Reinforcement

Technical Specification: Reinforcement
Technical Specification of Reinforcement
Doc. No: TS 03/___
Revision No.: R0
Revision Date:
Document Release Authorization
Prepared By Verified By Approved By Issued By
Signature Signature Signature Signature
Name Name Name Name

Designation Designation Designation Designation
Sr. No Description By When / Frequency Ref. Clause

1 Reference Standards QA Team Semi Annually 1
2 Material Specification QA Team Semi Annually 2
3 Sampling Plan QA Team Semi Annually 5
4 Acceptance Criteria QA Team Semi Annually 6
Revision No: 00 Date: Page 1 of 18

TABLE OF CONTENTS
1. SCOPE ......................................................................................................................................... 3
2. MATERIAL................................................................................................................................... 3
3. DELIVERY AND STORAGE............................................................................................................ 4
4. PRESERVATION & PROTECTION ................................................................................................. 5
5. SAMPLING PLAN......................................................................................................................... 7
6. ACCEPTANCE & TESTING OF MATERIAL ..................................................................................... 8
7. TOLERANCES & ACCEPTANCE OF THE REINFORCEMENT STEEL (WHILE RECEIVING ON SITE) 12
8. FABRICATION AND PLACEMENT OF REINFORCEMENT: ........................................................... 13
9. SPACER BLOCKS / COVER BLOCKS:........................................................................................... 14
10. SPLICING OF REINFORCEMENT BAR (MANUAL / COUPLER) .................................................... 14
11. APPROVAL OF NEW MANUFACTURER ..................................................................................... 16
12. READYMADE CUT & BEND STEEL (RCBS) ................................................................................. 17
13. MEASUREMENT: ...................................................................................................................... 18

TECHNICAL SPECIFICATION FOR REINFORCEMENT
1. SCOPE
This specification deals with the minimum requirements of materials, quality, preparation of BBS,
cutting, bending & placing. Any special requirements as shown or noted on the drawings shall
supersede over the provisions of this specifications with written approval of Engineer In-charge.
STANDARDS AND CODE OF PRACTICE

Following Indian Standards including all Amendment and latest Revisions form the part of this
Specification. An alternative equivalent National Specifications to suit the situatio n in which
the works are being executed, may be used but only with the written approval of the Engineer in charge
IS 432 Specification for mild steel and (Part I & II) medium tensile steel bars
IS 456 and hard
Code drawnfor
of Practice steel wire
Plain forReinforced
and concrete reinforcement.
Concrete
Specification for hot rolled mild steel and medium tensile steel deformed bars for
IS 1139
Concrete reinforcement.
IS 1200 Methods of measurement of building works
IS 1566 Specification for plain hard drawn steel wire fabric for concrete reinforcement
IS 1786 Specification for High Strength Deformed Steel Bars and Wires for Concrete
IS 2502 Reinforcement
Code of Practice for Bending and Fixing of Bars for Concrete Reinforcement
IS 2750 Specification for steel scaffolding
IS 3696 Safety code for scaffolding and ladders
IS 4014 Code of Practice for steel tubular (Part I & II) Scaffolding
Stacking and storage of Construction materials and Components at site-
IS 4082
Recommendations
IS 16172 Reinforcement Couplers For Mechanical Splices Of Bars In Concrete - Specification
2. MATERIAL
Reinforcement:
Reinforcement shall be of tested quality M.S. round rods conforming to IS: 432,
Wire mesh fabric conforming to IS: 1566,
Mild steel and medium tensile steel deformed bars conforming to IS: 1139 and
Cold twisted steel bars conforming to IS: 1786.
All reinforcement shall be clean, free from grease, oil, paint, loose mill scale, rust, dust, bituminous
material or any other material or substance that will destroy or reduce the bond.
The Binding wire shall be of 18 SWG hot deep G. I. the binding wire shall conform to IS 208 & the G. I.
coating shall conform to IS 4826
Mechanical couplers if used; it shall conform to IS 16172:2014

3. DELIVERY AND STORAGE

Reinforcement shall be stacked off the ground by 200mm minimum in clean conditions and protected
from contamination, rusting and shall not be in contact with soil throughout the length. For stacking
any hard platform or M.S. Stand can be used which ensures no water absorption & keep steel above
the ground level. The reinforcement shall be clean and free from oil, grease, and rust, loose mill scale,
salt and chemical contaminants at the time of receiving, stacking & fixing in position and concreting.
A single rack shall contain only same dia. of steel. Care shall be taken as the FIFO system is also
followed for consumption & steel shall be stacked accordingly.
In-case of shortage of the space; of two dia. can be stacked in same rack however there shall be vertical
separation between two dia. care shall be taken while doing so, the dia. of steel shall be easily visually
identifiable & shall be tagged accordingly.
All the stacked reinforcement steel shall be well identified with diameter of steel and following tags
shall be displayed
Tested and Approved
Tested but Hold
Rejected
Under testing
All the steel consignment shall receive on site along with the MTC (Manufacturer Test Certificate). The
steel shall preferably bear the ISI stamp on it for the acceptance along with the grade of steel
The M. S. Coupler shall have the identification mark on it and shall be received with MTC

4. PRESERVATION & PROTECTION

Prevention of rust staining:
Reinforcement left projecting above a concrete surface shall be cement washed if exposed in such a
way that rust staining of concrete surfaces is likely. Any rust staining of exposed surfaces shall be
cleaned immediately.
Protection & preservation of Reinforcement steel (stacked & installed)
All the reinforcement steel shall be protected against rusting. Rust / scales can be easily identified by
visual inspection. If any rusted reinforcement steel observed, the same shall be kept aside & shall be
stacked separately from other steel. All such steel shall be thoroughly cleaned by wire brush or by
suitable means & all rust shall be removed. The clean steel shall be then washed with fresh water jet
& shall be dried. After cleaning, these steels shall be checked for its unit weight (rolling margin) to
assure the reduction of diameter if any is with in permissible limit of rolling margin. These steels shall
be then applied with antirust polymer or epoxy coating such as Nitocote Polycem of Fosroc or
equivalent product either by brush or spray. These steels shall be consumed at high priority within 2
weeks of application or if stacked well under the shades can be preserved for not more than 3 months.
If the retention time of the stacked steel is more than 3 months, the same steel shall be either re-
coated or shall be epoxy treated. The care shall be taken that the coating is uniform & there are no
pin holes in the coating. The coating shall also be applied at the top & bottom of the steel rod.
The treatment mentioned above same can be used for the installed reinforcement with extra care of
all the vertical reinforcement steel shall be cleaned from rust, washed thoroughly with water jet, dried
& applied 1 to 2 coat of coating as per the manufacturers specification. However, in all cases the steel
shall be protected against fall of any matter or bending (for unintended use or coating shall be done
post bending if it is required to be bent for use). If bending is done & the same is not being cast with
concrete; the entire process shall be redone as the bending might damage the coating (as per the
discretion of Engineer In-Charge)
Epoxy coated steel
Concrete structures in aggressive environment (Marine / Industrial area) are subjected to chloride
attack. In order to protect concrete structures from chloride attack in aggressive environment, it is
necessary that protective coatings are applied to concrete and steel both to prevent ingress of
chlorides. In general, Epoxy coated steel through fusion bonding is preferred (FBECR)
Handling transportation and working:

Fusion Bonded Epoxy Coated Rebar (FBECR) bars are required to be handled with extreme care so that
coating is not damaged during transportation, handling / concreting. Thus, Fusion Bonded Epoxy
Coated Bars require padded contacts during transportation, stacking, handling and till the concreting

is done. The cut ends, welded spots and handling damages are required to be repaired with special
liquid epoxy compatible with the coating material as per specification of the coating agency.
Prior to sending the reinforcement steel for fusion bonding / epoxy coating, the reinforcement steel
shall comply to the minimum set Physical & Chemical requirements as per clause no 6. The proposed
coating shall be tested and shall be approved by Engineer In-charge. The coating material shall comply
to the annexure A of IS 13620 as below (for detailed aspect refer IS 13620)
Chemical Specimens without holidays (Holiday means a pinhole not visible to the unaided
resistance eye)
and specimens with 6 mm diameter intentional holes drilled through the
coating shall be tested. The temperature of the test solution shall be 30 5C.
Minimum test time shall be 45 days. The coating shall not blister, soften, lose
bond, nor develop holidays during this period. The intentionally made holes
shall exhibit no undercutting during the 45-day period.
Type of No film failures as evidenced by evolution of hydrogen gas at the cathode or
accelerated appearance of corrosion products of iron at the anode, shall take place during
corrosion test first hour of testing.
The test shall be continued for 30 days and the elapsed time for development
of the first holiday shall be recorded. No undercutting of the coating shall
occur at any holiday that develops during the test. If no holiday has
developed during the 30 days, single intentional hole 6 mm in diameter shall
be made in both the cathode and the anode. Then the test shall be continued
for an additional 24 h in which time no undercutting shall occur
Adhesion of No cracking of the coating shall be visible to the unaided/naked eye on the
coating outside radius of any of the three bent bars
Bond strength The mean bond strength at the measured slip of 0.025 mm and 0.25 mm for
to concrete coated bars shall not be less than 80 percent of the corresponding mean bond
strength for uncoated bars
Abrasion The resistance of the coating on each of the steel panels to abrasion by a
Resistance Taber abrasor or its equivalent using CS-10 wheels and 1 kg load, shall be
such that the weight loss shall not exceed 100 mg/1 000 cycles
Impact test The test shall be performed at room temperature. With an impact of 9 Nm,
no shuttering, cracking, or bond loss of the coating shall occur except at the
impact area, that is, area permanently deformed by the tup
Hardness test The average of four individual hardness measurements made in the area
between deformations or ribs on at least two coated reinforcing bars shall be
equal to, or shall exceed the Knoop Hardness number of 16
Testing of the Epoxy coated bar:

Post obtaining approval / acceptance of steel rods & epoxy coating material the coating shall be done.
The coating shall be done by expert & professional (pre-approved) agency under all controlled
conditions and facility for testing prior to dispatch of the coated rods. The coated steel shall have
tested for following parameters or shall be tested for following parameters from approved NABL lab;

Coating at least 90 percent of all coating thickness measurements shall be 0.1 mm to 0.3
thickness mm after curing. The coating thickness limits do not apply to patched areas. A
minimum of 15 measurements shall be taken approximately evenly spaced along
each side of the test bar. At least 90 percent of these measurements shall be
within the specified limits.
Continuity The coating shall be visually inspected after curing for continuity of the coating
of Coating and shall be free from holes, voids, contamination, cracks and damaged areas
discernible to the unaided eye. In addition, there shall be not more than an
average of two holidays per 300 mm when tested as A 67.5 volts holiday
detector shall be used in accordance with the detector manufacturers
instructions. The detector may be an in line DC detector or a hand held DC
detector
Adhesion The adhesion of the coating shall be evaluated by bending production coated bars
120 degrees (after rebound) around a mandrel of size as prescribed in Table
below for mandrel dia. The bend test shall be made at a uniform rate and shall
take up to 90 seconds to complete. The two longitudinal deformations shall be
placed in a plane perpendicular to the mandrel radius and the test specimen shall
be at thermal equilibrium between 25C and 35C.
Table below for Mandrel dia.
Bar Dia. Mandrel Dia. Bar Dia. Mandrel Dia.

6 60 25 200
8 80 28 225
10 100 32 280
12 100 36 280
16 125 40 400
18 150 45 450
20 150 50 500
22 200 All Dia. in mm
5. SAMPLING PLAN
Following sampling plan shall be followed for
A. Epoxy coating / chemical material
a. First time use
b. Change of coating agency
c. Change of coating agent
d. After every 6 months or as per the lot (to be assured by the coating agency
B. Epoxy coated steel bar testing
Nominal dia. of Bar, mm No of Sample

Up to 16 1 for every 1 tones
Above 16 and up to 25 1 for every 2 tones
Above 25 1 for every 4 tones
C. Regular reinforcement steel bar testing

For checking nominal mass, Physical properties, bend test and re-bend test, test specimen of
sufficient length shall be cut from each size of the finished bar/wire at random at a frequency
not less than that specified below:

Quantity (for Physical & Chemical Analysis)

For Cast / Heat below 100MT For Cast / Heat 100MT & above
2 to 3 Specimen / Dia. / Heat 3 Specimen / Dia. / Heat
D. Coupler / Mechanical Splices

As per IS 16172 Acceptance & Sampling criteria (each lot shall be tested)
Sr. No No. of Couplers Sample Size (workmanship, Sub Sample size Acceptance of
in the Lot finish & nominal size) (Tensile test) Failure.
Minimum Minimum Maximum
1 Up to 500 50 13 0
2 501 1200 80 20 1
3 1201 3200 125 32 2
4 3201 10000 200 32 2
5 10001 and above 315 50 3
E. Binding Wires
Samples shall be taken from each lot and tested for conformity to the standard
No. of coils in a No. of coils Permissible No. of coils

Lot for Physical Defective for Chemical
requirements requirements
Up to 25 2 0 1
26 50 3 0 1
51 150 5 0 2
151 300 8 1 2
301 and above 13 1 2
6. ACCEPTANCE & TESTING OF MATERIAL

The received materials shall check for
Grade
Name of Manufacturer
MTC with ISI marked license number
After above verification, the steel shall be tested on site for its rolling margin & onsite bend & re-bend
test. After satisfactory testing the steel shall be allowed to unload & the same shall be sent to the third
party lab for testing its physical & chemical properties as per IS 1786 criteria for every heat number &
every dia.
Failure of steel in any test shall be followed by retesting as per the provision of IS 1786 & shall be
necessarily witnessed by vendor, contractor & Engineer In-Charge
Note: the steel rod from which the test specimens were drawn shall be preserved & for witnessed
testing. The sample for retesting shall be drawn from same steel rod
All reinforcement to be used shall be tested for its mechanical and chemical properties from
approved list of third party lab as per sampling plan of IS 1786. Acceptance criteria as per IS
1786 below:

Property Fe 415 Fe 415D Fe 415S

0.2 percent proof stress/ yield stress, Min, N/mm2 415 415 415
0.2 percent proof stress/ yield stress, Max, N/mm2 - - 540
TS/YS ratio1), N/mm2 1.10, but TS 1.12, but TS 1.25
not less than not less than
485.0 N/mm2 500.0 N/mm2
Elongation, percent, min. on gauge length 5.65A, 14.5 18.0 20.0
where A is the cross-sectional area of the test piece
Total elongation at maximum force, percent, Min, on - 5 10
gauge length 5.65A, where A is the cross-sectional
area of the test piece
Property Fe 500 Fe 500D Fe 500S

0.2 percent proof stress/ yield stress, Max, N/mm2 - - 625
TS/YS ratio1), N/mm2 1.08, but TS 1.10, but TS 1.25
not less than not less than
545.0 N/mm2 565.0 N/mm2
Total elongation at maximum force, percent, Min, on - 5 8
Property Fe 550 Fe 550D Fe 600

0.2 percent proof stress/ yield stress, Max, N/mm2 - - -
TS/YS ratio1), N/mm2 1.06, but 1.08, but 1.06, but
TS not less TS not less TS not less
than 585.0 than 600.0 than 660.0
N/mm2 N/mm2 N/mm2
Total elongation at maximum force, percent, Min, on - 5 -
Constituents Maximum %
Fe Fe Fe Fe Fe Fe Fe Fe Fe 600
415 415D 415S 500 500D 500S 550 550D
Carbon 0.30 0.25 0.25 0.30 0.25 0.25 0.30 0.25 0.30
Sulphure 0.060 0.045 0.045 0.55 0.040 0.040 0.055 0.040 0.040
Phosphorus 0.060 0.045 0.045 0.55 0.040 0.040 0.050 0.040 0.040
Sulphure + Phosphorus 0.11 0.085 0.085 0.105 0.075 0.075 0.100 0.075 0.075

Note: the use of tolerance of above limit is solely depends as per IS 1786 criteria of Product Analysis.
The maximum limit of variation is as below:
Constituent Variation over Specified Maximum Limit % Max

Carbon 0.02
Sulphur 0.005
Phosphorus 0.005
Sulphur + Phosphorus 0.010
Bend Re-bend test On site
Dia. of bar Fe Fe Fe Fe Fe Fe Fe Fe Fe
415 415D 415S 500 500D 500S 550 550D 600
Up to including 20mm 3 2 2 4 3 3 5 4 5
Above 20mm 4 3 3 5 4 4 6 5 6
Re Bend
Up to including 10mm 5 4 4 5 4 4 7 6 7
Above 10mm 7 6 6 7 6 6 8 7 8
The Mechanical Splices / couplers shall be tested for ultimate load & tensile stresses as per the
provision in IS 1786 & IS 16172:2014
Coupler
The couplers shall be tested by manual tightening only unless otherwise specified (if tightening torque
is specified for fixing then the same shall be applied)
Every lot of coupler of each dia. & every lot of reducer shall be tested from the third party lab. A lot
size may vary with respect to the manufacturer. Every lot shall be tested
In any case if there is a change of source of the material (Steel, Binding wire & Coupler) third party
test is to be done first prior to approving the source and at the time of receiving the first lot of the
material
All the material shall be issued to site for use only after successful testing & conformance of the test
reports prior to that the material shall be in full custody of stores. Its stores responsibility to ensure
untested, under test, hold & rejected material is not being issued or used by the site & necessary
action shall be taken by the stores in-charge for the action suggested by Engineer In-Charge.
All the testing shall be done from approved NABL accredited third party lab listed in list of Approved
lab at no extra cost.

Binding Wires:
Physical tests:
1. Tensile Strength
Condition Tensile Strength
Finished other than Galvanized (MPa) Galvanized MPa
Annealed 500 Max 300 550
Soft drawn 550 Max -
Hard 450 650 -
Hard 600 800 -
Hard 700 950 550 900
2. Wrapping Test
Wire smaller than 5 mm diameter shall be subjected to wrapping test. The wire shall with
stand without breaking or splitting being wrapped eight times round its own diameter and
subsequently straightened
3. Bend Test
Wire of 5 mm diameter and over shall be subjected to bend test. The wire shall withstand
being bent through an angle of 90round a former of diameter equal to twice its own diameter
without breaking or splitting.
Chemical Properties:
Carbon by Volumetric 0.05 to 2.50 %, Total carbon by gravimetric method (carbon 0.1
percent) & carbon by thermal conductivity method (Carbon 0.005 to 2.000 percent)
Nickel by dimethyl glyoxime (gravimetric) method (Nickel 0.1 percent)
Chromium by persulphate oxidation method (Chromium 0.1 percent)
Molybdenum by -benzoinoxime method (Molybdenum 0.1 percent) & by thiocyanate
(photometric) method in low and high alloy steels (molybdenum up to 0.1 percent)
Silicon by the gravimetric method (Silicon 0.1 percent) & by photometric method in carbon
steels and low alloy steels (Silicon 0.01 to 0.05 percent)
Manganese by periodate spectrophotometric method in low and high alloy steels (Manganese
0.01 to 2.0 percent)
Tungsten by spectrophotometric method (Tungsten O-1 to 2 percent)
Retest
Regular Reinforcement steel bar
If the specimen fails to meet the specified requirements, twice the number of samples originally
selected shall be tested for each failure test (the test sample shall be selected from same rod from
which initial samples were drawn). The re-testing shall be witnessed by the supplier. If the results of
these retests meet the specified requirements of all the specimens, the lot represented by the samples
shall be accepted else rejected
Epoxy coated bar:

If the specimen fails to meet the specified requirements, twice the number of samples originally
selected shall be tested for each failure test. The re-testing shall be witnessed by the vendor (coating
agency). If the results of these retests meet the specified requirements of all the specimens, the
coated bar represented by the samples shall be accepted else rejected or entire lot shall be recoated
or the Engineer In-charge has to take decision with due consultation with involved parties

7. Tolerances & Acceptance of the Reinforcement steel (While receiving on site)
In case of coated or regular reinforcement steel, the acceptance is as specified in the clause no 4 shall
be followed.
Following tolerances are applicable In-case of;
1. Specified length
2. Nominal Mass
Specified Length:
If bars / wires are specified to be cut to certain lengths, each bar / wire shall be cut within deviations
of +75mm & 25mm on the specified length, but if minimum lengths are specified, the deviations shall
be +50mm & 0mm
Nominal Mass (Rolling Margin):

Tolerance in nominal mass is generally termed as a Rolling Margin.
Rolling margin is a ration of (difference between Actual unit weight & Theoretical unit weigh) to
(theoretical unit weight. It is expressed in %
Theoretical Unit weight:

Sr. Nominal Cross Sectional Mass per
No. Size (mm) Area (mm2 ) meter kg (Wthe)
1 4 12.6 0.099
2 5 19.6 0.154
3 6 28.3 0.222
4 8 50.3 0.395
5 10 78.6 0.617
6 12 113.1 0.888
7 16 201.2 1.58
8 20 314.3 2.47
9 25 491.1 3.85
10 28 615.8 4.83
11 32 804.6 6.31
12 36 1018.3 7.99
13 40 1257.2 9.86
Dia. (mm) Tolerance on the Nominal Mass Actual unit weight(Wact) =

Batch Individual Individual (Actual weight/ Actual Length*)
(average of 3 for Coil *The length of test specimen should not
Specimens) only be than 500mm
Up to and 7% 8% 8% Rolling Margin =
including [(Wact) (Wthe)] / (Wthe) %;
10
Over 10 up 5% 6% 6% IF Rolling Margin
to and (Wact) > (Wthe) +ve
including (Wact) < (Wthe) ve
16
Over 16 3% 4% 4%

8. FABRICATION AND PLACEMENT OF REINFORCEMENT:

The Contractor shall develop the Bar Bending Schedule (BBS) for all RCC structures/ structural part at
no extra cost to the client and shall get it reviewed and approved by the Engineer-in-Charge.
The BBS shall be prepared prior to raising Purchase Requisition (PR) as per defined lead period of
organization
No cutting bending shall be done without approved BBS
Reinforcement shall be cut and bent to the desired shape as per dimensions shown in the approved
bar bending schedule in line with the VFC drawings.
The cutting length of bars shall be derived in such a way that the no main steel is been lapped in NO
Lapping Zone as described or depicted in General drawing of Structural Consultants.
All steel reinforcement shall be fabricated and fixed in accordance with IS 2502 detailing, cutting,
bending tying etc. of reinforcement bars. Bars shall be firmly bound together with 18G galvanized
binding wire at all intersections to ensure that the network of rods will retain in its original form and
the cage will be so temporarily supported as to retain its correct position during the process of
concreting. All splices and lengths of overlaps in reinforcement shall be strictly in accordance with the
drawings.
Following are some type of tying the bars
Post tying of the bars, the excess length of the binding wire shall be either cut & the knot shall be ben
inside the core (not in cover zone) while cutting care shall be taken that the cut binding wires shall not
fall in the core or the free legs of binding wire & knots shall be bend inside the core of structure. No
binding wires free legs or knot shall protrude in cover zone in any case.
While placing the reinforcement at the required place care shall be taken that the nominal covers are
provided to all the face / sides of the member.

Generally, at the top of column at several times the column cage gets shifted while concreting & there
are higher chances of uneven cover to the reinforcement at top & hence cover spacer (Cover kanda)
shall be necessarily used at the corner & at the sides (in-case of shear wall). The cover spacer shall be
made as depicted in the sketch below
Its contractors responsibility to define & identify the best possible mode of placing / lowering the
reinforcement steel in desired shape, size & specification as described in Approved BBS & VFC drawing
with complete information to Engineer In-Charge
9. SPACER BLOCKS / COVER BLOCKS:

To maintain the specified amount of cover to the reinforcement, P.V.C. or concrete cover block of
grade equivalent or higher grade as that of structure shall be provided.
Unless specified otherwise, actual concrete cover should not deviate from the required nominal
cover by +10mm (IS 456). The concrete cover should be well cured and should have attained 28 days
strength.
If PVC cover used, third party test reports for strength should be made available for every lot.
For cover to be provided, higher of following:
IS 456 (table no 16, 16A)
Recommendation of geotechnical consultant (for Sub Structure)
Recommendation of structural consultant
All reinforcement shall be provided with proper specified cover. Providing precast concrete
circular disc shaped cover blocks with a hole at the center placed at regular interval (not more than
1000mm C/C) shall provide uniform cover to the structure.
This type of cover shall be put in stirrup / side reinforcement to ensure proper cover to the structure
10. SPLICING OF REINFORCEMENT BAR (MANUAL / COUPLER)

Splicing shall be strictly as per the details furnished to the contractor. Couplers of approved make can
also be used as specified/ approved by Structural Consultant/ Engineer's representative instruction in
official format/ official communication.
For general guidance of Splicing; following principles shall be followed as specified in IS 456.
Splices shall be provided as far as possible away from sections of maximum stress & as per

details furnished
Where more than one half of the bars are lapped at a section or where splices are made at
points of maximum stress, special precautions shall be taken as per the furnished specification
Lap length including anchorage value of hooks in flexural tension shall be Ld (as defined in IS
456) or 50 times dia. whichever is greater.
Mechanical Threaded Couplers:

The couplers shall be attached to the reinforcement bars by forging; hydraulic pressing or screw
couplers in special circumstances may be permitted. All operations relating to reinforcement
coupling shall be done using suppliers patented machine / equipment and in the presence of the
suppliers representative. The contractor shall submit relevant trade literature, Mill certificates,
certificate of origin and letters of approval for each proposed application. A sample of each type of
mechanical coupler shall be submitted for testing and approval prior to the use of any coupler in the
works.
The testing of the couplers shall be done through the NABL accredited lab only
TABLE 1: STEEL DIA. & COUPLER DETAILS

REBAR SIZE BAR OD LENGTH OF COUPLER ENGAGEMENT
16mm 22mm 56mm 22mm
20mm 27mm 71mm 29mm
25mm 35mm 85mm 35mm
28mm 38mm 91mm 38mm
32mm 44mm 96mm 40mm
Sampling and Testing of couplers:
TABLE 2: SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY

No. of Couplers in Sample Size Sub-Sample Acceptance
the Lot Sub-Sample Size Number
(1) (2) (3) (4)
Up to 500 50 13 0
501 to 1200 80 20 1
1201 to 3200 125 32 2
3201 to 10,000 200 32 2
10,001 and above 315 50 3
The couplers shall be selected at random from the lot and in order to ensure the randomness of
selection, random number table shall be used. For guidance and use of random number tables IS
4905 may be referred to.
a. Workmanship and Finish and Nominal Size
The number of couplers given in column 2 of above table 2 shall be taken from the lot and
examined for workmanship, finish and nominal size. A coupler failing to satisfy any of these
requirements shall be considered as defective. If no defective is found in the sample, the lot
shall be considered as conforming to these requirements.

b. Static Tensile Test

The lot having been found conforming to requirements of workmanship, finish and nominal
size shall be tested for static tensile test. For this purpose, sub-samples as given in column 3
of Table 2 shall be taken and subjected to this test. The number of couplers required in the
sub-sample may be taken from those already tested and found satisfactory according to 1.
c. The lot shall be considered to have satisfied the requirement of static tensile test as per 2 if
the number of defective couplers found in the sub-sample is less than or equal to the
corresponding acceptance number given in column 4 of Table 2.
11. APPROVAL OF NEW MANUFACTURER

Type tests are intended to prove the suitability and performance of a new type of coupler or a new
manufacturing process or introduction of new vendor/ plant. Such tests therefore, need to be applied
only when a change is made in the type of the coupler or in manufacturing process/
Conditions or crimping method or forging or threading machine.
1. Slip Test
For this type test, the manufacturer or the supplier shall furnish to the testing
authority a minimum of three samples of coupler of the largest size, three samples of
the medium size and three samples of the smallest size (selected from a regular
production lot).
The samples so selected shall be tested for compliance with requirements of slip test.
The total slip value measured in accordance with the test procedure shall not exceed
0.10 mm
If all the samples pass the requirements of slip test, the type of coupler or the change
under consideration shall be considered to be eligible for type approval which shall
be normally valid for a period of one year.
At the end of the validity period (normally one year) or earlier, if necessary, the testing
authority may call for fresh samples for type test for the purpose of type approval.
2. 100 Cycle Test
production lot).
The samples so selected shall be tested for compliance with requirements of 100 cycle
test. The mechanical splice shall withstand 100 cycles of the stress variation from 5 %
to 90 & of fy (where fy = 550 N/mm2) without loss of static tensile strength capacity

when compared with like specimen. The static tensile strength capacity of the test
piece shall be determined by testing it statically to failure subjecting it to stress cycles.
If all the samples pass the requirements of 100 cycle test, the type of coupler or the
change under consideration shall be considered to be eligible for type approval which
shall be normally valid for a period of two years.
At the end of the validity period (normally two year) or earlier, if necessary, the testing
3. Low Cycle Fatigue Test
production lot).
The samples so selected shall be tested for compliance with requirements of low cycle
fatigue test. The mechanical splice shall withstand 10 000 cycles of alternating tension
and compression load when tested
If all the samples pass the requirements of low cycle fatigue test, the type of coupler
or the change under consideration shall be considered to be eligible for type approval
which shall be normally valid for a period of two year.
At the end of the validity period (normally two year) or earlier, if necessary, the testing
4. High Cycle Fatigue Test (for Class L+H Coupler only)
production lot).
The samples so selected shall be tested for compliance with requirements of high
cycle fatigue test. The mechanical splice, when tested shall withstand 20, 00, 000
cycles of varying axial tensile load with a stress range, 2 a, of 60 N/mm2 without
failure. The upper stress, max , in the test shall be 0.6fy, where fy =550 N/mm2
5. The following acceptance criteria shall be complied with:
o If all the samples pass the requirements of the high cycle fatigue test, the type of the
coupler or the change under consideration shall be considered to be eligible for type
approval which shall be normally valid for a period of two year
o If one test sample fails, the test three additional samples of the same type and size
that have failed shall be tested. If all three additional test samples pass, the test is
passed and the type of the coupler or the change under consideration shall be
considered to be eligible for type approval which shall be normally valid for a period
of two year
o If two or more test samples fail the fatigue test, the test is failed.
At the end of the validity period (normally two year) or earlier, if necessary, the testing authority may
call for fresh samples for type test for the purpose of type approval.
12. READYMADE CUT & BEND STEEL (RCBS)

Readymade cut & bend steel shall be stacked at site as per the shape, dia. location & source. No two
shape, dia. Steel shall be mixed.
The grade of steel shall be conformed for its physical & chemical properties prior to use as per the
sampling plan of the
The ready cut bend steel shall be checked with respect to the approved & shared BBS with the
manufacturer.

The contractor shall prepare the Bar bending Schedule (BBS) as per the latest available VFC Structural
& Architectural layout along with the schedule of steel in accordance to IS 456, General drawing & in
accordance of SP34
All bend allowance & other things shall be considered for the cutting & bending length for steel
The BBS shall be prepared keeping in mind the required time line for cutting & bending at the factory.
Its a contractors responsibility to meet all the set time lines for preparing & submitting the BBS to
the cut & bend steel vendor on time failure to which the delay will be in account of the contractor
(this depends on the scope of work)
The BBS shall be made as per the required format approved by the Engineer Incharge or as per joint
agreement with the cut & bend steel vendor.
If the steel is procured from the same vendor & cutting & bending is also done by same vendor; at the
received of the consignment the steel shall be tested as per the dia.
The RCBS steel vendor shall share the production details to contractor for this regards for testing
All the RBCS shall be stacked well above ground on hard surface ensuring to deformation of bend steel,
no mixing of different grade, shape & size steel with each other. The stacked steel shall be properly
identifiable by dia., shape lot, location & numbers along with received date & challan no.
13. MEASUREMENT:
The mode of measurement shall be as prescribed in Bill Of Quantity (BOQ).
NOTE:
1. In the entire specification wherever it is specified about third party testing, it shall be done
only from NABL accredited Lab which are listed in Kalpatarus List of Approved Laboratories
2. Material / test reports of lab other than the listed lab shall not be considered or accepted
3. In case the listed laboratory does not have the facility of performing particular test then its
contractors responsibility to identify & suggest the laboratory name, Engineer In-Charge can
decide to do testing or not in that lab after deliberate internal discussion & approval with
the Quality team at corporate office

Reinforcement

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Reinforcement

Caricato da

Copyright:

Formati disponibili

Technical Specification: Reinforcement

Technical Specification of Reinforcement

Doc. No: TS 03/___

Document Release Authorization

Prepared By Verified By Approved By Issued By

Signature Signature Signature Signature

Name Name Name Name

Sr. No Description By When / Frequency Ref. Clause

Revision No: 00 Date: Page 1 of 18

Revision No: 00 Date: Page 2 of 18

TECHNICAL SPECIFICATION FOR REINFORCEMENT

STANDARDS AND CODE OF PRACTICE

Mechanical couplers if used; it shall conform to IS 16172:2014

Revision No: 00 Date: Page 3 of 18

3. DELIVERY AND STORAGE

Revision No: 00 Date: Page 4 of 18

4. PRESERVATION & PROTECTION

Protection & preservation of Reinforcement steel (stacked & installed)

Epoxy coated steel

Handling transportation and working:

Revision No: 00 Date: Page 5 of 18

Testing of the Epoxy coated bar:

Revision No: 00 Date: Page 6 of 18

Table below for Mandrel dia.

Bar Dia. Mandrel Dia. Bar Dia. Mandrel Dia.

B. Epoxy coated steel bar testing

Nominal dia. of Bar, mm No of Sample

C. Regular reinforcement steel bar testing

Revision No: 00 Date: Page 7 of 18

Quantity (for Physical & Chemical Analysis)

D. Coupler / Mechanical Splices

No. of coils in a No. of coils Permissible No. of coils

6. ACCEPTANCE & TESTING OF MATERIAL

Revision No: 00 Date: Page 8 of 18

Property Fe 415 Fe 415D Fe 415S

Property Fe 500 Fe 500D Fe 500S

Property Fe 550 Fe 550D Fe 600

Revision No: 00 Date: Page 9 of 18

Constituent Variation over Specified Maximum Limit % Max

Bend Re-bend test On site

Revision No: 00 Date: Page 10 of 18

Epoxy coated bar:

Revision No: 00 Date: Page 11 of 18

7. Tolerances & Acceptance of the Reinforcement steel (While receiving on site)

Nominal Mass (Rolling Margin):

Theoretical Unit weight:

Dia. (mm) Tolerance on the Nominal Mass Actual unit weight(Wact) =

Revision No: 00 Date: Page 12 of 18

8. FABRICATION AND PLACEMENT OF REINFORCEMENT:

Following are some type of tying the bars

Revision No: 00 Date: Page 13 of 18

9. SPACER BLOCKS / COVER BLOCKS:

10. SPLICING OF REINFORCEMENT BAR (MANUAL / COUPLER)

Revision No: 00 Date: Page 14 of 18

Mechanical Threaded Couplers:

TABLE 1: STEEL DIA. & COUPLER DETAILS

Sampling and Testing of couplers:

TABLE 2: SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY

Revision No: 00 Date: Page 15 of 18

b. Static Tensile Test

11. APPROVAL OF NEW MANUFACTURER

Revision No: 00 Date: Page 16 of 18

12. READYMADE CUT & BEND STEEL (RCBS)

Revision No: 00 Date: Page 17 of 18