SHAPOORJI PALLONJI & CO.

PVT
LTD.
PROJECT: SUNSHINE, SHRIRAM METHOD STATEMENT FOR
GRAND CITY REINFORCEMENT WORK
REVISION: RO Date: 13/10/2023

I) PURPOSE:

The purpose of this procedure is to ensure proper supervision and proper

quality control during execution for Reinforcement works.

II) SCOPE:

This procedure covers supervision and method of record keeping for carrying
out Reinforcement works in construction.

III) REFERENCES:

 Approved GFC drawing & Bar Bending Schedule (BBS) for the structure.
 National Building Code of India (NBC) - 2016
 IS 456, IS 2502, IS 1786, IS 9417, IS 2751, IS 13920 (Latest edition with all
amendments in force as on date and future ones till completion of job)
Technical Specifications & BOQ.
 CPWD Specification – 2019

IV) STORAGE:
Stacking of steel shall be done in a predefined place, on a raised platform
clear by 300mm above ground level; different diameter of steel shall be
proper labelled and stacked separately. In case of rainy season, steel to
be stored for longer period shall be covered with tarpaulin sheet.

V) PROCEDURE:
Material involved:
a.High strength deformed steel bars grade Fe500 / Fe550/ Fe550D
conforming to IS:1786
b.Steel binding wire, preferably not thinner than 18SWG. 20SWG wire may
be used in double-folded manner.
It is to be ensured that during laying all the bars are free from mud,
oil/grease, excessive rust etc. and the rolling margin is within permissible
limit as per provisions of IS:1786
Tools/Instruments involved:
a. Bar cutting machine
b. Bar bending machine
c. Binding hook
Process detail:

1) DELIVERY AND STORAGE

Reinforcement shall be stacked off the ground by 200mm 300mm in clean

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conditions and protected from contamination, shall not be in contact with soil
throughout the length. For stacking any hard platform of Wooden and concrete
sleeper or M.S. Stand can be used which ensures no water absorption & keep
steel above the ground level. Reinforcement stacks need to be properly covered
all round with tarpaulin to avoid any direct contact with water during raining.
The reinforcement shall be clean and free from oil, grease, and rust, loose mill
scale, salt and chemical contaminants at the time of receiving, stacking & fixing
in position and concreting.
In-case of shortage of the space, bars of two different diameters can be stacked
in same rack however there shall be vertical separation between two dia. care
shall be taken while doing so, the dia. of steel shall be easily visually identifiable
& shall be tagged accordingly.

All the stacked reinforcement steel

shall be well identified with diameter
of steel and following tags shall be
displayed

i) Tested and Approved

ii) Tested but Hold
iii) Rejected
iv) Under testing

REVIEWED BY: APPROVED BY:

(PQH) (PMC)

All the steel consignment shall receive on site along with the MTC (Manufacturer
Test Certificate). The steel shall preferably bear the ISI stamp on it for the
acceptance along with the grade of steel.

Prevention of rust staining:

Reinforcement left projecting above a concrete surface shall be cement
washed if exposed in such a way that rust staining of concrete surfaces is
likely. Any rust staining of exposed surfaces shall be cleaned immediately.
Any Steel, which is tied and exposed to atmosphere (above 30 days), shall be
protected from Corrosion by using Inhibitor – Cement Slurry as per
manufacturer’s Specification after obtaining approval from Developer / PMC. All
the exposed Reinforcement should be cleaned with Wire Brush before
application of Inhibitor Slurry.

Protection & preservation of Reinforcement steel (stacked & installed):

All the reinforcement steel shall be protected against rusting for all areas.
Contractor has to consume the TMT bars within 12 weeks from the date of
issuance. In case within these period if rust found, all such steel shall be
thoroughly cleaned by wire brush or by suitable means & all rust shall be
removed. These steels shall be then applied with antirust polymer or epoxy
coating as approved by EIC either by brush or spray by the respective

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contractor. If the retention time of the stacked steel is more than 3 months, the
same steel shall be either re-coated or shall be epoxy treated. Identify separate
area for off cuts and scrap. Diameter wise Scrap yard must be maintained with
in different temporary compartments.
Do not position storage yards near electrical sub stations or near high voltage
electrical lines. Follow first in, first out method.

Execution: Following step wise check shall be followed for reinforcement work
process

Cutting, Bending & Placing in Position:

1) Material received at site should have ISI certification mark or the supplier
should be pre-approved from QA department after verification of physical
and chemical properties as specified in IS 1786. Bars should be marked to
identify categories.
2) Sampling and testing criteria shall be as per “ITP: BSH/8.6/RF”. MTP
3) Bar Bending Schedule (BBS) for all RCC structures/ structural part shall be
prepared as per latest revision of drawing and shall be reviewed and
approved by the Developer/PMC Engineer-in-Charge. No cutting bending
shall be done without approved BBS.
4) Proper equipment / jig should be available for straightening the coiled
steel and mandrel for bending and cutter machine for cutting steel bars.
5) The cutting length of bars shall be derived in such a way that the no main
steel is been lapped in No Lapping Zone as described or depicted in
General drawing of Structural Consultants.
6) No laps to vertical bars (of Column, Shear Wall etc.) shall be allowed in
slab beam joints and shall be placed as per GFC drawing or as directed by
Structural Consultant.
7) The overlaps/splices shall be staggered as per GFC drawing or as directed
by Structural Consultant.
8) In case of binders, stirrups, links etc. the straight portion beyond the
curve at the end shall be not less than eight times the nominal size of the
bar.
9) In case of inadequate lap length or any special circumstances, laps have
to be welded as per guideline of relevant IS Codes or as directed by
Structural Consultant.
10) Bent bars of identical size, shape and type bundled together and
labeled correctly before placing for identification.
11) Steel should be free from grease, oil, mud, mould oil, mill scales,
rust scales, and loose concrete.
12) Bars shall be firmly bound together with 18G binding wire at all
intersections to ensure that the network of rods will retain in its original
form and the cage will be so temporarily supported as to retain its correct
position during the process of concreting.
13) Binding wires bent inwards to avoid contact in cover zone and/or
protrude out of concrete.
14) Beam-column junction’s reinforcement steel bars bunched or
spaced properly to avoid congestion.
15) Enough space between bars should be available to place and
compact concrete.
16) Radius of bend given to dowel at construction joints as per drawing
or as specified.
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 17) Bars of different types and diameters stored separately and clear
identification between tested and untested steel should be marked at site.
18) Reinforcement should be kept covered by tarpaulins or plastic
sheets to avoid excessive corrosion and other contamination.
19) Cover blocks should be of non-corrosive material such as plastic or
concrete/mortar but not wooden or broken tile, broken bricks or stone.
PVC made cover spacers should be used in the works.
20) Splices to be provided as far as away from sections of maximum
stress and must be staggered.
21) Where more than one-half of the bars are spliced at a section or
where splices are made at points of maximum stress, special precaution
should be taken, such as increasing the length of lap and / or using spirals
or closely spaced stirrup around the length of the splice (Staggered laps)
or as suggested by structural consultant. High Yield reinforcement must
be bent without the application of artificial heating.

22) Clear Cover:

Clear cover shall be maintained as specified in Approved GFC drawing.
Such as:
Clear Cover
a) 160 – 200 mm thick Shear Wall – 25mm
b) Pile Cap bottom – 75mm
c) Pile Cap Top & Side – 50mm
d) Column – 40mm
e) Tie Beam – 40mm

Note: Clear Cover for other structures as specified in Approved GFC

drawing

23) TOLLERENCE ON PLACING OF REINFORCEMENT:

Unless otherwise specified by the Developer/PMC/Structural Consultant,
reinforcement shall be placed within the following tolerances as per CPWD
Specification – 2019, (Cl no: 5.3A.9.3):

Tolerance in spacing
(a) For effective depth, 200 mm or less + 10 mm
(b) For effective depth, more than 200 mm + 15 mm

Special attention, if any:

24) SAFETY PRECAUTION:

 Ensure the personnel are provided with appropriate PPE (Safety shoe,
Helmet with chin straps, Gloves and Ear plug)
 Welding and gas cutting activities must ensure safety compliance, like
availability of flash-back arrestor, double earthling for welding machine,
separate identifications for oxygen and DA hose etc.
 Proper lighting, Housekeeping, is mandatory.
 Regular tool box meeting shall be conducted.
 ‘Work Permit’ to be maintained regularly.
 Covid-19 protocol shall be maintained as per latest directives/guidelines
of Central/State Government.
 Reinforcement work procedure should be carried out as per Methodology

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 and HIRA procedure.
 Any other relevant precautions as may be necessary as per provisions of
approved Project EHS Plan.

Tests/Inspections and acceptance criteria:

The criteria of MTP & ITP along with relevant IS codes of practice/ CPWD
Specifications should be followed.
Acceptance criteria as per IS 1786 below:

Property Fe 500D & Low alloy

Steel
0.2 percent proof stress/ yield stress, Min, N/mm2 500
0.2 percent proof stress/ yield stress, Max, N/mm2 -
TS/YS ratio1), N/mm2 ≥ 1.08, but TS not less
than 545.0 N/mm2
Elongation, percent, min. on gauge length 5.65A, where A is
the cross-sectional area of the test piece 12.0
Total elongation at maximum force, percent, Min, on gauge
length 5.65√A, where A is the cross-sectional area of the test
piece -

Note: the use of tolerance of above limit is solely depends as per IS 1786 criteria
of Product Analysis.
The maximum limit of variation is as below:
Constituent Variation over Specified Maximum Limit % Max

Carbon 0.02

Sulphur 0.005

Phosphorus 0.005

Sulphur + Phosphorus 0.010

Nominal Mass (Rolling Margin):

Tolerance in nominal mass is generally termed as a Rolling Margin.
Rolling margin is a ration of (difference between Actual unit weight & Theoretical
unit weigh) to (theoretical unit weight. It is expressed in %

Theoretical Unit weight:

Sr. Nominal Cross Sectional Mass per
No. Size (mm) Area (mm2 ) meter kg (Wthe)
3 6 28.3 0.222
4 8 50.3 0.395
5 10 78.6 0.617
6 12 113.1 0.888
7 16 201.2 1.58
8 20 314.3 2.47
9 25 491.1 3.85

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10 28 615.8 4.83
11 32 804.6 6.31

Dia (mm) Tolerance on the Nominal Mass Actual unit weight(Wact) =

Batch (av. Individual Individual (Actual weight/ Actual Length*)
of 3 for Coil only *The length of test specimen
Specimens should not be than 500mm
)
Rolling Margin (RM) =
Up to & ± 7% - 8% ± 8% [(Wact) – (Wthe)] / (Wthe) %;
including 10
Above 10 ± 5% - 6% ±6 If (Wact) > (Wthe), RM is +ve
up to & incl. If (Wact) < (Wthe), RM is -ve
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Above 16 ±3 - 4% ± 4%

REVIEWED BY: APPROVED BY:

(PQH) (PMC)