Section 1 REBAR ARRANGEMENT & CONSTRUCTION CARRYOUT 1. Understanding of Drawing 1) Examination of drawing When construction contract is completed, the contents of the drawings are surveyed and checked before construction work. Although it is a rule to survey the drawings right from the 1st page, it is common to check the scale and the number of floors of the building and then plan, elevation, exterior appearance, lines and windows of the building . Not only orientation, precautions and specifications, but front elevation, rear side elevation, right side elevation, left side elevation, partial development, partial section, and detail section, etc should be also looked over to be reminded in the construction site. As construction work progresses , present work should be checked and compared with instructions on the drawings , and an entire understanding of drawings should be preceded before the next step. Plan, structural plan, foundation, section, etc are checked if there is any suspicious portion because all the drawings are not made by only 1 person. There is also necessity of discussion when there is any question or changes in the work. In order to make smooth and steady progress of the work, a lot of time and repeated practice are required. In case of small scale of construction , it is progressed from the ground to the upper floor in general , however there is no determined rule. As construction work is not a simple one but rather complicated, it is difficult or impossible to explain all of the construction methods satisfactorily in written or spoken words alone. Clear understanding of basic knowledge is quite helpful. Plan of reinforcement should be drawn before reinforcement , however , when the scale of construction is large , plan of reinforcement is given in advance or shop reinforcement are also available . Although the trend has been to increase the usage of shop reinforcement for the smooth progress in the crowded city , field reinforcement is explained in this book due to the necessity of prompt applications in the field and its convenience. Every reinforcement has its own rule , however it could be changed when necessary under the permission of supervisor. For example , hooks at the tip of stirrup could be changed from Figure 1 to Figure 2. Figure 1 Figure 2 2)What is drawing? Drawings are used in every industrial field with the development of industries. Although their types and applications are different, there are agreed rules that are called IPC(International Graphic Code), accepted by everyone in each field. Specified rules and standards with reference to symbols, numbers, lines and letters are adapted to drawings to help everyone understand what they mean. When one begins to construct a building, one should carefully consider the implications of drawings. In this book, plan of reinforcement is briefed to help the workers understand them more easily. Drawings of construction work are grouped roughly as civil engineering and architecture. Although there are some differences, all the contents could be understood since they are all in accordance with IPC mentioned above. 3) Classification of drawing ① Shop Drawing Drawings that suggest overall dimensions of each member with symbols, numbers and lines for the construction work ② Detailed Drawing Detailed drawings that describe shapes , types and dimensions of each element for the bar-fabrication ③ Understanding of Drawing Drawings are in their own sequence beginning with the title and contents on the 1st page. Structure drawing of Rebar is for this case. There are several types of drawings which include machinery, electricity, sanitation, fire protection, communication, etc according to the type of work and there are details as follows. A) Construction i. Building layout ii. Elevation iii. Plane figure iv. Cross Section v. Part Detailed drawing B) Structure i. Drawing of column center ii. Plane figure of structure iii. Drawing of stairway and slab rebar arrangement iv. List of pillar , beam and retaining walls v. Detailed drawing of rahmen rebar arrangement C) In general, the order of drawing is in a sequence mentioned above, and all the drawings are in scale. ④ Scale (All the units in "mm") Among several types of rulers used in drawings, scale is indispensable. There are many types of scale. Among them 300mm scale is frequently used. It has carved line in the middle of each side, colored red, blue and black to distinguish its scale. Scale in red , Scale in blue , Scale in black Blue Red , Black Other different scales are available like , 4) Usage of symbol ① General symbol Description Symbol Length L Indication Rebar indication Area A Volume V Part cross section Symbol Distance of Rebar Diameter of Rebar High density No. of Rebar No. of cross section No. of drawing (Civil engineering, Architecture, Structure) Radius R No. of cross section No. of drawing Part detailed drawing (Civil engineering, Architecture, Structure) Main entrance Level indication(Plane) Sub entrance Scale S 1/200 Finish ▽ Level indication (elevation, cross section) No of layer & Member Structural plane ▼ EL. 0.0000 EL. 0.0000 Serial No. of Member Symbol per part of structure No. per layer ② Drawing Symbol Symbol Description Symbol Description B Bottom T Top N.F. Near Face F.F. Far Face E.F. Each Face E.W. Each way B.O.F Bottom of Foundation T.O.C Top of Concrete T.O.F Top of Foundation E.J. Expansion Joint Ab Size of a rebar(㎠) C.J. Construction Joint fck Strength of Concrete(kgf/㎠) fy Resistance strength of rebar(kgf/㎠) fcu(t) Compression strength of concrete per date(kgf/㎠) fe Available resistance power of ground(tonf/㎡) D(db) Nominal diameter of deformed rebar(mm) Fp Available resistance power per pile(tonf/㎡) CL Center Line & And H Height @ Distance THK. Thickness W Width CONC. Concrete TYP. Typical N.T.S Not to Scale ST’L Steel EL. Elevation Level FL. Floor Level 2. Characteristic of Rebar Throughout the reinforcement work, reinforcing bar strongly bonds to mixed concrete and this makes floor, wall and other members very strong. In other words, reinforcement is a bar that is embedded in the mixed concrete to make a member strong. Bar and concrete have low thermal expansion coefficients, 1×10-5 , and therefore have little thermal deformation or failure, cooperatively strengthening members. 1) Production process of rebar ① Ingot : made from melted iron ore and pig iron ② Billet : made from hot-rolled ingot ③ Reinforcing bar : manufactured per type by hot-roll process from the purchased billet Type Deformed Rebar Symbol Resistance Point (kgf/mm2) Classification SD 30A over 30 Green(D:General type) SD 30B 30 ~ 40 White(D:General type) SD 35 35 ~ 45 Red(HD:Density type) SD 40 40 ~ 52 Yellow(HD:Density type) SD 50 50 ~ 64 Black(HD:Density type) p.s.) KS Symbol of Deformed Rebar : indicate as SD300, SD350, SD400, SD500 ④ In SD400, S is steel, D is Deformed Bar, 40 indicates that resistance point is over 40kgf/mm2(=400N/mm2=4,000kgf/cm2). 2) Classification of rebar ① Regular bars : The length of one strip is 8,000mm by KS(Korean Standard). Each bundle has almost same weight. (basis of 1-2 ton) ② Irregular bars : Irregular bars that are made of leftovers or nonuniform bars. ③ Reinforcing bars that are mainly used in the construction site are SD40 high strength steel and SD30A mild steel, Each bar is colored yellow(HD) and green(D) respectively in order to identify them. Mild steel usually used as processed goods such as hoop , stirrup , etc. Type Deformed Bar Symbol Classification SD 30A Green(D) SD 40 Yellow(HD) SD 50 Black p.s.) SD:Steel Deformed 3) Type & Weight of rebar ▶If the worker in the construction site prepare the bars more than needed, there might be rust on the surface of the rebar. To prevent oxidation of the bar, it is advised to prepare moderate amount of the bars. ▶When you need to pile the bars near the construction site, they should be classified and piled on the big gravels to make the ventilation easy. And also cover the stocked bars to avoid humidity. ▶There are usually two types of deformed steel used in the construction work. ① SD30A(mild bar) - normal strength bar, has green-colored end ② SD 40(high tension bar) - high strength bar, has yellow-colored end ※Size, Weight of Deformed Bar(8m) (KS D3504) Content Type 1tonf 2tonf nominal diameter Per each Per meter Q’ty per Q’ty per (D)mm (kgf) (kgf) 1tonf (kgf) 2tonf (kgf) HD10 210 420 9.53 4.48 0. 56 941 1,882 HD13 120 240 12.7 7.96 0.995 955 1,910 HD16 75 150 15.9 12.48 1.56 936 1,872 HD19 56 112 19.1 18 2.25 1,008 2,016 HD22 41 82 22.2 24.32 3.04 997 1,994 HD25 32 64 25.4 31.84 3.98 1,019 2,038 HD29 25 50 28.6 40.32 5.04 1,008 2,016 HD32 20 40 31.8 49.84 6.23 997 1,994 4) Weight limit of rebar Size of Rebar Less Than D10 Weight limit 1 each - 0.8% 1 ton 7.0% D10 ~ D16 6.0% 5.0% D16 ~ D29 5.0% 4.0% More Than D29 4.0% 3.5% Remark Sampling of test piece and calculation of weight limit should be in accordance with KS D3504 3. Calculation for unit weight of Rebar 1) Unit weight ① Unit weight is the weight of bar per 1m. ※ FYI, the basic value in drawing and the length of rebar is “mm”. When calculating unit weight, you must convert into “m” from “mm”. ② Unit weight per rebar type Rebar Size Unit Weight Rebar Size Unit Weight HD10 0.56 f/m HD25 3.98 f/m HD13 0.995 f/m HD29 5.04 f/m HD16 1.56 f/m HD32 6.23 f/m HD19 2.25 f/m HD35 7.51 f/m HD22 3.04 f/m HD38 8.95 f/m ③ Basic unit conversion 1ton = 1,000kgf 1kgf = 1,000gf 1m = 100cm 1cm = 10mm 2) Calculation of length(L) in model ① ② ③ 4. Criterion of Rebar arrangement 1) Rebar coating ▶It means the shortest distance to the surface of concrete to cover rebar surface. Rebar coating thickness of each part must be considered in the period of plan after considering durability, refractory, safety in structure endurance & errors in construction carry-out. ▶There are examples of coating case as ground criterion for all construction without segmenting the case of ground and also the case of foundation regularly. ※ By the effect of CO2, humidity, acid gas, there will be going on of neutralization step by step from the surface of concrete. If the coating is small, its speed to arrive rebar will be faster . If so, the rust will expand, the adhesion of concrete coating will drop, white phenomenon will exist, senility of structure body will facilitate. (Unit:mm) Rebar Size Classification Minimum coating/thickness Remark Concrete pouring under water Foundation All rebar 100 Concrete burying under ground forever after land pouring concrete adjoined Foundation All rebar 80 Concrete part to expose to outdoor air and to adjoin land directly Wall, pillar over HD29 Beam (outside exposure below HD25 beam) Slab(foundation slab) below HD16 50 40 over HD35 40 below HD35 20 Beam, Pillar Tiehoop Stirrup Spiral rebar 40 Shell, Member All rebar 20 Slab, Wall, Under Flooring Concrete part not to adjoin land and outdoor air 60 ※ Note : “direct exposure to the air of outdoor” means the case of direct exposure of climate change and humidity change. < Independent foundation > < Pile foundation > Coating thickness 80 < Pillar > Coating thickness 80 Coating thickness 50 Cushion Hoop Coating thickness 40 Lean Concrete Lean Concrete < Beam > < Wall & Slab > Coating thickness 20 Wall Stirrup Coating thickness Slab Coating thickness In Shear wall, the arrangement of rebar should be to the inside of vertical rebar. ※Regarding wall, horizontal rebar should be arranged to the outside of vertical rebar. ※Regarding outside wall in underground which compressed by the land, more arranged rebar should be arranged to the outside after comparing the arrangement quantity between vertical rebar and horizontal rebar. 2) Rebar distance Classification Net Distance Distance Over 1.5 times of nominal diameter Deformed rebar Over 1.25 times of max. size of thick aggregate. Net distance Over high value in 25mm 3) Type of tying Regarding the working of tying , there are folded tying(lap splice) , compressed tying(welded splice) , mechanical spiral tying(mechanical splice). But compressed tying(welded splice) , mechanical spiral tying(mechanical splice) have to be effected over 125% of resistance strength(fy) in plan criterion. ① Folded tying (lap splice) It is tying method to fold the fixed length from end part to new tying part by using regular rope currently. ※ Folded tying(lap splice) Concrete Strength (kgf/Cm2) Rebar Type 210 SD30 (fy=3,000 ) 240 270 210 SD40 (fy=4,000 ) 240 270 The value in ( ) is the case of upper part rebar. Rebar Size Tying length of deformed rebar to be extended A Class Tying A Class Tying Under D19 31.5d (41.0d) 41.0d (53.3d) Over D22 39.3d (51.1d) 51.1d (66.4d) Under D19 29.4d (38.2d) 38.2d (49.7d) Over D22 36.8d (47.8d) 47.8d (62.2d) Under D19 27.8d (36.1d) 36.1d (47.0d) Over D22 34.7d (45.1d) 45.1d (58.6d) Under HD19 42.0d (54.6d) 54.6d (71.0d) Over HD22 52.4d (68.1d) 68.1d (88.5d) Under HD19 39.2d (51.0d) 51.0d (66.2d) Over HD22 49.1d (63.8d) 63.8d (83.0d) Under HD19 37.0d (48.1d) 48.1d (62.5d) Over HD22 46.3d (60.2d) 60.2d (78.2d) Tying length of deformed rebar to be compressed 21.6d 28.8d 1. The length of folded tying of rebars which have different diameter must over high value between the fixed length of high diameter rebar and the folded tying length of low diameter rebar . 2. The tying position must be placed to low stress / to compressed stress of concrete. 3. By the criterion of concrete structure plan , it is mentioned that it is available for folded tying in case of D29~D35 rebar. However, you have to check in advance the problem such as the net distance of rebar is not secured and also the tying length will be exaggerated if you apply folded tying of thick rebar. Generally, there are more advantageous case by using mechanical tying instead of folded tying in case of over D29 rebar. A class tying : must be zigzag(rotation) tying arrangement and arranged rebar quantity is over 2 times of required rebar quantity which defined in total block of tying part and also under 50% of rebar tying quantity within required folded length. B class tying : it is available for the tying of anti-earthquake plan and generally it is applicable to all construction site. Regarding SD500 , you must apply 1.25times of B class tying. ※ Regarding beam main bar tying , you must apply B class tying if you don't mention tying position specially. But, you can apply A class tying if you want to tying the compressed part of concrete. (the compressed part of concrete : upper part main bar places near center part of span, lower part main bar places near pillar) ※ The tying length of wall vertical length is available around 40db of under HD19 especially. Example of folded tying(lab splice) Vertical rebar Tying Length of Tension bar(Ls) Slab upper part Slab upper part Fixed length of Tension bar Tying Length of Tension bar(Ls) ⓐ Folded tying of vertical rebar in case the distance of rebar arrangement is different Wall S : Distance of Rebar Ls : Tying length of Tension bar ⓑ Folded tying of horizontal rebar Tying Length of Tension bar(Ls) Example) Length of folded tying to be extended of vertical & horizontal rebar Diameter Length ② Compressed tying(welded splice) It is the tying method to compress through heat-treatment end to end by using machinery. As shown in figure(A) , place 2 bars 3mm away , heat up both of the ends by using mechanical equipment and add pressure to weld splice them figure(B), usually available for all bars. ③ Mechanical spiral tying(mechanical splice). As the mechanical splice method , it is rebar tying method to connect the spiral part with nut & coupling by cutting screw by expanding the end of rebar over the regular size. (A) Connect Nut (C) Move Coupler (B) Connect Coupler (D) Move Nut 4) Fixing and tying ① In order to effect the adequate resistance strength of rebar, it is essential to obtain the enough adhesion strength with concrete. The more you increase the net distance & coating thickness of rebar, the larger of adhesion strength. ② Fixing length is the buried length in concrete to effect the adequate resistance strength of rebar and fix the length with the criterion of max. stress point of appropriate rebar. ③ The fixing and tying length of rebar is changing by the strength of material and type of rebar arrangement , etc. i. It will be lengthen by using HD(high density) rebar.(SD40 is 1.33times of SD30A) ii. It will be shorten by using HD concrete.(inverse proportion from square root of concrete strength) iii. It will be shorten if net distance and coating thickness of rebar increase. iv. It will be shorten by the restriction effect if it is surrounded by stirrup and tie hoop. ④ Caution : If the fixing and tying length of rebar will be shorten , the resistance strength of rebar will be reduced as long as the shortened length. Also, in case the heavy binding of splice part of rebar needlessly sometimes, binding has only the role to prevent the movement of rebar when pouring concrete and also no relation to adhesion strength of rebar. (the tensile of a D25 rebar is 5.04 4.0=20.16tonf) ⑤ If the position of extended rebar for the tying of poured concrete is wrong, it is available for bending of splice with the angle of under if error is trivial but you need to take additional action to increase the section of additional material if error is over that angle. ⑥ In case slab or wall rebar will be cutted by temporary exit such as material pick-up exit, etc, you must extend the rebar which is over the length of splice to both ends of exit. If width of exit is narrow or the length of rebar extended is shorten , the length of splice will be shorten when pouring exit concrete later. ⑦ Calculation of bar length What should be added to original length : splice length, fixed length Splice length : extra length to lap the bars Splice length Fixed length Fixed length : developed length when the bar is fixed ⑧ Method to calculate fixed length 90°Standard hook Fixed length of rebar which has standard hook fixed length of tension bar - In case of fixing to neighbor beam - fixed length of tension bar - In case of fixing to end pillar - ⑨ Tension bar and compression bar tension bar : The main usage is tension bar because rebar is reinforced material to reinforce the tension of weak point of concrete. compression bar : the rebar to be arranged in addition to increase the resistance strength in concrete material and it is mainly applicable to the pillar of high building to cover the compression. ⑩ Refer to the diagram (#22 page) for tying & fixing per rebar diameter Compression Tension 5) Form of fixed beam ※ When arranging beam, the marked on drawing as bending bar is mainly Japanese method of rebar arrangement. Our standard will be cut-bar instead of bending bar(Japanese method) . ① The length to extend to reverse side from max. Stress point of fixed length. Hook should place over the center of pillar. Fixed length St eff ress ( we ect par igh the t to t) Return point beam Return point is must not 1/4 point. (return point of upper bar is different from return point of lower bar) ※① is fixed length of tension upper bar. In case of fixing with standard hook, fixed length of rebar which has standard hook will be applied. If not, fixed length of tension bar will be applied. is generally fixed length of lower compression bar and it is available of fixation if it is extended to pillar over 15cm without hook. 6) Example of fixed length per rebar diameter ① Fixed length of tensile rebar Fixed length of tensile rebar in slab(SD 400) Str en gth Rebar (unit:mm) 24N/ 240kgf/ 27N/ 270kgf/ 30N/ 300kgf/ 35N/ 350kgf/ 40N/ 400kgf/ 300 300 300 300 300 400 380 360 330 310 540 510 490 450 420 730 680 650 600 560 Remark ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times Fixed length of tensile rebar in foundation, pillar, beam, wall(SD400) th ng re St Rebar 27N/ 270kgf/ 24N/ 240kgf/ General bar Upper bar General bar 30N/ 300kgf/ Upper bar General bar (unit:mm) 35N/ 350kgf/ Upper bar General bar 40N/ 400kgf/ Upper bar General bar Upper bar HD10 400 510 370 490 360 460 330 430 310 400 HD13 510 670 490 630 460 600 430 550 400 520 HD16 630 820 600 770 570 730 520 680 490 640 HD19 750 970 710 920 670 870 620 810 580 760 HD22 1080 1410 1020 1330 970 1260 900 1170 840 1090 HD25 1230 1600 1160 1510 1100 1430 1020 1320 950 1240 HD29 1430 1850 1350 1750 1280 1660 1180 1540 1110 1440 HD32 1570 2050 1480 1930 1410 1830 1300 1690 1220 1590 ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times ② Fixed length of compression bar Fixed length of compression bar(SD400) Str en gt Rebar h HD10 (unit:mm) 24N/ 240kgf/ 27N/ 270kgf/ 30N/ 300kgf/ 35N/ 350kgf/ 40N/ 400kgf/ 50N/ 500kgf/ 210 200 200 200 200 200 HD13 270 260 240 230 210 210 HD16 340 300 300 280 260 260 HD19 400 370 360 330 310 310 HD22 460 430 410 380 360 360 HD25 520 490 460 430 400 400 HD29 600 570 540 500 470 470 HD32 670 630 600 550 520 520 ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times 7) Example of splice length per rebar diameter 1) Classification of tension splice ㆍA class tying : must be zigzag(rotation) tying arrangement and arranged rebar quantity is over 2 times of required rebar quantity which defined in total block of tying part and also under 50% of rebar tying quantity within required folded length. ㆍB class tying : it is available for the tying of anti-earthquake plan and generally it is applicable to all construction site. Actual arranged rebar requirement Required rebar Q’ty Max. splice % within folded splice length 50% 50% 2 2 2) Upper bar : horizontal rebar without concrete harded over 300mm under splice part and fixed length 3) The rebar with folded splice without contacting directly each other in bending material must not depart over little value between 150mm or 1/5 of folded splice length. ① A class splice length of tension rebar Splice length of slab(SD400) Str en gth Rebar HD10 (unit:mm) 24N/ 240kgf/ 27N/ 270kgf/ 30N/ 300kgf/ 35N/ 350kgf/ 40N/ 400kgf/ 300 300 300 300 300 HD13 400 380 360 330 310 HD16 540 510 490 450 420 HD19 730 680 650 600 560 Remark ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times A class splice length of foundation, pillar, beam, wall(SD400) St ren gth Rebar 27N/ 270kgf/ 24N/ 240kgf/ General bar Upper bar General bar 30N/ 300kgf/ Upper bar General bar (unit:mm) 35N/ 350kgf/ Upper bar General bar 40N/ 400kgf/ Upper bar General bar Upper bar HD10 400 510 370 490 360 460 330 430 310 400 HD13 510 670 490 630 460 600 430 550 400 520 HD16 630 820 600 770 570 730 520 680 490 640 HD19 750 970 710 920 670 870 620 810 580 760 HD22 1080 1410 1020 1330 970 1260 900 1170 840 1090 HD25 1230 1600 1160 1510 1100 1430 1020 1320 950 1240 HD29 1430 1850 1350 1750 1280 1660 1180 1540 1110 1440 HD32 1570 2050 1480 1930 1410 1830 1300 1690 1220 1590 ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times ② B class splice length of tension rebar It is available for the tying of anti-earthquake plan and generally it is applicable to all construction sites. B class splice length of slab(SD400) Str en gt Rebar h HD10 (unit:mm) 24N/ 240kgf/ 27N/ 270kgf/ 30N/ 300kgf/ 35N/ 350kgf/ 40N/ 400kgf/ 390 390 390 390 390 HD13 520 490 470 430 410 HD16 700 660 630 580 550 HD19 940 890 840 780 730 ※When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times Remark B class splice length of foundation, pillar, beam, wall(SD400) (unit:mm) St ren gth Rebar General bar HD10 510 670 490 630 460 600 430 550 400 520 HD13 670 870 630 820 600 780 550 720 520 670 HD16 820 1070 770 1000 730 950 680 880 640 830 HD19 970 1260 920 1190 870 1130 810 1050 760 980 HD22 1410 1830 1330 1720 1260 1640 1170 1510 1090 1420 HD25 1600 2080 1510 1960 1430 1860 1320 1720 1240 1610 HD29 1850 2410 1750 2270 1660 2150 1540 2000 1440 1870 2050 SD500 1930 1830 1690 1.25 2650 rebar(fy=500N/㎟=5,000kgf/㎠), 2510 2380 apply 2200 HD32 using ※When times1590 2060 27N/ 270kgf/ 24N/ 240kgf/ Upper bar General bar 30N/ 300kgf/ Upper bar General bar 35N/ 350kgf/ Upper bar General bar 40N/ 400kgf/ Upper bar General bar Upper bar ③ Splice length of compression rebar Strength Rebar fck = 21N/ SD400 (fy=400N/ = 70N/ (210kgf/ =4,000kgf/ ) - 700kgf/ ) SD500 (fy=500N/ HD10 300 410 HD13 380 540 HD16 470 660 HD19 550 780 HD22 640 910 HD25 720 1030 HD29 840 1190 HD32 930 1320 =5,000kgf/ ) ④ Fixed length of tension bar which has standard hook fy=400N/㎟(4,000kgf/㎠) (diameter) fixed length of tension bar destroyed section of concrete min (diameter) tension tension 3db HD10 ~ HD25 4db HD29 ~ HD35 5db over HD38 or Str en gt Rebar h 24N/ 240kgf/ 27N/ 270kgf/ 30N/ 300kgf/ 35N/ 350kgf/ 40N/ 400kgf/ 50N/ 500kgf/ HD10 210 200 200 200 200 200 HD13 270 260 240 230 210 210 HD16 340 300 300 280 260 260 HD19 400 370 360 330 310 310 HD22 460 430 410 380 360 360 HD25 520 490 460 430 400 400 HD29 600 570 540 500 470 470 HD32 670 630 600 550 520 520 ※ When using SD500 rebar(fy=500N/㎟=5,000kgf/㎠), apply 1.25 times. ⑤ Fixed length and splice length of binded rebars. Increase the fixed length and splice length of binded rebars as follows. a) 3pcs binded rebars : increase 20% b) 4pcs binded rebars : increase 33% The splice of each rebar must not duplicated 5. Criterion of Rebar bend-processing 1) Bending of main bar and leftover length (unit:mm) fixed roller center pole fixed roller center pole (over 12d) Drawing (4d or over 60mm) Rebar size Rebar diameter HD10 9.53 HD13 12.7 HD16 Roller min. radius Condition A Leftover length Condition B Condition C 30 120 60 40 160 60 15.9 50 190 70 HD19 19.1 60 HD22 22.2 HD25 25.4 HD29 28.6 HD32 31.8 3d 3d 4d 70 12d 230 270 4d 80 90 80 310 110 120 350 120 130 390 130 2) Bending of stirrup, hoop and leftover length fixed roller center pole (unit:mm) fixed roller center pole Drawing Roller min. radius Condition A Leftover length Rebar size Rebar diameter HD10 9.53 HD13 12.7 HD16 15.9 35 100 HD19 19.1 60 120 HD22 22.2 HD25 25.4 20 2d 3d 3) Rebar processing form Rebar’s hook(one-side, both-sides) one-side both-sides Condition 30 70 80 6d 12d B Condition C 60 60 80 80 6d or 60mm 100 120 280 140 320 160 U type Closed type Transformational closed type 4) Slope dimension of rebar processing(hunch) 100 140 120 370 520 430 640 910 740 910 1290 1050 110 160 130 380 540 440 650 920 750 920 1300 1060 120 170 140 390 550 450 660 930 760 930 1320 1070 130 180 150 400 570 460 670 950 770 940 1330 1090 140 200 160 410 580 470 680 960 790 950 1340 1100 150 210 170 420 590 490 690 980 800 960 1360 1110 160 230 190 430 610 500 700 990 810 970 1370 1120 170 240 200 440 620 510 710 1000 820 980 1390 1130 180 260 210 450 640 520 720 1020 830 990 1400 1140 190 270 220 460 650 530 730 1030 840 1000 1410 1150 200 280 230 470 670 540 740 1050 850 1010 1430 1170 210 300 240 480 680 550 750 1060 870 1020 1440 1180 220 310 250 490 690 570 760 1080 880 1030 1460 1190 230 330 270 500 710 580 770 1090 890 1040 1470 1200 240 340 280 510 720 590 780 1100 900 1050 1490 1210 250 350 290 520 740 600 790 1120 910 1060 1500 1220 260 370 300 530 750 610 800 1130 920 1070 1510 1240 270 380 310 540 760 620 810 1150 940 1080 1530 1250 280 400 320 550 780 640 820 1160 950 1090 1540 1260 290 410 340 560 790 650 830 1170 960 1100 1560 1270 300 420 350 570 810 660 840 1190 970 1110 1570 1280 310 440 360 580 820 670 850 1200 980 1120 1580 1290 320 450 370 590 830 680 860 1220 990 1130 1600 1300 330 470 380 600 850 690 870 1230 1000 1140 1610 1320 340 480 390 610 860 700 880 1240 1020 1150 1630 1330 350 500 400 620 880 720 890 1260 1030 360 510 420 630 890 730 900 1270 1040 6. Tying method of Rebar When tying the bars, the hook is used in Korea and Japan. While in other countries, the wrench is used. Tying the bars requires many times of practice. All the places that two bars meet are recommended to tie. However, it is usually accepted to skip all other crossing point in case of light-loaded bars. There are several types of binding the bars such as cross tie, Saddle tie with twist, wall tie and double string tie, etc. 1) Cross tie Ties to fix the stirrup onto beam ties to prevent hoop from slipping down 2) Double string tie Same procedure when you use hook to tie the bars mostly used in Asian countries applicable to many construction sites such as wall, slab, etc. You must tie different tying each bars. 3) Saddle tie with twist Ties the bars in high beam or wall to fix them firmly or to avoid twisting off 4) Wall tie - The same procedures as saddle tie with twist and tie it as the method of right picture - Ties the bars that extend from the wall to keep the required positions and distances between them 5) References ① Every crossing point of the bars at the bottom span should be tied, and wound more than 3 times. ② When tying the bars at the top span, tie the bar changing the tying direction(one time to left and next to the right) ③ When tying the bars in a slab, you may skip every other, but it is better to wind the hoop before tying the bars. ④ It is advised to wind the hoop 3 times at the important crossing point. ※ There are several kinds of ties, and in construction works, #20 tie is normally used in folded state. 7. Bar support , Spacer ① Bar support is usually to hold the location of placed bars, and spacer maintains the cover depth of a member as intended. ② In addition, they also prevent dispersions of located bars due to high impacts and undesirable vibrations. Especially in reinforced concrete, cover depth, which is one of the important factors for durability, should be seriously considered. ③ Undoubtedly, bar support and spacer should be strong or even stronger enough to to support the bar and endure high impacts ④ When metal is used to reinforcement, spacer must have special rust protection on the portions nearest the face of the concrete by attaching pvc cap. Part Type Area : 4m2 - 8EA 16m2 - 20EA Bar Space - around 1.5m (Closer than 1.5m at the end) Foundation Foundation Beam Remark By calculation if Mat thickness is over 1,500 Install to top span, bottom span, sides At the 1st tie hoop in the top span In the middle of pillar in the middle span less than 1.0m of pillar width 2EA More than 1.0m of pillar width 3EA Pillar Steel Reinforcement Wall Basement Outside Wall Q’ty & Layout & Concrete material At the first tie hoop in the top span 1.5m from the top in the mid span Transverse spacing 1.5m Within 1.5m at the end Beam Bar Space - around 1.5m (Closer than 1.5m at the end) Slab Bar 1pc(1.3/m2) per width by long, each 1m at the top & bottom bar At the top and the bottom except side beam Also on the sides in the side beam 8. Conventional processing work tools Once the construction work is initiated, reinforcement needs to be manufactured, several different tools are used depending on the type of work. 1) Types of conventional tools. ① Bending die : die to bend the bar on ② Bender : bends the bars ③ Hammer : adds force to cut the bar ④ Lower cutting blade ⑤ Upper cutting blade ⑥ Mat plate to fix the cutbar ⑦ Various types of bar bender and bar cutter are available(see Chapter.3) 2) Preparation before reinforcement of rebar work ① Fabricate the bar bending die (The height should be about 850mm). ② Prepare the power cable to connect the bending machine and binding machine ③ Prepare chalk or other writing instrument to mark the dimension. ④ Prepare the tools and bending die. <Bending Table> Bending Pin Bending Plate <Manual Bender> Prepare per rebar size <Mat> <Low cutting blade> <Manual Cutter> <Hammer> <Upper cutting blade> 3) Tools needed if assembling does a. Measuring tape ~ measures the dimension b. Hook ~ a tool to tie the bar(usually used in Korea and Japan). Wrench is used in Europe and South-East Asia c. Conventional shearing machine ~ cuts a bundle of binding wires to bind the bars in a beam, a pillar(divide to half) or a slab(divide to 3parts) d. Plumb ~ using to assemble the pillar bar vertically e. Bar-tying hook ~ ties #8 wire <Measuring tape> <Inch Ruler> <Plumb> <Bar-tying hook> ※ Tools mentioned above are rather old type ones, and newly developed tools are in the construction site now. 9. Point of conventional processing work 1) Marking the bending point (example : D10~D13 stirrup , hoop) Mark the bending point on the bending die. Be sure to nail the bending panel on the bending die to fix it firmly. Nail Processed dimension Bar backstopper pin Working point Keep the 1.5d of tolerance from the working point (in case of D10, keep the 15mm of tolerance) 2) Determining the location of the manual bender Be careful Make space +20mm width from the bending start pin. The space of working point must over 20mm than using rebar. The position of bender must have space of 20mm from working point to bender using to head of handle. (install within eye shot) 3) Processing Bend the bar a little more than intended angle. Make sure that there is 20mm of distance between the tip of bender and bending point. The distance between these two points should be neither too far nor too close for high bending accuracy. With your left hand, gently push the bender outward to bend the bar, while you grab the bar with your right hand to fix it firmly. 4) Posture and position of foot It is recommended that bending direction should be from right to left. The left hand that pushes outward to bend the bar should be at the level of your belt. Your right foot just turns the direction, while your left foot moves quickly to bending direction(Weight shift along bending direction) 5) Currently using machinery General Bender TYB-D35 Mobile Cutter TYC-D29A 10. Calculation of the quantity of Rebar material 1) Extra of rebar ① In case of deformed bar, extra is 3% in general when including fixed & splice length of rebar, however, it is proportional to bar size. 16mm or larger : more than 5% extra 3% of 100ton is 100×0.03 = 3ton ② Rebar calculation included extra 3-8% after calculating fixing & splice. Therefore, those works will prevent from the reason of illegal construction practices with correct quantity & regular position carryout of construction by calculating bar-list with shop drawing. ③ If rebar will be processed in rebar processing factory , basically extra is as follows. In construction work 3%, in engineering work 6%, support work 3~4%. You have to consider the economical efficiency and construction carryout efficiency in site after analyzing in advance about extra percentage per rebar size by the criterion per construction carryout area. 2) Base plate(Footing) <Example : 1> <Example-1> In 2000×2000 foundation, shown as above, requirement of bar includes 20pcs HD22 bars of 1,840mm (80(cover depth)×2(both ends) = 160mm is extracted from 2,000(original length of foundation), 2pcs D19 assist bars of 2,601mm(1,840)×1,414 2 ), diagonal direction) and 4pcs short diagonal bars(2 bars in each diagonal direction) of 2,318mm(1,640(200mm is extracted from main bar length 1,840mm)× ( 1,414 ( 2 ). ① HD22 1,840mm×20(foundation) = 36,800mm Weight = 36.8m(36,800mm)×3.04(unit weight) = 111.872kgf ② HD19 2,600mm(long bar)×2 = 5,200mm Weight = 5.20m(5,200mm)×2.25(unit weight) = 11.700kgf HD19 2,310mm(short bar)×4 = 9,240mm Weight = 9.24mm(9,240mm)×2.25(unit weight) = 20.79kgf ⓐ Actual requirement of bar is ① HD22 = 111.872kgf ② HD19 = (11.700kgf+20.79kgf) = 32.49kgf ※ LOSS(left bar strip) : The original length of bar before cutoff is usually 8,000mm. In case of ①above, 4pcs 1,840mm bars are produced and 640mm of bar strip is left. 5 bars are needed for foundation, hence 640×5 = 3,200mm of bar strip is left. Its net weight is 3.20m(3,200mm)×3.04(unit weight) = 9.72kg. ⓑ Actual requirement of bar is 8m×3.04(unit weight)×5 bars = 121.6kg <Example : 2> ① What is the weight of D10 8m bar? 0.56kg×8m = 4.48kg ② How many D13 bars(8m criterion) in 2ton? 2,000kg÷(0.995kgX8m) = 251EA(standard is 240EA) ③ Arrangement in foundation (base plate F) ( All the unit in drawing should be in 'mm') HD16 rebar 200mm space HD19 rebar 300mm space HD13 reinforcement bar 3EA HD16 = 2,000-(80(cover depth)×2(both ends)) = 1,840 (cutoff dimension) HD19 = 3,000-(80(cover depth)×2(both ends)) = 2,840 (cutoff dimension) ₂ ₂ HD13 = 1840 +2840 = 1840×1840+2840×2840 = 3,383 (cutoff dimension) ₂ ₂ (Note. x = x×x, 10 = 10×10 = 100) Here, multiply unit weight and number, then net weight of bar is HD16 = 1.84m(1,840mm)×1.56kg = 2.87kg 2,840 ÷ @200 = 14.2 → 14 ⇒ 14+1 = 15EA 2.87kg×15 = 43.05kg HD19 = 2.84m×2.25kg = 6.39kg 1,840 ÷ @300 = 6.13 → 6 ⇒ 6+1 = 7EA 6.40kg×7 = 43.73kg HD13 = 3.38m(3,380mm)×0.995kg = 3.36kg Weight = 3.36kg×assist bar(3+3) = 20.16kg ※Among 6 assist bars, two(2) of them in 3,380mm and the other(4) in 12,320mm (4x3,080mm : 300mm shorter) Net weight is 43.05+44.73+21.60 = 109.38kg and add 5% extra, hence 114.84kg is required. 3) Base(footing) and pillar As various footing types like continues footing, single footing and mat footing, there are many shapes of footing, that is, triangle, right triangle, square, rectangle, pentagon, circle, multi-layer plate, etc. In this book triangle shape footing and single reinforcement footing are dealt with. In case of footing shown left cover depth, the type of bar and the size of HD22@200 bar should be considered. In addition, the reinforcement at footing-pillar junction should be included here. HD19-6EA Before bar cutoff, the size of C1, HD22@200 the area of main reinforcement, the size of hoop and the spacing of F1 plane stirrup are all considered consulting the bar list. cover50 Calculation : cover80 Footing shown left is in contact with soil, hence cover depth is 80mm at each end(80×2 = 160 at both ends). Section 160mm is extracted from footing length 2,000mm, and this(1,840mm) is divided with spacing 200mm. D10@300 D10@300 upper part, lower part @150 HD22-8EA Then 10 reinforcement(at every 9 spacing +1 at the end) is required here. Now reinforcement is in two directions and therefore we need 20 reinforcements. 4) Pillar Similar to footing, there are many shapes of pillar, that is, triangle, right triangle, square, rectangle, pentagon. circle, etc. The worker is recommended to earn a lot of working experience. ① Calculation of pillar In calculation, tie hoop, stirrup, main bars in column and the others should be included here. D10@300 D10@300 upper part, lower part @150 First extract cover depth from hoop size (400mm), and cover depth in the basement and above the ground should be different. HD22-8EA Net length cover depth 400 - (40+40) = 320 (dimension)×4(4sides) ⇒ 1,280 + 100mm of hook then, cutoff length is 1,380mm. Since net length of hook is 100mm, only 100mm of extra length is added here. If the bar size is D10, one end is hooked in circular, so 2 times of bar diameter (20mm) is extracted here, As 5 hooks are needed and hook length is 100mm at each end(200mm in total), 80mm is extracted from 100mm. Then this 80mm is added to produce 200mm of hook length. 5) Calculation of main rebar If you will carry-out with 8,000mm rebar including both fixed length(anchor) from total length of 1 span , you just add the splice length from rebar diameter to use. Example) Total length 62,000mm + both fixed length(anchor) 1,000mm = Gross Total 63,000mm. When using HD19 rebar, splice length is 19×40d = 760mm. Rebar 8,000mm - splice length 760mm = 7,240mm. Gross Total 63,000mm ÷ 7,240mm = 8.7 piece (long bar 8piece & rest 5,080mm) Above splice length is 5,080mm including anchor. You can calculate it as above , but you have to carry-out the splice position as soon as closely by calculating several methods if spice position is not fit well. <Sample of processing> END long bar processing end top-bar center top-bar in span end top-bar center top-bar in span CENTER splice rebar long bar outside end outside end 6) Calculation of top rebar Please refer to the method in construction site as follows because it is very difficult to explain in theory. If 1 span is 8,000mm, 4,000mm will be center part and add 40times(40d) + rebar thickness is the length of top rebar in center part & end. You cut as 4,000mm +760mm = 4,760mm. ※ When assembling current processing status , center part is from beam to upper part rebar splice position and end is lower part rebar splice position if splice rebar 2 pcs 4,580mm + long bar processed 1pc as upper part rebar and splice rebar 1pc 4,580mm + long bar processed 2pcs as lower part rebar will be used. And so, you assemble it mutually crossed and upper part is 2 bar from 3 bar from splice position. 7) Calculation of hoop ① If pillar size is width 400mm length 500mm, actual processing size is 320mm, 420mm except cover 40mm each(both 80mm). ② When processing hook by hand, it will be included 40mm from total length. When using Taeyeon's bending machine, it will be included 50mm from total length . coating thickness 40 process size ③ Cut size : (420×2)+(320×2)+50 = 1,530mm ※ Example of hoop usage : To avoid wrong bending of main bar and to restrict inner concrete , you maintain the space and no problem to assemble with 135°hoop at one side. 8) Calculation of stirrup ① If beam size is length 500mm , actual processing size is 420mm , 420mm except cover 40mm each(both 80mm). If beam size is width 300mm , actual processing size is 220mm , 220mm except cover 40mm each(both 80mm). ② Including hoop 50mm , you can use Taeyeon's bending machine. END CENTER Process size ③ Cut size : (420×2)+(220+50(hook)=1,100mm ※ Example of stirrup usage : To surround tension & compression bar and to restrict inner concrete , you maintain the space and bend with over 135°as stirrup end length. Taeyeon bending machine will be processed 90°or 135°with free by manufacturing of special tool & electric circuit. 9) Fact of processing According to rebar thickness and to bending angle , 2 times of rebar thickness will be used because of bending by circle of bending part than the length per actual straight line. <Tolerance of rebar process size> Item Symbol stirrup, tie hoop A, B 5 below HD25 A, B 15 over HD29 A, B 20 - 20 Drawing main bar length after processing Tolerance( ) 10) Changed size if it bent 1 angle per specification When bending 1 angle, rebar D10 will be increased by 2cm each. When bending 1 angle, rebar D13 will be increased by 2cm each. When bending 1 angle, rebar D16 will be increased by 3cm each. When bending 1 angle, rebar D22~25 will be increased by 5~6cm each. Because bending part will be bent like R type, rebar will be less used per rebar diameter. Regarding processed rebar, it will be less used also by measuring with outside diameter size. If actual cut size is D10, (42×2)+(32+8(hook)) = 124cm Note) Process size must be outside diameter size of processed rebar. 11) Tolerance of processed size Item stirrup, tie hoop, spiral rebar processed size others Tolerance( ) 5 under D25 of deformed bar 15 D19~D41 of deformed bar 20 total length after processing 20 11. Foundation(Base) rebar arrangement 1) Foundation(base) work In foundation work, the lean concrete underneath the footing concrete, is very important. Without it, constuction site, on which a building will be raised up, it would not be clean and stable disturbing construction work. Be sure to make lean concrete working mat having at least 50mm of thickness. If F.L. of lean concrete is not fit, there are difficulty in fix S.L. 2) The height of spacer Bar spacer is used to maintain the arranged bar balanced. When arranging the bars or flooring, stones and bricks can not be used to support them. You have to prepare spacer in advance because there are high possibility of unbalance when using stones or bricks to level the ground. (in case of spacer height lean concrete top is 60mm) < Cover thickness of rebar > part to not contact land part to contact land over 80mm of cover thickness in foundation rebar lean concrete over 50mm of cover thickness than pile head on base concrete ※ The reason that the top of piles is embedded into foundation is that , in case of an earthquake , the pile causes bending fracture. Especially , when the ground is unstable , there should be specified directions on the drawings.(in case pile cover bending moment & compresssion or cover tension properly only) 6-D13(circular arrangement) PC Steel wire 2 times of pile diameter Fillup CON’C HOOP D13@150×4 (foundation CON’C) Hole closure PC or PHC PILE 3) Independent Foundation(Single Footing) Usually in double footing and floating foundation , remained bar length is bent up and down to splice them together as depicted below. However, the remaining parts of the bar can be cut off to reinforce the foundation. <In case of securing splice length> when securing splice length <In case of not securing splice length> In case of below splice length standard hook 4) Foundation(base) pillar tie hoop The main purpose of the tie hoop is to restrain the transverse load in order to relieve vertical load into pillar. Even though foundation concrete has capacity to support the loads from the pillars, tie hoops help main bars be fixed at which they should be and it is important job. <Before reinforcement> slab <After reinforcement> main bar pillar tie hoop should be @300 distance per the drawing regulation, tying footing lean concrete MAT bottom tie hoop spacer pillar ※ The tie hoops at the bottom hold the bars of the pillar in lean concrete and marking on the mould form is compared with drawing to ascertain the center of the pillars. <Foundation plate> pillar location marking eccentric The outer pillar must check main bar line. 5) Foundation(base) upper-support(Wooma) rebar - Foundation thickness : below T=1,000mm for HD16, over T=1,000mm for HD19 space should be @1000-@1500 12. Pillar rebar arrangement 1) Indication of pillar(C) Main bar drawing - It indicates the length of span by the criterion of pillar and wall, etc. and indicates the position of pillar & wall. <Example> C - pillar BC1 - #1 underground pillar 1C1 - #1 first-story pillar 500×500 - actual size of concrete 8-HD19 - 8pcs of HD19mm rebar D10 @250 - install per 250mm of HOOP distance D10 @250 - install per 250mm of DIA HOOP distance ※ Be careful of this point if there are rebar quantity's differences according to pillar assembly x0, x1 or y0,y1 direction. 2) Indication of floor 2SL(upper concrete) 2FL(upper part’s closing condition) Height of floor 1) GL - GROUND LEVEL 2) FL - FLOOR LEVEL (ground level per floor) 3) SL - SLAB LEVEL (upper part of structure per floor) 3) Sequence of pillar assembling < Stand the same to diagonal direction if each side is even. > < Stand the same to all directions if each side is odd. > < Stand the same to one direction if each side is even & odd. > 4) Tying method of pillar ① Even the tiny little requirement for the construction should be taken into consideration. Keep the pillar reinforcements vertically and splice the bars 3 times. Upper and lower parts of the reinforcements should be cross-tied. ② When tying the corner of tie hoop, it is better to wind the tying wires changing directions up and down to let it not to be hung down. It is also recommended that worker wind the tying wires at least one time in advance to hold the main bar to its original position. main bar tie bar ③ Tie bar for assisting pillar should be at every distance to install tie hoop . Diamond type General type ④ Bind the tie hoops clockwise(as shown below) and spacing at the top and bottom levels of vertical reinforcement should be within of hoop spacing beginning at 50mm from the bottom of the floor. 5) Position of pillar tying ① In pillar bar slice, follow the instructions on drawings in order to splice them adequately, that is, if not, the length of reinforcement is not fit for column with the reason that usual 8,000mm bar is cut into two 4,000mm bars to splice. good location of splice available location of splice bad location of splice [Note] It is desirable that reinforcing bar should be in a variety of sizes, but 8m bar is usually available in the market. In other words, if you need a bar other than 8m in size, you should give a customerorder for it, which does not go well with economical strategy. Reinforcing bars from D10~D16 do not have much problem in using them as reinforcement for slabs or bearing walls. We have some advantages here. Bar loss and the frequency of splice will be decreased if using bars of 8m ~ 12m length by mixing. ② Splice of pillar and pillar over 75 under 75 max. 150 Dowel rebar splice fixing max. slope max. 150 splice/ fixed length of tension bar slope rebar splice using dowel rebar 6) Cross assembling of pillar and beam(only for outer pillar) ① Don't fill up tie hoop to assemble beam the crossed part of pillar & beam. In this case , there are difficulty in carrying out the construction but you must fill up tie hoop of outside. Especially, you should prevent from the protruded main bar by filling up tie hoop on outer pillar and edge pillar. pillar pillar tie hoop beam from current rebar arrangement carry-out of construction ② In case over 600mm of pillar size , you should fill up support tie hoop by shop drawing. You should get rid of support tie hoop in order to worker's entrance to pillar tube to connect #8 wire for working of pillar outer appearance. After this, the worker should not forget to bind the assist wire before he gets out. ※ In case the splice length for pillar splice is shorter than required, be sure to destroy the concrete to maintain splice length but it is impossible possibility to execute actually. Therefore, you should check the availability of welding splice, compressed splice, mechanical splice. 7) Correction of pillar ① Bend the bar gently at a very low level ② Pillar correction angle should not exceed of overall angle ③ Heat should not be added to correct the main bar because it makes the strength of rebar, just destroy the part that needs correction and bend it of overall angle. ④ Destroy the part that needs correction and modify it. These are 2 cases of correction depending on correction angle. ⓐ When the correction grade is low If corrected angle is about , insert the bar into pillar after bending. Bending after concrete work. ⓑ When the correction grade is higher than , change the bending angle to and cover the pillar as thin as possible. Increase to minimum pillar thickness Pillar rebar protruded to outside. 8) Detailed drawing of pillar and beam rahmen(arrangement) ① Don't apply compression splice length except pure compression material. Regarding bending material , apply B class splice for tying near max. stress point and apply A class splice for the rest block. fixed length A class tension splice 2nd floor HO main head A class tension splice The fixation of upper bar calculates fixed length from the main bar bend area of pillar’s upper part, not from the inside of pillar 1st floor HO space When the beam is arranged, the bottom bar should be all tied, and the stirrup upper binding supported by spacer should be tied 2,3 times tightly. tension splice (over B class splice length) tension splice ② Apply to anti-earthquake slab rebar In case all plane of pillar have beam Lo max. size of pillar section max. max. beam lower part bar In case some plane of pillar has beam (ground outside pillar) So 8db(main bar) Lc/6 24db(hoop bar) 45 1/2(min size of pillar section) 30 13. Beam rebar arrangement 1) Principle of beam rebar arrangement ① Calculate the size and depth of beams according to the drawing and arrange them in a suggested order, that is, exterior beams and big beams(G) & deep beams first and then binding small beams(B beams) later. ② Supervisor has to check if the bar used at the top span meets the requirement on the drawing. Shorter bar than required might be used to save cost when the span is longer than 8,000mm, the bar standard. ③ The bar might deflect from undesirable vibration when placing concrete if the double reinforcement or top end bar are tied with tying wires. To prevent this, 3 pieces of stirrups are used to tie the bars at the top and as many pieces to place double-leg bar & top bar on the bottom bar. <The height will be changed by th rebar size> Stirrup:end support(S.T.) Center support(S.T.) ④ Cap tie bar should carry out 1 by 1 at least. ※ The 1st stirrup should be arranged with the space 50mm from the perimeter of side pillar. 1st stirrup arrangement beside of big beam main bar 1st stirrup arrangement beside of pillar’s main bar big beam @/2 or under 50mm from side pillar @/2 or under 100mm from side big beam ※ The splice for upper part rebar of beam's end and lower part rebar of beam's center apply tension splice length. <Main bar arrangement> 0.3L1 OR 0.3L2 0.3L1 OR 0.3L2 middle/ big value middle/ big value 12db Ldh min 15㎝ 0.125L1 0.125L1 min 15㎝ or continuance min 15㎝ or continuance 0.125L1 0.125L2 L1 L2 <Distance of stirrup> S2 S1 S3 50 50 end 0.25L1 center 0.5L1 L1 S4 50 end 0.25L1 end 0.25L2 center 0.5L2 L2 ※ Apply the above except the case of marking separately on beam chart. ※ S1-S4 : stirrup distance 2) Types of stirrup <a> Open type - beam without cap tie bar - beam to be arranged by front end without twisting - beam without anti-earthquake plan <b> Closed type ① slab on both sides ② slab on one-side ③ no slab on both sides over 45cm splice against total distance of member over 30cm - beam with front end and twist - in case of anti-earthquake plan 3) Position of beam tying(splice) ※ Splice location : diagonal line ① Calculation of bender When bent bars are used to reinforce beams, bending point of the bar is usually calculated as distance from the center of the pillar. However, it is formal to divide it into 4 parts from the end of beam reinforcement to the other end. wall girder pillar ② An example for processing Anchorage(fixed) bars are classified as the top bars and the bottom bars, when the former have tensile loads and the later have compression loads. Therefore, the top bars and bottom bars set fixed splice length with same method because it has difficulty in working separately for processing and assembling.(criterion of concrete structure plan) In a real construction, 40d is used for both of them for convenience sake. ③ Cover depth of beams ⓐ Stirrup with spacer should be tied several times. ⓑ Pay attention when arranging reinforcements in order to have enough cover depth. X beam spacer cover thickness 40 Y beam height 40 Y beam X beam Tension fixation 4) Bending position of bender (classification of tension & compression) Tension fixation A class tension splice bent bar A class tension splice (Top floor) penetration of bent bar top bar bent bar (General floor) ※ Using the bent bars in beams is Japanese style, while cutoff bar is now in common. 5) Beam rebar arrangement(CUT TYPE) ① In case of beam 0.3L or 0.3L1 big value 0.3L or 0.3L1 big value ② In case of girder 0.3L or 0.3L1 standard hook fixed length big value 0.3L or 0.3L1 big value Note 1) * : apply general bars splice length(A class splice) as standard splice length & fixed length of rebar(22page 6)) for above size 2) ** : fixed as standard hook form about center part bottom bar's 25% 3) splice length according to splice position of rebar arrangement - tying on upper part rebar(beam) tying except upper part rebar(beam) - tying on lower part rebar(beam) tying except lower part rebar(beam) block : apply A class tension rebar splice block : apply B class tension rebar splice block : apply A class tension rebar splice block : apply B class tension rebar splice 6) Beam rebar arrangement by using stepped pulley The types of step are classified as planar step, elevated step, step in material according to their shapes. In each case, arrangement is in vertical or in horizontal. If the worker has no choice but to bend the bar, bend it at low grade. When the mid span of a beam has steps as shown below left, the bar might be necessarily bent, which is quite undesirable. The load tends to straightly pass through. If pulled out, the bar does not straighten as it looks. Far from straightening, it will break or fracture. Needless to say, it is recommended that the worker cut the bars and arrange them separately, as depicted below. breakable due to the tension tension fixed length Wrong method Correct method tension fixed length 7) Hunch beam ① Bend the bars at the bottom in a hunch former and anchor them onto the pillar. ② Bend a half of the bars at the bottom to let the anchorage length penetrate the pillar and anchor near the hunch point. ③ One size bigger stirrup should be used at the hunch point. S.T. one size bigger stirrup stirrup 8) Pillar-holding rebar (Butterfly stitching rebar/Stirrup closing rebar) ① As few drawing gives direction on pillar-holding rebar, it is common to use it at every third stirrup. If not, all junctions of pillar-holding rebar should be confined per every stirrup. <butterfly stitching rebar> processing (current) (revised) Better if one end hooked 135° 9) Symbol of beam ·Continuous end of beam ·Center of beam ·Exterior of beam ·Interior of beam ·Outside of beam center top bar : HD22-2 end stirrup:arrange 200mm distance-D10 lower part bar : upper part : HD22-3 HD22-3 end top bar : HD22-2 center stirrup-arrange 250mm distance-D10 support bar : HD13-2EA END(end) EXT(exterior) CENT(center) 400×500(stirrup process size : 320×420) tension splice (B class splice) stirrup : arrange 200mm distance-D10 upper part bar : HD22-3EA support bar : HD22-3EA lower part bar : HD22-3EA END(end) CENT(center) 300×500(stirrup process size : 220×420) 10) Detailed drawing of beam rahmen(arrangement) horizontal rebar : HD10@200(arrange 200mm distance-D10) vertical rebar : HD10@200(arrange 200mm distance-D10) END(end) CENT(center) 400×500(stirrup process size : 320×420) tension splice hoop : arrange 250mm distance-D10 support big bar : arrange 250mm distance-D10 400×400(hoop process size : 320×320) main bar : 10-HD19 tension splice (B class splice) Each floor bottom structure plane figure symbol & beam chart symbol ※ You should check pillar size & rebar Q’ty per each floor, and also arrange after checking rebar Q’ty & drawing of outer pillar’s front and side. 14. Caution if beam assembling does 1) Lean concrete working mat beneath the underground beam helps to ease the arrangement of bars. If gravel or brick is used to support underground beam, the reinforcement in the beams might deflect to break the top of stirrup. Furthermore, it might disturb the arrangement of reinforcement at the bottom of beam and so cover condition of vertical & horizontal is not fit. Stirrup as criterion must tie without breakage 2 times, 3 times when tying upper part. 100mm from pillar rebar breakable of stirrup tying spacer all bottom bars should be tied 2) When placing the concrete, it is usual to place concrete again after curing, and repeat the same procedure. During this procedure, protruded bars may become damaged or underground beam and floor slab may not fit very well because of shrinkage. Also, it will be not cleaned well because of dust if you will do concrete job with arrangement of ground slab without neighbor ground cleaning completely. 3) In the author's view, it is recommended that, after completing lean concrete working mat, the worker build up the fence around the reinforcement zone, in which the bars are arranged, to cast in concrete at the same time. It would be quite efficient since 2 cast-in procedures can be reduced to 1 procedure and it also saves time and cost considering input of material & carpenter. 4) Regarding beam rebar arrangement by using stepped pulley , you must be processed separately because the continuity of rebar arrangement is different for lower part rebar , and pay attention to the difficulty in entering of G bar & G bar when assembling B(small beam) lower part rebar. 15. Tying position(splice location) of underground tie beam <Tying position in case footing slab get forced from weight of top> <Tying position in case footing slab get forced from the soil > <Tying position in case footing slab get not forced from the soil> <Arrangement method in case footing beam get forced from the soil> tension fixation pillar mainbar tension fixation <Arrangement method in case footing slab get forced from the soil> Example : actual fixed length of D22 is 770mm if pillar size is 500mm, actual anchorage length is 370mm p.s.) Fixed splice length and standard hook(anchor) length refers to concrete structure plan’s criterion 16. Calculation of beam rebar Bent bar that is placed above(up) and below(down) of beam is Main-Bend, and bent bar that is placed on both sides of beam is Side-Bend. Main-Bend ※ Hunch angle should not exceed 45°(bent angle is "bent angle") Side-Bend Calculation of all 2 types of bent bar is the same except the way of extracting pure height of main bar from stirrup height(thickness). Either span of , from one end can be accepted depending on their uses. 1) Calculation of up-down bend(Main-Bend) in the beam Provided that the height of beam is 500mm , the length of span is 8,000mm and the size of pillar is 500mm , then the steel requirement is as follows. 100 cover beam height inner length left up·down cover ST height right up·down cover ① 8,000mm-(500mm-40mm-40mm)-(500mm-40mm-40mm)=7,160mm 7,160mm÷4=1,790mm Hence, the value of ① is 1,790mm ② 1,790mm×2=3,580mm(value of ②) are extracted hunch length from inner length ③ Extract cover depth from 500mm(beam height : 420mm) and multiply this by 1.4, and again extract 20mm(D10 diameter), [500mm - (40mm×2)]×1.4 - 20mm = 568mm, and then we have 568mm. ※ Calculation of hunch Hunch = the height of stirrup×1.4 - 20(bar diameter of top and bottom stirrup×2) ④ fixed length is 40d in usual, hence provided that used bar is HD19,19mm×40d=760mm The length of anchor ⑥ is 760mm- pillar fixation 400mm=360mm ⑤ 400mm + ① 1,790mm = 2,190mm ⑥ 400mm is the rest value except cover 100mm from width of pillar. The length indication when spreading above calculation is as follows. ※ Total length 9,806mm for 8,000mm bar, the splice length is 2,566mm. (example) 9,806mm-8,000mm=1,806mm, Total length is 1,806mm+760mm(splice length)=2,566mm 2) Calculation of side bend in the both sides of beam 100 cover beam height 280(ST height) actual height END CENTER inner length ST height left right(up·down distance) ① 8,000mm - (420mm - 70mm - 70mm) - (420mm - 70mm - 70mm) = 7,440mm, side-bend height that is, 8,000mm - (280mm×2) = 7,440mm, and then 7,440mm× ② Center point is , and then 7,440mm× = 2,232mm. = 2,976mm. ③ Hunch length is calculated from hunch height multiply 1.4. 280mm×1.4 = 392mm, hence hunch length is 392mm. ④ Fixed length is 40d in usual, hence provided that used bar is HD19, 19mm×40d = 760mm is fixed length , 760mm - 400mm(pillar fixed) = 360mm(anchor value⑥) value① 2,232mm + 400mm = 2,632mm(actual distance of end upper part) ⑤ Cover depth(100mm) is extracted from pillar size(500mm) 500mm - 100mm = 400mm If the bent bar mentioned so far is straightened in a line, it is like shown below. total length ※ Total length required is 9,744mm and provided that the standard bar length is 8,000mm, we need to splice here and the splice length is 2,504mm. example) 9,744mm - 8,000mm = 1,744mm 1,744mm + 760mm(splice length) = 2,504mm(total length) ※ To summarize, Main-Bend's return bend point is lx point, Side-Bend is point, you can find the bending to exterior side(to center part). lx 17. Slab rebar arrangement 1) Slab rebar arrangement Slab type classification 2-way slab rebar arrangement method (ly < 2lx Type) 1-way slab rebar arrangement method (ly < 2lx Type) main block main block Slab main bar arrangement type classification Bent bar type - Union type of outer beam and slab 0.3L or 0.3L1 big value 0.3L or 0.3L1 big value 90°standard hook apply A class splice of tension bar if upper part bar tying on location (apply B class splice of tension bar on the rest location) - Union type of outer wall and slab 0.3L or 0.3L1 big value 0.3L or 0.3L1 big value wall apply A class splice of tension bar if upper part bar tying on location (apply B class splice of tension bar on the rest location) ⓑ Cut bar type - Union type of outer beam and slab 0.3L or 0.3L1 big value 0.3L or 0.3L1 big value 90°standard hook apply A class splice of tension bar if upper part bar tying on location (apply B class splice of tension bar on the rest location) - Union type of outer wall and slab 0.3L or 0.3L1 big value 0.3L or 0.3L1 big value wall apply A class splice of tension bar if upper part bar tying on location (apply B class splice of tension bar on the rest location) ③ Rebar arrangement details of slab stepped pulley In case H < 75mm or t/4 H≤75mm or t/4 In case t/4 < H < t and H < 150 splice length of tension bar standard hook splice length of tension bar 1-HD13 or over main bar In case t < H < 2t 4-HD13 or over main bar standard hook slab arrangement distance using closed type STR ※ In case H > 2t, consult with structure planner. ※ In case there are stepped pulley on slab center part, you should fix by using 90° standard hook for slab lower part rebar. outside wall inside slab 90 standard hook ④ Slab and wall union details ⑤ Tolerance range of slab , beam , pillar , wall rebar arrangement ⓐ Allow to 6mm as tolerance of D in case under 600mm of slab, beam, pillar, wall. Allow to 10mm as tolerance of D in case over 600mm of slab, beam, pillar, wall. ⓑ Allow to 50mm as tolerance in case bent point or end point of length direction rebar(but, except for end of concrete) ⓒ Big bar of pillar and stirrup of beam can get the space till 0~6mm as space cover thickness cover thickness length from main bar 2) Principle of rebar arrangement ① The worker measures the real length between beams and arranges the reinforcement bars consulting the drawing, main bars in the short direction and sub. bars in the long direction. ② Bent bars at the top should be extended into the exterior beam reinforcement, and be sure for the bars at the top and bottom to be hooked and tied considering tensile and compressive force to slabs. It is not allowed if you put on slab upper part rebar as it is or put into the beam under 10D of rebar thickness of lower part rebar. Slab bar arranges over 80mm space from side of beam bar. (There are no need to fixing by bending if you can get fixed length from end of beam) ※ The arrangement in slabs should be in accordance with the drawing and be sure not to bend if it is a web reinforcement. ③ It is quite advised to use spacer and bar support to keep the required shape and strength, and tie the reinforcement every other grid. The placement of concrete should be conducted after all the reinforcements and ties are assured. ④ In case the thickness of slab is 120mm, the height of bent bar should be 60mm. Use bar support in order to maintain the space between bars at the top and bottom and then the distance will be correct. Lower part bar will be worked by maintaining cover with spacer. ⑤ Tie the bars at the top and the bottom irrespectively. Tying the bars is conducted in alternate and do not let the tying positions coincide with each other, so that the bars at the top sustains upper loads and the bars at the bottom handles undesirable loads. 3) Calculation of slab plate It is wrong method in case you cut the length of cut bar(top point) in advance by calculating point from center to center of beam. Therefore, you determine the end by calculating as the criterion of short LX from the rest plate by deducting both width parts. L calculate end ※ When bending in slab, using the hunch former will enhance the accuracy and workability. Hunch former can be made with bars on construction site. If the bar is bent with hands, the length and the height of hunch will different whenever it is made. Please work with hunch former because bent bar decline to left/right side if you bending too slantly to fit the height with hunch angle 45°. inner end 4) Sequence of slab rebar arrangement center upper part end lower part upper part bar(TOP) lower part bar(BOTTOM) end center <A-A section> inner end ① lower main bar of transverse direction ② end lower part bar of longitudinal direction ③ end upper part bar of longitudinal direction ④ bending after tying ⑤ center lower part bar of longitudinal direction ⑥ end upper part bar of transverse direction ⑦ bending after tying ⑧ upper part cut bar of longitudinal direction ⑨ upper part cut bar of transverse direction ※ Phenomenon in case there are no formal arrangement of slab ① In slab arrangement, bent bar should arrange (bend on return bend point) by above procedure. But total length is not fit by coming inside as diagonal length to bend after assembling upper part bar, lower part bar completely when using arrangement method on construction site regularly. ② In formal rebar arrangement, it consists of main bar, sub bar(upper part 2 layer, lower part 2 layer). But it has difficulty in maintaining rebar up/down distance by folding top sub bar over main bar and sub bar(upper part 3 layer, lower part 3 layer). 5) Sequence of base slab rebar arrangement Lx Lx/4 fixed length of tension bar which has standard hook inner end Lx/4 center end Lx/4 underground tiebeam obtains the cover thickness over 80mm for arrangement of slab lower part bar upper part bar Lx/2 Lx/4 Lx/4 Lx/2 Lx/4 end center inner end <A-A section> lower part bar ① lower main bar of transverse direction (end center part) ② center lower part bar of longitudinal direction (center part) ③ tying bent bar of longitudinal direction ④ center upper part bar of longitudinal direction ⑤ tying bent bar of transverse direction tying bent bar of longitudinal direction (bend opposite side after tying) ⑥ end lower part bar of longitudinal direction bending bent bar of transverse direction (bend opposite side after tying) ⑦ end upper part bar of longitudinal direction ⑧ center upper part bar of transverse direction ⑨ end upper part bar of transverse direction ※ Arrange the bars in numerical order suggested above. ※ Use spacer and bar support to install within 1m each transverse & longitudinal direction for upper & lower part rebar and also install to 1st rebar for each end. 6) Check after assembling slab After construction of slabs, the supervisor should check following matters. ① Are pillars of adjacent floor(usually upper floor) well positioned having intended dimensions? ② Is cover depth of slab well distributed and balanced? ③ Is there any abnormally inclined bent bar? ④ Are spacer and bar support rightly installed to be strong bar splice all right? ⑤ Is slab Bar splice all right? ⑥ Is reinforcement at the opening acceptable? ⑦ Enough splice length to the next floor? Any dissatisfaction with items above will lead to poor construction and safety problems. In particular, if it is the matter of columns, it is very difficult to rebuild it and has poor appearances. And it is also an economical burden to the builder. 7) Position of slab tying direction direction direction direction tension splice good position for tying 8) Understanding of slab drawing ① If all bottom of slab symbol is different per span, rebar arranged to main bar direction for short side. If span will be reverse direction, you should check in advance because main bar will be reverse direction. (especially in case slab stepped pulley) down 200mm to right side from left side of solid line SLAB DOWN plane open part plane figure section cross section In the plane drawing of open part, you can see the inside as above when you see to arrow direction with dotted line and also you can know in detail with chart about the size of beam and also which rebar will be installed. Especially, you should check section drawing well. If you cut plane, you can see elevation(verticality), reversely if you cut elevation, you can see plane. In any drawing and plane, we mark section for the part to understand difficultly to help you for processing and arrangement on right section of drawing. It is best way to get the training of supervisor and you must study symbols on drawings. ② 1S1(1 means 1st floor , S means Slab , 1 means #1(type)) slab thickness 120mm Y1(upper part bar) HD10@250 distance slab thickness 150mm Y1(upper part bar) HD10@300 distance Y1(upper part bar) HD10@300 distance Y2(lower part bar) HD10@300 distance Y2(lower part bar) HD10@300 distance Y2(lower part bar) HD10@250 distance X1(upper part bar) HD10@250 distance X2(lower part bar) HD10@250 distance ※ Reference : dot line means lower part rebar , solid line means upper part rebar Classification Symbol 1st floor Type Thickness 1S2 B 1S1 A Transverse direction(Lx) Longitudinal direction(Ly) X1 X2 Y1 Y2 150 HD10@200 HD10@200 HD10@200 HD10@200 120 HD10@250 HD10@250 HD10@300 HD10@300 ③ Detailed drawing of beam and slab's connected part SLAB upper part rebar doesn’t tie to beam main bar ※ Author's viewpoint : If you did not study shop drawing completely, you will solve question if you will start construction by discussing to check wrong one after visiting construction site after checking the drawing under construction over 80%.(especially, carpenter's process is over 80%). 9) Principle of ground slab ① Bar arrangement in the floor slab begins 50mm from the slab wall side having constant spacing. ② Arranged bars should be strong enough not to deflect when a person steps on them. Unscreened gravel and bricks can not be used in order to keep spacing between bars, and specified bar supports and spacers should be used to maintain the dimensions and shapes of the slab as intended. ③ After arrangement, single bar might need to be cut off with oxy-acetylene cutting in the requirements of collecting well or manhole. In such cases, there could be cracks at the end tips of bars, and therefore more reinforcement and splice should be adopted here. tension splice tension splice ※ The most important thing in floor slab - Base Tamping ▶ After shovelling , the land must be tamped with vibration compactor. ▶ Even though drawing does not refer to tamping, the worker must bear it in mind as specification indicates. However, it is real situation that there are little workers to keep it. ▶ Both the client and the builder should hold it in common that even the neglect of construction rules and standards will lead to fatal harms to both of them. 18. Wall rebar arrangement 1) Sequence of rebar arrangement ① The worker is not allowed to change the rules and instructions of reinforcement without permission. All the reinforcement should be in accordance with drawings and specifications. Especially in retaining walls, if the retaining wall, which needs double reinforcement, is placed in the sequence of the first main bar, assist bar, the second main bar and then another assist bar, it might be an easy way but wrong one. All the placement should be in the specified sequence. ② Placement sequence of wall suggested below main bar width fixing bar sub bar width fixing bar reinforcement bar ③ Place the stirrup closing bar densely and keep the thickness exactly. Especially in the reinforcement of water tank, fabricate the reinforcement as specifically suggested. And place the reinforcement at a time. In case the tank is big, the reinforcement should be in zigzag and in the top span tying wire should be wound at least one time before tying. If not, main bar would swing and would not maintain the required shape. Simple cut bar reinforcement or hooking in the bar is also a wrong reinforcement. 2) Principle of assembly and rebar arrangement binding saddle tie with twist corner it should be tied with 1,2 times wound depending on @ distance tying to maintain distance of upper part Assist bars might deflect when concrete is cast-in or due to loose bindings. To avoid this undesirable deflection, width-fixing bar, which is similar to stirrup in shape is fabricated to place in assist bars. ① Begin the placement of assist bars from 100mm above the floor place the stirrup ② Stirrup(closing bar) at every third step ※ Caution in reinforcement of retaining wall When numbers of bars are placed in the retaining wall, the worker should be considerate. If the tie between main bars and assist bars is loosened, the reinforcement would lean toward. Make sure that tying of main bars and fixing bars always go together in turn. 3) Crosspoint main bar and horizontal rebar arrangement <Single arrangement> <Single and double arrangement> U bar wall vertical rebar wall horizontal rebar U bar wall horizontal rebar <Double arrangement> U bar <Straight wall> wall horizontal rebar 4) Details of wall on top floor <Top floor outer wall> <Top floor inner wall> slab upper part bar 90°standard hook roof floor slab tension splice roof floor slab wall vertical bar wall horizontal bar over 150 slab lower part bar wall ※ The end of wall vertical rebar on top floor should obtains unification by fixing correctly on slab and processed to get 90°standard hook. ※ The upper part rebar of slab to contact outer wall should be fixing splice or making tension folding splice and wall outer vertical rebar. 5) Tying position of revetment(retaining wall) As a rule, bar splice in pillars and beams is not allowed, and if horizontal bar is better to be anchored in the pillar of every span. <resistance wall> pillar <underground retaining wall> pillar horizontal bar inside inside outside beam vertical bar outside outside inside foundation beam good position to tie <stirrup closing bar> B class tension splice ※When the inserting bars as arranged straight bar are inserted at the underground beam tension splice tension splice fixed length no problem if fixed length will be obtained ※ As shown above left, there is a possibility for stirrup vertical bar to be protruded by the lack of cover thickness of fixing part. It is recommended to adjust to fix the bar into the stirrup. 6) Indication of revetment(retaining wall) arrange to 300mm distance of vertical High Density 16mm rebar arrange to 200mm distance of vertical High Density 19mm rebar arrange to 200mm distance of horizontal Density 16mm rebar arrange to 200mm distance of horizontal Density 19mm rebar <Symbol on wall > RW(Retaining Wall) = Underground wall(wall to resist against ground pressure) Wall = Wall THK = Thickness of wall V = Vertical rebar H = Horizontal rebar T = Width Tie bar H = Hunch, it is classify easily per type against tie hoop 19. Other rebar arrangement 1) Stairway rebar arrangement ⓐ Place the bars in the suggested sequence according to drawing. Double reinforcement should not be bent. ⓑ There are a few extended bars from pillars or beams to the stairs . You should assemble by using standard hook(anchor) in case of assembling to cut without bending bars for this working. Example) ⓐ Place the bars in the numerical order shown below ⓑ Bend ④ bars after binding ⓒ Cut ⑥ after binding tension fixation lower part bar upper part bar ※ Special notice for the bar-arrangement fix to corner pass rebar (lower part rebar) ten sio nf ixe dl en gth tension fixed length 2) Balcony(Cantilever) tension fixation upper support rebar spacer spacer vertical/horizontal D10-@220 tension fixation upper support rebar spacer spacer ① The most important part in cantilever is the bar at the top above distribution bars. It is common to anchor the top bars into a beam, however, they can be anchored in a slab so long as there is no difference between their levels. To obtain adequate fixed length is most important. ② Bars at the bottom should be anchored securely to provide for earthquake and tornado. ③ When the level of cantilever and slab plate are different, bars in the slab should be anchored onto the beam. If the bars at the top are bent to be anchored onto the opposite slab, there might be a crack due to tensile strength. The bars at the top should be maintained with bar support. 3) Parapet rebar arrangement The expansion of topping concrete at the top of a building due to variations of daylights will pass out great compression load to the parapet. Therefore, the double reinforcement in the parapets are better to be D13(reinforcement bar) anchored onto beams or slabs. Parapet might occur vertical crack mainly because the length is long. It is effective to avoid crack by arranging to outside of horizontal rebar. tension fixed length 4) Reinforcement of slab open point in L<1000 m min. 600 .1 20 minimize open part 0 Reinforce each rebar to both open part as rebar distance 75mm for +1 unit of rebar Q’ty to be cut existing rebar from open part. In case open part is over 300mm, 4 edges should reinforce 1-HD16 Use 90°standard hook rebar Explanation : 1) In case the length of open part is over 1,000mm , you should arrange after receipt of permission of structure supervisor if there are no rebar arrangement detailed drawing. 2) *mark :arrange to single arrangement if established rebar arrangement is single arrangement arrange to double arrangement if established rebar arrangement is double arrangement 3) ----- is established slab rebar 4) Rebar to not specified of rebar size must use same size rebar as established arrangement 5) Details of reinforced rebar on concrete wall open point ① Circle type open part circle type open part distance should be over “D” max. 600 max. 600 1-HD16 In case of over D>450mm 1-HD16×1800mm Explanation : 1) In case the size of open part is D<150mm, omit vertical & horizontal rebar 2) mark : arrange to single arrangement if established rebar arrangement as siugle(double arrangement as double) ② Square type open part min. 600(TYP) min. 600 open part 6) Rebar arrangement of slope way in main entrance 90°standard hook D10→120 lamp slab rebar arrangement 7) Trench rebar arrangement ten si len on f gt ixe h d tension fixed length tension fixed length tension fixed length tension fixed length 20. Steel frame(Deck plate S-ring) In arranging the bars at the top, mount the deck plate and place the bars on the furrows of deck plate firstly. And then arrange the top bars above deck plate and connect these top bars with what lied on the deck plate using hook to maintain the constant space between them. ※ What is Deck plate S-ring ? In order to connect working of lower part & upper part rebar in deck plate, the arranged method shows on drawing. As you can see as below, there are rebar arrangement operation by using rebar D10 Deck plate S-ring. However, if some construction site would like to reinforce D10 rebar by hand, there are possibility to reinforce rebar roughly because its working is very hard and with low efficiency. If so, it is weak point of construction carry-out and high possibility of problem after construction. "S"-shaped ready-made hook manufactured by Taeyeon Machinery Co. Ltd. is convenient to install and has efficiency to keep distance and keep cover. 21. Caution and consideration of construction carry-out 1) A man-day The amount of reinforcement that a skilled worker can place a day is, in case of slabs, 0.26acre ~ 0.33acre in area, about 500kg~700kg if converted in weight. ※ Daily work capacity(varies with working environment) Classification Q’ty(kg) factory, school over 700 apartment, house below 700 KR 130,000 per worker’s labor cost in 2006 year. <processing separately> Classification Q’ty(kg) D10 stirrup, tie hoop 600 D13 stirrup 800 bending 5ton/1 person <cutting separately> 2) Weight of concrete ① Specific weight of plain concrete(without reinforcement) is 2,300kg/1m3 ② Specific weight of concrete with reinforcement in it is 2,400kg/1m3 ③ Specific gravity of lightweight concrete with perlite or gas-foaming agent is only 0.6~1.2 3) Load and external force In construction, load and external force are critically important factors to be considered. Load is classified as fixed load and occupied load, where the former is the weight of building itself and the later is the weight of people, furniture, equipment, etc.. Occupied load is classified again as long-term load and short-term load. ① The weight that 1m2 (square meter) sustains in long-term loading is ⓐ Human or furniture 200kg/1m2 ⓑ Snow load 50kg/1m2 ② If weak at the long-term load : There might be a crack in walls or beams. ③ If weak at the short-term load : There might be not a crack but part breakage due to external impact. 4) Crack and shrinkage ① Crack of concrete is not simple problem to catch with several symptom such as crack direction, etc but it is required to the inspection of professional. Regularly, the crack under 0.3mm will be happened by dry shrinkage for beginning vulcanization. ② Shrinkage of the building If the length of the building is longer than 50,000mm, there is expansion or shrinkage of the building, 10mm ~ 20mm, within temperature range from -18°C ~36°C. (temperature difference×10-5×the length of building = difference length by temperature gap(expansion or shrinkage)) ③ In case of Korea, temperature difference is 54°C, from -18°C in winter to 36°C in summer, According to the formula above, expansion in Korea is 27mm maximum from 54°C×( ×50,000mm) = 27mm, hence there should be expansion splice in some parts on high building & walls to prevent crack of the building. 5) Caution if construction work does ① Distance of main bars against girder(beam) ⓐ Beam plays an important part in a building, receiving the load from slabs and passing it out to pillar. Therefore the reinforcement in beams should be seriously taken into consideration and accuracy. Top bars, bottom bars, reinforcement bars, bent bars and middle bars are placed in beams and distance of reinforcement should be more than 25mm or 1.25 times of the largest aggregate that is in the mixed concrete, over 1.5times distance of rebar diameter. ⓑ Splice length of top bar in beams should be required fixed length if it extends to the center of column and therefore sustains tensile force. Splice of the bottom bars in beams should be within from the end of beams, where load is almost 0, and the top bars should avoid the end span of beams.(min. rebar cost will be over 0.35%) ② Pillar ⓐ Pillar also has important role to divide total weight and compression power of building. Distance of main bar also arrange bar fairly, distance per rebar and rebar will be over 40mm or over 1.5times of rebar using. ⓑ The minimum size of column is more than 200mm and cross sectional area should be more than 600cm2 ⓒ Splice length applies B class splice length. 6) Reinforcement to prevent shrinkage of wall The building might get shrinkage on building by the expansion of temperature in day or the down of temperature in night. Rebar concrete has expansion or shrinkage, and so there are possibility of unexpected rebar. Therefore, the point of crack possibility must reinforce outer wall without open part. Arrangement direction of correct reinforced bar, it can be checked crack correctly, it is principle to arrange bars vertically against crack direction. If there are crack on both edges of wall by the expansion of roof, reinforced bar is principle to arrange bars vertically against crack direction and you reinforce the reinforced bar of highest wall to outer top pillar & retaining wall of building. The expansion ratio of roof will be bigger toward outside and very small roof on center of building. Also, 1st floor contacts ground do not effected of the influence of temperature. Therefore , the part of highest influence by expansion & shrinkage of roof is outside wall and there are expecting many cracks. Without marking on shop drawing, you must arrange construction with your sincerity with our experiences. 7) Cleaning It is better to install concrete after cleaning always before installing concrete. When you checking construction site, there are many other materials to decline the quality of concrete such as soil, sawdust, trash. You must delete it inevitably. After concrete job, you must break concrete of ground and brush concrete on rebar with hammer drill, wire brush , hammer on next floor splice part, wall, pillar. 8) Problem if oxy-acetylene cutting does ① Don't use the oxygen arc cutter near the pile of unused bars. If you use the oxygen arc cutter near the piled bars, high heat from cutting rod will be transferred to unused bars causing thermal deformation or unexpected failure. Automated cutting machine and bending machine are recommended. ② Oxygen arc cutter will drop tensile strength of the bar, which is critically important to the reinforcement of the structure, and there might be problems in structural safety. ③ Manual bar cutters have been normally used in the construction sites so far. However, in order to increase the effectiveness and ensure perfectness, automated cutting machines and bending machines are highly recommended. <Reference> Rebar arrangement should arranged by the shop drawing. Technicians must increase the ability to see shop drawing if it is the recent drawing by limit strength plan method. 22. Gas pressure welding of Rebar 1) Definition of gas pressure welding It is welding method directly of raw material itself to press under the condition which is before heat melting(1,200°C~1,300°C) for junction part with oxy-acetylene gas to fix on both side rebars to connect in carrying out of rebar concrete structure building. Also, it is economic splice method than folded tying (lap splice), mechanical spiral tying(mechanical splice) and also the strength of junction part is stronger than raw material. ※ Rebar splice is classified to folded tying (lap splice) , mechanical spiral tying(mechanical splice), compressed tying(welded splice). Folded tying (lap splice) is commonly have used as important method for rebars of small diameter before. However, Folded tying (lap splice) has irrationality such as complexity of rebar arrangement and bigger material section and also the increase of mold cost and so it is prohibited to folded tying (lap splice) for over D29 deformed rebar on Korean concrete standard specification and mechanical spiral tying(mechanical splice), compressed tying(welded splice) will be applied frequently. Therefore, compressed tying(welded splice) is stronger and economical splice method than Folded tying (lap splice) if rebar arrangement with density or rebar diameter is bigger and it is using for the rebar over D29. 2) Composition of automatic pressure welding equipment <Welding units> ① Oxygen pressure controller ② Acetylene pressure controller ③ Acetylene outlet hose ④ Oxygen outlet hose ⑤ Welding torch ⑥ Welding tip(4 edges) <Compressor units> ① Pump ② Pedal pump ③ Hydraulic pressure hose ④ RAM cylinder ⑤ External cylinder ⑥ Fixed clamp ⑦ Flexible clamp ⑧ Rebar 3) Working sequence to tie gas pressure welding The method of gas compressed tying(welded splice) is classified to manual gas compression and automatic gas compression method and the principle is same but difference is by manual or automatically for splicing. ① Grinding the section of rebar with flat by using grinder ② Install rebar for splicing to pressure welding equipment ③ Heat and pressure - Heat rebar with gas mixed oxygen acetylene - Heat machine will be used multi-hole burner - Heat and pressure at the same time - Don't heat till the temperature of rebar melting but heating to 1,300°C as rebar exterior temperature (it is different from welding splice) - Pressure to 300~400kg/cm2 per rebar 1cm - Use hydraulic regularly for pressure machine 1st heat pressure 2nd heat pressure pressure power 3rd heat pressure temperature temperature pressure power time(second) < Time passage of heat, pressure power > - It shows time-passage of standard heat, pressure power as above graph. - If starting heat, pressure from A point, the section space will be decreased on B point and finally adhere completely to D point. - It makes inflation by increasing pressure between F-G to keep this temperature 4) Required time to heat for pressure welding per diameter Rebar diameter Required heat time Rebar diameter Required heat time HD16 40 ~ 50sec HD25 1min 15sec ~ 1min 45sec HD19 50 ~ 60sec HD29 1min 45sec ~ 2min 15sec HD22 60 ~ 1min 20sec HD32 2min 15sec ~ 2min 55sec 5) Inspection of gas pressure welding Instruction of welded part includes visual inspection, ultrasonic detecting test and tensile test, etc. Selection of inspection test should be determined in accordance with suggestions on the drawings. ① Visual inspection welding distortion, deflection, shape and dimension and any other defect can be inspected with eyes. ② Tensile test - In case of manual welding equipment, tensile test is conducted for sampled specimen - In case of automated welding machine, test piece is manufactured for tensile test ③ Ultrasonic detecting test In inspection of welded part, visual inspection and destructive or nondestructive test are run parallel in general. Among these, destructive test not only takes times and costs but also had some errors because only a few test pieces are sampled from the entire welding spliced bars. As a solution, reliable nondestructive test is conducted to find out defects from all welded parts 6) Caution if pressure welding works ① The builder will get the admission of person in charge to select gas pressure welding worker. ② You must check and maintenance inevitably before working for oxygen , acetylene instrument and protect it from direct rays. ③ The compression section should be decreased by cutting of plane after deleting oil, paint, cement piece, etc but to be cut the neighbor surface by grinder. ④ The final pressure of rebar discharge direction should be over 300kgf/cm2 per dimension. The diameter of compression protrusion part should be over 1.4times of rebar diameter and diameter of compression protrusion part should over 1.2times and the form should be smooth. But , it is followed by in case it is fixed by shop drawing separately. 23. Mechanical tying of Rebar 1) What is mechanical tying of rebar? It is essential construction method for large scale civil engineering construction such as high-building, bridge, dam, etc and underground building anti-earthquake plan and also special construction. It is a splice method for strong economic quality assurance if folded tying method is impossible in case rebar arrangement with density and rebar diameter is bigger and so by the increase of rebar strength & concrete strength. It is applicable for deformed rebar to use rebar concrete building. In foreign countries, it was verified from 1960 and it is using for Korean construction site from mid-1990. 2) Type of mechanical tying of rebar screw type inflation compression joint rib cut type type type site tie type taper type joint fixed body adhesion type others joint rib compressed jack adhesion type hydraulic mortar gas injection type compression compression type 3) Screw-type tying of rebar rebar warehouse-in → make rebar screw process drawing → start processing of screw type → deliver to construction site(3~10days from order date) process type inflation type compression type bury rebar joint rib by process inflate of rebar processing part largely by mold mold (example) rebar type (example) rebar 25mm - M30 25mm - M25.5 case screw type screw processing case screw type prove the confidence prove the confidence after after processing of low processing of low-mid carbon steel bar(SD300) carbon steel bar(SD300,400) available for large available for large merit production production available for production on construction site demerit the inflation processing end might has low confidence if it is caused by processing vulcanization of mold in case high carbon steel bar low confidence after binding 2 rebars low confidence in case of bending the compression processing end might has low confidence if it is caused by processing vulcanization of mold in case high carbon steel bar low confidence in case of bending joint rib cut type taper type processing screw after deleting screw processing with rebar joint rib with fixed size angle of rebar front end (example) rebar 25mm - M26 case screw type cut screw type prove the confidence after processing of low-midhigh carbon steel bar(SD300,400,500) available for large production available for production on construction site prove the confidence after processing of low carbon steel bar(SD300) available for production on construction site coupler size is 10% longer than inflation & compression type by the deviation of size of rebar joint & rib low confidence of omission & untying for testing tension strength and repeat test inflation screw swage screw joint-rib screw taper screw cut processing cut processing cut processing cut processing pre-cut after mold inflation mold compression pre-cut processing angle processing case screw case screw case screw cut screw 4) Site connection-type tying of rebar outbreak of splice → carry-in of parts(arrival to site within 12hours after ordering) → assembly & construction carry-out → inspection comparing other splice part classification joint fixed body adhesion type process type precision processing & molding per part of splice part base on joint groove of rebar(no artificial processing of rebar) precision processing & molding per part of splice part base on nominal diameter of rebar(no artificial processing of rebar) available to assemble without processing screw on rebar available to assemble without processing screw on rebar ease to bind regardless of rebar type(foreign & domestic rebar , deformed rebar , comb-pattern rebar , X type) available for large production per rebar title available for deformed rebar only in Korea and low confidence of binding in case disorder of tolerance of rebar joint rib and trademark need pre-education for building assembler need pre-education for building assembler merit outer diameter of coupler demerit double faced compression jack coupler fixed pin rebar lock nut length after binding joint rib compressed jack adhesion type connection jack lock coupler fixed body 5) Other tying of rebar classification process type merit demerit mortar injection type gas compression type splice part to perform platform on heat & compression splice rebar joint & rib groove & inside method of both ends of rebar by of connection part using oxygen & acetylene hydraulic compression type splice method to adhere sleeve by pressing outside sleeve after closing rebar to soft sleeve using to pre-cast(PC) splice construction method using in Japan mostly and prove the confidence of tension compression using in europe partly splice part is large and long excessively and low confidence per rebar type difficulty of confidence proof of construction site carry-out product big tolerance of construction site carry-out per condition of temperature difficulty of confidence proof of construction site carry-out product troublesome of purchase separately of compressed rebar for compression reinforcement to classify to produce compression bar & regular bar difficulty of reinforcement because the possibility of displacement of pressure strength for 1pc & 100pcs and also the movement of pressure tool