Corrosion resistant TMT bars and which one to choose?

13-Jun-2016 06:37 am 0

Silver steel turns brown if left unhindered in the atmosphere is something every one of us has seen,
somewhere or the other. The hindrance to this corrosion is concrete. Concrete creates an optimum
pH range around the steel which protects the steel from corrosion. But still they corrode mainly in
marine and coastal environment and the corrosion of steel bars inside concrete is especially
problematic as rust has a higher volume than steel. This results in cracking and even breaking of the
concrete from the surface.
Corrosion happens mainly when the water leaches down the surface and either it reacts with acidic
gases like CO2 or SO2, or the high amount of chloride admixes.
Which TMT is appropriate for your project?

Structure type

Environmen
t

Super-structure

Structures to retain water

(like tanks)

Exposure conditions

TMT ba

Mild

Aggressive conditions, except

those situated in coastal area.

TMT +

Moderate

Surfaces sheltered from severe

rain but remains wet
except water with marine salts.

TMT +
CRS or

Severe

Concrete surfaces exposed to severe

rain or Completely immersed in seawater
or coastal environment

CRS(al
FBEC(B

Extreme

Surfaces exposed to Corrosive fumes, liquid or

solid aggressive chemicals

CRS

Zinc Co

FBEC rebars(Fusion bonded epoxy coating)-An epoxy powder is first clung by electrostatic charges
with a hot bar. The powder melts covers and then cools to produce a well-adhered continuous
protective coating. This layer provides protection to rebar against corrosion. It is very useful for the
protection against chloride ion.

CRS (Corrosion resistance steel) rebars Elements like Copper, Chromium & Phosphorus are
blended while making the bar itself. They are the most useful rebars we have for protection against
severe environmental condition for superstructures. A Cu-Cr TMT rebar is 1.5 to 1.9 times more
corrosion resistant than a normal TMT. Each element helps to prevent the corrosion in its own way

For rust to develop there must be pores. Copper plugs pores in rust and stops it from further
growth.
Phosphorus acts as an inhibitor for the reaction that form rust.
Chromium content has improved resistance against the hollow surfaces that are created by
the formation of rust.

SAIL (HCR) and TATA steel (TISCON CRS) are some of the examples of CRS rebars.
Zinc coated TMT bars-Zinc is deposited on a rebar by galvanization (deposition of zincs layer on a
metal body by ion transfer). Coating firstly acts as a physical barrier between the source of corrosion
and rebar. Even if the layer breaks, the zinc atoms around that place dissolute to protect the bar
even further. The advantage of using Zinc coated bars is that flexibility is not lost during this process
and bars can be easily bent or can handle roughly. SRMB Srijan Ltd. makes SRMB AZAR which is a
zinc coated rebar.
TMT Re-bars + Corrosion Inhibiting Admixture It can be used in the substructures when the soil
conditions are normal and free from excess chloride and sulphates. It can be used with concrete in
the superstructures in a mild environment in all except those situated in coastal areas with heavy
and continuous rains and snow. A Bipolar Concrete Penetrating Corrosion Inhibiting Admixture is
added in concrete as well. It doesnt act as a barrier but slows down the corrosion process to a
unnoticeable standstill. It need not be in direct contact with the steel. Its vapour move in the
concrete microstructures and stops corrosion at a microlevel.

A detailed introduction to TMT bars

11-Jun-2016 10:23 am 0

TMT bars are used by many construction firms on a daily basis. Many builders and developers
now buy TMT bars online, which is making their job easier. In this article, you will get fundamental
truths regarding the manufacturing of TMT bars, what functions do each element in the composition
serve and some of the current researches that are going regarding TMT and cost-cutting.
The Thermo-Mechanical Treatment
A low-cost low-carbon steel bar is heated to 1200 degree, then it is kept in a quenching (rapid
cooling) box. The upper layers start crystallising and shrinking. The shrinking of the upper layer
creates optimum pressure in the hot inner layers for formation of correct crystals. A microprocessor
maintains the temperature gradient across layers by controlling the water supply to the quenching
box.

It is then taken out of the box and allowed to cool slowly. This creates a boundary between hard and
tensile outer layer and tough, refined & ductile inner layers. At the boundary, there is an intermediate
layer which contains the properties of both the inner and outer layer. If the cooling and the pressure
changes are not regulated it leads to the formation of weak areas.
As there is no need for twisting to further harden the rebar, torsional defects are absent in TMT bars.

Purpose that each element serves

The International Standardisation Organisation(ISO) has limited the maximum weight percentage of
carbon, sulphur, phosphorus and if sulphur and phosphorus both are present for gradation of TMT
bars under Fe415, Fe415D etc. i.e. if a bar meets these percentages and the yield strength and
elongation requirements, it is allowed to be called the respective grade. The presence of each
element has advantages and disadvantages.
Maximum concentration in percentage of total weight allowed in TMT bars by ISO for
gradation
Search:

Constituent

Fe415

Fe415D

Fe500

Fe500D

Fe550

Fe

Carbon

0.30

0.25

0.30

0.25

0.30

0.2

Sulphur

0.060

0.045

0.055

0.040

0.055

0.0

Phosphorus

0.060

0.045

0.055

0.040

0.050

0.0

Sulphur and Phosphorus

0.110

0.085

0.105

0.075

0.100

0.0

Showing 1 to 4 of 4 entries
Carbon- The tensile strength increases, but ductility reduces. Hence, ISO has selected an optimum
level above which the strength is not required for most cases.
Sulphur- Its presence is considered as an impurity as it increases the brittleness of the rebar.
Phosphorus- It increases the strength but decreases the ductility faster than the carbon, hence it is
also considered an impurity.
Chromium- It increases the weldability and corrosion resistance. ISO doesnt limit its concentration, it
being costly does.
Copper- Increases the strength and the corrosion resistance. Its limit is not specified by ISO.
Though ISO hasnt limited copper, manganese and chromium concentrations but as their effect on
ductility is similar to carbon their carbon equivalents are calculated. The value carbon equivalent is
limited by the ISO.
Current research
Taking inspiration from the Iron Pillar of Delhi, which is standing from 1600 years without any
corrosion, a study from IIT Kanpur has concluded that it is due to the presence of phosphorus which
leads to the formation of a protective passive film on the surface. This layer has exceptional
corrosion resistance abilities. However, phosphorus leads to brittleness and thus, is limited by
current standards. But the study concludes that phosphorus can be blended in such ways to at least
match the corrosion resistance offered by chromium. An added advantage of using phosphorus
would be the reduction in the price of rebars.
Another study in International Journal of Engineering Research & Technology (IJERT) related to cost
savings during the bending process of TMT bars, concludes that using the machine while bending
TMT bars can save costs 28% less than bending manually. For an average sized company, the
machine and cost of installation can be recovered within four to five months. The bending is also
more uniform and quicker.

I-Beam and H-Beam Whats the difference?

10-Jun-2016 13:50 pm 0

Known in India as I-beams and H beams but also commonly referred to as universal beams. These
beams are named after the I and H-shaped look of their cross section. The vertical middle section of
the beam is called web and the horizontal section is known as flange.

These beams are designed to hold a lot of weight. Beams are used as an element in framing floors,
and they can also be used with joists and beams wherever extra load bearing capacity is needed.
But whats the difference between an H-beam and an I-Beam? The two beams look similar but used
for different parts of the construction and different types of construction.
Flanges of Beams
Both the beams have top and bottom flanges, the only difference is on an H-beam the flanges stick
out farther from the web. On an I-beam, the flanges are shorter and not so wide. The distance from
the end of the flange to the web is comparatively shorter.
Spans
For longer spans, H-beams are much useful than I-beams because they can be fabricated to any
size. H-beams can be used for spans up to 330 feet whereas, I-beams are suitable for spans of 33
feet to 100 feet.
Fabrication of I & H Beams

The fabrication processes used is another difference between these two beams. I-beams are made
by milling and rolling steel, and they are limited by the capacity of the milling equipment, which is the
reason why I-beams have smaller flanges. H-beam can be built up to any size or height.
However, it is crucial to use the optimal beam for the application. The thickness of the web is very
important since it takes all the pressure.

steel reinforcement for home builders

1. What is steel reinforcement? Why is it required in a concrete structure?
Concrete is a material that is very strong in compression, but weak in tension. To compensate for this
imbalance in a concrete slab behavior, steel reinforcement bar is cast into it to carry the tensile loads. The
surface of the reinforcement bar may be patterned to form a better bond with the concrete. Steel should
necessarily be strong in tension and, at the same time, be ductile enough to be shaped or bent. Steel
rebar is most commonly used as a tensioning devise to reinforce concrete to help hold the concrete in a
compressed state.

The aim of the reinforced concrete designer is to combine the reinforcement with the concrete in such a
manner that sufficient of the relatively expensive reinforcement is incorporated to resist tensile and shear
forces, whilst utilizing the comparatively inexpensive concrete to resist the compressive forces.
To achieve this aim, the designer needs to determine, not only the amount of reinforcement to be used,
but how it is to be distributed and where it is to be positioned. These decisions of the designer are critical
to the successful performance of reinforced concrete and it is imperative that, during construction,
reinforcement be positioned exactly as specified by the designer.
Steel rebars can take both tensile as well as compressive loads. Steel & concrete have got similar
temperature coefficients, making them expand/contract together and help the bonding.
The welding of reinforcement is generally not permitted for high tensile steel, since heating of hot rolled
bars causes brittle fracture in the reinforcement. In the case of cold worked deformed (CTD) steel bars,
heating causes the reinforcement to revert to mild steel as it loses the effects of strain hardening. Welding
is normally permitted on mild steel and in some cases quenched and self tempered steel rebars.
2. What are the different grades of reinforcement steel available?

Mild steel bars conforming to IS: 432 (Part I) and Cold-worked steel high strength deformed bars
conforming to IS: 1786 (grade Fe 415 and grade Fe 500, where 415 and 500 indicate yield
stresses 415 N/mm2 and 500 N/mm2 respectively) are commonly used. Grade Fe 415 is being
used most commonly nowadays. This has limited the use of plain mild steel bars because of
higher yield stress and bond strength resulting in saving of steel quantity.
Fe 500 D, Fe 550D (where D denotes ductile) and Fe600 grade in normal, EQR (Earthquake
Resistant) & CRS (Corrosion Resistant) quality.
What is TMT bar? What is the difference between TMT, Tempcore and Thermex
reinforcement bars?
Thermo Mechanical Processing, also known as Thermo-Mechanical Treatment (TMT), is a
metallurgical process that integrates work hardening and heat treatment into a single process.
Thermex and Tempcore are both reputed trade names registered by the two major providers of
TMT technology. When properly operated both Thermex and Tempcore can produce good
quality TMT rebars. Both are highly complex technologies involving specialized computerized
equipments to control and produce desired grade and quality of steel.
Manufacture of high strength reinforcing steel is usually carried out through one of three
alternative process routes:
1. Hot rolling after micro-alloying
2. Hot rolling followed by cold work and
3. Hot rolling followed by heat treatment (TMT).
3.

The TMT process is actually a heat treatment imparted to steel on-line just after rolling.
4.

What are the different sizes of TMT available?

Normally TMT is available in 6-50 (mm) (6,8,10,12,16,20,25,28,32,36,40,45,50), where 6-12 mm is
available in coil as well as straight form .Cold-worked steel high strength deformed bars start from 8 mm
diameter. For general house constructions, bars of diameter 6 to 20 mm are used.
5. Quality factors to be cheked during purchase of steel reinforcement:
Weight/unit length: TMT Rebars should have standard weights, lengths as mentioned in

the standards (IS 1786).

Bond Strength: TMT Rebars should have uniform and precise parallel rib pattern, which
ensures excellent bonding with concrete, and provides superior strength to the buildings.

Dimensions: Rebars should have close dimensional tolerance and superior surface finish,
Bendability: Rebars must have high elongation so that they are capable of absorbing large
amount of energy by plastic deformation before undergoing failure by fracture. This
facilitates easy bending, making work easier and faster at construction sites.

Weld-ability: TMT Rebars should have low carbon equivalent which is directly related to
hydrogen induced cold cracking (the most common weld defect for steel). Higher
concentration of carbon and other alloying element tend to increase hardness and
decrease weld-ability. TMT process can produce the desired yield strength with steel of
relatively lower carbon equivalent by adjusting the on-line heat treatment parameters. Low
level of carbon content leading to excellent weldability.

Corrosion Resistant: TMT Rebars should have minimum or negligible residual stresses in
order to prevent any chance of rusting.
Earthquake Resistance: TMT Rebars having high UTS/YS ratio signifies that steel is
capable of elongating to a large extent when loaded beyond yield point as in the situation
of an earthquake. It is with this view that some of the international specifications stipulate
fairly high values for the UTS / YS ratio
Durability & Strength: TMT Rebars should have very low level of Sulphur (S) and
Phosphorous (P) as they reduce the strength of the material and make them brittle. Excess
level of S can lead to hot shortness wherein the melting point of steel gets lowered, thus

making steel more prone to failure under extreme high temperature conditions. Excess
level of P can lead to cold shortness wherein the steel undergoes brittle fracture while
working in extremely cold condition and thus becomes more prone to cracking.
Cost Savings: TMT Rebars having high UTS/YS ratio and high elongation results in
lesser consumption of the similar TMT of the same sectional properties but with low
UTS/YS ratio and lesser elongation. Usually TMT with high strength saves about 1012% steel than corresponding lesser strength TMT.
Manufacturing technology: TMT Rebars should be produced using the superior and clean
steel billets with highly controlled steel chemistry with very low levels of sulphur and
phosphorus (less than 0.035% Lower the level of sulphur and phosphorous, more is the
strength of steel.), and very low levels of inclusion and tramp elements. To ensure this
Check the manufacturers website to identify manufacturing process.
Steel test certificates are issued from NABL (National Accreditation Board of
Laboratories) certified Laboratory.

Physical properties of various grades of steel reinforcement

Chemical properties of various grades of steel reinforcement

6. Corrosion resistant (CRS) Rebars:
Steel reinforcement bar corrosion is a particular problem where the concrete is exposed to salt water.
Uncoated, corrosion resistant low carbon chromium alloyed, epoxy coated, galvanized or stainless steel
rebars can be used in this situation at greater initial cost, but at significantly lower cost over the service
life. Extra care is taken during the transport, fabrication, handling, installation, and concrete placement
process when working with epoxy coated rebar, because damage reduces the long term corrosion
resistance of these rebars

Advantages of using CRS rebars:

Longer Life, suited for coastal environment.
High yield strength coupled with good ductility and bendability.
No extra precaution required in material handling and transportation.
No maintenance required during fabrication.
More suitable under poor workmanship conditions at site.
No extra precaution during welding.
Can be bent and re-bent around very small mandrels.
Can be used as a reinforcement material in the seismic zones.
7. What is the checklist for steel reinforcement before the placement/pour of
concrete?
Steel bars are clear, free from loose mil scales, dust and loose rust ,coats of paints, oil or
other coatings which may destroy or reduce bond strength.
Steel bars should be stored in such a way as to prevent corrosion.

Steel bars should not be clean by oily substance to remove the rust.
The bar is bent correctly and accurately to the size and shape as shown in drawings.

If possible, bar of full length is used.

Overlapping bars do not touch each other and these should be kept apart with concrete.
The overlap if given should be staggered.
The cranks in the bar at the end should be kept in position by using spots.
The steel bars should not be disturbed while lying cements concrete,
Reinforcements shall be placed and tied such that concrete placement is possible
Without segregation, and compaction possible by an immersion vibrator.
Required cover under steel bars should be given before laying the cement concrete

8. Why cover blocks are required to be placed before concreting? What are
their sizes?
Cover blocks are placed to prevent the steel rods from getting exposed to the atmosphere, and to place
and fix the reinforcements as per the design drawings. Once the steel is exposed to the atmosphere,
corrosion starts. Sometimes it is commonly seen that the cover gets misplaced during the concreting
activity. To prevent this, tying of cover with steel bars using thin steel wires called binding wires (projected
from cover surface and placed during making or casting of cover blocks) is recommended. Covers should
be made of cement sand mortar (1:3). Ideally, cover should have strength similar to the surrounding
concrete, with the least perimeter so that chances of water to penetrate through periphery will be
minimized. Provision of minimum covers as per the Indian standards for durability of the whole structure
should be ensured.

Cover block supporting steel

Shape of the cover blocks could be cubical or cylindrical. However, cover indicates thickness of the cover
block. Normally, cubical cover blocks are used. As a thumb rule, minimum cover of 2" in footings, 1.5" in
columns and 1" for other structures may be ensured.
Cover has the most significant effect on the long term durability of reinforced concrete and therefore of
the structure. Excess cover should be avoided as micro cracking due to bending stress can result in the
growth and development of cracks and resulting corrosion of reinforcement or member loss due to
spalling. The correct cover is required to ensure that reinforced concrete members meet their specified
design requirements.

Lack of cover on parapet anchors/starter bars results in loss of durability, pop outs and corrosion of steel
reinforcement bars.

9. How important are transverse reinforcements like links and stirrups? What
precautions should be taken while tying them?
Transverse reinforcements are very important. They not only take care of structural requirements but also
help main reinforcements to remain in desired position. They play a very significant role while abrupt
changes or reversal of stresses like earthquake etc.
They should be closely spaced as per the drawing and properly tied to the main/longitudinal
reinforcement.

10. What is a lap or development length? Where and how should they be
provided?
Lap length is the length overlap of bars tied to extend the reinforcement length.. Lap length about 50
times the diameter of the bar is considered safe. Laps of neighboring bar lengths should be staggered

and should not be provided at one level/line. At one cross section, a maximum of 50% bars should be
lapped.
In case, required lap length is not available at junction because of space and other constraints, bars can
be joined with couplers or welded (with correct choice of method of welding).

11. What is anchorage length?

This is the additional length of steel of one structure required to be inserted in other at the junction. For
example, main bars of beam in column at beam column junction, column bars in footing etc. The length
requirement is similar to the lap length mentioned in previous question or as per the design instructions.

12. For a given diameter, how do we calculate the weight of steel per meter
length of the steel bar and vice versa?
For any steel reinforcement bar, weight per running meter is equal to d 2/162 Kg, where
d is diameter of the bar in mm. For example, 10 mm diameter bar will weigh
(10x10)/162 = 0.617 Kg/m
13. What is the Stress-Strain curve? what is the importance of YS, UTS and
Percentage Elongation?

Stress-strain curve is an extremely important graphical measure of the materials mechanical properties
Yield stress: Is the stress a material can withstand without permanent deformation, Yield strength is
usually stated as the stress at which a permanent deformation of 0.2% of the original dimension will
result, known as the 0.2% yield stress.
OR
The stress at which a non-proportional elongation equals to 0.2 % of the original gauge length takes place
(where gauge length is 5.65sqrt A. where A is the cross sectional area of the test piece).
Ultimate Tensile Strength: The maximum stress a material can withstand in a tensile test.
OR
The maximum load (force) reached in a tensile test divided by the effective cross sectional area of gauge
length portion of the test piece.
Percentage Elongation: When a material is tested for tensile strength it elongates a certain amount
before fracture takes place. The two pieces are placed together and the amount of extension is measured
against marks made before starting the test which is expressed as a percentage of the original gauge
length.
contact rabishnair@yahoo.co.in