What is Rebar?

Steel reinforcement bars or rebars are used to improve the tensile strength of the
concrete, since concrete is very weak in tension, but is strong in compression.
Steel is only used as rebar because elongation of steel due to high temperatures
(thermal expansion coefficient) nearly equals to that of concrete.

Fig 1: Reinforcement Steel Bar

Grades of Rebar in Different Codes

Table 1: Grades of Rebar in Different Codes
American Euro British
Indian Standard (IS:
Standard (ASTM A Standard(DIN Standard BS4449:
1786)
615) 488) 1997

Grade Fe – 415, Fe –
Grade 75 (520) BST 500 S GR 460 A
500, Fe – 500D

Grade 80 (550) BST 500 M GR 460 B Grade Fe – 550

Types of Steel Reinforcement Bars

Major types of steel bars used in the construction are as follows,
 1. Mild Steel Bar
The surface of the mild steel bars are plain and round in shape. They are
available in various sizes of 6 mm to 50 mm. They are used in concrete for
special purposes, such as dowels at expansion joints, where bars must slide in a
metal or paper sleeve, for contraction joints in roads and runways, and for
column spirals. They are easy to cut and bend without damage.

Fig 2 : Mild Steel Bar

For structural buildings like bridges and other heavy structures, mild steel bar is not recommended due to no
great bonding between concrete and steel, slippage and strength.
Grades in mild steel bars
1. Mild Steel Bars

 Mild steel bars grade-I designated as Fe 410-S or Grade 60.

 Mild steel bars grade-II designated as Fe-410-o or Grade 40.
2. Medium Tensile Steel Bars designated as Fe- 540-w-ht or Grade 75.

Physical Requirement of Mild Steel Bars

Table 2:Physical Requirement of Mild Steel Bars
Types of Nominal size of Ultimate Tensile Stress Yield Stress Elongation
bar in N/mm2 N/mm2 Percentage min
Mild Steel Grade I or
Grade 60

For Bars upto 20mm 410 250 23

For Bars above 20mm

410 240 23
upto 50mm

Mild Steel Grade II or

Grade 40

For Bars upto 20mm 370 225 23

For Bars above 20mm

370 215 23
upto 50mm

Medium Tensile Steel

Grade -75

For Bars upto 16mm 540 350 20

For Bars above 16mm

540 340 20
upto 32mm

For Bars above 32mm

510 330 20
upto 50mm

2. 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.
Types of Deformed Steel Bars
1. TMT Bars (Thermo Mechanically Treated Bars)
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.
 Fig 3: Deformed TMT Steel Bar

Characteristics of TMT Rebars

 Better ductility and malleability
 High yield strength and toughness
 More bonding strength
 Earthquake resistance
 Corrosion resistance
 High thermal resistance
 Economical and safe in use
 No loss in strength at welded joints
 Ordinary electrodes used for welding the joints
2. High Strength Deformed Bars
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.
 Fig 4: Deformed HSD Steel Bar

Characteristics of HSD Rebar

 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.

3. Other Types of Rebars

Depending upon the type of material used in the production of rebar, different types of rebars are
1. European Rebar
European rebar is made of manganese, which makes them bend easily. They’re
not suitable for use in areas that are prone to extreme weather conditions or
geological effects, such as earthquakes, hurricanes, or tornadoes. The cost of
this rebar is low.

2. Carbon Steel Rebar

As the name represents, it is made up of carbon steel and is commonly known as
Black Bar due to carbon colour. The main drawback of this rebar is that it
corrodes, which adversely effect the concrete and structure. The tensile strength
ratio coupled with the value makes black rebar one of the best choices.

Fig 5: Carbon Steel Rebar

3. Epoxy-Coated Rebar
Epoxy-coated rebar is black rebar with an epoxy coat. It has the same tensile
strength, but is 70 to 1,700 times more resistant to corrosion. However, the
epoxy coating is incredibly delicate. The greater the damage to the coating, the
less resistant to corrosion.

Fig 6: Epoxy-Coated Rebar

4. Galvanized Rebar
Galvanized rebar is only forty times more resistant to corrosion than black rebar,
but it is more difficult to damage the coating of galvanized rebar. In that respect,
it has more value than epoxy-coated rebar. However, it is about 40% more
expensive than epoxy-coated rebar.

Fig 7: Galvanized Rebar

5. Glass-Fiber-Reinforced-Polymer (GFRP)
GFRP is made up of carbon fibre. As it is made up of fibre, bending is not
allowed. It is very resistant to corrosion and is costly when compared to other
rebars.
 Fig 8: Glass-Fiber-Reinforced-Polymer Rebar

6. Stainless Steel Rebar

Stainless steel rebar is the most expensive reinforcing bar available, about eight
times the price of epoxy-coated rebar. It is also the best rebar available for most
projects. However, using stainless steel in all but the most unique of
circumstances is often overkill. But, for those who have a reason to use it,
stainless steel rebar 1,500 times more resistant to corrosion than black bar; it is
more resistant to damage than any of the other corrosive-resistant or corrosive-
proof types or rebar; and it can be bent in the field.

What a Mechanical rebar splices for rebars re the

Types of Mechanical Splices
Mechanical rebar splices for rebars in concrete construction is an effective
method of joining reinforcing bars. These are designed based on codes of
standard practice.

Mechanical splices in reinforced concrete construction should meet the building

code requirements for developing tension and compression as required

Types of Mechanical Splices for Rebars

There are four major types of mechanical splices:

o Compression only mechanical splices or end bearing splices

o Tension and compression mechanical splices

o Mechanical lap splices or tension only mechanical splice

o Dowel bar mechanical splices

 Fig.1: Mechanical Splices for Reinforcement Bars
Compression Only Mechanical Splices or End Bearing Splices
As it may be noticed from its name, this type of splice can resist compression
stress merely. The compressive stress is transferred by vertical bearing from one
bar to another one.

Compression only mechanical splices can be used when tension stress is not
occurred. Therefore, if this condition cannot be guaranteed, then it is advised to
avoid the use of compression only mechanical splices for reinforcement bars.

Steel filled coupling sleeve and strap type steel coupling sleeve are the two most
commonly used examples of end bearing splices.

The former can be used to splice rebar sizes ranges from No. 36 to No. 57
whereas the latter is suitable for splicing bar size ranges from No.22 to No.57.
 Fig.2: Steel Filled Coupling Sleeve Splice

Fig.3: Strap Type Steel Coupling Sleeve Splice

It should be known that the end of the rebars need to be saw cut in the case of
strap type steel coupling sleeve, but no special end preparation is needed for
steel filled coupling sleeve.

Tension and Compression Mechanical Splices for Rebars

This type of mechanical splice can resist tension and compression stress. There
are sizable numbers of commercially manufactured tension and compression
mechanical splices.

Tension and compression mechanical splices types, designated bar sizes to be

spliced by each splice type, the grade of the steel bar which is spliced using
certain type of tension and compression mechanical splice, and installation
condition of each mechanical splices are provided in Table-1.

Number of tension and compression mechanical splices is shown from Figure-4

to Figure-7.

Table-1: Tension and Compression Mechanical Splice Types, Their Designated Steel
Number, Steel Bar Type and Applications
Size ranges of steel bar suitable
Tension-compression mechanical splice type Type of steel bar
to be spliced
Cold-swaged steel coupling sleeve 10 to 57 Deformed bar

Cold-swaged coupler with taper-threaded ends 10 to 57 Deformed bars

Coupler for thread-like deformed reinforcing bars 19 to 57 Deformed bars

Extruded steel coupler with parallel threaded

13 to 57 Deformed bars
ends

Deformed and plain

Friction-welded bar coupler with parallel threads 19 to 57
round bars

Deformed and plain

Friction-welded coupler with taper-threaded ends 16 to 57
round bars

Grout-filled coupling sleeve 10 to 57 Deformed bars

Grout-filled coupling sleeve with parallel thread

13 to 57 Deformed bars
at upset bar ends

Grout-filled coupling sleeve with taper thread 19 to 57 Deformed bars

Shear screw and rail coupling sleeve 13 to 57 Deformed bars

Shear screw and wedge coupling sleeve 13 to 57 Deformed bars

Steel-filled coupling sleeve 13 to 57 Deformed bars

Taper-threaded steel coupler 10 to 57 Deformed bars

Threaded coupler with standard national coarse Deformed and plain

13 to 36
threads round bar
Threaded coupler with upsized bar threads, cold Deformed and plain
13 to 57
forged round bar

Threaded coupler with upsized bar threads, hot Deformed and plain
13 to 36
forged round bar

Upset bar and coupling sleeve with straight Deformed and plain
16 to 43
threads round bar

Fig.4: Cold Swaged Coupling Sleeve

Fig.5: Cold Swaged Coupler with Taper Threaded End

Fig.6: Coupler for Thread-Like Deformed Reinforcing Bars

 Fig.7: Extruded Steel Coupler with Parallel Threaded Ends
Mechanical Lap Splices or Tension Only Splices
This type of splice is suitable for the case where tension forces are present only.
Therefore, if such condition is not guaranteed, then it is recommended to avoid
its use.

Comparatively, mechanical lap splices are shorter than lap splices because of
the use of coupling sleeves to connect reinforcement bars. Therefore,
mechanical lap splices are considerably suitable for repairing structures because
smaller concrete area need to be removed compared with lap splices.

Shear screw and double wedge coupling sleeve and steel coupling sleeve with
wedge are two examples of mechanical lap splices. The former is suitable for bar
number 10 to 22 and the latter suitable for bar number 13 to 19.

Fig.8: Shear Screw and Double Wedge Coupling Sleeve

Fig.9: Steel Coupling Sleeve with Wedge

Dowel Bar Mechanical Splices
Dowel bar mechanical splices are flanged couplers that can resist tension and
compression forces.

This splice is nailed to the end or sides of the formworks through holes created in
the flange. The connection between reinforcement bars and the splice is through
internal threads of the splice.

Dowel bar mechanical splices are suitable for construction joints to transfer
tension and compression loads.

Various types have been produced such as cold-swaged steel flanged coupler
with taper threaded ends, coupler with standard national coarse threads and
flange, coupler with taper threads and mounting plate and integrally forged
coupler with flange.

Fig.10: Cold-Swaged Steel Flanged Coupler with Taper Threaded Ends

Fig.11: Coupler with Standard National Coarse Threads and Flange

What
? Rebaring technique
Rebaring technique in reinforced concrete construction is a method for proper
fabrication and placement of reinforcement bars as per the design and drawings
for RCC works.

We know that, concrete is very strong in compression and weak in tension. The
reinforcement bars or rebars are good in tension, that are incorporated with
concrete to make use of its tension property.

Estimation of reinforcement bars for a reinforced concrete work is done by the

engineer in charge. The engineer provides us with the specific details of the
number of reinforcement bars, the shape and size of each bars for each work.

There are different types of loads that including tension, compression, lateral,
horizontal and torsion that are forms of pressure, against which the concrete has
to show its strength.

The strength gained by the R.C.C structure is dependent on the method, as well
as the techniques that are employed to install the reinforcement bar. The
reinforcement bars are mainly patterned over its surface to facilitate proper
bonding with the concrete.
 Necessity of Rebaring Technique in Reinforced Concrete
Construction
The steel reinforcement mostly is divided into two categories i.e.

o Primary Reinforcement or Main Steel reinforcement

o Secondary reinforcement or distribution reinforcement

Main steel reinforcement bars are employed in R.C.C structures to ensure

resistance against the whole design loads coming over it. The secondary
reinforcement bars are mainly employed due to durability as well as for aesthetic
reasons.

This reinforcement guarantee resistance for localized areas, like limited cracking.
These also offer resistance against the stresses that are created due to
temperature variations.
The main bars employed of specified diameter are bent at the ends. The stirrups
are reinforcements that are provided laterally, to keep the main bars of the
structural elements like beams and columns, in position.

The stirrups may be circular, square, rectangular, helical or diamond shape

based on the cross-section of the structural element. The reinforcement bars in
the corners may be L – shaped.

The caging for the structural element under consideration must be properly tied,
so that during concreting no bar is disturbed from its position. This is a check to
be always kept in mind during concreting, else it is a threat to the durability of the
structural member.

The rebars are mainly provided at the junctions where the formwork of the
structural element is closed as well as at the point where a new structural
element needs to be bond with the former one.

Operations in Rebaring for Reinforced Concrete Works

The three main operations carried out in rebaring for reinforced concrete
construction bars are cutting, bending and tying. The diameter of reinforcement
bars used reinforced concrete work mainly ranges from 6 to 42mm. These
reinforcement bars come from the steel mill in specified lengths.
So, during installation, the reinforcement bars must be cut into required size. The
design engineer shows the details about the bars bending and related works,
based on which the workers proceed the work. The rigid connection is made
between all the members of the rebars with the help of steel wires.

Equipments used for Rebaring Techniques

The equipment that is used for rebaring operations is developed with time, as the
size of bars is increasing. Larger size bars are difficult to be handled by hand
operation.
The usage of chisel and hammer was an earlier practice used for bar bending.
The bar is held fixed with the help of three thick bars over a bar bender bench.
Then the bending is done by means of manual force, operated with the help of
levers. To tie the rods, cutting pliers were used, and tied by steel wires.

The enormous demand for work and bars with large diameters have made to
depend on machines for bar bending. This improved method helps in reduction of
time consumed by an ordinary method.

Different Types of Rebaring Equipments are:

The different equipment that is used for rebaring based on cutting, bending and
tying operation are explained below.

Equipment used for Cutting of Reinforcement Bars

1. Electric Rebar Cutters
Electrical cutters that can cut diameters up to 16mm are employed. These
consume power to cut the bars. Higher varieties are available in the market.

2. Heavy Duty Rebar Cutter

These are a higher version of the same, the heavy-duty cutters, that have the
capability to cut the bars up to 42mm. At a time, these cutters can cut three to six
bars at a time. These cutters make use of oil bath lubrication, that makes the
operation noiseless. The system is simple and hence easy to use.
3. Wire Rope Cutter
The cutting blade of wire rope cutters is made of steel with a titanium coating.
They have a high-speed cutting. These cutters are employed to cut the bars up
to a diameter of 20mm. They cut a single bar within 8 seconds, so fast and so
clean cut.

4. Rebar Cutting Shear

Rebar cutting shear is a cutter used to cut the stirrups at the equal size in a huge
amount. These can also be used for cutting the pipe section, angle or channel
sections.

Equipment Used for Bending of Reinforcement Bars

1. Electric Automatic Rebar Benders
This machine helps to bend the bars either on site or at the workshops, based on
the convenience. The machine is noiseless. It operates only during the bending
procedure.

2. Spiral Hoop Radial Benders

This machine is used to get radius in the bars that are of higher diameter. It has
rotating rollers, of which one is adjustable to hold the bars.

Equipment used for Tying of Rebars

As in rebar cutting machines, the rebar tying machines too are available, both
manmade and automatic.

1. Manual Rebar Tying Machine

Manual rebars have a net weight of 680 to 700 grams, which can be used to tie a
combination of bar size. Their size is mostly in the range of 300mm x 25mm.
These are cheap and can be used for any working or weather conditions.
2. Automatic Rebar Tying Machine
There are automatic rebar tying machines that can help tying bars up to a range
of 32mm. It requires 16 seconds for each tie. These rebaring machines can
facilitate completion of a large volume of work within limited time. This method
does not compromise on the quality as well as efficiency.

There are many agencies, that supply the bar bending, cutting and tying
operation, based on the set of specifications provided to them. These suppliers
also advise whether the concrete formwork must fully or completely erected
before they are ready to supply the tied-up bars as per specification.

Safety During Rebaring

To prevent injury, the bars that are extended intentionally for later work must be
covered with any plastic caps or “plate caps”. There are certain caps called
mushroom caps, that too can be provided so that scratches or injuries can be
avoided.

Types Different types of rebaring equipment used

for Reinforcement Cutting and Bending
Different types of rebaring equipment are used for cutting, bending and tying of
reinforcement in reinforced concrete construction. These types of rebaring
equipments are discussed in this article.
Types of Rebaring Equipment used for Reinforcement
Works in RCC
The below flowchart shows the process undergone in rebaring and their
respective equipment available.

Reinforcement Cutting Equipments

Electric Rebar Cutters
Electric rebar cutters are bar cutting equipment that can cut bars up to 16mm
diameters. They can cut bolts and high strength tensile bars. They require a
charging time of 25 minutes.

When the equipment is fully charged, it can cut 75 pieces of 16mm diameter and
110 pieces of 13mm diameter bars with ease. It possess an adjustable head that
can rotate in 180 degrees. The below figure shows an electric rebar cutter.

Fig.1: Electric Rebar Cutter

Specially designed hydraulic electric motors are available which are very easy to
operate. They have the advantage of no sparks or flames. They also have no
large abrasive blades that make use of trailing hoses. The system make use of
hydraulic oil, tool kit and a carrying case. These are portable in nature.

These helps in cutting bars that have epoxy coating (if any) within 5 seconds.
These are available in 16 to 32 mm diameter cutting capacities. Here there is a
knob that is adjusted as per the size of the bar placed to cut.
 Fig.2: Electric or Hydraulic Rebar Cutting Equipment
Heavy Duty Rebar Cutter
Heavy duty rebar cutter as the name specifies can cut bars of large diameter, up
to 42mm. The equipment is highly sophisticated and developed that, it can cut
three to six pieces of the bars at a single cutting. The cutter is of general type.

To ensure protection of its internal gear and for lasting performance, it has a
tightly sealed oil type. The machine gains fame in its excellent power and cutting
speed. The blade is treated with heat to reduce the damage of the blade during
the cutting.
Fig.3: Heavy Duty Cutting Machine Example Model- TYC -D35 with the operation
of cutting three pieces of bars at a single time
Wire Rope Cutters
Wire rope cutters are equipment used to cut the wire ropes under required
specification. The blade used for the wire rope cutters are made of high strength
steel with a coating of titanium to ensure precision and longevity of the blade.

The cutting capacity of these cutters varies from 1.5mm to 20mm diameter wire
ropes. The time taken to cut the wires are 8 seconds. This equipment too gains a
rotating head, that would turn in 180 degrees. The system weighs around 6.3kg.
 Fig.4: Heavy Duty Hydraulic Wire Rope Cutters
Rebar Cutting Shear
The process of cutting of large number of bars on a regular basis is carried out
with the help of rebar cutting shear equipment. These are machines used by
large manufacturers, who bring the bars as per the demand of the engineer and
specifications. Such method will give ready to use bars on site, with no cutting at
the site.

The machine possesses upper and lower jaws, that is kept in such a way to hold
the rebar in position. The separation of any uncut rebars or condense cut piles
are done with the help of raking tines.

Fig.5: Rebar Cutting Shear Equipment

Reinforcement Bending Equipment
Electric Automatic Rebar Benders
Electric automatic rebar benders bending equipment is ideal for contractors,
manufacturers and the builders who can perform the bending of bars with ease,
gaining accuracy. T
his system is used both on site and in the shop by the manufacturers. The
machines run quietly and work only when the bending has to be made. This
would help in avoiding unnecessary wear within the machine.

The figure below shows an electric automatic rebar bending machine. The
system provides us with rollers and collars that would facilitate the use of wide
range of bar diameters.

Fig.6: Electric Automatic Rebar Bending Machine

Compared to manual bending techniques, the fatigue and injury problems with
the workers are reduced. To ensure safety, flush mounted start and stop buttons
are provided.

The maximum capacity of these machines is up to 32mm. The diameter of

bending and bending angle varies with a different model of the machine.

Spiral Hoop Radial Benders

Spiral Hoop Radial Benders are machines that are designed for the spiral
bending of reinforcement bars that have large diameters. They have two driving
rolls, of which one is adjustable to help in holding different diameter bars.
 Fig.6: Spiral Hoop Radius Bending Machine
Reinforcement Tying Equipment
Manual Rebar Tying Machines
Here the cutting, twisting, and tying of the rebar are done in place. The method
involves experienced labor with handy equipment for wire tying. This method is
low cost having no sort of maintenance.

This method is employed in all weather condition. Small projects make use of
such methods. The tying equipment weighs almost 0.68kgs. Any combination of
bar sizes can be tied by this method.

Fig.7: Reinforcement Tying Equipment

Automatic Rebar Tying Equipment
These are equipment that ties bars automatically for sizes up to 32mm. They
take for 1.6seconds for a single tie. They have torqued adjustments; these are
adjusted to have different tying tightness.

Depending on the size of the rebar, each wire spool will tie almost 120 to 200
rebars.

Fig.8: Automatic Rebar Tying Equipment

Electric Cutting and Bending Equipment for Reinforcement
Works
This equipment help in undergoing the process of cutting and bending in a
combination. These machines are portable in nature. The machine has a cutting
speed of 180 degree, that creates a bend within 7 seconds.

Fig.9: Electric Reinforcement Bar cutting and Bending Equipment

These equipments can be used for cutting and bending of bars up to 16mm
diameter range. No requirement for changing the attachments are carried out,
that makes the equipment faster and easy to use.