Contents

1. Scope................................................................................................................................................2
2. IS Standards.....................................................................................................................................2
3. Terminology.....................................................................................................................................3
4. Materials..........................................................................................................................................3
5. Workmanship...................................................................................................................................4
6. Quality Management.......................................................................................................................7
7. Submittal & Certification Required..................................................................................................8
8. Safety Management.........................................................................................................................8
9. Environment Management..............................................................................................................8
10. Completion & Delivery.................................................................................................................8
11. Method of Measurement............................................................................................................8
12. Annexures: NIL...........................................................................................................................9
TECHNICAL SPECIFICATIONS: REBAR

1. Scope
This specification applies to all reinforcement work provide in R.C.C. and Pre-stressed concrete
construction. It covers reinforcement work carried out with all grades of reinforcement steel and
applies to all projects of Godrej properties Ltd. It does not cover the work associated with
provision of high tensile steel bars, wires or strands used in pre-stressed concrete.

2. IS Standards
Work shall be carried out as per latest version of Indian Standards and Code of Practices. List
given hereunder is not to be considered as conclusive and is for reference and guidance only.
Any discrepancies /conflict noticed shall be directed to the Owner /Owner’s Authorized
Representative for his direction/approval. However as a general rule more stringent
specification shall take precedence.

1. IS 226 Specification for steel standard quality

2. IS 228 Methods for chemical analysis of steels

3. IS 280 Specification for mild steel wire for general engineering purpose.

4. IS 432 Specification for mild steel and medium tensile steel burn and hard drawn
steel wires for concrete requirement.
Part 1 Mild steel and Medium tensile steel bars.

Part 2 Hard drawn steel wire.

5. IS 456 Code of practice for construction and design of reinforced concrete.

6. IS 816 Code of practice for use of metal arc welding for general construction in mild
steel
7. IS 961 Specification for structural steel : high tensile steel bars

8. IS 1566 Hard drawn steel wire fabric for concrete reinforcement.

9. IS 1599 Method of Bend test

10. IS 1642 General requirements for fire protection.

11. IS 1785 Cold drawn stress relieved wire (part I)

12. IS 1786 Specification for high strength deformed steel bars and wires for concrete
reinforcement.
13. IS 2751 Code of practice for welding of MS bars.
 14. IS 2502 Code of practice for bending and fixing of bars for concrete reinforcement.

15. IS 4082 Recommendation on stacking and storage of construction materials at site

16. IS 5525 Recommendation for detailing of reinforcement in RCC work.

17. IS 9417 Recommendation for welding cold worked steel bars for reinforced concrete
construction
18 IS 13920 Ductile detailing of RC structures subjected to Seismic Forces

3. Terminology
The following terms and abbreviations shall have the specific meanings as described hereunder.
For terms that are not described herein, the definitions as stated in the applicable Indian
Standard Specifications shall apply.

3.1 Reinforcement: is a common steel bar, and is commonly used as a tensioning device
in concrete structures holding the concrete in compression. It is usually formed from carbon
steel, and is given ridges for better mechanical anchoring into the concrete
3.2 Rust: is a general term for a series of iron oxides. In general usage, the term is applied to red
oxides, formed by the reaction of iron and oxygen in the presence of water or air moisture.
3.3 Splicing: Connection of two or more pieces of linear material.
3.4 Shop Drawing: is a drawing or set of drawings produced by the contractor, supplier,
manufacturer, subcontractor, or fabricator. Shop drawings are typically required for pre-
fabricated components.
3.5 Binding wire: is a steel annealed wire used to tie the rebar together at their points of
intersection with each other.
3.6 Cover block: Is a block of approved material and appropriate size used to position the rebar
such as to result in the required distance between the rebar and concrete surface [cover]
3.7 Coupler: Is a special mechanical splicing device used to connect two pieces of rebar placed
end to end. Couplers are used in place of laps

4. Materials
4.1. Rebar: Unless otherwise specified in drawings, the steel bars shall be of “High strength
deformed steel bars and wires” conforming to the IS 1786 (latest revision), in the following
strength grades:
a. Fe 415, Fe 415D;
b. Fe 550, Fe 550D; and
c. Fe 600

Where “Fe” stands for specified minimum 0.2% proof / yield stress in N/mm2 and
“D” stands for same specified minimum 0.2% proof / yield stress but with enhanced
specified minimum percentage elongation.
 4.2. Binding Wire: The wires used for tying rebar together shall be 16 or 18 gauge, annealed
mild steel wires conforming to IS: 280 (latest revision). If specified in the BOQ the binding
wires may be PVC coated.
4.3. Cover Blocks: Cover blocks shall be of non-corrosive material such as mortar / concrete
blocks and plastic but not wooden or broken bricks or stone. Designed custom made PVC
cover spacers shall be permitted to be used in the Works.
4.4. Mechanical couplers: The Taper/ parallel Treaded Mechanical Splicing system should
conform to Type – II Mechanical Splice as classified under ACI-318 OF 2005, ( Defined as; A
full mechanical Splice shall develop in tension or compression, as required at least 1.25fy of
the bar and shall develop the specified tensile strength of the spliced bar)
Mechanical properties of the couplers shall be as under:

a. Tensile Strength - > or = to the actual strength of the bar.

b. Compression Strength - > or = to the actual strength of the bar.
c. Mode of failure – In rebar (outside coupler area)
d. Ductility: > 20% elongation at ultimate load.

4.5. The Physical Dimensions (these are indicative & may vary from manufacturer to
manufacturer)of the couplers shall be as under:

OUTER DIA COUPLER LENGTH BAR ENGAGEMENT

S.N. REBAR SIZE mm
mm mm mm
1 16 22 56 22

2 20 27 71 29

3 25 35 85 35

4 28 38 91 38

5 32 44 96 40

5. Workmanship
5.1. Storage: Reinforcement bars received at site shall be stored clear of the ground with the
use of timber sleeper, concrete sleeper or any other means. Each diameter of bars shall be
stacked separately. In the event of the rebar having to be stored through the rainy season,
adequate protection shall be provided by way of coating of cement slurry and covering by
tarpaulin sheets.

5.2. Bar Bending Schedule: Unless provided by the Engineer, the contractor shall generate a bar
bending schedule showing the shape, size, cut lengths and other details of each bar type.
The bar bending schedule shall be submitted for the approval of the Engineer.
5.3. Cutting: All reinforcement shall be cut cold, unless otherwise permitted by the Engineer.
The cutting lengths of bars to be cut shall be calculated so as to result in the cut/bent bar of
correct dimensions facilitating the bars to achieve the desired cover when placed in the
forms. The ends of the bars shall be cut square and sharp edges, if any, shall be ground.

5.4. Bending:
[Link] bars shall be accurately bent according to the sizes and shapes shown on the
detailed working drawing / bar bending schedules. They shall be bent gradually by
machine or other approved means. Reinforcing bars shall not be straightened and re-
bent in a manner that will injure the materials.
[Link] containing cracks or splits shall be rejected. They shall be bent cold, except bars of
over 25 mm. in diameter which may be bent hot if specifically approved by the
Engineer.
[Link] that depend for their strength on cold working shall not be bent hot. Bars bent
hot shall not be heated beyond cherry red colour (not exceeding 6450C) and after
bending shall be allowed to cool slowly without quenching.
[Link] incorrectly bent shall be used only after straightening and re-bending such as not
to injure the material. No reinforcement bar shall be bent when in position in the work
without approval, whether or not it is partially embedded in hardened concrete. Bars
having kinks or bends other than those required by design shall not be used Placing &
Tying
[Link] reinforcement bars are bent aside at construction joints and afterwards bent
back into their original position, care should be taken to ensure that at no time the
radius of the bend is less than 4 bar diameters for plain mild steel or 6 bar diameters
for deformed bars. Care shall also be taken when bending back bars to ensure that the
concrete around the bar is not damaged.

5.5. Placing & fixing:

[Link] shall be accurately fixed by any approved means maintained in the
correct position as shown in the drawings by the use of blocks, spacers and chairs as
per I.S. 2502 to prevent displacement during placing and compaction of concrete.
[Link] the time concrete is placed, reinforcement shall be free from mud, oil, or other non-
metallic coatings that decrease bond. Except for pre-stressing steel, steel
reinforcement with rust, mill scale, or a combination of both shall be considered
satisfactory, provided the minimum dimensions (including height of deformations) and
weight of a hand-wire-brushed test specimen comply with applicable specifications
[Link] intended to be in contact at crossing point shall be securely bound together at all
such points with number 16 gauge annealed soft iron wire.
[Link] vertical distances required between successive layers of bars in beams or similar
members shall be maintained by the provision of spacer bars at such intervals that the
main bars do not perceptibly sag between adjacent spacer bars.
[Link] of crossing bars shall not be permitted for assembly of reinforcement unless
authorized by the engineer.
[Link] of parallel reinforcing bars bundled in contact to act as a unit shall be limited to
four in any one bundle. Bundled bars shall be enclosed within stirrups or ties.
 [Link] should be ensured that the ends of the binding wire are turned inwards and do not
project into the cover region.
[Link] rods which are likely to remain exposed for a period of more than 3
months shall be adequately protected against corrosion by painting them with a coat
of cement wash.
[Link] otherwise specified, reinforcement shall be placed within the following
tolerances:
5.5.10. Tolerance in spacing

For effective depth, 200 mm or less + /- 10 mm

For effective depth, more than 200 mm + /- 15 mm

5.6. Cover
[Link] cover is the design depth of concrete cover to all steel reinforcements,
including links. It is the dimension used in design and indicated in the drawings. It shall
be not less than the diameter of the bar.
[Link] amount of cover to reinforcement shall be as shown on the drawings. In the
absence of this information on the drawings, cover shall be provided as per guidelines
of IS 456.
[Link] actual cover provided shall be not less than the cover shown on the drawing nor
shall it exceed the nominal cover by 5mm.
[Link] correct cover shall be maintained by cement mortar cover blocks or other
approved cover blocks. When precast concrete blocks are used to provide the cover,
their strength shall be equal to or more than the strength of concrete in the member.
[Link] strength and spacing of cover blocks in slabs should be adequate to sustain the
load of the reinforcement cage and other construction loads imposed on it.
[Link] blocks shall be properly tied to the reinforcement in such a manner that they
cannot be displaced from their position during erection of reinforcement, formwork
and during concrete placement.

5.7. Lapping of rebar:

Laps shall be strictly as per the drawing or as directed by the Engineer For general guidance,
the following principles shall be followed.
[Link] shall be provided as far as possible away from sections of maximum stress and
be staggered & as per details indicated in the drawings.
[Link] more than half of the total bars shall be lapped at any section.
[Link] 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, such as
increasing the length of lap and/or using spirals or closely spaced stirrups around
the length of the splice.
[Link] splices shall not be used for bars larger than 36 mm diameter: For larger
diameters, bars may be welded. 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.
 [Link] splicing of welded wire fabric is to be carried out, lap splices of wires shall be
made so that the overlap measured between the extreme cross wires shall be not less
than the spacing of cross wires plus 100 mm.

5.8. Welded joints and mechanical Connections (couplers)

[Link] joints or mechanical connections in reinforcement may be used but in all cases
of important connections, tests shall be made to prove that the joints are of the full
strength of the connected bars.
[Link] of reinforcement shall be done in accordance IS 9417. (Recommendation for
welding cold worked steel bars for RCC). Welded joints shall preferably be located at
points where steel will not be subject to more than 75 percent of the maximum
permissible stresses and welds so staggered that, at any one section, not more than 33
percent of the rods are welded.

6. Quality Management
The contractor shall put in place a comprehensive Quality management plan to ensure that
the work is carried out as per specifications and compliance to all requirements are
established and demonstrated through comprehensive documentation. The contractor shall
engage a qualified Quality Manager to implement the quality plan. Till such time a Quality
Management Plan and ITP is approved, the following provisions shall apply.
6.1. The rebar shall be procured only from pre-approved manufacturers. Rebar shall not be
procured from secondary manufacturers / re-rollers unless approved in writing by the
Engineer.
6.2. Contractor shall procure and provide reinforcing steel bars conforming to IS specified and
shall comply with all physical, chemical and mechanical tests. Bars without “ISI’ /
identification marking shall not be brought to site.
6.3. Any rebar brought to site shall not be used in the works unless its characteristics are tested
and found complying with the requirements of the applicable specifications. Till such time
the rebar is not permitted to be used in work, it shall be separately stored and identified to
preclude its use.
[Link] specified agreed in the approved ITP, at least one sample shall be drawn from every
50 MT of rebar received at site of each diameter.
6.5. Cover to rebar shall be ensured by providing adequate numbers of cover blocks and chairs.
At the time of approval of the pour card, integrity of the cover blocks and their spacing shall
be inspected to ensure that they have not been displaced during installation of formwork.
6.6. The position of the rebar shall be inspected after placing concrete in the forms to ascertain
that the rebar are not damaged or displace from their original position and the desired
cover has been achieved.
6.7. Any rebar that has been installed in the works but is likely to exposed for a prolonged
period before concreting takes place shall be protected by application of a coat of water
cement grout.
7. Submittal & Certification Required
7.1. The contractor shall maintain a comprehensive record of the concrete works as per the
approved ITP. All records shall be in hard copy, signed by the Quality manager, unless
electronic records are permitted by the Engineer.
7.2. The following documents shall be submitted to the Engineer for approval and record:
a. Manufacturers Test Certificate for every batch / lot of rebar brought to the site
b. Test certificate from an Independent Third Party Lab as applicable
c. Bar Bending Schedule for different pours
d. Test certificate regarding strength of coupler joint [if applicable]

8. Safety Management
Apart from general safety and health hazards like working at heights, falling objects etc., the
contractor shall assess the hazards associated with concrete works and shall take specific
action to mitigate against the same. Some of the hazards associate with rebar works are
listed for general guidance below.
a. Touching of hot objects
b. Flying sparks, metal chips or pieces
c. Piercing by falling or tripping on sharp objects

9. Environment Management
Apart from general environmental impact of construction activities, the contractor shall assess
the environmental impact associated with rebar works and shall take specific action to mitigate
against the same. Some of the environmental aspects associate with rebar works are listed for
general guidance below.

[Link] & Delivery:

Work related to rebar construction shall not be deemed as complete till such time all the
following conditions are fulfilled:

10.1. There are no defects in the rebar work or defects have been rectified to the satisfaction
of the Engineer. Specifically, the cover required for the rebar should have been achieved as
per permissible tolerances, as seen after the completion of concrete pour.
10.2. The concrete of which rebar forms a part has been accepted by the Engineer, unless the
rebar is meant to be permanently protruding outside concrete
10.3. All quality documents, test certificates have been submitted

11. Method of Measurement

Reinforcement shall be measured as follows:

11.1. Lengths of different diameters of bars actually used including authorized overlaps shall be
measured nearest to a centimeter and their weight calculated.
11.2. If rebar is procured by the contractor, weight per metre given in table 3.8 shall be used.
 11.3. If rebar is supplied by the client free of cost on tonnage basis to the project site, per
metre weight for each diameter of the bar shall be fixed by the Engineer from actual
stocks of steel available at site or weight per meter given in table 3.8 shall be used.
11.4. Chairs and spacer bars shall not be measured and paid for. For reconciliation purpose it
will be taken into account, if steel is supplied free of cost by the Owner.
11.5. In case of welded coupled joints, measurement for payment shall be equivalent to the
length of overlap, as per design.
11.6. Quoted rates shall include, in addition to cost of material,
a. Cover blocks
b. Cutting, bending, placing and fixing in position.
c. Binding wire as approved.
d. Cleaning of bars
e. Decoiling of steel
f. Double handling if any.
g. All necessary scaffolding
11.7. In case rebar is supplied by the Owner free-of-cost, the quoted rate shall include, in
addition to 4a) to 4d) above, loading, Transportation & Unloading from Owner’s store to
work site and returning surplus material back to store.

[Link]: NIL