3.9.

Curing
Supervising Concrete Works 3. Manufacturing Concrete 3.9. Curing
IN PROGRESS

3.9.1. ACI 308R-01 Guide to Curing Concrete

The completion of cement hydration requires that adequate moisture and favorable temperatures
be maintained after concrete is placed. The process of providing the required water (moisture) and
maintaining a favorable temperature for a period of time after placing concrete is referred to
as curing.
ACI 308R-01: 1.3—Curing and the hydration of portland cement
1.3.1 Hydration of portland cement—Portland cement concrete is a composite material in which
aggregates are bound in a porous matrix of hardened cement paste. At the microscale, the
hardened paste is held together by bonds that develop between the products of the reaction of
cement with water. Similar products are formed from the reactions between cement, water, and
other cementitious materials.
The cement-water reaction includes both chemical and physical processes that are collectively
known as the hydration of cement.
Curing should begin immediately after finishing. Curing is needed to ensure continued hydration of
the cement, strength gain of the concrete, and a minimum of early drying shrinkage.
Along with deposition and consolidation proper curing of the concrete is extremely important.
Curing may be considered as the method whereby the concrete is assured of adequate time,
temperature, and supply of water for the cement to continue to hydrate. The time normally
required is 3 days and optimum temperatures are between 40 to 80°F. As most concrete is
batched with sufficient water for hydration, the only problem is to ensure that the concrete does
not become dried out. This may be accomplished by ponding with water (for slabs), covering with
burlap or polyethylene sheets or spraying with an approved curing compound.
Curing is one of the least costly operations in the construction of quality concrete. and one that is
all too frequently overlooked. Concrete, if allowed to dry out during the curing stage, will attempt
to shrink. The developing bonds from the cementitious reaction will attempt to restrain the
shrinkage from taking place. But the end result is always the same: the shrinkage wins out and a
crack forms as the shrinkage stresses are always higher than the tensile strength of the concrete.
Curing measures should be initiated when the concrete surface begins to dry, which starts as
soon as the accumulated bleed water evaporates faster than it can rise to the concrete surface’
3.9.2. Evaporation
The rate of evaporation is influenced by air and concrete temperatures, relative humidity, wind, and
radiant energy from direct sunshine. The driving force for evaporation of water from the surface of
concrete is the pressure difference between the water vapor at the surface and the water vapor in
the air above that surface; the greater the pressure difference, the faster the evaporation. Vapor
pressure at the concrete surface is related to the temperature of the water, which is generally
assumed to be the same as the concrete surface temperature. The higher the concrete surface
temperature, the higher the surface water-vapor pressure.
3.9.3. Initial curing
For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative
environments, or both, surface drying can begin well before initial set and well before initiation of
finishing operations. Under such conditions, it is necessary to reduce moisture loss by one or
more initial curing techniques, such as fogging, the use of evaporation reducers, or by modifying
the environment with sunshades, windscreens, or enclosures. Because finishing can involve
several separate and time-consuming operations, initial curing measures may need to be
continued or reapplied until finishing is complete.
3.9.4. Final curing
The concrete surface should be protected against moisture loss immediately following the
finisher or finishing machine. Significant surface-drying can occur when curing measures are
delayed until the entire slab is finished because the peak rate of evaporation from a concrete
surface often occurs immediately after the last pass of the finishing tool, as tool pressure brings
water to the surface. This is especially true when the finished texture has a high surface area such
as a broomed surface. Therefore, it is necessary to control moisture loss immediately after
finishing.
When the conclusion of finishing operations coincides with the time of final set, final curing is
applied at exactly the right time to reduce the peak rate of moisture loss. A delay in final curing
can result in considerable water loss.
3.9.5. Intermediate curing
The combination of a curing compound as an intermediate curing method followed by water-
saturated coverings as a final curing method is more common in bridge construction than in
building construction.
ACI 318-08:
5.11.1— Concrete (other than high-early-strength) shall be maintained above 50 °F and in a moist
condition for at least the first 7 days after placement, except when cured in accordance with
5.11.3.
5.11.2 — High-early-strength concrete shall be maintained above 50 °F and in a moist condition for
at least the first 3 days, except when cured in accordance with 5.11.3.
3.10. Construction Joint
Supervising Concrete Works 3. Manufacturing Concrete 3.10. Construction Joint
IN PROGRESS

ACI 318-08: 6.4 Construction Joints

6.4.1 — Surface of concrete construction joints shall be cleaned and laitance removed.
6.4.2 — Immediately before new concrete is placed, all construction joints shall be wetted and
standing water removed.
6.4.3 — Construction joints shall be so made and located as not to impair the strength of the
structure. Provision shall be made for transfer of shear and other forces through construction
joints. See 11.6.9.
6.4.4 — Construction joints in floors shall be located within the middle third of spans of slabs,
beams, and girders.
6.4.5 — Construction joints in girders shall be offset a minimum distance of two times the width of
intersecting beams.
6.4.6 — Beams, girders, or slabs supported by columns or walls shall not be cast or erected until
concrete in the vertical support members is no longer plastic.
6.4.7 — Beams, girders, haunches, drop panels, shear caps, and capitals shall be placed
monolithically as part of a slab system, unless otherwise shown in design drawings or
specifications.
Construction joints, as distinguished from expansion joints, are required by construction
operations but do not necessarily allow movement across the joint. Plan construction joint
locations ahead of placing, and adhere to these locations, if possible. Generally, they marked the
top of a lift, the end of a monolith, or the end of a day’s work. They should be properly located,
neat, and well bonded.
Unplanned Construction Joints
Breakdowns, lack of concrete delivery, or many other construction problems may make it
necessary to stop placement of concrete at locations other than those previously planned. The
designer and the inspector should require that tentative plans and details for installing such a
construction joint may be made ahead of time. When need for an unplanned construction joint
arises, consult with the designer regarding possible effects of the joint on structural behavior or
safety.
When joints are not indicated on the plans, locate and construct them so as to least impair
strength of the structure. In construction of unplanned joints, observe all of the precautions and
methods discussed above.
3.11. Embedment in Concrete
Supervising Concrete Works 3. Manufacturing Concrete 3.11. Embedment in Concrete
IN PROGRESS

ACI 318-08: 6.3 Embedments in concrete

6.3.1 — Embedments of any material not harmful to concrete and within limitations of 6.3 shall be
permitted in concrete with approval of the licensed design professional, provided they are not
considered to replace structurally the displaced concrete.
6.3.3 — Conduits, pipes, and sleeves passing through a slab, wall, or beam shall not impair
significantly the strength of the construction.
6.3.4 — Conduits and pipes, with their fittings, embedded within a column shall not displace more
than 4 percent of the area of cross section on which strength is calculated or which is required for
fire protection.
6.3.5 — Except when drawings for conduits and pipes are approved by the licensed design
professional, conduits and pipes embedded within a slab, wall, or beam (other than those merely
passing through) shall satisfy 6.3.5.1 through 6.3.5.3
6.3.5.1 — They shall not be larger in outside dimension than 1/3 the overall thickness of slab, wall,
or beam in which they are embedded.
6.3.5.2 — They shall not be spaced closer than three diameters or widths on center.
6.3.5.3 — They shall not impair significantly the strength of the construction.
4.1. Classess of Reinforcing Bars
Supervising Concrete Works 4. Materials 4.1. Classess of Reinforcing Bars
IN PROGRESS

Standard specifications for reinforcing bars are stipulated in various codes and standards –
among them: the Philippine National Standards (PNS), American Society for Testing and Materials
(ASTM), Japan Industrial Standards (JIS), etc. These standards govern the strength grades, rib
patterns, sizes and lengths, mechanical properties and marking of bars.
These standard and specifications provide minimum requirements for construction of reinforced
concrete structural elements of buildings. These standard and specifications may apply to all
matters pertaining to construction and material properties as long as these are not in conflict with
the National Structural Code of the Philippines.
Reinforcement shall be deformed reinforcement, with the exception of plain reinforcement which
shall be permitted for spirals or tendons. Reinforcing steel must conform to applicable ASTM
standard specifications.
Materials, products, or equipment specified by reference to a standard or by reference to a
manufacturer materials , products, or equipment ensuring an equal or higher quality than the
standards or manufacturers mentioned will also be acceptable. It will be incumbent on the
contractor to verify the same equivalent or higher quality and submit comparative data (both
specified and proposed data for review.
Steel bars for concrete reinforcement are generally divided into two classes:

• the plain round bar

• the deformed bar
Deformed steel bars—Deformed bars are round steel bars with lugs, or deformations, rolled into
the surface of the bar during manufacturing. These deformations create a mechanical bond
between the concrete and steel. Deformed steel bars are the most common type of reinforcement
used in structural concrete.

Typical deformed Reinforcing

Bar (Courtesy of Reinforcing Steel Institute)
Deformed Reinforcement
Deformed reinforcing bars shall conform to one of the following specifications: (NSCP)

• PNS 49 : 2002 – Specification for Steel Bars for Concrete Reinforcement

• ASTM A 615M – Specification for Deformed and Plain Billet Steel Bars for Concrete
Reinforcement
• ASTM A616 including S1 “Specification for Rail-Steel Deformed and Plain Bars for Concrete
Reinforcement” including Supplementary Requirement S1
• ASTM A 617 “Specification for Axle-Steel Deformed and Plain Bars for Concrete
Reinforcement.
• ASTM A 706 “Specification for Low-Alloy Deformed Bars for Concrete Reinforcement”
• JIS G 3112* “Steel Bars for Concrete Reinforcement”
Plain round bars are steel bars without protrusions and are basically used for slab on ground. Its
use has declined in popularity as even slab on ground employ deformed bars.
Plain bars for spiral reinforcement shall conform to the specification listed under deformed
reinforcement a, b, c, d, and e. Plain wire for spiral reinforcement shall conform to “Specification
for Steel Wire, Plain for Concrete Reinforcement” (ASTM A 82), except for wires with a specified
yield strength fy exceeding 415 MPa, fy shall be the stress corresponding to a strain of 0.35
percent if the yield strength specified in the design exceeds 415 MPa
Welded Wire Fabric
Welded plain wire fabric bonds to concrete by the positive mechanical anchorages at each welded
wire intersection. Welded wire fabric is a prefabricated reinforcement consisting of a parallel
series of high-strength cold-drawn or cold-rolled wires welded together in square or rectangular
grids. Each wire intersection is electronically resistance-welded by a continuous automatic welder.
Pressure and heat fuse the intersecting wires into a homogeneous section and fix all wires in their
proper position. Plain wires, deformed wires, or a combination of both may be used in welded wire
fabric.

4.1. Classess of Reinforcing Bars

Supervising Concrete Works 4. Materials 4.1. Classess of Reinforcing Bars
IN PROGRESS

Standard specifications for reinforcing bars are stipulated in various codes and standards –
among them: the Philippine National Standards (PNS), American Society for Testing and Materials
(ASTM), Japan Industrial Standards (JIS), etc. These standards govern the strength grades, rib
patterns, sizes and lengths, mechanical properties and marking of bars.
These standard and specifications provide minimum requirements for construction of reinforced
concrete structural elements of buildings. These standard and specifications may apply to all
matters pertaining to construction and material properties as long as these are not in conflict with
the National Structural Code of the Philippines.
Reinforcement shall be deformed reinforcement, with the exception of plain reinforcement which
shall be permitted for spirals or tendons. Reinforcing steel must conform to applicable ASTM
standard specifications.
Materials, products, or equipment specified by reference to a standard or by reference to a
manufacturer materials , products, or equipment ensuring an equal or higher quality than the
standards or manufacturers mentioned will also be acceptable. It will be incumbent on the
contractor to verify the same equivalent or higher quality and submit comparative data (both
specified and proposed data for review.
Steel bars for concrete reinforcement are generally divided into two classes:

• the plain round bar

• the deformed bar
Deformed steel bars—Deformed bars are round steel bars with lugs, or deformations, rolled into
the surface of the bar during manufacturing. These deformations create a mechanical bond
between the concrete and steel. Deformed steel bars are the most common type of reinforcement
used in structural concrete.

Typical deformed Reinforcing

Bar (Courtesy of Reinforcing Steel Institute)
Deformed Reinforcement
Deformed reinforcing bars shall conform to one of the following specifications: (NSCP)

• PNS 49 : 2002 – Specification for Steel Bars for Concrete Reinforcement

• ASTM A 615M – Specification for Deformed and Plain Billet Steel Bars for Concrete
Reinforcement
• ASTM A616 including S1 “Specification for Rail-Steel Deformed and Plain Bars for Concrete
Reinforcement” including Supplementary Requirement S1
• ASTM A 617 “Specification for Axle-Steel Deformed and Plain Bars for Concrete
Reinforcement.
• ASTM A 706 “Specification for Low-Alloy Deformed Bars for Concrete Reinforcement”
• JIS G 3112* “Steel Bars for Concrete Reinforcement”

Plain round bars are steel bars without protrusions and are basically used for slab on ground. Its
use has declined in popularity as even slab on ground employ deformed bars.
Plain bars for spiral reinforcement shall conform to the specification listed under deformed
reinforcement a, b, c, d, and e. Plain wire for spiral reinforcement shall conform to “Specification
for Steel Wire, Plain for Concrete Reinforcement” (ASTM A 82), except for wires with a specified
yield strength fy exceeding 415 MPa, fy shall be the stress corresponding to a strain of 0.35
percent if the yield strength specified in the design exceeds 415 MPa
Welded Wire Fabric
Welded plain wire fabric bonds to concrete by the positive mechanical anchorages at each welded
wire intersection. Welded wire fabric is a prefabricated reinforcement consisting of a parallel
series of high-strength cold-drawn or cold-rolled wires welded together in square or rectangular
grids. Each wire intersection is electronically resistance-welded by a continuous automatic welder.
Pressure and heat fuse the intersecting wires into a homogeneous section and fix all wires in their
proper position. Plain wires, deformed wires, or a combination of both

4.2. Marking on reinforcing bars

Supervising Concrete Works 4. Materials 4.2. Marking on reinforcing bars
IN PROGRESS

Logo or Symbol
The logo or symbols found in reinforcing bars can be the initials or the name of the company
registered for manufacturing purposes.

Table 1-2 indicates the Philippine National Standards (PNS49:1986). showing the various grades
for reinforcing bars with the corresponding dash marks.
Dash (Parallel to the Rib) or Number
The dash or number marked on reinforcing bars signify the grade (tensile strength).
Dot (a minimum of 3 mm. in size)
The dot marking signifies the reinforcing bar size or its nominal diameter. Table l-3 obtained from
Philippine National Standards (PNS49: 1986) shows the list of reinforcing bar diameters with its
corresponding bar dots.
 Note: For bar having diameter
of 12mm to 36mm, multiply the number of (dots) by 4 to obtain the nominal bar diameter except for
25 mm diameter
Wmark
The W mark on reinforcing bar signifies its weldability.
Color Grade
The Color Code is painted on the surface of the ends of each bar signifying its grade (tensile
strength). Figure 1-2 illustrates a PNS markings for grade 275, D32 and weldable deformed bars.

• White-Grade 230
• Yellow-Grade275
• Green-Grade 415
Note. Red color signifies weldable bars
PNS 49:2002
4.3. Bar Supports
Although bar supports are not concrete reinforcing agents, its use is necessary in maintaining the
position of reinforcement.
What’s important is that the design of the structure is based on having the steel in the right place.
Incorrect reinforcing steel placement can and has led to serious concrete structural failures. For
example, lowering the top bars or raising the bottom bars by ½ inch more than that specified in a
6-inch-deep slab could reduce its load-carrying capacity by 20%.
Placing reinforcement atop a layer of fresh concrete and then pouring more on top is not an
acceptable method for positioning. You must use reinforcing bar supports, which are made of
steel wire, precast concrete, or plastic. Chairs and supports are available in various heights to
support specific reinforcing bar sizes and positions. In general, plastic accessories are less
expensive than metal supports.
The Concrete Reinforcing Steel Institute’s Ready Reference Reinforcing Steel Resource Guide or the
classic Placing Reinforcing Bars has three tables that show most of the currently available
supports in the various materials and describing the situation where each is most effectively used.
Bar supports may consist of metal, concrete, fiber-reinforced concrete, plastic or other materials.
Most widely used are factory made wire bar supports made of plain wire or stainless steel wire.
The lower portions may be provided with special rust protection by a plastic covering, or as a
whole or as a part of the stainless wire. Precast concrete blocks and fiber-reinforced cement
supports, plain or provided with tie wires, and dowel blocks are commonly used to support bars in
footings and slabs on grade. All-plastic supports are most commonly used as side form spacers,
but may also be used on horizontal work.

If types and arrangements of bar supports are not specifically indicated in the contract
documents. they will generally be supplied in accordance with usual industry practices. Spacer
blocks with cast in tie wire may be used with the written agreement of the Engineer for support of
the bottom layer of reinforcement in the non-exposed areas only. The blocks shall be of minimum
size and made from cement-sand-small aggregate mix to match surrounding concrete strength.
appearance and durability. In exposed concrete use high density plastic supports, hot-dipped
galvanized bar supports with plastic feet, or stainless steel as required.
Classes of Bar Supports
The following items were obtained from the Concrete Reinforcing Steel Institute (CRSI Manual of
Standard Practice). Discussions presented herein are intended to serve as a guide for the selection
and utilization of bar supports to position reinforcing bars in reinforced concrete. We do not imply
nor express approval for the use of these products. Any product pictured or described herein are
listed for general informational purposes only. The selection and use of bar supports should not
be substituted for the judgement of an experienced engineer or architect as to the best way of
achieving specific design requirements in the field.
Wire Bar Supports
Based on long-term experience and field observations, bar supports made in accordance with the
wire sizes and geometrical dimensions have performed satisfactorily.
Precast Concrete Bar Support
Precast concrete bar supports are normally supplied in three styles: (1) plain, (2) with wires, and
(3) doweled. Plain concrete bar supports are used to support bars off the ground. Concrete bar
supports with wires are commonly supplied with two 16 gauge tie wires cast in the center.
Concrete bar supports with wires are used against vertical forms or in positions necessary to
support the concrete bar support by tying to the bars. Doweled concrete bar supports are cast
with a hole in the center, approximately 56.25mm deep, and large enough to insert a #4 bar with a
90° bend at the top used to support top bars above the, concrete bar support. At the same time
the concrete bar support can be used to support bottom bars off the ground by placing them on
either side of the dowel bar. Properly spaced, precast concrete bar supports sufficiently support
the bars within the tolerances established for the placement of bars.

Cementitious Fiber-Reinforced Bar Supports

Cementitious fiber-reinforced bar supports are commercially available in two types: plain, or with
wire, and are available in various sizes, shapes and dimensions. It is chemically inert and bond
naturally to the concrete as it has similar coefficient of thermal expansion to that of the
surrounding concrete. Cementitious fiber-reinforced supports can be used for both horizontal and
vertical reinforcing steel support, but must be fastened to the vertical steel. These supports are
available in units offering multi-support heights for the same support
All-Plastic Bar Supports and Side Form Spacers
All-plastic bar supports may be used for horizontal and vertical reinforcing steel. It may have a
snap-on action or other method of attachment. All-plastic supports are light weight nonporous and
chemically inert to concrete. Properly designed, all-plastic bar supports should rounded seating so
as not to punch holes in the formwork and should not deform under load when subjected to
normal temperatures encountered in use nor should it shatter or severely crack under impact
loading when used in cold weather.
5.1. Fabrication Work Activities
Supervising Concrete Works 5. Fabrication of Reinforcement Bars 5.1. Fabrication Work Activities
IN PROGRESS

Fabrication work usually includes the following activities:

1. Marking of Reinforcing Bars – marking of reinforcing bars is done to mark the cutting point
usually from straight bars prior to the cutting process.
2. Cutting of Reinforcing Bars – cutting of reinforcing bars is done in preparation for bending.
3. Bending of Reinforcing Bars – bending of reinforcing bars is done with reference to
approved shop drawings.
4. Bundling and Tagging of Reinforcing Bars – bundling and tagging of reinforcing bars are
employed for easy identification of the structural sections (e.g. column, beam/girders,
slabs, walls. stairs, etc.) it belongs.
5. Delivery of Reinforcing Bars – should fabrication be done outside the jobsite, delivery of
reinforcing bars should be considered as one major activity in rebar work. Non delivery of
fabricated items would result to delay of installation work.
6. Storing of Reinforcing Bars- although storing is done during delivery or right after
fabrication usually adjacent the fabrication yard, such activity also requires time and labor
and must be given emphasis especially in a constricted jobsite.

An illustration of a typical work flow for fabricating reinforcing bars. Other activity not mentioned
but important should also be considered especially during the actual execution of work.
5.2. Fabrication
Supervising Concrete Works 5. Fabrication of Reinforcement Bars 5.2. Fabrication
IN PROGRESS

The fabrication of bars includes cutting-to-length of straight bars, cutting-to-length and bending to
shape of bent bars, and the bundling and tagging of bars for handling and for identification on the
job. A general knowledge of these steps, which go before delivery of reinforcing bars to the job,
may be helpful to the steelman.
CRSI 4.18 Fabrication of Reinforcing Bars
It is recommended that all reinforcing bars be shop fabricated, as fabrication operations can be
performed with greater accuracy in the fabricating shop. All bar bending should conform to the
typical bar bends, standard end hooks, and ACI standard fabricating tolerances. The detailer shall
prepare a bar cutting list and bar bending schedule for fabricators use to cut and fabricate the
reinforcing bars.
CRSI 4.19 Placing Drawings
In preparing the placing drawings for a specific structure, the detailer determines the quantity of
reinforcing bars, bar lengths, bend types, and bar positioning from the information and instructions
provided on the project drawings and in the project specifications. Placing drawings are prepared
specifically for each individual structure. Project specification should allow for an adequate time
frame for the submission, correction and approval of the placing drawings. Placing drawings are
not design documents since they only convey the Engineers intent. Thus the project specifications
should not require that a Professional Licensed Engineer prepare or check and seal the placing
drawings

5.3. Bar Cutting

Supervising Concrete Works 5. Fabrication of Reinforcement Bars 5.3. Bar Cutting
IN PROGRESS

CRSI 4.21 Field Cutting of Reinforcing Bars

Various means are used to cut reinforcing bars at the job-site. Smaller size bars can usually cut by
a bar cutter, all bar size can be cut by power saw or rebar cutting machine or by flame-cutting such
as using as oxy-acetylene torch.
Regarding flame-cutting, tests have shown that any effect of flame-cutting is localized to the end-
cut surfaces. Only a very short distance, approximately 3/16 inch (5mm) from the flame-cut ends
is affected. Hardness testing was used to evaluate the effects of flame-cutting on the tensile
properties of the bars. From the tests it was concluded that flame-cutting had no adverse effects.
Flame cutting of epoxy-coated reinforcing bars is not recommended.
After obtaining the length of each bar from the bar cutting schedule, sorting into type and size
then marking the required length is done prior to cutting. The length of each bar indicated on the
bar schedule is obtained from the Cutting and Bending List.
The main purpose of cutting and bending list is to determine the most economical length of
straight bars from which the required cut length of reinforcing bars are obtained.
Shop drawings should be submitted far enough in advance to allow time for a meeting of mind
among the architect, the engineer, the prime contractor, the subcontractor, and the owner.
5.4. Bar Bending
Supervising Concrete Works 5. Fabrication of Reinforcement Bars 5.4. Bar Bending
IN PROGRESS

Minimum Diameter of
Bend
Bending of reinforcing bars are done manually or with the use of a bending machine. Bar bending
must be performed in accordance with the workshop drawings and the bar fabrication details.
Diameter of bend is measured in the inside of the reinforcing bars. The actual overall dimension of
a standard minimum bend may vary from the design dimension by an amount up to the sum of the
cutting tolerance and the accumulative bending tolerances. The actual overall dimension may vary
since the length of a straight bar beyond the end of the curve in a hook will take up all cutting and
accumulative bending tolerances.
ACI 318-08: 7.0 Details of Reinforcement
7.1 — Standard hooks
The term “standard hook” as used in this Code shall mean one of the following:
7.1.1 — 180-degree bend plus 4db extension, but not less than 2-1/2 in. at free end of bar.
7.1.2 — 90-degree bend plus 12db extension at free end of bar
7.1.3 — For stirrup and tie hooks

a. No. 5 bar and smaller, 90-degree bend plus 6dbextension at free end of bar; or
b. No. 6, No. 7, and No. 8 bar, 90-degree bend plus 12db extension at free end of bar; or
c. No. 8 bar and smaller, 135-degree bend plus 6dbextension at free end of bar.
d. 7.2 — Minimum bend diameters
7.2.1 — Diameter of bend measured on the inside of the bar, other than for stirrups and ties in
sizes No. 3 through No. 5, shall not be less than the values in the table shown.

Minimum Diameters of Bend (NSCP 1993 – 5.7.2 Minimum Bend Diameter

7.2.2 — Inside diameter of bend for stirrups and ties shall not be less than 4db for No. 5 bar and
smaller. For bars larger than No. 5, diameter of bend shall be in accordance with above table.
7.2.3 — Inside diameter of bend in welded wire reinforcement for stirrups and ties shall not be less
than 4db for deformed wire larger than D6 and 2db for all other wires. Bends with inside diameter of
less than 8db shall not be less than 4db from nearest welded intersection.
7.3 — Bending
7.3.1 — All reinforcement shall be bent cold, unless otherwise permitted by the licensed design
professional.
7.3.2 — Reinforcement partially embedded in concrete shall not be field bent, except as shown on
the design drawings or permitted by the licensed design professional.

Hooked bar details for development of

standard hooks
Sampling is a trial fabrication subject for approval by an authorized representative prior to mass
production.
Bar Cutting & Bending Schedule

• The main purpose of cutting and bending list is to determine the most economical length of
straight bars from which the required cut length of reinforcing bars are obtained.

• The length of each bar indicated on the bar schedule is obtained from the Cutting and
Bending List.
Example of cutting and bending list shows the

• Structure
• Location/position of RSB
• Shape and dimension
• Bar size
• Cut length
• No. of pieces
• Weight
Example of a bar cutting and bending schedule
5.5. Bundling and Tagging
Supervising Concrete Works 5. Fabrication of Reinforcement Bars 5.5. Bundling and Tagging
IN PROGRESS

CRSI 7.4 Standard Bundling and Tagging

7.4.1 Bundles
A bundle should consist of one size, length, or mark (bent) of reinforcing bars with the following
exceptions:

1. Small quantities of bars maybe bundled together for convenience

2. Groups of varying bar lengths or marks (bent) that will be placed adjacent maybe bundled
together.
7.4.2 Lifts
Lifts are classified in two categories:

1. Shop lifts generally are units of reinforcing bars as loaded for shipment
2. Field lifts are units of reinforcing bars as required for field handling by the contractor.
A field lift may consist of single bundles or two or more smaller bundles tied together. A shop lift
may consist of one or more bundles, the same as field lifts or consist of two or more field lifts.
Straight and bent bars will not be combined in the same lift.

A typical example of a bar tag indicating the number of pieces, size, length, structural mark and
grade of reinforcing bar that has been fabricated.
7.4.4 Ties
Bundles and lifts should be securely tied; gage and spacing of ties should be as follows: minimum
No. 9 gage wire for large bundles and/or lifts; minimum No12 gage wire for small bundles. Ties
are generally spaced 10 to 15 feet (3 to 4.5 m) on centers. Ties are not intended for use in lifting
bundles.
7.4.5 Tags
Tags should be made of durable and waterproof material and marked in a legible manner with
waterproof markings; one tag per bundle, attached by wire. Identification tags should show the
grade of steel, number of pieces, size, and mark or length of bars.
 Example of a bar tag
Either on the same tag or on a separate tag, the bundle is identified by the number of pieces, size
and length of straight bars. In addition to this, the bent code mark is shown for bent bars. The
steel grade for both bent and straight bars, and oftentimes the structural mark should the bundled
bars composed of parts of a structural member.

6.1. Fundamentals
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.1. Fundamentals
IN PROGRESS

Reinforcement placement shall be;

• Accurately placed
• Adequately supported
• Secured against displacement
Fabricated reinforcing bars should be placed as near the structures as possible to reduce the time
required to carry them. These reinforcing bars may be installed by laborers or skilled steelmen.
The latter should place the reinforcing bars at the fastest rate with little or no supervision required.
Reinforcing bars are installed based on the reviewed bar placement schedule. Coordinate work
with other trades as necessary to assure proper placement of pipes, conduit, sleeves, fixture
boxes, etc. in relation to reinforcement accessories and formworks.
Installation work is generally composed of the following activities:

1. Marking or Setting-out – to assure that reinforcing bars will fall within the given tolerable
alignment, spacings, concrete covering limits, elevations, etc., reference lines must be first
established. Sometimes this task is already done by a surveyor, but still in the case of slab
reinforcements, markings for bar spacings are necessary prior to laying down all the
reinforcing bars.
2. Hauling of Reinforcing Bars – when reinforcing bars are to be lifted on upper floors, it may
be a potential problem if lifting machines are not fully utilized by the rebar contractor. This
is a time consuming activity that could also lead to a possible loss of time or waiting time
for steel fixers. Proper planning and coordination with other trade works is necessary to
have the assurance of a smooth flow of materials.
3. Placing of Reinforcing Bars – this activity involves the positioning, tying, and splicing of
reinforcing bars based on the structural detail drawing prior to pouring of concrete.
6.2. Splicing Reinforcement
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.2. Splicing Reinforcement
IN PROGRESS

Reinforced concrete structures are generally designed so that the separate parts act as a single
unit. This makes it necessary to properly locate construction joints and provide continuity in the
steel reinforcement through the joints. Just as it is impossible to cast all the concrete at one time,
it is also impossible to provide full length continuous bars in most structures. This is because of
manufacturing, fabrication, or transportation limitations. Since splices in reinforcement cannot be
avoided, it is necessary for the engineer to provide for properly design splices.
Practical construction limitations on bar lengths must be considered. Except for slabs on grade,
long lengths of horizontal bars projecting far beyond required construction joints generally
undesirable. A normal lap splice at or near the joint is preferable. Vertical bar lengths in columns
and walls are most severely restricted. In multi-story construction, column bars, usually one story
in height. However, with heavily reinforced columns and staggered location of splices, vertical
bars can extend two stories in height. In high walls, vertical bars extending full height are
sometimes difficult to hold in position and may need to be spliced at one or more locations, either
to suit the constructor’s concrete operations or the location of the construction joints as
determined by the engineer.
Tabulation and Illustration of Spacing Limits of Reinforcing Bars
Splices are made at construction joints between footings and columns or walls, between columns
below or above a floor, or between walls and floors. Bars project through the joints and are either
lapped with other bars or connected directly by welded or mechanical splices.
Bars are spliced usually by lapping, when used as horizontal bars in walls, temperature bars in
slabs, or vertical bars extending through horizontal construction joints in high walls and piers etc.
Reinforcement shall continue through construction joints for sufficient distances to develop bond
requirements, and bars shall not be spliced in joints. Provide additional reinforcement in all
construction joints in walls, beams and slabs at right angles to joints, and where indicated.
Avoid splicing reinforcement at points of maximum stress. Splices used shall provide laps of
lengths noted on drawings and be in accordance with ACI code. All construction joints, laps and
additional reinforcement shall be shown on shop drawings.
Types of splices

1. Lapped Splices – In most cases, lapped splices are easier to do and are more economical
for small size bar than the other types. The length of lap varies with the concrete strength,
the yield strength of the steel and the bar size. Laps are always shown on detailed drawings
and will be found either in the details or in the general notes. Due to close spacing of bars, it
is not always possible to provide lap splices. In some cases, especially on large size bars,
the amount of lap might be sufficient to make another type of splice more economical. The
 engineer may specify a particular type. But more often, he will provide a choice of types to
the contractor. The bar fabricator will need to know the type selected so proper end
preparation of the bars can be made in his shop if required. Also he will need to show
details on the placing drawings for use by the steelmen.
2. Welded Splices – In precast concrete work, welded splices are almost always necessary.
Concrete members are usually cast with bars or plates projecting and these projections are
connected from member to member by butt or lap-welded splices. One should always
check whether the reinforcing bars that it intends to welds are weldable.
3. Mechanically Coupled Splices – There are two general types of proprietary mechanical
splice devices, (a) couplers and (b) end-bearing. Couplers are used to resist both tensile
and/or compressive forces. End-bearing devices are used for splices capable of
transferring compression forces only.
Following are some of the important points on Chapter 12 – Development and Splices of
Reinforcement of ACI Code 318-08 Building Code Requirements for Structural Concrete.
ACI 318-08: 12.14 Splices of Reinforcement
12.14.1 — Splices of reinforcement shall be made only as required or permitted on design
drawings, or in specifications, or as authorized by the licensed design professional.
12.14.2 — Lap splices
12.14.2.1 — Lap splices shall not be used for bars larger than No. 11 (36mm) except as provided
in 12.16.2 and 15.8.2.3.
12.14.2.2 — Lap splices of bars in a bundle shall be based on the lap splice length required for
individual bars within the bundle, increased in accordance with 12.4. Individual bar splices within a
bundle shall not overlap. Entire bundles shall not be lap spliced.
12.14.2.3 — Bars spliced by noncontact lap splices in flexural members shall not be spaced
transversely farther apart than the smaller of one-fifth the required lap splice length, and 6 in.
12.15.3 — When bars of different size are lap spliced in tension, splice length shall be the larger
of ld of larger bar and tension lap splice length of smaller bar
ld = development length
12.16.2 — When bars of different size are lap spliced in compression, splice length shall be the
larger of ldc of larger bar and compression lap splice length of smaller bar. Lap splices of No. 14
(43mm) and No. 18 (57mm) bars to No. 11(36mm) and smaller bars shall be permitted.
12.17.2.5 — In spirally reinforced compression members, lap splice length of bars within a spiral
shall be permitted to be multiplied by 0.75, but lap length shall not be less than 12 in.
12.14.3 — Mechanical and welded splices
12.14.3.1 — Mechanical and welded splices shall be permitted.
12.14.3.2 — A full mechanical splice shall develop in tension or compression, as required, at
least 1.25fy of the bar.
12.14.3.3 — Except as provided in this Code, all welding shall conform to “Structural Welding Code
— Reinforcing Steel” (AWS D1.4).
12.14.3.4 — A full welded splice shall develop at least 1.25fy of the bar.
6.3. Tying Reinforcement
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.3. Tying Reinforcement
IN PROGRESS

The proper tying of reinforcing bars is essential in order to maintain their position during work
done by other trades and during concrete pouring. The wire is typically 16½- or 16-gauge black,
soft, annealed wire, although heavier reinforcement may require 15- or 14-gauge wire to hold the
proper position of the rebar. A variety of tie types (ties are basically wire twists for connecting
intersecting bars), are used in the concrete reinforcing industry. CRSI’s Placing Reinforcing
Bars illustrates the types of ties and describes the situation where each is most effectively used.
When tying bars, there is no need to tie every intersection—every fourth or fifth is normally
sufficient. The tie contributes no strength to the structure, so more are necessary only when the
steel might become displaced during concrete placement. Be sure to keep the ends of the tie
wires away from the surface of the concrete where they could rust. For preassembled mats or
reinforcing steel, tie enough intersections to make the assembly rigid enough for placing—typically
every intersection around the outside and every other in the middle of the mat. Tack welding the
intersections is typically not permitted, because it reduces the cross section of the bars.
There are various types of ties used when securing reinforcing bars. Much of the tying is done on
flat, horizontal form works such as floor slabs, and many backaches can be saved if one learns to
bend and tie stiff-legged instead of squatting. The location and type of splices are shown on the
detailed drawings. No substitution in type or location should be made without proper authority and
specific instructions as to application.
6.4. Placing Reinforcement
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.4. Placing Reinforcement
IN PROGRESS

Getting it in the right place and keeping it there during concrete placement is critical to the
structure’s performance. Reinforcement should be placed as shown on the placing drawings.
There, the detailer will indicate the number of bars, bar lengths, bends, and positions.
7.5 — Placing reinforcement
7.5.1 — Reinforcement, including tendons, and post tensioning ducts shall be accurately placed
and adequately supported before concrete is placed, and shall be secured against displacement
within tolerances permitted in 7.5.2.
7.5.2 — Unless otherwise specified by the licensed design professional, reinforcement, including
tendons, and post-tensioning ducts shall be placed within the tolerances in 7.5.2.1 and 7.5.2.2.
7.5.2.1 — Tolerances for d and for concrete cover in flexural members, walls, and compression
members shall be as follows:
except that tolerance for the clear distance to formed soffits shall be minus ¼ in. In addition,
tolerance for cover shall also not exceed minus 1/3 the concrete cover specified in the design
drawings and project specifications.

7.5.2.2 — Tolerance for longitudinal location of bends and ends of reinforcement shall be ±2 in.,
except the tolerance shall be ±1/2 in. at the discontinuous ends of brackets and corbels, and ±1 in.
at the discontinuous ends of other members. The tolerance for concrete cover of 7.5.2.1 shall also
apply at discontinuous ends of members.
Spacing limits for reinforcement
7.6.1 — The minimum clear spacing between parallel bars in a layer shall be db, but not less than 1
in. (db = nominal diameter of the bar). Clear distance should also not be less than one and one-third
times the nominal maximum size of of the coarse aggregate, except in the judgement of the
Engineer, workability and methods of consolidation are such that concrete can be placed without
voids – CRSI 8.5
7.6.2 — Where parallel reinforcement is placed in two or more layers, bars in the upper layers shall
be placed directly above bars in the bottom layer with clear distance between layers not less than
1 in (25mm)
7.6.3 — In spirally reinforced or tied reinforced compression members, clear distance between
longitudinal bars shall be not less than 1.5db nor less than 1-1/2 in.
7.6.4 — Clear distance limitation between bars shall apply also to the clear distance between a
contact lap splice and adjacent splices or bars.
7.6.5 — In walls and slabs other than concrete joist construction, primary flexural reinforcement
shall not be spaced farther apart than three times the wall or slab thickness, nor farther apart than
18 in (40mm)
Bundled bars
7.6.6.1 — Groups of parallel reinforcing bars bundled in contact to act as a unit shall be limited
to four in any one bundle.
7.6.6.2 — Bundled bars shall be enclosed within stirrups or ties.
7.6.6.3 — Bars larger than No. 11 (36mm) shall not be bundled in beams.
7.6.6.4 — Individual bars within a bundle terminated within the span of flexural members shall
terminate at different points with at least 40db stagger.
7.6.6.5 — Where spacing limitations or concrete cover requirements are based on bar diameter, db,
a unit of bundled bars shall be treated as a single bar of a diameter derived from the equivalent
total area.
6.5. Concrete protection for
reinforcement
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.5. Concrete protection for reinforcement
IN PROGRESS

The proper coverage of bars in the concrete is very important to protect the bars from fire hazards,
possibility of corrosion, and exposure to weather. The American Concrete Institute’s ACI 318
Publication Building Code Requirements for Structural Concrete and Commentary provides
standards for minimal concrete coverage.
One important reason for placing the reinforcing steel properly is to achieve the right amount of
concrete cover—the amount of concrete between the reinforcing steel and the surface of the
concrete member. Cover is necessary to assure that the steel bonds to the concrete well enough
to develop its strength. The requirements for minimum cover are usually listed in the project
specifications or shown on the drawings. Where not specified, the minimum cover for cast-in-
place concrete is specified by the ACI 318 Building Code.
Cast-in-Place concrete (non-prestressed) minimum concrete cover shall be provided for
reinforcement. If not specified, the minimum standard covers should be observed as shown in the
table. This was tabulated for the purpose of illustrating the positioning of reinforcements after
concreting.

Minimum Concrete Cover

7.7.1 — Cast-in-place concrete (non-prestressed)
Unless a greater concrete cover is required by 7.7.6 (Corrosive Environment) or 7.7.8 (Fire
Protection), specified cover for reinforcement shall not be less than the following:

Cast-In-
Place Concrete (Nonprestressed)
7.7.4 — Bundled bars
For bundled bars, minimum specified concrete cover shall not be less than the equivalent
diameter of the bundle, but need not be greater than 2 in.; except for concrete cast against and
permanently exposed to earth, where specified concrete cover shall not be less than 3 in.
7.7.6 — Corrosive environments
In corrosive environments or other severe exposure conditions, amount of concrete protection
shall be suitably increased, and the pertinent requirements for concrete based on applicable
exposure categories shall be met, or other protection shall be provided.
7.7.8 — Fire protection
If the general building code (of which this Code forms a part) requires a thickness of cover for fire
protection greater than the minimum concrete cover specified, such greater thicknesses shall be
specified.
6.6. Offset Reinforcing bars
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.6. Offset Reinforcing bars
IN PROGRESS

Offset bent longitudinal bars shall conform to the following:

7.8.1.1 — Slope of inclined portion of an offset bar with axis of column shall not exceed 1 in 6.
7.8.1.2 — Portions of bar above and below an offset shall be parallel to axis of column.
7.8.1.3 — Horizontal support at offset bends shall be provided by lateral ties, spirals, or parts of
the floor construction. Horizontal support provided shall be designed to resist 1-1/2 times the
horizontal component of the computed force in the inclined portion of an offset bar. Lateral ties or
spirals, if used, shall be placed not more than 6 in. from points of bend.
7.8.1.4 — Offset bars shall be bent before placement in the forms.
7.8.1.5 — Where a column face is offset 3 in. (75mm) or greater, longitudinal bars shall not be
offset bent. Separate dowels, lap spliced with the longitudinal bars adjacent to the offset column
faces, shall be provided.
6.7. Placing Drawing
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.7. Placing Drawing
IN PROGRESS

Placing drawings are working drawings akin to erection or assembly type drawings, instructing the
field steelmen where to place the reinforcing bars within the formwork. Placing drawings may also
indicate the bar support layout and a placing sequence, thus facilitating the efficient installation of
the reinforcing bars.
Placing drawings are prepared by Detailers, trained technicians who are extremely proficient in
interpreting the structural information shown by the contract documents. At no time does a
Detailer make an engineering decision. In fact, in today’s litigious society, a Detailer would be
foolish to accept this responsibility.
ACI 315 Detailing Standard
The USA consensus standard for detailing reinforcing bars for site-cast reinforced concrete
construction is promulgated by the American Concrete Institute: “Details and Detailing of
Reinforcement (ACI 315-99)”.
ACI 315 clearly addresses the responsibilities of the Architect/Engineer regarding placing
drawings:
“The responsibility of the Architect/Engineer is to furnish a clear statement of design requirements to
the Detailer. The Architect/Engineer’s project specifications or structural drawings must not merely
refer the Detailer to an applicable building code for information to use in preparing the placing
drawings. Instead, this information shall be interpreted by the Architect/Engineer and shown in the
form of specific design details or notes for the Detailer to follow. Where omissions, ambiguities, or
incompatibilities are discovered, additional information, clarifications, or corrections shall be
requested by the Detailer and provided by the Architect/Engineer. The Architect/Engineer should
require in the project specifications that placing drawings be submitted for approval.”
Regarding the Detailer’s responsibility, ACI 315 states:
“The responsibility of the Detailer in preparing placing drawings is to carry out all instructions on the
Contract Documents. “
Design Responsibility
Structural Detailing of Reinforcement – Proper structural detailing of reinforcement is critically
important to attain the desired level of performance of reinforced concrete structures. Adequate
anchorage or embedment lengths and splices of reinforcing bars are crucial. Since the structural
details of reinforcement are critically important, it is unrealistic for the Architect/Engineer to
require or expect the Detailer to perform the structural detailing – the Detailer is not qualified to do
so.
The ACI 318 Building Code properly assigns certain responsibilities to the Architect/Engineer
regarding the structural detailing of anchorage or embedment lengths and splices of
reinforcement. In Chapter 26 of the Code, Section 26.6.1.1 states:
“Design information that the licensed design professional shall specify in the construction
documents:

• Type, size, location requirements, detailing, and embedment length of reinforcement

• Location and length of lap splices
• Type and location of mechanical and welded splices”
This point is further emphasized in Section 26.6.2.2(c), which states:
“Splices in reinforcement shall be made only as permitted in the construction documents, or as
authorized by the licensed design professional.”
Approval of Placing Drawings
Some project specifications require that reinforcing steel placing drawings be sealed by a licensed
Professional Engineer employed by the Fabricator. The application of a licensed Professional
Engineer’s seal implies that the Engineer was “in responsible charge of”, not merely a contributor
to, the work. In some states, a contributor may seal a drawing only if the registrant in responsible
charge also seals the drawing.
Also some states, in their statutes on professional engineering practice, specifically prohibit the
sealing of any drawings except those prepared under the supervision of the “design professional”
or “Engineer-of-Record” in responsible charge. One way in which a licensed Professional Engineer
employed by the Fabricator could ethically seal the placing drawings would be to, in effect,
redesign or re-engineer the structure.
Preparation of Placing/working drawing includes the following:

• Bar cut off/bend point

• Splice location
• Number of bars
• Placing dimension
• Cut length
• Bar position/location
6.8. Tolerances on placement
Supervising Concrete Works 6. Installation of Reinforcing Bars 6.8. Tolerances on placement
IN PROGRESS

Although bars should be placed as close to the specified position as possible, there will always be
a little bit of variation. The tolerances on rebar position, as defined by ACI 117, “Tolerances for
Concrete Construction and Materials,” are shown in the table. Remember what this means: a
tolerance, according to ACI 117, is the permitted variation from a given dimension—in other words,
how far off the rebar actually is from what’s shown in the drawings. So, for example, if the clear
distance between the outside of a reinforcing bar and the face of a 6-inch-wide concrete beam is
specified to be 2 inches, the tolerance allows it to be no less than l 5/8 inches. The tolerance on
the position of longitudinal bars, is pretty loose— ±3 inches. That’s because the exact position is
not that critical, as long as the proper cover is maintained and the specified number of bars are
included.
Here are some things to remember about placing rebar:
Bar supports are not intended as support for construction equipment such as concrete pumps,
buggies, or laser screeds.
Spacing of bar supports depends upon the size of the reinforcing bar being supported. For
example, for a one-way solid slab with #5 temperature-shrinkage bars, high chairs are used at 4
feet on center; for #4 bars, high chairs would be placed 3 feet on center.
Placing reinforcement onto layers of fresh concrete or adjusting the position of bars or welded
wire reinforcement during concrete placement should not be permitted. The ill-advised practice in
slab construction of placing reinforcement on the subgrade and pulling it up during concrete
placement is called “hooking.”
Spacers for vertical concrete (wall construction) have traditionally been optional. Side form
spacers include double-headed nails, precast concrete blocks (dobies), and proprietary all-plastic
shapes.
The engineer, contractor, and inspector all have the responsibility to see that the reinforcing bars
in concrete construction are properly placed.
Deviation from specified location: In slabs and walls, other than stirrups and ties ±3 in. Stirrups:
depth of beam in inches divided by 12. Ties: width of column in inches divided by 12.