Reinforcement and

Structural Steel
 CONTENT

q Steel Manufacturing Process

q Types of Reinforcement Steel and Application
q Grades of Structural Steel
q Various Types of Standard Sections
 IRON

What is Iron

q Iron is a chemical element with symbol Fe (from Latin: ferrum)

q Atomic number 26. It is a metal in the first transition series.
q It is by mass the most common element on Earth, forming much
of Earth's outer and inner core.
q Combined with varying (but tiny) amounts of carbon, iron makes
a much stronger material called steel, used in a huge range of
human-made objects, from cutlery to warships, skyscrapers, and
space rockets.
 IRON

What is Iron

q Fourth most common element in Earth's crust (after oxygen, silicon,

and aluminum)
q Second most common metal (after aluminum), but because it reacts so
readily with oxygen it's never mined in its pure form (though meteorites
are occasionally discovered that contain samples of pure iron).
q Like aluminum, most iron "locked" inside Earth exists in the form
of oxides (compounds of iron and oxygen).
 IRON

Iron Ores

Iron oxides exist in seven main ores (raw, rocky minerals mined from Earth):

q Hematite (the most plentiful)

q Limonite
q Goethite
q Magnetite
q Pyrite
q Siderite
q Taconite (a combination of hematite and magnetite).
 IRON
Iron Ores
 IRON
Iron Ores
 IRON

Iron content in Iron Ores

q Hematite and magnetite have about 70 percent iron

q limonite has about 60 percent
q pyrite and siderite have 50 percent
q while taconite has only 30 percent
 IRON

Types of Iron
Pure iron is too soft and reactive to be of much real use, so most of the
"iron" we tend to use for everyday purposes is actually in the form of
iron alloys: iron mixed with other elements (especially carbon) to make
stronger, more resilient forms of the metal including steel.

Broadly speaking, steel is an alloy of iron that contains up to about 2

percent carbon, while other forms of iron contain about 2–4 percent
carbon. In fact, there are thousands of different kinds of iron and steel,
all containing slightly different amounts of other alloying elements.
 IRON

Types of Iron
Pig Iron
Cast Iron
Wrough Iron
 IRON
Pig Iron
q Basic raw iron is called pig iron because it's produced in the form of
chunky molded blocks known as pigs.
q Pig iron is made by heating an iron ore (rich in iron oxide) in a blast
furnace: an enormous industrial fireplace, shaped like a cylinder, into
which huge drafts of hot air are introduced in regular "blasts".
q The iron made in a blast furnace is an alloy containing about 90–95
percent iron, 3–4 percent carbon, and traces of other elements such
as silicon, manganese, and phosphorus, depending on the ore used.
q Pig iron is much harder than 100 percent pure iron, but still too weak
for most everyday purposes.
 IRON

Cast Iron

q Cast iron is simply liquid iron that has been cast: poured into a mold
and allowed to cool and harden to form a finished structural shape,
such as a pipe, a gear, or a big girder for an iron bridge.
q Pig iron is actually a very basic form of cast iron, but it's molded only
very crudely because it's typically melted down to make steel.
q The high carbon content of cast iron (the same as pig iron—roughly
3–4 percent) makes it extremely hard and brittle.
 IRON

Wrought Iron
q Cast iron assumes its finished shape the moment the liquid iron alloy
cools down in the mold.
q Wrought iron is a very different material made by mixing liquid iron
with some slag (leftover waste).
q The result is an iron alloy with a much lower carbon content.
q Wrought iron is what people used to use before they really mastered
making steel in large quantities in the mid-19th century.
 STEEL

Steel is type of iron alloy, but it has a much lower carbon

content (less than 2%) than cast and wrought iron and other
metals are often added to give it extra properties.
STEEL
 Structural Steel
The Modern Steel
Production
Process

qIron making
qPrimary Steel making
qSecondary Steel making
qContinous Casting
qPrimary forming
 Structural Steel

Iron is converted to steel by lowering carbon % by using oxygen.

Two processes of STEEL MAKING

Basic oxygen Furnace (BOF) Electric arc furnaces (EAF)

Structural Steel
Raw materials:
iron ore, coke, sinter, and limestone.
Iron ores are mainly iron oxides and
i n c l u d e m a g n e t i te , h e m at i te ,
limonite, and many other rocks.

The resulting molten iron also

refe r re d to a s h o t m eta l st i l l
contains 4-4.5 percent carbon and
other impurities that make it
brittle.
 Structural Steel

Primary steelmaking has two primary methods: BOF (Basic Oxygen

Furnace) and the more modern EAF (Electric Arc Furnace) methods.

BOF methods add recycled scrap steel to the molten iron in a

converter. At high temperatures, oxygen is blown through the metal,
which reduces the carbon content to between 0-1.5 percent.

EAF methods, however, feed recycled steel scrap through use high-
power electric arcs (temperatures up to 1650 C) to melt the metal
and convert it into high-quality steel.
Structural Steel
Structural Steel
 Structural Steel

Secondary steelmaking involves treating the molten steel produced from

both BOS and EAF routes to adjust the steel composition. This is done by
adding or removing certain elements and/or manipulating the temperature
and production environment.

Depending on the types of steel required, the following secondary

steelmaking processes can be used:
q Stirring
q Ladle furnace
q Ladle injection
q Degassing
q CAS-OB (composition adjustment by sealed argon bubbling with oxygen
blowing)
 Structural Steel
Continous Casting
Machine
Structural Steel

In continuous casting machine, the

molten steel is cast into a cooled mold.

The shell strand is withdrawn using

guided rolls and fully cooled and
solidified.

The strand is cut into desired lengths

depending on application.
slabs for flat products (plate and strip)
blooms for sections (beams)
billets for long products (wires) or thin
strips
 Structural Steel
Continous Casting
Machine
 Structural Steel

slabs for flat

products (plate
and strip)
Structural Steel

blooms
(beams)
Structural Steel

billets for long products

(wires) or thin strips
 Structural Steel

In primary forming, the steel that is cast is then formed into various
shapes, often by hot rolling, a process that eliminates cast defects and
achieves the required shape and surface quality.

Hot rolled products:

flat products,
long products,
seamless tubes,
specialty products.
Structural Steel
 Structural Steel

Secondary forming techniques give the steel its final shape and properties.
These techniques include:

•Shaping (cold rolling), which is done below the metal's recrystallization point,
meaning mechanical stress—not heat—affects change.
•Machining (drilling)
•Joining (welding)
•Coating (galvanizing)
•Heat treatment (tempering)
•Surface treatment (carburizing)
STEEL MANUFACTURING PROCESS
STEEL
STEEL
STEEL
STEEL
 STEEL

Reinforcement steel is
normally referred
to steel bars which are
us e d i n co m b i n at i o n
with plain concrete to
make it reinforced
concrete.
 STEEL

Structural steel are

referred to sections, hot
rolled or cold formed,
with larger moment of
inertia (or second
moment of area).
 STEEL

Structural steel are

referred to sections, hot
rolled or cold formed,
with larger moment of
inertia (or second
moment of area).
REINFORCEMENT STEEL
 REINFORCEMENT STEEL

What is Rebar?

Steel reinforcement bars or rebars are

used to improve the tensile strength of
the concrete, since concrete is very
w e a k i n t e n s i o n , b u t i s s t ro n g i n
compression.
 REINFORCEMENT STEEL
Following are the major reasons for using steel rebars:
01. Steel is highly ductile material. It can deform without losing its toughness and is non-
brittle.
02. Young’s Modulus of steel is equal in both tension and compression (2.0 – 2.1 x
105 N/mm2). It means increase/decrease in length of steel bar on pulling/pushing will be same.
03. Coefficient of thermal expansion (increase in length corresponding to increase in
temperature) of concrete and steel is almost equal. This ensures the bond strength during
thermal expansion, thus preventing bond failure. Moreover, if not same the bar will
contract/expand more than concrete and will create problem.
04. Steel undergoes the same strain or deformation as the surrounding concrete in
order to prevent discontinuity, slip or separation of the two materials under load.
05. It can be recycled easily
06. It can be welded easily.
07. Widely and cheaply available compared to other ductile metals.
Reinforcement Steel

Types of Rebar

1. Mild Steel Bar

2. Deformed Steel Bar
 Reinforcement Steel
Mild Steel Bar
 Reinforcement Steel
Deformed Steel Bar
Deformed steel bars have ribs, lugs and
indentation on the surface of the bar, which
reduces the major problem that is faced by
mild steel bar due to slippage and good
bonding is achieved between concrete and
rebar.
The tensile properties is higher compared to
other rebars. These bars are produced in
sections from 6 mm to 50 mm dia.
 Reinforcement Steel
Types of Deformed Steel Bar

1. TMT Bars (Thermo Mechanically Treated Bars)

2. High Strength Deformed Bars

3. Other Types of Rebars

Carbon Steel Rebar
Epoxy-Coated Rebar
Galvanized Rebar
Glass-Fiber-Reinforced-Polymer (GFRP)
Stainless Steel Rebar
 Reinforcement Steel
High Strength Deformed Bars (HYSD)
High strength deformed bars are cold
twisted steel bars with lugs, ribs, projection
or deformation on the surface.
It the extensively and majorly used for
reinforcement purposes in a
construction. These bars are produced in
sizes or sections from 4 mm to 50 mm in
diameter
 Reinforcement Steel
Characteristics of High Strength Deformed Bars (HYSD)
Low carbon value – HSD Bars have lower carbon level, resulting in good ductility, strength
and welding ability.
Superior bonding strength – HSD bars are well known for their excellent bonding strength
when used with concrete.
Welding capability – Since these bars have lower carbon content, they have 100% welding
capability than conventional bars.
High tensile strength – HSD bars feature high tensile strength. They offer great asset in
construction process, where a lot of bending and re bending is required.
Wide application range – These bars have wide application range like in building residential,
commercial and industrial structures, bridges, etc.
Satisfactorily malleability – Minimum weight and maximum strength and suitable for both
compression and tension reinforcement.
 Reinforcement Steel
TMT Bar
Thermo Mechanically Treated Bars are hot
treated bars that are high in strength used
in reinforced cement concrete (RCC) work.
It is the latest induction in the MS steel bars
with superior properties such as strength,
ductility, welding ability, bending ability and
highest quality standards at international
level.
 Reinforcement Steel
TMT Bar
 Reinforcement Steel
TMT Bars are better because:
q TMT bars do not surface flaws when compared with HYSD bars as unlike HYSD bars, as the
manufacturing process in the TMT bars does not involve twisting or torsional stress.
q When compared with TMT bars, HYSD bars increase the consumption of steel by 8% to 11%
when used in the same construction.
q TMT bars come with a stronger external layer, something which is missing in HYSD due to
ductile nature of the core and hard crystalline surface of TMT steel.
q When compared with TMT bars, HYSD bars cannot provide flexibility and ductility, thus limiting
their use in different types of construction works.
q TMT bars have less residual stress due to the better manufacturing process and have better
tensile strength when compared with HYSD bars.
q TMT bars are effective in earthquake-prone zone and cope better with sudden load surges and
absorption when compared with HYSD bars.
q TMT bars are more corrosion resistant when compared with HYSD bars, this is mainly due to
rapid quenching and tempering used in TMT bar manufacturing process.
Reinforcement Steel
Reinforcement Steel
Reinforcement Steel
 Structural Steel

Structural steel
Advantages of Structural Steel
Disadvantages of Structural Steel
 Disadvantages of Structural Steel

q Steel is an alloy of iron. This makes it susceptible to corrosion. This

problem can be solved to some extent using anti-corrosion
applications.
q It has high maintenance costs as it has to be painted to make it
corrosion-resistant.
q Skilled labour required
q There are extensive fireproofing costs involved as steel is not fireproof.
In high temperatures, steel loses its properties.
q Buckling is an issue with steel structures. As the length of the steel
column increases the chances of buckling also increases.
q Steel has a high expansion rate with changing temperatures. This can
Structural Steel
Structural Steel
Structural Steel
Disadvantages of Structural Steel
Test Samples
Test Samples
 STRUCTURAL SECTIONS

Structural steel are

referred to sections, hot
rolled or cold formed,
with larger moment of
inertia (or second
moment of area).
 STRUCTURAL STEEL

Structural steel are

referred to sections, hot
rolled or cold formed,
with larger moment of
inertia (or second
moment of area).