PROCEDURE FOR REINFORCEMENT

Doc. No: WPM.B.02

DOCUMENT RELEASE AUTHORIZATION

1
 Table of Contents

Chapte
Title of Page No.
r chapter
No.
Table of contents 2

History of Revisions 3

1 Purpose 4

2 Scope 4

3 Definitions 4

4 Responsibility 6

5 References 6

6 Flow Chart 7

7 Procedure 8

8 Quality Metrics 12

9 Records 12

10 Attachments 13

11 Tolerance and Acceptance Criteria 13

12 Do’s and Don’ts 15

2
 History of Revisions

Chapter/
Revisio Revision Clause no. &
n No. issue text affected Reason for revision
date
0 -- First Issue

1 -- Due to Brand change

Change from ISO :9001: 2015

2 Entire Procedures

Clause 9.0
3 Requirement of Factory cut bars.
Procedure
Critical Action Points from Learning’s of
Clause 10.0 Group Kaizens2012 incorporated: Cut
4
Procedure Length of the samples of Steel mentioned.
Number
of samples to be tested incorporated.

5 -- Change of Word Mark

6 Cl 3, 4, 5, 7, 8, 9

Inclusion of Stress- Strain Curve of Steel,

7 Cl 4, 6, 7, 8
8 Cl 7
Flowchart, Standardization System, Dos and
Don’ts, Pictures
Inclusion of
Two level checking of reinforcement
Lapping of reinforcement as focused point
Monthly Training on reinforcement activity ,
tagging of steel as per BBS

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1. PURPOSE:
To document a procedure for laying of reinforcement steel in RCC Structures. To ensure that
the laying of reinforcement in RCC Structures on site is as per the Technical Specifications of
the Company.

2. SCOPE:
To establish, monitor and control all activities during laying of reinforcement in RCC
Structures shall be applicable across all the projects of the Company.

3. DEFINITIONS:
 Reinforcement: It may be defined as a mesh of high yield deformed steel bars or wires
used as a tensioning device in concrete structures holding the concrete in compression. It
is usually formed from carbon steel and is given ridges to form a better bond with the
concrete. The word rebar is used interchangeably with the word reinforcement. It is
normally termed as Fe 415, Fe 500, Fe 500 D etc. The nomenclature “Fe” indicates
Ferrous and the number followed by the nomenclature indicates the minimum Yield
Strength of the bar in N/mm2. The letter ‘D’ indicates the category with the same
specified yield stress but with enhanced specified minimum percentage elongation.

4
 Typical picture of Reinforcement Bars
 Bar Bending Schedule (BBS): It is a tabular statement showing the diameter wise length,
shape, numbers and spacing of rebar for a structural element. BBS shall be prepared in
accordance with IS 2502 (latest revision) i.e. Code of Practice for Bending and Fixing of
Bars for Concrete Reinforcement.
 Binding Wire: It is a wire used to tie the rebar together at their points of intersection
with each other. 18 Gauge Galvanized Iron Binding Wire. Double knot tying of
binding wire
 Cover Block: A block of suitable material and appropriate size used to position the rebar
such as to result in the required distance between the rebar and concrete surface (cover).
 Stress – Strain curve of Steel: Stress Strain Curve is a behavior of steel when it is
subjected to load. In Stress – Strain Curve, stresses are plotted along the vertical axis and
strains on the horizontal axis.

 The various points on the curve indicate

o Proportional limit (P): Indicates that the value of stress and strain remains
proportional.

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 o Elastic Limit (E): Indicates the value of stress up to which the material is
perfectly elastic. The material to return to its original position if unloaded
before crossing the point E.
o Yield Point (Y): The point after which the material extension takes place more
quickly with no or little increase in load. Stress associated with point Y is
called as Yield Stress.
o Ultimate Stress Point (U) : The maximum strength that the material bears
before breaking also called as Ultimate Stress Point.
o Breaking Stress (Point of Rupture)(B): The point where the material breaks.
The stress associated with this point is called as Breaking Stress

 Elongation: The increase in length of a tensile test piece under stress. The elongation
at fracture is conventionally expressed as a percentage of the original gauge length of
a standard test piece.

 Gauge Length: It is the length of the steel bar which is being tested. The length is
generally measured between the grips of the machine for the test.

4. RESPONSIBILITY:
Task
Completion of works as per relevant WPM
(work procedure manual), Latest GFC
drawings, latest approved revision of PQP
(Project Quality Plan)
Initial checking and inspection of the
Reinforcement works
Final checking and inspection of
reinforcement works
Random checking of BBS (50%)
Achieve Zero NCs in reinforcement activity
Responsibility
Project Manager MIPCL- SAKTHI
ASSOCIATESS
Engineer In charge- SAKTHI ASSOCIATESS,
Engineer in charge MIPCL
Engineer- In charge MIPCL.
Quality-in-charge- MIPCL
Project Manager MIPCL- SAKTHI
ASSOCIATESS

5. References:
 Technical Specifications
 Approved latest Project Quality Plan
 Contract Document and BOQ
 Structural GFC Drawings
 IS 1786 (Latest Revision) : High Strength deformed steel bars and wires for concrete
reinforcement.
 IS 2502 (Latest Revision) : Code of Practice for Bending and Fixing of Bars for
Concrete Reinforcement.
 IS 4082 (Latest Revision) : Stacking and Storage of Construction Materials and
Components at Site.
 6. Flow Chart:

Start

Receipt of Incoming Availability of

Material Approved WMS
Provision of
for reinforcement
MTC by
Supplier

Material not to be MTC available

unloaded with the incoming
material
No
Yes

Stack the material diameter wise with the Tag

displayed
as “Under Testing”

Take samples Receipt

and sendofthe
Report
same to the Third Party for
Remove
Physical and Chemical Testing
material in 3 days

Is the
Reject the Material
Report Satisfactory

No
Yes
Store dept in coordination with Quality department to take clearance from Quality Department to use of
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 Preparation of Bar Bending Schedule (BBS)

by Contractor

Checking and Approval of BBS by Building-in-

charge

& Cross checking of BBS by Building-in-charge of

other building. Sample checking of Quality

EHS Cutting and Bending of Steel as per approved BBS

Cut and bent steels shall be
Management
inspected as per BBS and tagged
floor, tower and element wise
for shifting

Placing and fixing the steel as per Structural Drawing and Codal Requirements

Checking the Work by the Process Owner

Rectify

Take necessary corrective action Is the work

as per requirement

No

Yesper Check list

Perform the subsequent activity as

End
 PROCEDURE:
Incoming Material:

 All incoming steel should be accompanied with a Manufacturer Test Certificate. Identification
mark with batch production /cast etc. shall be available on the bundles. In addition to this, the
quality of the steel to be verified as per the Inspection and Test Plan (ITP) by testing the steel
in NABL Accredited Third Party Lab as per requirements of IS 1786 (Latest revision) and
report 300duly produced before utilizing the steel as required.
 In case if the steel fails in any of the Physical or Chemical Test as per the Third-Party Test
Report, the material shall be rejected and the Supplier to take the steel back within 3 working
days.

Stacking of Material:

 All reinforcement shall be clean, free from oil, paint, dirt or any other substances that will
destroy or reduce the bond and shall be stacked on either timber/ sleeper wood or MS frames,
concrete pedestals of height not less than 300 mm from the ground level.
 The steel shall be stacked diameter wise separately and shall have the Tag of dia of steel,
grade of steel, status of testing like “UNDER TESTING, PASS, FAIL and HOLD. The steel
cleared by the quality department shall be issued to the contractors by stores.
 Cut and bent steels shall be inspected as per BBS and tagged floor, tower and element wise
for shifting. This tag shall not be removed until placing the steel

Placing of Steel: Following points to be taken care while cutting, bending and placing of steel

 Before placing of steel in the structural member, the structural member shall be made free
from dirt, loose scales, paint, oil and grease and kept clean to receive the reinforcement.
 TWO LEVEL CHECKING- Preparation of Bar bending schedule shall be done by
Contractor as per the Structural Drawing. It shall be checked by Building-in-charge and Cross
checked by building-in-charge of other building. Sample (50%) checking of BBS shall be
done by Quality Manager. Similarly, placed reinforcement at site shall be checked by
building-in-charge and cross-checked by building-in-charge of another building. shall be
followed by building-in- charge for the placed reinforcement before concrete casting.
For factory cut bars, BBS shall be prepared and given to supplier.
 To avoid mixing up between cut and bent steel going to different location other than intended
location, tagging shall be done by the BBS engineer tower wise, floor wise and element wise.
 Fabrication of reinforcement shall be done mechanically or with hand but to the correct radius.
Bars with any visible defects such as cracks, splits shall not be used. Mandrel shall be used for
bending the steel 20 mm diameter and above. Diameter of Mandrel used for bending of bars
shall be as per Table 4 of IS 1786: 200
 Cover blocks shall be of non-corrosive material such as plastic or PVC but not wooden or
stone. However, concrete cover blocks shall be of the same grade as of concrete pour. Cover
to the reinforcement shall be provided as per the Structural drawing. Actual Concrete cover
shall not deviate from the required nominal cover by + 10mm and – 0 mm.
 Minimum Spacing of Reinforcement:
The minimum horizontal distance between parallel reinforcement shall not be less than as
follows:
o Diameter of bar when bars are of same diameter and diameter of thickest bar when
bars or more than one size are used.
o Maximum size of coarse aggregate plus 5 mm. A greater distance should be provided
when convenient.

The vertical distance between two horizontal main bars shall not be less than as follows:

o 15 mm.
o Two- third of the nominal maximum size of aggregate.
o Maximum size of the bar (whichever is the greatest).
 Stirrup hooks shall be bent at 45 °. It is important during earthquakes or seismic activity. The
first link shall be at a distance of 50 mm from the bearing of the Structural Member.

 Binding Wire: It shall be of gauge 18 galvanized iron confirming to IS 280 and shall be free
from rust, oil, paint, grease, loose mill scale or any other material undesirable for the
reinforcement and concrete or which may prevent adhesion of concrete with reinforcement.
Binding wire shall not protrude in the cover zone.
 Reinforcement steel shall not sag between supports and shall not be displaced during
concreting. If required, steel chairs, supports, spacer bars, ties etc shall be placed at
appropriate spacing
 Typical Arrangement of Chairs to support the bars

 In case of vertical structural members like walls and columns, the reinforcement shall be kept
in position by adequate supports. Bars of full length shall be used to minimize wastage.

Supports for keeping reinforcement in position

  LAPPING OF REINFORCEMENT (FOCUSED POINT): Laps for Compression and
Tension Reinforcement shall be provided as per the Structural Drawing. Crank depth and
length shall be ensured while lapping reinforcement to ensure verticality for load transfer. It
shall be 1H: 6 V.
o Splices shall be provided as a way as possible from sections of maximum stress and
shall be staggered as per the structural drawing.
o Not more than 50 % of the bars shall be lapped at a particular section.
o In cases where more than 50 % of the bars are lapped at a particular section,
precautions such as increasing the length of lap or using closely spaced stirrups around
the laps can be taken.
o Laps shall not be used for bars larger than 36 mm in diameter. For larger diameter,
bars may be welded. In case where welding is not practically possible, lapping of bars
larger than 36 mm may be permitted and additional spirals shall be provided around
the lapped bars.

 TRAINING ON REINFORCEMENT ACTIVITY

Monthly training on reinforcement activity shall be given to Contractor by MLDL Engineer

 Mechanical Threaded Couplers: Couplers shall be used for bars over diameter 36 mm. In
such cases, lap splices shall not be used. However, bars may be welded for larger diameter,
but no welding is allowed for Secondary Steel.
 Protective treatment shall be given to bars as per the following table depending upon the
duration for which the Bars are exposed to environment.

Sr Duration of Exposure
No to Environment
1 More than 2 months
2 More than 6 months
3 More than 12 months
Protective Treatment
Brush Coat of Cement Slurry
Zinc rich Coat
Epoxy Coat

Critical Action Points from Learnings of Group Kaizens

 Samples that are cut for testing from the lots received shall be cut from the middle of the bar
i.e. in a 12 m length rebar, 3 m from both sides to be left out and the sample pieces shall be taken
from the middle 6 m length.
 Strength ratio shall be checked (Proof stress/ Ultimate Tensile Strength) shall conform to Is
1786 (latest revision). Min strength ratio shall be 1.10.
 A minimum of 2 test pieces shall be taken as sample for testing for every 50 MT (for primary
steel) or every change of heat no (for Secondary Steel)
 Stacking of steel shall be done as procedure for handling, preservation and storage
8 Quality Metrics (Effectiveness and Efficiency Measures): There shall be no defect during
execution.

9 Records

Name of Records Retention Time and Disposition

Bar Bending Schedule -FT. 04.WPM.B.05
Check list for Reinforcement- 5 Years after Defect Liability Period
(CT.03. WPM.B.05) post which the document shall be
Test Certificate for Reinforcement shredded.

10 Attachments
 Bar Bending Schedule - FT. 04.WPM.B.05
 Check list for Reinforcement- (CT.03. WPM.B.05)

11 Tolerance and Acceptance Criteria

Item Description Tolerance and Standards
Rebars
Height of Reinforcement Minimum 1 m
Stand
Height of Reinforcement Minimum 300 mm
bars above ground level
Bending

Not heated beyond cherry red colour

Heating temperature of
bars bent hot
Radius of bend of
reinforcement bars bent
aside at construction joints
and afterwards bent back
into their original position
(not exceeding 645
1. Not less than 4 bar diameters for
plain mild steel
2. Not less than 6 bar diameters for
deformed bars.
 1. Brush coat of cement wash which are Re-testing for
over 3 months exposed. physical and
Age of reinforcement bars 2. Zinc rich coat which are exposed chemical
exposed to be adequately for more than 6 months or more. properties is
protected against corrosion 3. Epoxy coat which are exposed mandatory
for more than a year. before starting
the concrete
pour for such
exposed
conditions.
Actual Cover 1. Not less than cover shown in the
drawing.
2. Shall not exceed nominal cover by +
10 mm
Lapping of bar at any Not more than 50 % of total bars/ as per
section drawing / as directed by Engineer
Lap Splices
Diameter of bars for which Over 36 mm
lap splices are not to be
used For larger diameters, bars may be
welded. No welding permitted for
secondary steel.

In cases where welding is not practical,

lapping of bars larger than 36 mm
diameter may be permitted and
additional spirals should be provided
around the lapped bars.
Overlap measured between Not less than spacing of cross wires plus
extreme cross wires when 100 mm
splicing of welded wire
fabric is carried out
Position of welding on Where steel will not be subject to more IS 9417
reinforcement than 75 % of max. Permissible stresses
and welds so staggered that at any one
section, not more than 33 percent of
rods are welded.
Rebars
Reinforcement (Cast -in-
situ and Pre-cast
Main and Secondary Rebars According to GFC drawings
(numbers/sizes)
Anchorages and Lap Required Lap length not less than that
Lengths specified in the drawing
Links, Stirrups and According to GFC
trimming bars structural
drawings(numbers/sizes).
Spacing of links not more than specified.
Rebar Condition Rebars must be securely and properly tied
in place i.e when we try to move the
fixed rebars, it should not get dislocated
form its placed location.
Rebars must be free from concrete
droppings, corrosion etc.
 tests as per the agreed ITP for the
project. The summary of test report (i.e
steel test report summary sheet) must be
endorsed by the Quality- in-charge of
project based on the approved external
NABL accredited laboratory report.
Any welded steel fabric used in the
project shall comply with the contract
specifications. Welding not allowed for
Secondary Steel.
No non-conforming reinforcement
detected through test records has been
installed or fixed in the structure.

12 Dos and Don’ts

SR DO DON’T
NO S S
1 Receipt of Incoming
Material
All incoming material shall have MTC Do not unload the vehicle until a
valid MTC is available along
with Material
2 Stacking of Material
Proper identification and tagging system Do not unload the steel on the
(“UNDER TESTING, PASS, FAIL” ) ground as it may come in contact
shall be with oil, paint, dirt or any other
established in the reinforcement stacking substance which might affect the
yard. Steel shall be stacked dia wise bond between steel and concrete.
separately at a height of min 300 mm
from ground level on concrete/ MS
pedestals.
3 Testing of Material
Use the steel only after receipt of valid Do not use the steel until receipt of
Third-Party Test Report for Steel a third party test report.
4 Cutting and Bending of
Steel
Cutting and bending of Steel shall be done Excessive bending of steel may
as per the Codal Provision lead to cracking of steel.

5 Cover to Reinforcement
 Use noncorrosive material for cover Do not
blocks like PVC, plastic or concrete of 13 Use corrosive material as cover.
same grade used for the structural 14 Provide less cover to
member. Actual Cover shall not deviate reinforcement
from the nominal cover by + 10 mm and - It affects the durability of the
0mm. structure thereby reducing the life
of the structure.

6 Spacing of Reinforcement
Provide appropriate spacing between the Provision of inadequate spacing
rebars to enable concrete to flow through between reinforcement leads to
the rebars thereby enabling defect free congestion of reinforcement
concrete. leading to honey combing of
concrete thus affecting the
durability of concrete.

SNo Particulars Accepted Rejected Remar

ks
1 Whether Checklist for formwork has been cleared (it shall be
ensured that the structural member is cleaned and free from
dirt, loose scales, paint, oil and grease.)
& all points closed to start reinforcement work?
2 Grade of Steel used
3 Dia. of Main Steel & Distribution Steel
4 Test conducted on received material & report
5 Structural drawing checked and latest revision being used.
6 Bar Bending Schedule (TWO LEVEL CHECKING)
7 Cutting & bending satisfactory
8 Corrosion treatment of bars, if required satisfactory (mention
chemical used)
9 The reinforcement bars shall be placed in position as
specified in the drawings and shall be secured in position
using binding wire (as per the BOQ)
10 cover blocks of approved brand and vendor or cover blocks
manufactured from the same grade of concrete to be used
11 The stirrups of the girder are arranged such that the ring
closure of alternate ring is on same side.
12 LAP LENGTH (FOCUSED POINT) /Anchorages
13 Chairs / cover blocks placed
14 Binding wire not touching shuttering and proper binding
15 Fixtures / inserts / conduits in position MEP clearance
obtained
16 Expansion joints / water bar provided (if applicable for the
member inspected)
17 At junctions, all the vertical bars are tied properly i.e. main
bars & distribution bars.

18 Dowels & positioning provided as per drawings

( Attachment:- Check list for BBS work )