CHAPTER 7

REINFORCING STEEL

As a Steelworker, you must be able to cut, bend, produced by using the lowest water-cement mixture
place, and tie reinforcing steel. This chapter describes possible without sacrificing workability.
the purpose of reinforcing steel in concrete
Because concrete is plastic when it is placed
construction, the types and shapes of reinforcing steel
forms are built to contain and form the concrete until
commonly used, and the techniques and tools used by
it has hardened In short forms and formwork are
Steelworkers in rebar (reinforcing steel) work. This
described as molds that hold freshly placed concrete
chapter begins with a presentation of fundamental
in the desired shape until it hardens. All the ingredients
information about concrete to help you understand
of the mix are placed in a concrete mixer, and after a
rebar work fully.
thorough mixing, the concrete is transferred by
numerous methods, such as by bucket, by
REINFORCED CONCRETE wheelbarrow, and so forth, into the formwork in which
the reinforcing steel has already been placed.
As a Steelworker you will be primarily concerned
with reinforcing steel placement but you should to Concrete reaches its initial set in approximately 1
some extent, be concerned with concrete as well. hour under normal conditions and hardens to its final
Concrete with reinforcing steel added becomes set in approximately 6 to 12 hours. Before the initial
reinforced concrete. Structures built of reinforced set, concrete must be placed in the forms and vibrated
concrete, such as retaining walls, buildings, bridges, to consolidate it into the formwork and ensure
highway surfaces, and numerous other structures, are complete coverage of all reinforcing bars. Finish
referred to as reinforced concrete structures or operations, such as smooth troweled finishes, must be
reinforced concrete construction. performed between initial and final set. After the final
set, concrete must be protected from shock, extreme
temperature changes, and premature drying until it
CONCRETE MATERIALS
cures to sufficient hardness. Concrete will be
self-supportive in a few days and attain most of its
Concrete is a synthetic construction material made potential strength in 28 days of moist curing. For
by mixing cement, fine aggregate (usually sand), further information on concrete, refer to Builder 3 &
coarse aggregate (usually gravel or crushed stone), 2, Volume 1, NAVEDTRA 12520.
and water in proper proportions. This mixture hardens
into a rocklike mass as the result of a chemical reaction CONCRETE STRENGTH
between the cement and water. Concrete will continue
to harden and gain strength as long as it is kept moist As stated previously, the strength of concrete is
and warm. This condition allows the chemical reaction determined by the water-cement ratio. The strength of
to continue and the process is known as curing. ready-mixed concrete ranges from 1,500 to about
Durable, strong concrete is made by the correct 5,000 pounds per square inch (psi); and, with further
proportioning and mixing of the various materials and attention paid to proportioning, it can go even higher.
by proper curing after the concrete is placed. Under usual construction processes, lower strength
concrete will be used in footers and walls and higher
The correct proportioning of the concrete
strength in beams, columns, and floors. The required
ingredients is often referred to as the mix. The quality
strength of concrete on a given project can be found
of the concrete is largely determined by the quality of
in the project plans and specifications for a specific
the cement-water paste that bonds the aggregates
project.
together. The strength of concrete will be reduced if
this paste has water added to it. The proportion of NOTE: Quality control is important to ensure
water to cement is referred as the water-cement ratio. specific design requirements are met. If the design
The water-cement ratio is the number of gallons of specifications do not meet minimum standards,
water per pounds of cement. High-quality concrete is structural integrity is compromised and the structure

7-1
is considered unsafe. For this reason, the compressive loose or scaly rust is inferior. Loose or scaly rust can
strength of concrete is checked on all projects. be removed from the steel by rubbing the steel with
burlap or similar material. This action leaves only the
The strength of the concrete is checked by the use
firm layer of rust on the steel to adhere to the concrete.
of cylindrical molds that are 6 inches in diameter and
12 inches in height. Concrete samples must be taken NOTE: Reinforcing steel must be strong in
on the jobsite from the concrete that is being placed. tension and, at the same time, be ductile enough to be
After being cured for a time period that ranges shaped or bent cold.
between 7 to 28 days, the cylinders are “broken to
failure” by a laboratory crushing machine that
Reinforcing steel can be used in the form of bars
measures the force required for the concrete to fail.
or rods that are either plain or deformed or in the form
For further information on concrete strength and
of expanded metal, wire, wire fabric, or sheet metal.
testing, refer to Engineering Aid 3, NAVEDTRA Each type is useful for different purposes, and
10696, and NAVFAC MO 330. (The MO 330 should
engineers design structures with those purposes in
be maintained in a battalion’s tech library.)
mind.

PURPOSES AND TYPES OF

Plain bars are round in cross section. They are
REINFORCING STEEL
used in concrete for special purposes, such as dowels
at expansion joints, where bars must slide in a metal
Reinforced concrete was designed on the principle
or paper sleeve, for contraction joints in roads and
that steel and concrete act together in resisting force.
runways, and for column spirals. They are the least
Concrete is strong in compression but weak in used of the rod type of reinforcement because they
tension. The tensile strength is generally rated about offer only smooth, even surfaces for bonding with
10 percent of the compression strength. For this concrete.
reason, concrete works well for columns and posts that
are compression members in a structure. But, when it Deformed bars differ from the plain bars in that
is used for tension members, such as beams, girders, they have either indentations in them or ridges on
foundation walls, or floors, concrete must be them, or both, in a regular pattern. The twisted bar, for
reinforced to attain the necessary tension strength. example, is made by twisting a plain, square bar cold.
Steel is the best material for reinforcing concrete The spiral ridges, along the surface of the deformed
bar, increase its bond strength with concrete. Other
because the properties of expansion for both steel and
forms used are the round and square corrugated bars.
concrete are considered to be approximate] y the same;
that is, under normal conditions, they will expand and These bars are formed with projections around the
contract at an almost equal rate. surface that extend into the surrounding concrete and
prevent slippage. Another type is formed with
NOTE: At very high temperatures, steel expands longitudinal fins projecting from the surface to
more rapidly than concrete and the two materials will prevent twisting. Figure 7-1 shows a few of the types
separate. of deformed bars available. In the United States,
deformed bars are used almost exclusively; while in
Another reason steel works well as a
Europe, both deformed and plain bars are used.
reinforcement for concrete is because it bonds well
with concrete. This bond strength is proportional to
the contact surface of the steel to the concrete. In other
words, the greater the surface of steel exposed to the
adherence of concrete, the stronger the bond. A
deformed reinforcing bar adheres better than a plain,
round, or square one because it has a greater bearing
surface. In fact, when plain bars of the same diameter
are used instead of deformed bars, approximately 40
percent more bars must be used.

The rougher the surface of the steel, the better it

adheres to concrete. Thus steel with a light, firm layer
of rust is superior to clean steel; however, steel with Figure 7-1.—Various types of deformed bars.

7-2
 Eleven standard sizes of reinforcing bars are in use rebar could be procured locally and could be metric.
today. Table 7-1 lists the bar number, area in square Table 7-3 is given for comparison. Remember that bar
inches, weight, and nominal diameter of the 11 standard numbers are based on the nearest number of
sizes. Bars No. 3 through 11 and 14 and 18 are all one-eighth inch included in the nominal diameter of
deformed bars. Table 7-2 lists the bar number, area in the bar. To measure rebar, you must measure across
square inches and millimeters, weight in pounds per foot the round/square portion where there is no
as well as kilograms per meter, and nominal diameter of deformation. The raised portion of the deformation is
the 8 standard metric sizes. At various sites overseas, not measured when measuring the rebar diameter.

Table 7-1.—U.S. Standard Reinforcing Bars

U.S. Standard Reinforcing Steel Bars

Bar Size Area Square Weight lb Diameter

Designation Inches Per Foot
inches mm

#3 .11 .376 .375 9.53

#4 .20 .668 .500 12.7
#5 .31 1.043 .625 15.88
#6 .44 1.502 .750 19.05
#7 .60 2.044 .875 22.23
#8 .79 2.670 1.000 25.40
#9 1.00 3.400 1.128 28.58
#10 1.27 4.303 1.270 31.75
#11 1.56 5.313 1.410 34.93
#14 2.25 7.650 1.693 43.00
#18 4.00 13.600 2.257 57.33

Table 7-2.—Metric Reinforcing Bars

METRIC REINFORCING STEEL BARS

BAR SIZE AREA WEIGHT DIAMETER

DESIGNATION
Sq. Inches Sq. mm Lb Per Ft KG/M Inches mm

10m .16 100 .527 .785 .445 11.3

15m .31 200 1.054 2.355 .630 16.0

20m .47 300 1.563 2..355 .768 19.5

25m .78 500 2.606 3.925 .992 25.2

30m 1.09 700 3.649 5.495 1.177 29.9

35m 1.55 1000 5.213 7.850 1.406 35.7

45m 2.33 1500 7.820 11.775 1.710 43.7

55m 3.88 2500 13.034 19.625 2.220 56.4

7-3
 Table 7-3.—Comparison of U.S. Customary and Metric Rebar

U.S. Standard Bar Metric Bar Metric

Bar is:
Bar Size Area Sq. Inches Bar Size Area Sq. Inches
#3 .11 10m .16 45% larger*

#4 .20 10m .16 20% smaller

#4 .20 15m .31 55% larger

#5 .31 15m .31 Same
#6 .44 .47 6.8% larger
#7 .60 .47 22% smaller

#7 .60 .25m .78 30% larger

#8 .79 25m .78 1.3% smaller

#9 1.00 30m 1.09 9% larger

#10 1.27 30m 1.09 14% smaller
#10 1.27 35m 1.55 22% larger
#11 1.56 35m 1.55 0.6% smaller
#14 2.25 45m 2.33 3 .5% larger
#18 4.00 55m 3.88 3 .0% smaller
*NOTE: % Difference is based upon area of rebar in square inches.

Reinforcing Bars or rolled axle steel (-A-). Figure 7-2 shows the
two-grade marking system.
Reinforcing bars are hot-rolled from a variety of
The lower strength reinforcing bars show only
steels in several different strength grades. Most
three marks: an initial representing the producing
reinforcing bars are rolled from new steel billets, but
mill, bar size, and type of steel. The high strength
some are rolled from used railroad-car axles or
reinforcing bars use either the continuous line system
railroad rails that have been cut into rollable shapes.
or the number system to show grade marks. In the line
An assortment of strengths are available.
system, one continuous line is rolled into the
60,000 psi bars, and two continuous lines are rolled
The American Society for Testing Materials
into the 75,000 psi bars. The lines must run at least
(ASTM) has established a standard branding for
five deformation spaces, as shown in figure 7-2. In the
deformed reinforcing bars. There are two general
number system, a “60” is rolled into the bar following
systems of bar branding. Both systems serve the basic
the steel type of mark to denote 60,000 psi bars, and a
purpose of identifying the marker size, type of steel, “75” is rolled into the 75,000 psi bars.
and grade of each bar. In both systems an identity mark
denoting the type of steel used is branded on every bar
by engraving the final roll used to produce the bars so Expanded Metal and Wire Mesh
as to leave raised symbols between the deformations. Reinforcement
The manufacturer’s identity mark that signifies the
mill that rolled the bar is usually a single letter or, in Expanded metal or wire mesh is also used for
some cases, a symbol. The bar size follows the reinforcing concrete. Expanded metal is made by
manufacturer’s mark and is followed by a symbol partly shearing a sheet of steel, as shown in view A
indicating new billet steel (-N-), rolled rail steel (-I-), figure 7-3. The sheet steel has been sheared in parallel

7-4
 Figure 7-3.—Expanded or diamond mesh steel reinforcement.

concrete pads that do not have to bear substantial

weight, such as transformer and air-conditioner pads.

Welded Wire Fabric

Welded wire fabric is fabricated from a series of

wires arranged at right angles to each other and
electrically welded at all intersections. Welded wire
fabric, referred to as WWF within the NCF. has
various uses in reinforced concrete construction. In
building construction, it is most often used for floor
slabs on well-compacted ground. Heavier fabric,
supplied mainly in flat sheets, is often used in walls
and for the primary reinforcement in structural floor
slabs. Additional examples of its use include road and
runway pavements, box culverts, and small canal
linings.

Four numbers are use-d to designate the style of

wire mesh; for example, 6 by 6-8 by 8 (sometimes
written 6 x 6 x 8 x 8 or 6 x 6 - W 2.1 x W 2.1). The
first number (in this case, 6) indicates the lengthwise
spacing of the wire in inches; the second number (in
this case, 6) indicates the crosswise spacing of the wire
in inches; the last two numbers (8 by 8) indicate the
Figure 7-2.—American standard reinforcing bar marks. size of the wire on the Washburn and Moen gauge.
More recently the last two numbers are a W number
lines and then pulled out or expanded to form a that indicates the size of the cross-sectional area in the
diamond shape between each parallel cut. Another wire in hundredths of an inch. (See table 7-4.) WWF
type is square, rather than diamond shaped, as shown is currently available within the Navy stock system
in view B, figure 7-3. Expanded metal is customarily y using the four-digit system, 6 by 6-8 by 8, as of this
used during plastering operations and light reinforcing writing, but if procured through civilian sources, the
concrete construction, such as sidewalks and small W system is used.

7-5
 Table 7-4—Common Stock Sizes of Welded Wire Fabric

STYLE DESIGNATION Weight

Current Previous Approximate lb
Designation Designation per 100 sq. ft.
(by W—Number) (By Steel Wire Gauge)
PANELS / SHEETS

6x6—W1.4xW1.4 6x6—10x10 21

6x6—W2.1xW2.1 6x6—8x8 29

6x6—W2.9xW2.9 6x6—6x6 42

6x6—W4.0xW4.0 6x6—4x4 58
4x4—W1.4xW1.4 4x4—10x10 31
4x4—W2.1xW2.1 4x4—8x8 43
4x4—W2.9xW2.9 4x4—6x6 62
4x4—W4.0xW4.0 4x4—4x4 86
ROLLS

6x6—W1.4xW1.4 6x6—10x10 21
6x6—W2,9xW2.9 6x6—6x6 42

6x6—W4.0xW4.0 6x6—4x4 58

6x6—W5.5xW5.5 6x6—2x2 80
4x4—W4.0xW4.0 4x4—4x4 86

Light fabric can be supplied in either rolls or flat about one-sixteenth inch (1.59 mm) in depth with
sheets. Fabric made of wire heavier than W4 should holes punched at regular intends.
always be furnished in flat sheets. Where WWF must
be uniformly flat when placed, fabric furnished in rolls Tension in Steel
should not be fabricated of wire heavier than W 2.9.
Fabricators furnish rolled fabric in complete rolls Steel bars are strong in tension. Structural grade
only. Stock rolls will contain between 700 to 1,500 is capable of safely carrying up to 18,000 psi and
square feet of fabric determined by the fabric and the intermediate, hard, and rail steel, 20,000 psi. This is
producing location. The unit weight of WWF is the SAFE or WORKING STRESS; the BREAKING
designated in pounds per one hundred square feet of STRESS is about triple this.
fabric (table 7-4). Five feet, six feet, seven feet, and
seven feet six inches are the standard widths available When a mild steel bar is pulled in a testing
for rolls, while the standard panel widths and lengths machine, it stretches a very small amount with each
are seven feet by twenty feet and seven feet six inches increment of load. In the lighter loadings, this stretch
by twenty feet. is directly proportional to the amount of load (fig. 7-4,
view A). The amount is too small to be visible and can
be measured only with sensitive gauges.
Sheet-Metal Reinforcemat
At some pull (known as the YIELD POINT), such
Sheet-metal reinforcement is used mainly in floor as 33,000 psi for mild steel, the bar begins to neck
slabs and in stair and roof construction. It consists of down (fig. 7-4, view B) and continues to stretch
annealed sheet steel bent into grooves or corrugations perceptibly with no additional load.

7-6
 middle to the opposite side pull away from the middle.
This is similar to what happens inside the beam.
For instance, take a simple beam (a beam resting
freely on two supports near its ends). The dead load
(weight of the beam) causes the beam to bend or sag.
Now, from the center of the beam to the bottom, the
forces tend to stretch or lengthen the bottom portion
of the beam. This pad is said to be in tension, and that
is where the steel reinforcing bars are needed. As a
result of the combination of the concrete and steel, the
tensile strength in the beam resists the force of the load
and keeps the beam from breaking apart. At the exact
center of the beam, between the compressive stress
and the tensile stress, there is no stress at all-it is
neutral.

In the case of a continuous beam, it is a little

different. The top of the beam maybe in compression
along part of its length and in tension along another
part. This is because a continuous beam rests on more
than two supports. Thus the bending of the beam is not
all in one direction. It is reversed as it goes over
intermediate supports.
To help the concrete resist these stresses,
engineers design the bends of reinforcing steel so that
the steel will set into the concrete just where the tensile
stresses take place. That is the reason you may have to
bend some reinforcing rods in almost a zigzag pattern.
The joining of each bar with the next, the anchoring
of the bar ends within concrete, and the anchoring by
overlapping two bar ends together are some of the
important ways to increase and keep bond strength.
Figure 7-4.—Tension in steel bars.
Some of the bends you will be required to make in
reinforcing bars are shown in figure 7-5.
Then, when it seems the bar will snap like a rubber
band it recovers strength (due to work hardening). The drawings for a job provide all the information
Additional pull is required (fig. 7-4, view C) to necessary for cutting and bending reinforcing bars.
produce additional stretch and final failure (known as Reinforcing steel can be cut to size with shears or with
the ULTIMATE STRENGTH) at about 55,000 psi for an oxygas cutting torch. The cutting torch can be used
mild steel. in the field.
Before bending the reinforcing bars, you should
BENDING REINFORCING BARS
check and sort them at the jobsite. Only after you
check the bars can you be sure that you have all you
The job of bending reinforcing bars is interesting
need for the job. Follow the construction drawings
if you understand why bending is necessary. There are
when you sort the bars so that they will be in the proper
several masons. Let us go back to the reason for using
order to be bent and placed in the concrete forms. After
reinforcing steel in concrete—the tensile strength and
you have divided the different sizes into piles, label
compressive strength of concrete. You might compare
each pile so that you and your crew can find them
the hidden action within a beam from live and dead
easily.
loads to the breaking of a piece of wood with your
knee. You have seen how the splinters next to your For the job of bending, a number of types of
knee push toward the middle of the piece of wood benders can be used. Stirrups and column ties are
when you apply force, while the splinters from the normally less than No. 4 bar, and you can bend them

7-7
 127.75
Figure 7-5.—Typical reinforcement bends.

127.76
Figure 7-6.—Bar-bending table.
cold by means of the bending table, as shown in figure of the bend and pulling on the handle, you can produce
7-6. Typical stirrup tie shapes are shown in figure 7-7. a smooth, circular bend through almost any angle that
Stirrups are used in beams; as shown in figure 7-8. is desired.
Column ties are shown in position in figure 7-9.
Bending Guidelines and Techniques

When the bars have to be bent in place, a bending Make bends, except those for hooks, around pins
tool, like the one shown in figure 7-10, is effective. By with a diameter of not less than six times the bar
placing the jaws of the hickey on one side of the center diameter for No. 3 through No. 8 bar. If the bar is larger

7-8
 127.77
Figure 7-7.—Stirrup and column ties.

45.482A
Figure 7-9.—Column steel in place.

45.481
Figure 7-8.—Steel in place in a beam

than 1 inch (25.4 mm) (No. 9, No. 10, and No. 11 bar),
the minimum pin diameter should be eight times the
bar size. For No. 14 through No. 18, the pin diameter
should be ten times the diameter of the bar.
29.183
To get smooth, sharp bends when bending large Figure 7-10.—Bending tool.
rods, slip a pipe cheater over the rod. This piece of pipe
gives you a better hold on the rod itself and makes the Bend Diameters
whole operation smoother. You can heat No. 9 bars and
If you do not want your rod to crack while it is
larger to a cherry red before bending them, but make
being bent, bend it gradually, not with a jerk. Also, do
sure you do not get them any hotter. If the steel not make your bends too sharp. Bends made on a
becomes too hot, it will lose strength, become brittle, bar-bending table or block are usually too sharp, and
and can even crack. the bar is somewhat weakened. Therefore, certain

7-9
minimum bend diameters have been established for The Iron master Portable Hydraulic
the different bar sizes and for the various types of Rod Bender and Shear
hooks. These bending details are shown in figure 7-11.
You can use many different types of bends. The one The Ironmaster portable hydraulic rod bender and
you select depends on where you are to place the rods. shear (fig. 7-12) can cold-work reinforcing bars into
For example, there are bends on heavy beam and various shapes for use in concrete construction work.
girder bars, bends for reinforcement of vertical The machine is capable of working reinforcing bars
columns at or near floor levels, bends for stirrups and up to and including No. 11 bars, which is equivalent
column ties, bends for slab reinforcement, and bends in a cross-sectional area to 1 1/4-inch (31.75 mm)-
for bars or wire for column spiral reinforcement. To square or 1 1/2-inch (38.1 mm)-round bar.
save yourself some time and extra work, try to make In addition to all sizes of reinforcing bars, the
all bends of one kind at one time instead of Ironmaster will also work bars of higher carbon
remeasuring and resetting the templates on your content desired in the fabrication of anchor bolts, and
bending block for different bends. so forth. However, limitations must be imposed when
considering bar of 1-inch (25.4 mm) diameter or
greater that have a carbon content of greater than 0.18
percent, such as SAE 1020 cold-finished steel. Bars
under 1 inch (25.4 mm) in diameter should have a
carbon content of no greater than 0.37 percent, such
as SAE 1040 C. F. steel.
Although the Ironmaster is powered to work steels
of heavier sections than 1 1/2-inch (38.1 mm)
reinforcing bar, the manufacturer must place safety
limitations on it when considering various alloys and
shapes of steel. Users will undoubtedly adapt this
versatile machine to perform work other than common
bar bending, such as bending flats and angles.
However, the primary intention of the manufacturer
was to produce a machine for bending concrete
reinforcing steel. The manufacturer recommends that
the Ironmaster not be used on steels heavier than 1
1/4-inch (31.75 mm)-square or 1 1/2-inch (38.1
mm)-round reinforcing bar.

127.281
Figure 7-12.—Ironmaster portable hydraulic bender and
Figure 7-11.—Standard hook details shear.

7-10
Standard Hook Bending accept only the number of bars specified, suti as No.
7 roll for No. 7 bar (fig. 7-15).
Standard hook bending (fig. 7-13) is
1. Plain the rebar between the cleat slide upright
accomplished on the turntable section located on top
and the radius roll, which is placed over the center pin,
of the machine. Before you start any bending
procedure, the turntable must be at the START
position as shown in figure 7-14. As an example,
when you desire to bend a 180-degree hook in apiece
of No. 11 reinforcing bar, setup the machine as shown,
using the following: bending cleat with cleat slide and
drive pin, main center pin, and No. 11 radius roll. As
a safeguard, the radius rolls have been designed to

127.284
127.382 Figure 7-15.—Radius rolls for bending rebar on an
Figure 7-13.—Ironmaster bar-bending unit. Ironmaster.

127.283
Figure 7-14.—ExampIe of bending a 180-degree hook with No. 11 rebar.

7-11
with the end of the rebar protruding a sufficient distance Multiple Bending
for the cleat slide to be upright to engage it where you
want the bend to commence. Multiple bending is accomplished the same way
as standard hook bending for bars up to No. 8 simply
2. Move the cleat slide to contact the rebar and
by placing the bars in the machine one on top of the
tighten the locking screws.
other.
3. Move the positioner slide bar until the roller
contacts the rebar and tightens the T handle. Table 7-5 shows the bars that may be bent by the
Ironmaster and the number of bars it will bend in one
4. Set the desired angle ‘of bend on the graduated operation.
control rod which is under the right side of the working
table. This is done by placing the trigger pin of the rear On the side of the machine next to the shear is the
adjustable stop (toward the rear of the machine) in the shearing support (fig. 7-16). This support holds the
hole corresponding to the angle of bend, in this case, bars square between the shear blades and prevents
180 degrees. This rod is graduated from 5 degrees to them from “kicking up” during shearing. The upper
190 degrees at 5-degree intervals. jaw of the shearing support is adjustable. For bars
three-fourths inch and smaller, place this jaw in the
LOWER position. For larger bars, use the UPPER
NOTE: ENSURE THE FRONT ADJUSTABLE
position. NEVER SHEAR WITHOUT USING THIS
STOP TRIGGER PIN IS IN THE “O’ HOLE, so the
SUPPORT.
turntable will return to and stop in the START position
when retracted after the bend. To operate, insert the bar to be cut to the farthest
point possible toward the inside of the blades (fig.
5. Advance the engine throttle to operating speed, 7-15), making sure that the blades are in the fully
and move either the rear bending control lever or slide OPEN or RETRACT position. With light downward
bending control lever to the bend position. This actuates pressure on the shear control lever, hold the bar in this
the bend cylinder. The lever will stay in the bending position until the shear grips. Continue applying
position until the bend is completed, the rack movement pressure downward to the full limit of the lever until
disengaging the cylinder, and the levers returning to the bar is sheared To retract the shear, pull the lever
neutral automatically. up.

6. To remove the rebar from the machine after the The same-size bar that can be bent can be sheared
bend is completed, apply light intermittent reverse Multiple shearing, however, can be accomplished only
pressure to the lever until the bar releases from the on bars of less than 0.44-square-inch area. When
radius roll. After removal of the hook from the machine, shearing more than one bar at a time, always place the
move the lever to the position shown on “retract” to bars side by side in the shear, as shearing with bars
return the turntable to the START position. piled on top of each other may cause blade failure.

Table 7-5.—Single Operation Multibending

Bar # Bar Size in Inches Number of Bars that can be

Bent in One Operation

3 3/8rd 6
4 1/2rd 4
5 5/8rd 3
6 3/4rd 3
7 7/8rd 2
8 1 rd 2
9 1 rd 1
10 1 1/8 sq 1
11 1 1/4 sq 1

7-12
 bars should be avoided because it reduces the bond
between the bars and the concrete. Use a piece of
burlap to remove rust, mill scale, grease, mud, or other
foreign matter from the bars. A light film of rust or
mill scale is not objectionable.
Bars are marked to show where they will fit. You
may work according to either one of the two
most-used systems for marking bars; however, the
system you use should agree with the marking
system which appears on the engineering or
assembly drawings. The two marking systems used
are as follows:
1. All bars in one type of member are given the
127.285 mark of that member. This system is used for column
Figure 7-16.—Ironmaster bar-cutting unit. bars, beam bars, footing bars, and so on.
2. The bars are marked in greater detail. These
Table 7-6 shows the number of bars that can be sheared
marks show exactly where the bar is to be placed. In
at one time.
addition to the type member (that is, beam (B), wall
The care and maintenance of the Ironmaster (W), column (C), and so on), the marks show the floor
portable hydraulic rod bender and shear consist on which the bars are to be placed and the size and
primarily of lubrication and cleaning. There are grease individual number of each particular bar. Instead of
fittings on the machine. Keep these points well showing the bar size by its diameter measurement, the
lubricated with a good grade of grease, but do not mark shows the bar size in code by eighths. The
overlubricate, as the surplus grease will collect dirt examples shown below show the second type of
and rust scale from the rebars. When greasing the marking system.
shear pin, work the shear arm up and down until grease
appears between the arm and the side ears. When using
2B805 2 = second floor
the stirrup bending attachment, keep the center pin
clean and well lubricated. B = beam member
8 = 8/8- or 1 -inch (2.5 cm)-square bar
Rust scale from the rebar will accumulate in the
holes in the turntable and worktable and in the serrations 05 = part of the second floor plan designated
in the bending cleat and roller slide. Keep these cleaned by the number 5
out, particular] y when changing over to or from the
stirrup bending attachment or changing a center pin by
2B0605 2 = second floor
means of a solvent-soaked rag or brush. Keep the
B = beam member
worktable as clean as possible to minimize the amount
of rust scale dropping through to the rack and gear. 06 = 6/8- or 3/4-inch (1.9 cm)-round bar
05 = part of second floor plan designated
PLACING AND TYING by the number 5
REINFORCING STEEL
Tie wire is used to hold rebar in place to ensure
Before you place reinforcing steel in forms, all that when concrete is placed the bars do not shift out
form oiling should be completed. Oil on reinforcing of position. Sixteen gauge wire is used to tie

Table 7-6.—Multishearing

Bar Size Quantity

3,4,5,6 4
7 3
8 2
9, 10, 11 1

7-13
reinforcing bars. About 12 pounds (5.4 kg) of wire is
required to tie an average ton (0.9 tome) of bars.

NOTE: Tie wire adds nothing to the strength of

the steel.

A number of different types of ties can be used

with reinforcing bars; some are more effective than
others. Figure 7-17 shows six types of ties that are
identified below according to the letters of the
alphabet used to show individual ties.

A. SNAP TIE or SIMPLE TIE. The wire is simply

wrapped once around the two crossing bars in a
diagonal manner with the two ends on top. These are
twisted together with a pair of sidecutters until they are
very tight against the bars. Then the loose ends of the
wire are cut off. This tie is used mostly on floor slabs.
B. WALL TIE. This tie is made by going about 1
1/2 times around the vertical bar, then diagonally
around the intersection, twisting the two ends together
until the connection is tight, but without breaking the
tie wire, then cutting off the excess. The wall tie is used
on light vertical mats of steel. 127.80
C. DOUBLE-STRAND SINGLE TIE. This tie is a Figure 7-17.—Six types of ties.
variation of the simple tie. It is especially favored for
heavy work
D. SADDLE TIE. The wires pass halfway around
one of the ban on either side of the crossing bar and are
brought squarely or diagonally around the crossing bar
with the ends twisted together and cut off. This tie is
used on special locations, such as on walls.
E. SADDLE TIE WITH TWIST. This tie is a
variation of the saddle tie. The tie wire is carried
completely around one of the bars, then squarely across
and halfway around the other, either side of the crossing
bars, and finally brought together and twisted either
squarely or diagonally across. The saddle tie with twist
is used for heavy mats that are to be lifted by a crane.
45.480
F. CROSS TIE or FIGURE-EIGHT TIE. This type Figure 7-18.—Reinforcement bar accessories.
of tie has the advantage of causing little or no twist in The proper coverage of bars in the concrete is very
the bars. important to protect the bars from fire hazards,
possibility of corrosion, and exposure to weather.
The proper location for the reinforcing bars is
When not specified, minimum standards given below
usually given on drawings (table 7-7). In order for the
and in figure 7-21 should be observed.
structure to withstand the loads it must carry, place the
steel in the position shown. Secure the bars in position
in such a way that concrete-placing operations will not FOOTINGS-3 inches at the sides where concrete
move them. This can be accomplished by the use of is cast against the earth and on the bottoms of footings
the reinforcing bar supports shown in figures 7-18, or other principal structural members where concrete
7-19, and 7-20. is deposited on the ground.

7-14
 127.83
Figure 7-19.—Precast concrete block used for rebar support.

WALLS-2 inches for bars larger than No. 5,

where concrete surfaces, after removal of forms,
would be exposed to the weather or be in contact with 127.85
Figure 7-20.—Rebar hung in place.
the ground; 1 1/2 inches for No. 5 bars and smaller;
3/4 inch from the faces of all walls not exposed
inches (76.2 mm) of concrete between the steel and
directly to the ground or the weather.
the ground. If the concrete surface is to be in contact
COLUMNS—1 1/2 inches over spirals and ties. with the ground or exposed to the weather after
BEAMS AND GIRDERS—1 1/2 inches to the removal of the forms, the protective covering of
nearest bars on the top, bottom, and sides. concrete over the steel should be 2 inches (50.8 mm).
It maybe reduced to 1 1/2inches (38.1 mm) for beams
JOISTS AND SLABS—3/4 inch on the top, and columns and 3/4 inch (19.5 mm) for slabs and
bottom, and sides of joists and on the top and the interior wall surfaces, but it should be 2 inches
bottom of slabs where concrete surfaces are not (50.8 mm) for all exterior wall surfaces. This
exposed directly to the ground or the weather. measurement is taken from the main rebar, not the
NOTE: All measurements are from the outside of stirrups or the ties.
the bar to the face of the concrete, NOT from the main
NOTE: Where splices in reinforcing steel are not
steel, unless otherwise specified.
dimensioned on the drawings, the bars should be
Footings and other principal structural members lapped not less than 30 times the bar diameter nor less
that are against the ground should have at least 3 than 12 inches (table 7-7). The stress in a tension bar

Table 7-7.—Length of Lap Splices in Reinforcing Steel

INCHES OF LAP CORRESPONDING TO NUMBER OF BAR DIAMETERS*
Number Size of Bars
of
#3 #4 #5 #6 #7 #8 #9 #10 #11 #14 #18
Diameters
30 12 15 19 23 27 30 34 39 43 51 68
32 12 16 20 24 28 32 36 41 45 55 73
34 13 17 22 26 30 34 39 44 48 58 77
36 14 18 23 27 32 36 41 46 51 61 82
38 15 19 24 29 34 38 43 49 54 65 86
40 15 20 25 30 35 40 46 51 57 68 91
Minimum lap equals 12 inches!
*Figured to the next larger whole inch

7-15
 127.286
Figure 7-21.—Minimum coverage of rebar in concrete.

can be transmitted through the concrete and into

another adjoining bar by a lap splice of proper length.

To lap-weld wire fabric/wire mesh, you can use a

number of methods, two of which are the end lap and 127.85
the side lap. In the end lap method, the wire mesh is Figure 7-22.—Bars spliced by lapping.
lapped by overlapping one full mesh, measured from
the ends of the longitudinal wires in one piece to the
ends of the longitudinal wires in the adjacent piece,
and then tying the two pieces at 1-foot 6-inch (45.0
cm) centers with a snap tie. In the side lap method, the
two longitudinal side wires are placed one alongside
and overlapping the other and then are tied with a snap
tie every 3 feet (.9 m).
145.66X
Reinforcing bars are in tension and therefore Figure 7-23.—Correct and Incorrect placement of
should never be bent around an inside corner beams. reinforcement for an inside corner.
They can pull straight through the concrete cover.
Instead, they should overlap and extend to the far face
square, and the end of the top bar resting on it is cut
for anchorage with 180-degree hooks and proper
in a bevel fashion, thus permitting a butt weld. For bars
concrete coverage (fig. 7-23).
which will bear a load in a horizontal position, a fillet
The bars can also be spliced by metal arc welding weld is preferred. Usually, the two bars are placed end
but only if called for in the plans and specifications. to end (rather than overlapping), and pieces of flat bar
For bars which are placed in a vertical position, a butt (or angle iron) are placed on either side. Fillet welds
weld is preferred. The end of the bottom bar is cut are then made where the metals join. The welds are

7-16
made to a depth of one half of the bar diameter and for then the ties are spaced out as required by the placing
a length eight times the bar diameter. plans. All intersections are wired together to make the
assembly rigid so that it may be hoisted and set as a
The minimum clear distance between parallel bars unit. Figure 7-25 shows atypical column tie assembly.
in beams, footings, walls, and floor slabs should either
be 1 inch (25.4 mm) or 1 1/3 times the largest size After the column is raised, it is tied to the dowels
aggregate particle in the concrete, whichever distance or reinforcing steel carried up from below. This holds
is greater. In columns, the clear distance between it firmly in position at the base. The column form is
parallel bars should be not less than 1 1/2 times the bar erected and the reinforcing steel is tied to the column
diameter or 1 1/2 times the maximum size of the coarse form at 5-foot (4.5-m) intervals, as shown in figure
aggregate. Always use the larger of the two. 7-26.

The support for reinforcing steel in floor slabs is

The use of metal supports to hold beam
shown in figure 7-24. The height of the slab bolster is
reinforcing steel in position is shown in figure 7-8.
determined by the required concrete protective cover.
Note the position of the beam bolster. The stirrups are
Concrete blocks made of sand-cement mortar can be
tied to the main reinforcing steel with a snap tie.
used in place of the slab bolster. Wood blocks should
Wherever possible you should assemble the stirrups
never be used for this purpose. Highchairs (fig. 7-18)
and main reinforcing steel outside the form and then
can be obtained in heights up to 6 inches (15 cm).
place the assembled unit in position. Precast concrete
When a height greater than 6 inches is required, make
blocks, as shown in figure 7-27, maybe substituted for
the chair out of No. 0, soft, annealed iron wire. To hold
metal supports.
the bars firmly in position, you should tie the bars
together at frequent intervals where they cross with a
The horizontal and vertical bars are wired securely
snapat.
to each other at sufficiently frequent intervals to make
Steel for column ties may be assembled with the a rigid mat. Tying is required at every second or third
verticals into cages by laying the vertical bars for one intersection, depending upon the size and spacing of
side of the column horizontally across a couple of bars, but with not less than three ties to any one bar,
sawhorses. The proper number of ties are slipped over and, in any case, not more than 4 to 6 feet apart in
the bars, the remaining vertical bars are added, and either direction.

127.86
Figure 7-24.—Steel in place in a floor slab.

7-17