Good Construction Practices

with
LONG STEEL PRODUCTS

July 26, 2017

 Institute for Steel Development & Growth
(INSDAG)
• Registered as a Society and is a Not for Profit
organisation.
• Promoted by Ministry of Steel and all Major Steel
Producers (SAIL, Tata Steel, RINL, JSW, JSPL and Essar
Steel).
• Members include Producers, Builders, Fabricators,
Architects, Consultants and Individuals.
• Promotion of Steel based construction through
Education, Training, Seminars, Publications, Consultancy.
 INSDAG Activities
 Working on Cost effective Steel Intensive Design
Options
 Revision/Updating of Steel Based Codes & Standards
 Prepare Design Handbook, Manuals & Reports(65+60)
 To Train the Trainers, Students & Professionals (CPD)
 Expert Advisory Service & Increasing Member Base
 Consultancy Service to Demonstrate Concepts
 Networking with Member Organisations
 Marketing Initiatives & Change Mindset
 Skill Development & Rural activities for Steel promotion
 Content
• Quality Control
• BIS Certification
• How to Identify TMT Bars
• Correct Concrete Grade & Covers
• Good Practices during construction with Rebars
• Typical Rebar Detailing
• Seismic Requirement
• Common Detailing errors
• Cutting, Bending, Fixing, Binding, Placing, Storing
– Safety Measures
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 Quality

 Nov 2007 :MOCA– 17 steel products (9 standards withdrawn)

 Feb 2010 :MOCA+MOS—7 standards made mandatory
 Mar 2012 : 9 standards (IS 1993 excluded)
 Sept 2012 :Quality order in force with few relaxations
 BIS Mandatory Quality Certification
• Order : Enforcing quality Standards critical to
Consumers’ health, safety & power distribution
• Very few organizations have availed Certification for
benefit of consumers
• Necessity: Steel products covered with BIS voluntarily
license schemes. Large domestic production and
import of inferior quality of steels are being used in
power, infrastructures etc.
• Required: To plug the defective Imports and to
ensure qualitative compulsion for production,
procurement, stocking and supply of steel products
used for critical application areas
Steel products shall be procured from
Major, Primary and Organized units
 Rebars Usage: Paradox
 Concrete most popular Material Cement
 Concrete = Cement + Steel Only a few manufacturers
 Cement – 100% BIS Marked
Standard Equipments
 Steel --- ??????
Good process control

Steel
 Many Manufacturers

 Many Makeshift units

 Process Control & QA not adequate

 Revealed 46% are not meeting quality requirement

 Mean reasons: High S,P,S+P & low YS etc
 Presence of Excess Phosphorus makes the Steel Brittle
Phase I: 7 Steel Products under Certification
• IS 1785 pt 1 : Plain hard drawn steel wires cold drawn
stress relieved
• IS 1785 Pt 2 : Plain hard drawn steel wires

• IS 6003 : Intended wires for pre stressed concrete

• IS 6006 : Stressed relieved strands for pre stressed

concrete
• IS 13620 :Fusion bonded epoxy coated rebars

• IS 14268 : Seven ply strands for pre stressed

concrete
• IS 277: Galvanised Steel Sheets (Plain & Corrugated)
Phase II : 9 Steel Products under Certification
 IS 2830: Carbon steel cast billet ingots, billets,
blooms and slabs for rerolling into steel into
general structural purposes(314)
 IS 2831: Carbon steel cast billet ingots, billets,
blooms and slabs for rerolling into steel into low
tensile structural purposes(57)
 IS 1786:2008 High strength deformed steel bars
and wires for concrete reinforcement (598)
 IS 2062:2011 Hot Rolled Finished products in
Medium and High Tensile grades(280)
IS 2830 & 2831: Parent grade for rerolling into med &
high tensile structural to get products like IS 2062 & IS 1786
to satisfy composition (C,S,P),CE & mechanical properties.
Phase II : 9 Steel Products under Certification

 IS 2002: Steel plates for pressure vessels use at

intermediate and high temperature including
boilers(7)
 IS 2041: Steel plates for pressure vessels use at
moderate and low temperature(2)
 IS 648 : CRNO-fully processed type electrical
steel sheet and strip(3)
 IS 15391 :CRNO-semi processed type electrical
steel sheet & strip(3)
 IS 3024 : CRGO-Grain oriented electrical steel
sheet and strip(1)
 Challenges & Concerns
Rerolling Mills thru IF route, cannot produce IS:1786 &
IS:2062 both products are have very critical applications.

New codes made : Organizations to manufacture mild

steel for non critical applications as per IS 15911 : 2010
(0.075% P)

Non Critical applications as per IS 15911 : 2010,

Doors & Window frames, window bars, Grills, gates, Hand
Railings, Fencing Posts, Building Hardwares etc
 Steel Products Used for Construction
Non Flat / Longs Flat

Round, Bars ,Wire Rods, Structural– Plates, HR Coil / Strips ,CR , CF,
Light, Med, Heavy Tinplate ,GP/GC/Elect Sheet
TMT Bars and Good Practices with RCC
 Indian Scenario
• Low skill of construction workers.

• Knowledge gap on good construction

practices.

• Sub-optimal quality of construction

materials – lowest structural safety.

• Construction materials – Recognized as

Non-Engineered products.
 Design Issues
• The basic concept of RCC design is Ductile
Design - Ductility refers to a structure’s ability
to undergo large deformation before failure.
• Utilizing ductile behaviour of the structure is
therefore most desirable as this enables the
structure to withstand higher shocks without
collapse.
• Ductile Design can be achieved by Under
Reinforced Section.
 Design Issues

• Shear failure is a brittle type of failure and occurs

without warning.

• Over Reinforced Sections leads to Shear failure.

• In the shear design, reinforcement is restrained

from yielding.
 Detailing Issues
• The cost of Reinforcement in RCC
structures will contribute 15 % to 25%
of cost of project.

• Therefore, the activities to be controlled

are planning, indenting, ordering,
procurement, inventory management,
storage, utilization, measurement,
reconciliation etc.
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
Producers
Type Nomenclature Grades Code Conformity Size Availability Application Qualities
(Major)

High Strength but

Low Elongation,
General Unorganized
Cold Twisted Poor Weldability
CTD Bars or TOR Construction. sectors.
Deformed Fe415 IS 1786 8-36 mm and Poor
Steel Preferably Non Mostly re-
Bars Bendability,
Critical. rollers.
Vulnerable to
corrosion.
Thermo TMT Bars Fe415/500 IS 1786 8-36mm High Rise Buildings, Excellent RINL
Mechanically /550/500D Bridges, General Bendability and
Treated Construction Weldability. High
(Quenched (Critical) Fatigue resistant.
and High Elongation.
Tempered-
QST)

Corrosion CRM Fe415 IS 1786 8-36 mm Coastal, Marine or High Corrosion RINL
Resistant underground resistance
TMT construction. properties.

HSCRM Fe500 IS 1786 8-36 mm Coastal, Marine or High Strength & RINL
underground Corrosion
construction. resistance
properties.
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
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
Common Defects of TMT bars
 Underweight
 Defective Geometry (oversized ribs or
worn out ribs)
 Rolling defects
 Twisting defects
 Production defects from defective raw
materials
 Wrong Chemistry
 Contd….
Identifying TMT bars

 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 14-18%.
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)
Identifying TMT bars
 Concrete Types
Minimum Concrete grade as per IS 456 : 2000 is M20
Clear Covers - For protection against corrosion and fire –
No relation with the main rebar diameter
 Slab = 20 mm
(for 8/10 mm dia main bars 15 mm 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 be provided)
 Foundation = 50 mm
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 rejection.
Corrosion
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.
Do not leave the rebars in the open. Be careful
about the acidic environment. Use tarpaulin sheets
to cover while in storage.
 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 restricted as 1.2 m (4’-0”)
7. Concrete should be thoroughly compacted around the
embedment and corners of formworks by suitable means.
 Importance of Consistency

 The strength of the chain depends on its weakest link.

 Any rebar which has lower strength at any point makes the
whole length weak and makes the structure unstable during
impact/ fatigue loading.
 Good Construction Practices as per Codal Provision

Lapping:

• Lap splices shall necessarily be staggered.

• 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.
Welded Lap Joints
Isolated footing is the most common type of foundation
Foundation stage
Development Length of
Column Rebars in Footing

Longitudinal bars of the column need

to be extended (anchored) for certain
minimum length (called development
length) inside the footing block

Improper/unequal
extension would reduce
overall load carrying
capability.
 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.
 Check at bottom, column main bars are plumb and bent min
300 mm or 24 x D whichever is more or as per drawing.
 Foundation
If the Foundation is not Deep
• If the foundation is not very deep
and is less than about 4 feet beam
at the plinth or ground floor level
may be avoided.
• But please make sure that the
stirrups are closely spaced @
100mm (4 in.).
• This spacing should continue at
least 300 mm (1 2 in.) into the
foundation footing and go up right
up to junction of the column with
the beam at the first floor level.
 Foundation
If the Foundation is Deep
• If the foundation is deep and
then Plinth Beam is a must.

• In this case the stirrup spacing

of @ 100 mm (4 Inch) is
required to go down from the
plinth level up to 300 mm into
the footing. This spacing is
required for 500 mm going
above the plinth also.
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

Lap length in
columns with
1:6 max slope at
splice point.

Alternate Position
Laps shall be 50xD and generally staggered @ 650 mm (14”) c/c
 Columns
For Stilt columns, (columns
not supported by walls on
either side) there must always
be beams at plinth level.
• In this case spacing between
stirrups does not exceed 75
mm (3 in.) throughout the full
height of the column.
• This should not only cover the
height of the stilt column, but
extend additionally for at least
500 mm (2 0 in.), above and
below where the stilt column
ends.
 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

 Intersection of Beams - Bottom Steel:

a) Secondary beams shall be lesser depth,
keeping the beam soffits are at same level.

b) Secondary beam bottom steel should pass OVER the main steel beam bottom
steel.
48
 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
 Chairs for Slab
Chairs shall be designed to take manual and mechanical loads
during slab casting chair is meant to maintain spacing
between two meshes of slab top and bottom.

Chair shall not be touching to shuttering

BEAM – COLUMN JUNCTION

57
 BEAM – COLUMN JUNCTION

Check that main beam bars are passing through column main bar
Chajja
Cantilever Slab
Cantilever BEAM
 Slab Stage
Tying of Rebar Mesh

Rebars in slab cage should preferably be tied at every meeting point of

the rebars. This will help in increasing the strength of the cage.

While concreting rebars should not move out/in.

 Some Facts

 58.6% of total land area vulnerable to

EARTHQUAKE
 8.5% of total land vulnerable to
CYCLONE
 5% of total land vulnerable to FLOODS
 Ductility requirement of Earthquake Resistant Buildings
(IS : 13920 )
Seismic Map of India

These stipulations
shall be adopted
strictly in Zone III,
IV and V.
 Uttarpradesh Districts– Seismic Zone
ZONE II ZONE III ZONE IV
Lalitpur, Sonbhadra, Chandauli, Ghazipur, Saharanpur, Muzaffarnagar,
Jbansi, Varanasi, Jaunpur, Azamgarh, 11 Baghpat, Bijnor, Meerut,
Mahoba,
Jalaun, Gorakhpur, Sultanpur, Raebareli, Ghaziabad, Gautambuddh
Banda, Faizabad, Unnao, Lucknow, Nagar, JP Nagar, Rampur,
Kausambi, Barabanki, Sitapur, Hardoi, Moradabad, Bulandshar,
Allahabad andKannauj, Mainpuri, Firozabad, Shravasti, Balrampur,
parts of Agra, Siddharthnagar,
Etah, Mahamayanagar,
Etawah, Maharajganj, Kushinagar,
Auraiya, Farukkabad, and parts of
and parts of Pilibhit,
Fatehpur, Mirzapur, Pratapgarh,
Shajahanpur, Kheri,
Pratapgarh, Kanpurnagar, Auraiya, Etawah,
and Mirzapur Agra, Mathura, Aligarh, Badaun, Baharaich, Gonda, Mathura,
Aligarh, Budaun, Bareilly,
Bareilly, Pilibhit, Kheri, Baharaich,
Basti, Sant Kabir Nagar,
Gonda, Basti, Sant Kabir Nagar, Deoria and Ballia
part of Deoria and Ballia.

65
1. All 135o Hook or Stirrups, minimum extension shall be 6xd,
Minimum 65 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).
67
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.

68
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.

69
70
Column Failure during Earthquake at Imphal,
Manipur – Jan 4, 2016

71
SOME COMMON STEEL
DETAILING ERRORS
 Cutting

Small sizes (upto 16 mm diameters) bars can be cut by

Hacksaw blades or Chop saw machine. 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.

Use cut pieces/scraps for chairs. Avoid using full length

bars for making chairs.
 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. Ensure
inspection of reinforcement fixing intermittently to avoid
redoing.
 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 of minimum 150 mm (6”) above ground. 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.

Issue reinforcement on FISRT-IN-FIRST-OUT BASIS to

minimize oxidation loss.
Reinforcement Steel Stockyard
BAD HANDLING OF
REINFORCEMENT
BARS
BAD HANDLING OF STOCKYARD
THREADED END COVERED WITH PLASTIC CAPS
88
 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.
Preparation of BBS and Record of Consumption
• Prepare bar bending schedule from approved,
latest revised drawings only.
• Plan intelligent cutting from full length bars by
preparing cutting length.
• Cutting length shall be worked out after considering
bend effect.
• Keep painted specimen bars for comparison with
production.
• Use cut pieces for ancillary works and record
consumption.
 Thumb Rules of Estimation

Rebars for Column = 160 kg / m3

Rebars for Slabs = 80 kg / m3

Rebars for Beams = 120 kg / m3

Rebars for Foundations = 60 kg / m3

Rebars for Stairs = 120 kg / m3

Rebars for Lintels and Chajja= 50 kg / m3

 Summary
• Definition & Responsibilities
• Need for BIS Certification
• Identification of TMT Bars
• Concrete Grade & Covers
• Good Practices with Lap, Foundation, Column, Beam,
Slabs, Stair
• Typical Rebar Detailing – Beam/column junction,
Chajja, Cantilever Beam & Slab
• Seismic Requirement – Stirrups, Laps, Beam-Column
Junction
• Common Detailing errors
• Cutting, Bending, Fixing, Binding, Placing, Storing
92
Thank You

NIBEDITA DEY
ins.steel @gmail.com

Institute for Steel Development & Growth

ISPAT PRAGATI BHAWAN
793, Anandapur
Kolkata-700 107