D.M.

CONSUNJI TECHNICAL TRAINING CENTER

REBAR WORKS

TTC-IN-008-Ø

Registration Mark: Distribution Mark:

This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.
 TABLE OF CONTENT

I. MECHANICAL PROPERTIES …………………………………………………………………………….. 2

II. PHYSICAL PROPERTIES ……………………………………………………………………………….. 4
III. CHEMICAL PROPERTIES ……………………………………………………………………………..... 6
IV. MODES OF FAILURE ……………………………………………………………………………………. 8

V. PLANNING
5.1. PREPARATION FOR CUTTING LIST ……………………………………………………………….... 9
5.2. BEAM CUTTING LIST ……………………………………………………………………………….…. 11
5.3. COLUMN CUTTING LIST …………………………………………………………………..………….. 15

VI. IMPLEMENTATION
6.1. CUTTING & BENDING REBARS ……………………………………………………………………... 20
6.2. REBAR SPLICING …………………………………………………………………………………….... 21
6.3. PRE-CAGING ………………………………………………………………………………………….... 22
6.4. TAGGING & LABELLING …………………………………………………………………………….... 23
6.5. SUPERVISORY & PRODUCTIVITY ………………………………………………………………….. 24

VII. QUALITY CONTROL

7.1. CHECKLIST GUIDE …………………………………………………………………………………….. 26
7.2. REBAR MONITORING ………………………………………………………………………………..… 27
7.3. COMMON ERRORS IN REBAR INSTALLATIONS ………………………………………………….. 31

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

1
 I. MECHANICAL PROPERTIES

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

2

Tensile Strength of Rebars
Registration Mark:
Yield Strength
is the stress w/c a predetermined
amount of permanent deformations occurs
Proportional Limit
is the stress w/c stress-strain
diagrams deviates from a straight line
Tensile Strength
is the maximum stress a steel bar can resist
Testing of Tensile & Yielding
Elongation Test
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.
3
 II. PHYSICAL PROPERTIES

2.1. BAR DIAMETER AND WEIGHT

 Permissible variation of wt. of steel bar shall not exceed 6% (except 8mm w/c is 10%)

Simple Formula: Wt = 0.00616d ²* Length

say: 25mmØ x 10.5m

Wt = 0.00616 (25) ²* 10.5

Wt = 40.425 Kg

Uses:
• Billing
• Estimating
• Control
• Purchasing

Registration Mark:
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

4
 2.2. LUGS

Lugs

Bond Stress

Bond Stress

III. CHEMICAL PROPERTIES

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

Connection of Concrete to Rebars

 3.1. MIRCO ALLOY REBAR PROPERTIES

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

6
 3.2. TEMP-CORE REBAR PROPERTIES

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

7
 IV. Mode of Failures

Types of Failures

1. Mechanical Failure – due to Inadequate Strength

2. Serviceability Failure

 Cracks
 Corrosion
 Carbonation
 Chlorides
 Alkali’s silica reaction
 Freeze & Thaws

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

8
 V. PLANNING

5.1. PREPARATION OF CUTTING LIST

1. Study the Plan View

Take note of Gridlines

Beam Names

Orientation of Columns

Different Elevations

Distances

Other Architectural & MEPF

2. Study the Typical Detail

Understand how the rebar behaves

Identify Splice Zones

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

9
 3. Understanding the Rebar Schedule

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

10
 5.2. BEAM & GIRDER

Column Thickness (+) Clear Span Length (+) Concrete Covers (-)

Quantity Bar Diameter Length Location

Concrete Covers (-) 4 pcs 25ø 7.320m TB

Hooks (+)
4 pcs 25ø 2.660m ETB 4 pcs 25ø 2.660m ETB

2 pcs 16ø 6.800m WB

Hooks (+)2 pcs 25ø 4.285m EBB
4 pcs 25ø 7.320m BB
Length = Column Thickness + Clear Span Length + Hooks - Covers

B-1 Beam Name

A 46 pcs Stirrup Schedule & Quantity
400 x 600 Beam Dimension

Registration Mark:
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

11
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

12
 Details
 It must be simple to Understand
 Drawing must not be too much
crowded
 During layout, adjust line weight
accordingly
 During layout, adjust color
combinations accordingly
 Before printing, always check
preview
 Avoid too much paper
 Text must be readable
 Always label the drawings
properly
 Always put page title, sheet
content & sheet number

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

13
 Typical Plan
So designer can easily
understand your approach
Must be based on Plans

Key Plan
Guide in Locating Beams
Plan View
Table of Contents

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

14
 5.3. COLUMN CUTTING LIST

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

15
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

16
 Key Plan

Typical Plan

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

17
 Details

Schedules

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

18
 Tables

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

19
 VI. IMPLEMENTATION
6.1. CUTTING & BENDING

Manual /Conventional Machine Aided

Cutting & Bending

Pros/Cons/Safety Pros/Cons/Safety
●Simple ●Skilled

●Cheap ●Expensive
●Low Risk ●Moderately Risk

Fully Automated

Pros/Cons/Safety
 Technical
 Very Expensive
 Low Risk

6.2. REBAR SPLICING

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

20
 1. Lap Splice 2. Mechanical Coupling

 Simple
 Prone to Congestion

3. Gas Pressure Welding

 Skilled
 Equipment
 Risk

Registration Mark:
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

21
 6.3. PRE-CAGING

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

22
 6.4. TAGGING & LABELING

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

23
 6.5. SUPERVISION & PRODUCTIVITY

1. SUPERVISION

You need Qualities of a Good Leader The end result of leadership is Productivity How do we
measure productivity?

Registration Mark:
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

24
 2. PRODUCTIVITY

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

25
 VI. QUALITY CONTROL
7.1. CHECKLIST GUIDE

1.) Cutting and bending shall be in accordance with the approved rebar cutting list.

2.) Concrete cover shall be maintained using spacer blocks made from the required strength of
concrete and fixed firmly into place with a tie wire.

3.) Internal supports (chair bars) are to be used when the top mat of reinforcement is liable to deflect
under its own weight. This will be cut and bent from suitable reinforcing steel.

4.) Reinforcement shall be adequately supported and tied to prevent displacement during concreting.

5.) At all construction joints, sufficient length of starter bar shall be left protruding to allow specified
splice lengths for adjacent pours.

6.) All reinforcement shall be free from oil, grease, mud or any material that may adversely affect its
bonding with concrete.

7.) All reinforcement must be thoroughly inspected before the Concrete Pouring Request is signed.

Registration Mark:
TTC-IN-008-Ø
Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

26
 7.2. REBAR MONITORING

1. Gathering Necessary Data

2. Compute for
the Required
Commercial Weight

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

27
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

28
 3. Compute for wastage Percentage

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

29
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

30
 7.3. COMMON ERRORS IN REBAR INSTALLATION

TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

31
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

32
 TTC-IN-008-Ø
Registration Mark: Distribution Mark:
This document is a sole property of D.M. Consunji Technical
Training Center. Any disclosure, unauthorized reproduction
or use is strictly prohibited except with permission from
DMCTTC. Only documents with standard stamps of DMCTTC
are considered official.

33