for Foundations = 70 kg / m3

Rebars for Stairs = 120 kg / m3

Rebars for Sunshade = 50 kg / m3