Estimating reinforcing bars

How the bid price is determined

BY WILLIAM C. BLACK
CHIEF ENGINEER
REINFORCING BARS, PILING AND CONSTRUCTION
SPECIALTY SALES
BETHLEHEM STEEL CORPORATION

uppliers of reinforcing bars usually provide cer-

S tain added services in addition to furnishing

fabricated reinforcing bars to the job site. One
important function is estimating. This is per-
formed by estimator specialists who study a set of con-
tract drawings and specifications and, from their
FABRICATED DEFORMED CONCRETE
REINFORCING BARS

Area
SIZE EXTRAS

Weight Extra per

knowledge of construction and reinforcing bars, are Bar size sq. in. lb per ft 100 lb
able to develop a list of quantities of material which #18 4.00 13.600 $ 2.00
they believe or “estimate” are required to build the #14 2.25 7.650 2.00
structure under consideration. From this information #11 1.56 5.313 1.00
the necessary pricing is developed so that a bid can be
#10 1.27 4.303 1.00
submitted to the general contractor. In a few metropol-
#9 1.00 3.400 1.00
itan areas this estimating service is provided by esti-
#8 0.79 2.670 1.00
mating bureaus which contract with a number of rein-
forcing bar supplier clients and prorate the cost of the #7 0.60 2.044 1.00
service among the various users. #6 0.44 1.502 1.25
It is important that the contract drawings and specifi- #5 0.31 1.043 1.50
cations give complete detailed information about the re- #4 0.20 0.668 2.00
inforcing bars. The estimate is a line-by-line takeoff and #3 0.11 0.376 6.00
complete details will usually insure a more accurate es- # 2* 0.05 0.167 15.00
timate. When the estimator has to guess and make as-
sumptions, the quality of the estimate may be impaired. QUANTITY EXTRAS
A prudent estimator will tend to figure quantities on the
Extra per
safe side when there is a question of what is actually re- Quantity 100 lb
quired. This, of course, can increase the amount of the
material quotation. The estimator’s other alternative is Over 300 tons None
to contact the architect or engineer and attempt to clar- 100-300 tons $0.25
ify that which is not clear. This can be a very frustrating 50-99 tons 0.50
experience as answers are not always forthcoming. The 20-49 tons 0.75
estimator usually works under a tight deadline and must Under 20 tons** 1.25
move forward and complete the estimate. Of course the
bid can be qualified and limited to the assumptions
made, but this can lead to having the bid rejected as be- the current published size extras for fabricated bars
ing nonresponsive. from a major rebar fabricator. Note that the size extra for
#3 bars is $4.00 per hundred pounds or $80 per ton more
EXTRAS ADDED TO BASE PRICE than for #4 bars. This shows that it is generally more eco-
One aspect of preparing quantity estimates for fabri- nomical to specify #4 rather than #3 bars for approxi-
cated reinforcing bars is the way in which charges for ex- mately equal areas of steel. Similar comparisons could
tras (per hundredweight of material) may be added to be made for other sizes.
the base price. The principal extras are for size, grade, Quantity: Extra charges may be incurred depending
bending and quantity. on the total weight of steel ordered. The table also shows
Si ze : Extras for size may vary; therefore it is necessary the current quantity extras for fabricated re i n f o rc i n g
for the estimator to segregate by size. The table shows bars from the same fabricator whose size extras are giv-
en. This shows that there may be a job size penalty in 23 jobs—showed class of splice, per
breaking down smaller structures at bidding time for ACI 318.
separate acceptance.
Grade: Some grades of bars have an extra, making it 24 jobs—gave a table of splice lengths
necessary for the estimator to segregate by grade as well (inches), generally conform-
as size. ing to ACI 318, but not
Bending: Extra charges are applied for all shop bend- always.
ing. The estimator must segregate the total quantity of
bending into three classes as follows, based on current 10 jobs—merely referenced ACI 318 or
industry definitions: CRSI Manual of Standard
Practice (or silent).
• LIGHT BENDING—All #3 bars, all stirrups and ties, and
all bars #4 through #18 which are bent at more than six 14 jobs—had miscellaneous other
points in one plane, or bars which are bent in more combinations.
than one plane (unless “special bending”). Also includ-
ed are all one-plane radius bending with more than One of our conclusions is that some of the odd com-
one radius in any bar (three maximum), and any com- binations are due to different designers working on the
bination of radius and other type bending in one plane same contract.
(radius bending being defined as all bends having a ra-
dius of 12 inches or more to inside of bar).
* Standard tolerances are given in the Manual of Standard Practice published
• HEAVY BENDING—Bar sizes #4 through #18, which are by Concrete Reinforcing Steel Institute, 180 N. LaSalle Street, Chicago, Illi-
bent at not more than six points in one plane (unless nois 60601.

classified as light bending or special bending) and sin-

gle-radius bending.

• SPECIAL BENDING—All bending to tolerances more

restrictive than those shown in industry standards, all
radius bending in more than one plane, all multiple
plane bending containing one or more radius bends,
and all bending for precast units.*

Typical extra charges may be of the order of $4.00 per

hundred pounds for light bending and $1.75 per hun-
dred pounds for heavy bending. Since light bending
costs $2.25 per hundred pounds ($45.00 per ton) more
than heavy bending, it is more economical to specify,
for example, #4 bent bars rather than #3 where total re-
quired areas are approximately equal. Multiple bends
such as continuous truss bars in bridge deck slabs are
more costly per hundred pounds since they usually have
more than six bends per bar and come under the “light
bending” extra. Figure 1. Using contract drawing information (top) the
estimator visualizes how the detailer would handle the bars
LAP SPLICES (bottom) before he can estimate quantities. See Figure 2
for a much better way for the designer to treat this corner.
Ideally, the length and location of all lap splices should
be shown in the contract documents. Unfortunately, this
is seldom the case in the real world. Recently we sur-
veyed 139 jobs currently being serviced around the con-
tinental United States. The results indicated that splice Figure 2. Preferred
way of showing wall
information was given in the following ways:
corner in Figure 1.
Overall cost of
46 jobs—indicated splice lengths in horizontal wall
bar diameters, generally 24, reinforcement is
36 or 40. reduced because only
the bent corner bar is
22 jobs—provided splice dimensions charged the heavy
on plans, sections, or details. bending extra.
Splice location
The estimator must first determine the location of all
splices so as to calculate the total quantity required. This
is fairly straightforward for columns where the typical
detail may show a splice at each floor level. It is not so
obvious for elements such as walls with long runs of hor-
izontal bars. The estimator has a double problem here:
(1) he needs to determine the quantity of splices re-
quired in each run of bars; and (2) he also must make a
judgement decision as to how many feet of the run will
be estimated as bent and how many as straight.
An example is shown in Figure l. The contract draw-
ings show a wall cross section and indicate “#5 at 12 hor-
izontal both faces.” The outside face bars are bent
around each corner and extended 2 feet 2 inches. The in-
side face bars extend in straight. The estimator must vi-
sualize how the detailer would actually handle it. In this
example the estimator has assumed three bars per run in
30-foot stock lengths, plus a bent bar at each end for the
outside bars. This approach minimizes the weight of
bent bar required, and therefore the quoted price of the
material, without adding extra splices. A far better and
more economical solution would be for the designer to
show separate corner bars 2 feet 2 inches on a side (Fig-
ure 2). The estimator would then figure the inside and
outside horizontal bars in an identical manner, as
straight bars. The only bars that would require the heavy
bending extra would be the bent corner bars, thereby re-
ducing the overall cost of the horizontal wall reinforce-
ment. The inside face bars would probably be figured as
a run of four bars, each approximately 30 feet long, with
three splices. It is important to recognize that the stan-
dard industry method of pricing bending is on a hun-
dredweight basis. Placing a bend at the end of a longer
bar causes the bending extra to be applied to the entire
weight of the bar.
Fabrication, transportation and construction limita-
tions should have been considered by the designer when
determining permissible splice locations (or prohibition
of splices). The estimator is not in a position to make
these decisions.
Length of lap
Once the estimator has determined where the splice
is, he must determine its length. If the splice lengths are
specified as a certain number of bar diameters for all
splices (33 percent of jobs in survey) or clearly dimen-
sioned on the plans and sections (16 percent) there is
no problem. If the splice is specified as Class A, B or C ac-
cording to ACI 318 (17 percent) the estimator must cal-
culate this length or have look-up tables such as those
in the ACI Detailing Manual—1980. Even then there are
questions, as spacing and edge cover are variable, and a
reduction can be made when spirals are involved. An
estimator would normally apply the “top bar” factor re-
quired by the code* to all splices with more than 12 inch-
es of concrete under the bars. Howe ve r, he may have a
problem if the contract documents do not indicate
whether horizontal wall bars are top bars or not. The de-
signer should state explicitly if he has provided for top
bar effect and which splices are affected, including hor-
izontal wall bars. If the contract documents are silent on
this, the estimator would usually assume that no top bar
effect is required for walls, and splices would be figured
as “other.”
Probably the most frustrating experience for an esti-
mator or a detailer is to have the contract documents
spell out splices “in accordance with ACI 318” and be
otherwise silent. This is of absolutely no help to the esti-
mator; he is in no position to determine conditions of
tension or compression, class of splice, top bar effect,
confinement, and the like. He must then contact the ar-
chitect or engineer to determine what is required. All too
often the response is “You fellows are the experts; work
out the solution yourself,” or “What do you recom-
mend?”
BUTT SPLICES
Butt splices, which are less frequently encountered,
may be either mechanical or arc welded. The majority
of butt splices used today are mechanical. There are nu-
merous proprietary types, including the following:
• metal filled sleeve
• hot forged sleeve
• cold forged sleeve
• forged sleeve with threaded stud
• taper threaded sleeve
• thread deformed rebar with matching sleeve
• cement mortar filled sleeve
• end bearing sleeve
Detailed descriptions are given in the Concrete Rein-
forcing Steel Institute’s publication, “Reinforcement An-
chorages and Splices.”
It is the job of the architect-engineer to indicate where
butt splices are required and to further define whether
they are to be end bearing (compression only), metal
filled sleeves (compression only), or tension splices. For
* “Building Code Requirements for Reinforced Concrete (ACI 318-77)” is spe-
cific regarding “top reinforcement” requiring a multiplier of 1.4 and defining
top reinforcement as horizontal reinforcement so placed that more than 12
inches of concrete is cast in the member below the reinforcement. However,
the commentary to the code states that “Recent research studying other mat-
ters has seemed to reflect a lessening of this effect when the horizontal ‘top’
bar is in a wall or wall-like beam with multiple runs of other horizontal bars
plus vertical bars and/or ties and stirrups. This suggests that some water and
air may be entrapped by other reinforcement and not be free to reach the
‘top’ bars.” However, judgment regarding interpretation of these provisions
should be made by the designer, not the estimator.
tension splices, the engineer decides whether they must
develop 125 percent of minimum specified yield
strength (per ACI 318) or the minimum ultimate tensile
strength (per ACI 359 and others). If splices must be stag-
gered, the designer must also indicate this as well as the
amount of stagger.
The estimator must know which kinds of splices are
permitted as this affects his estimate. The firm for which
he is doing the estimating may include the splice sleeve
Figure 3. Anchorage for dowels in Drawing A would probably
be estimated exactly as shown, whereas for the deep
footing (B) a check of the required anchorage length might
be made by the estimator.
itself in the bid or may only include special end prepa-
ration of the bars, if required. If the sleeve is included,
the estimator obviously must figure the quantity of
splices required for each bar size and must follow rea-
soning similar to that for lapped splices. Even if others
are furnishing the splice sleeve, the estimator must de-
termine any end preparation necessary and the quanti-
ty of ends involved for each bar size.
ANCHORAGES
Anchorages are usually not a problem for the estima-
tor since he generally is able to follow the contract doc-
uments. When hooked anchorages are specified they
probably would be estimated without regard to whether
the minimum code anchorage lengths have been pro-
vided. Usually the hooks are on beam or slab bars shown
anchored fully into the support. Column dowels are
sometimes a problem. Figure 3A shows a dowel appar-
ently extending down to the footing mat reinforcement,
with a standard 90-degree hook. In this case, the esti-
mator would probably figure it just that way, regardless
of whether the anchorage length exceeded or even met
code requirements. However, if the footing or mat depth,
as illustrated in Figure 3B is very large, the estimator
might check the required anchorage length per CRSI Re-
inforcement Anchorages and Splices or the ACI Design
Handbook (SP 17) to determine if he should use it. Inci-
dentally, these two documents are not in agreement.
Figure 4. Extra column ties may be required at the location
of bends in column steel which is offset bent, as shown in
this detail reproduced from the ACI Detailing Manual.
This makes it all the more important that the designer
should indicate his wants clearly and concisely.
If a straight bar length of anchorage or embedment is
shown and the contract drawings are not specific as to
amount, the estimator figures either all the way to the
bottom of the footing (the usual way) or assumes ten-
sion bar anchorage. He is never in a position to assume
compression anchorage.
COLUMN TIES
The estimator must determine the size, length and
quantity of column ties. Where the contract documents
are complete with schedules and typical column details,
this is fairly straightforward. Howe ve r, where no typical
sections are shown, the estimator does have decisions to
make. He either must contact the architect-engineer for
clarification or assume an arrangement such as shown
in Figure 4 for multiple story heights, which has been
taken from the ACI Detailing Manual. These details as-
sume that at least some of the vertical column bars are
offset bent and that extra ties are required at the bend lo-
cation. This is true of the majority of building designs. If
butt splices are involved, the estimator has to make an-
other decision: whether to add extra column ties adja-
cent to the butt splice, as shown in Figure 5. The extra
ties are presumably required to replace ties eliminated at
the splice. This is a judgment call and depends on the
tie spacing and the length of the splice sleeve. Ne ve rt h e-
less, it is possible that tie spacing is large enough so that
no ties would be eliminated by the splice. This becomes
 Figure 5. Extra ties may also
be required in the region of
butt splices in column bars,
presumably to replace ties
which may have been
displaced by the splice
location.
more complicated if the splices are staggered. It is espe-
cially important that the estimator be accurate with ties,
as all ties (and stirrups) are subject to the light bending
extra and affect the quoted price out of proportion to
their weight.
BAR SUPPORTS
Suppliers of reinforcing bars frequently include as part
of their service a quantity survey for bar supports. Bar
supports may consist of concrete, metal or other ap-
proved materials. Standard specifications for wire bar
supports are included in the CRSI Manual of Standard
Practice, which is revised periodically to reflect latest
practice. The contract documents should indicate types
of bar supports permitted and for wire supports, the
class of protection. Most widely used are standard i ze d
factory-made wire bar supports and reinforcing bars.
After identifying the types of bar supports permitted
and the class of protection required, the estimator must
make a quantity survey. He will base his quantities on re-
quirements shown in the contract documents or as cov-
ered in the CRSI Manual of Standard Practice. This in-
volves first determining the number of rows of supports
required. In continuous elements such as slab bolsters
or rebar support bars the number of rows must be con-
verted into lineal feet. For individual elements such as
high chairs or rebar “standees,” the number of pieces per
row must also be determined.
Unless otherwise shown in the contract documents,
the estimator would figure bar supports for slabs on
grade for support of top bars only. For foundation mats
more than 4 feet thick, supports are not normally
provided for top bars. The estimator would usually take
off individual standees spaced at 4 feet in each direction
and assume that bars in the top mat in one direction
(approximately every 4 feet) would be lowered two
bar diameters to be used as a continuous horizontal
bar support.
The estimator has a choice, when making a quantity
Figure 6. Supports for bars in foundation mats and slabs on
ground include individual high chairs with sand plates for
soil bearing (HCP) and continuous high chairs for upper bar
support (CHCU). Standees—reinforcing bars fabricated to
order with bent legs resting on lower mat of bars—are also
used. Dowel blocks are common in western areas of the
United States. Drawing from CRSI Manual of Standard
Practice.
survey for one-way supported slabs, if not otherwise de-
fined in the contract documents. When estimating the
bar supports for the top reinforcement, he could figure
continuous high chairs or individual high chairs with #4
support bars. Economy usually determines his decision.
Where it is feasible to use a temperature bar as a sup-
port bar, individual high chairs will almost always be
more economical for building slabs. In certain areas of
the country continuous high chairs, with runners, are
specified for bridge decks to support the top mat from
the bottom mat of rebars, where an all-straight-bar de-
sign is involved. The estimator would figure on the con-
tinuous chairs in this instance as a contract requirement.
Furnishing of spacers against vertical or sloping forms
to maintain prescribed side cover and cross position of
reinforcing bars has not been standardized within the
reinforcement industry. Estimating or detailing such
spacers with the reinforcement is not a normal industry
practice, and the CRSI manual indicates that they are to
be furnished by the general contractor (see related arti-
cle on page 825).
SUMMARY
An attempt has been made to give some insight into
the business of making a quantity survey (estimating) of
reinforcing bars. Only a few of the many variables have
been briefly touched on. It has been said many times
that an estimator’s quantity survey may determine (1)
whether the rebar fabricator is successful in securing a
certain contract and (2) whether it turns out to be a prof-
itable contract or not. In other words, the rebar estima-
tor is a very important cog in the reinforced concrete
construction wheel.
Editor’s note:
Publications of the Concrete Reinforcing Steel Institute cited
in this article are for sale by CRSI. Address all inquiries to
their office at 180 North LaSalle Street, Chicago, Illinois
60601.
ACI Detailing Manual—1980 is available from Concrete Con-
struction Publications, 426 S. Westgate, Addison, Illinois
60101 for $39.95 postpaid; check should accompany order.
ACI members may wish to order directly from ACI to obtain
member discount.
PUBLICATION#C810793
Copyright © 1981, The Aberdeen Group
All rights reserved