Information

ICL/FER/SPECIALS/02/0619
Reinforcement Continuity Strip: Why Use ‘Specials’?
A comparison study of ‘specials’ v ‘standards’
Good practice as standard practice, or ‘anything goes’?
On every credible UK project, concrete reinforcement is
specified (to BS4449:2005+A3:2016) and required to be
Executive Summary CARES approved. ‘Cut and bent’ requirements are designed
This study compares using ‘off to a range of shape codes (BS8666:2005 refers).
the shelf’ stock lengths
(‘standards’) with purpose- These shape codes are the basis for designers to define all
made ‘specials’.
dimensions, uniquely to the needs of the project. After
To make the comparison ‘real’, careful quantification (avoiding wastage) the reinforcement
the study is based on the is fabricated to order by CARES approved fabricators,
concrete cores of a residential bundled and uniquely labelled to suit, then delivered in sync
construction project in which with the site programme.
FERBOX was incorporated.
This process is accepted and adopted as good standard practice, ensuring that design intent is satisfied, whilst meeting the
Analysis found 20% wastage of
materials (i.e. if stock lengths
practicalities of construction and the quality assurance needs of professional stakeholders. This rationale also applies to threaded
were to have been used) plus couplers.
consequent wasted labour and
other indirect costs. However, when it comes to reinforcement continuity strip (where the reinforcement is uniquely subjected to the additional demands
of rebending on site) it can often appear - somewhat inexplicably - as if ‘anything goes’.
This report also found that
using made-to-measure A structural component, not an accessory
‘specials‘ results in increased
Using reinforcement continuity strip shouldn’t significantly compromise reinforcement design,
construction efficiencies and
yet it often does. UK CARES approved continuity strip manufacturers are adept at the timely
considerably improved health
and safety on-site, by much fabrication of their products, to accommodate principal design and construction practicalities.
reduced exposure to power Nonetheless, there is widespread use of continuity strip brought into the UK, often without
tools and other avoidable risks. any recognisable form of approval, and treated by some as if an insignificant ‘accessory’.

As a structural component, Such products tend to be entirely ‘standard’ in their configuration (with a ‘one size
reinforcement continuity strip fits all’ approach to anchorage, lap and casing length). They offer little to address
requires performance the needs of reinforcement design and often prove wasteful in application.
validation. A CARES approved
system such as FERBOX meets
the QA needs of stakeholders
Varying the reinforcement and casing dimensions to suit, results in what we know
and enables compliance with as ‘specials’. For UK CARES approved fabricators, these simply incorporated
the National Structural variations help to ensure that design intent is met, whilst also making life much
Concrete Specification (NSCS). easier for contractors.
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’

Reinforcement design
There is a strong argument for ‘specials’ to achieve the required reinforcement design (many compromises are made with
standard units, which often don’t correctly address design requirements for anchorage, lap and concrete cover).
The following clauses from EC2 are used by way of example:

Consider 8.3 and 8.4 Avoid this kind of

(for good bond and partial anchorage
bearing stress) and arrangement, which
whether longitudinal could lead to
reinforcement (top cracking and
only) is required to reduction in
link all continuity stiffness. Continuity
reinforcement. reinforcement
should not be
Consider 5.6.4 regarded as ‘stand-
(analysis) and 6.5 alone’. For most
(design) strut and tie applications it should
models. Continuity interact with main
reinforcement reinforcement
anchorage should be (variable anchorage
designed to interact depths are easily
with main accommodated in
reinforcement. manufacture).

CARES. It matters.
Reinforcement continuity strips are important structural components that require performance validation.

CARES Technical Approval provides this validation through a process of structural testing, regular mechanical testing and audit.
This meets the quality assurance needs of professional stakeholders and enables compliance with the National Structural
Concrete Specification (NSCS).
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’

Improving cost and efficiency

The plans show locations of reinforcement
continuity strip for the walls of two slip-formed
concrete cores in a typical London residential
Making your decision project - Creekside Wharf, Greenwich
When specifying or procuring (constructed December 2016 to March 2017).
reinforcement continuity strip,
there are three key questions:

• Use off-the-shelf standard

units?
• Use purpose-made ‘specials’?
• Use a CARES Technically Core ‘A’
Approved system? 22 storeys
Some customers say to us…
‘‘We’ll just buy a pallet of Alphabetical key represents
‘standards’...they’re cheaper.’’ FERBOX locations, as used in
wastage analysis.
We’d like to challenge this
popular belief by evaluating
the concrete cores in a typical
London residential project:
Creekside Wharf, Greenwich.

Core ‘B’
12 storeys

Alphabetical key represents

FERBOX locations, as used in
wastage analysis.
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’
Material wastage
The table below summarises the volume of reinforcement continuity strip required for Core A. The grey columns reflect what was actually supplied
and used (‘specials’). The blue columns reflect what would have been supplied (and part wasted) if stock length ‘standards’ were to have been used.
Based on commonly available stock length casings of 1.200m or 1.250m, using ‘standards‘ results in 16.7% or 21.6% wastage respectively.

If off-the-shelf 'standards' used, then WASTAGE ANALYSIS:

Number of cases used

to make FERBOX joint
Core ‘A’

Concrete joint length

as made-to-measure

then number of cuts

FERBOX joint length
number and length required (results If off-the-shelf 'standards' used, then
Structural member

If 'standards' used,
22 storeys are shown for 1.200m or 1.250m the overall metreage required, less the

as drawn (mtrs)

required on site
(mtrs) See Note 1

length See Note 2

casing lengths, being representative of metreage of made-to-length 'specials'

FERBOX key
Note 1: common market options) equals wastage
The actual FERBOX
joint lengths Casing length (m) Casing length (m) Wastage (m) Wastage (m)
supplied were 1.200 Extn 1.250 Extn 1.200 % 1.250 %
generally less than Core A wall 1A Ⓐ 2.204 2.100 2 2 2.400 2 2.500 1 0.300 14.3% 0.400 19.0%
the concrete joint Core A wall 1A Ⓑ 3.332 3.300 3 3 3.600 3 3.750 1 0.300 9.1% 0.450 13.6%
lengths, at the Core A wall 2A Ⓒ 14.189 14.100 11 12 14.400 12 15.000 1 0.300 2.1% 0.900 6.4%
request of the Core A wall 3A Ⓓ 1.947 1.800 2 2 2.400 2 2.500 1 0.600 33.3% 0.700 38.9%
customer (to Core A wall 3A Ⓔ 5.750 5.550 5 5 6.000 5 6.250 1 0.450 8.1% 0.700 12.6%
provide flexibility
Core A wall 4A Ⓕ 1.786 1.650 1 2 2.400 2 2.500 1 0.750 45.5% 0.850 51.5%
for the slip-form
Core A wall 4A Ⓖ 7.061 6.900 6 6 7.200 6 7.500 1 0.300 4.3% 0.600 8.7%
mechanism).
Core A wall 5A Ⓗ 1.691 1.650 1 2 2.400 2 2.500 1 0.750 45.5% 0.850 51.5%
Note 2: Core A wall 6A Ⓙ 2 x 0.813 2 x 0.750 2 2 2.400 2 2.500 2 0.900 60.0% 1.000 66.7%
At the request of Core A wall 6A Ⓚ 2 x 1.375 2 x 1.200 2 2 2.400 2 2.500 0 0.000 0.0% 0.100 4.2%
the customer, the Core A wall 7A Ⓛ 2.046 1.950 2 2 2.400 2 2.500 1 0.450 23.1% 0.550 28.2%
individual FERBOX Core A wall 7A Ⓜ 1.022 0.900 1 1 1.200 1 1.250 1 0.300 33.3% 0.350 38.9%
casing lengths were Core A wall 8A Ⓝ 5.409 5.250 4 5 6.000 5 6.250 1 0.750 14.3% 1.000 19.0%
manufactured Core A wall 9A Ⓟ 2.910 2.850 2 3 3.600 3 3.750 1 0.750 26.3% 0.900 31.6%
(where feasible in Core A wall 10A Ⓠ 1.890 1.800 2 2 2.400 2 2.500 1 0.600 33.3% 0.700 38.9%
accommodating lap Core A wall 11A Ⓡ 1.344 1.200 1 1 1.200 1 1.250 1 0.000 0.0% 0.050 4.2%
legs) to 1.200m or Core A wall 12A Ⓢ 2.360 2.250 2 2 2.400 2 2.500 1 0.150 6.7% 0.250 11.1%
less (individual Core A wall 13A Ⓣ 1.544 1.500 1 2 2.400 2 2.500 1 0.900 60.0% 1.000 66.7%
casing lengths of up
Core A wall 14A Ⓤ 1.466 1.350 1 2 2.400 2 2.500 1 1.050 77.8% 1.150 85.2%
to 2.400m are
Core A wall 15A Ⓥ 2.660 2.550 2 3 3.600 3 3.750 1 1.050 41.2% 1.200 47.1%
ordinarily possible).
Core A wall 16A Ⓦ 1.216 1.200 1 1 1.200 1 1.250 0 0.000 0.0% 0.050 4.2%
Total per level 66.203 63.750 54 62 74.400 62 77.500 20 10.650 13.750
16.7% 21.6%
Total per 22 levels 1,456 1,403 1,188 1,364 1,637 1,364 1,705 440 234.300 302.500
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’
Material wastage
The table below summarises the volume of reinforcement continuity strip required for Core B. The grey columns reflect what was actually supplied
and used (‘specials’). The blue columns reflect what would have been supplied (and part wasted) if stock length ‘standards’ were to have been used.
Based on commonly available stock length casings of 1.200m or 1.250m, using ‘standards‘ results in 16.0% or 15.8% wastage respectively.

If off-the-shelf 'standards' used, then WASTAGE ANALYSIS:

Core ‘B’

Number of cases used

to make FERBOX joint
Concrete joint length

as made-to-measure

then number of cuts

FERBOX joint length
number and length required (results If off-the-shelf 'standards' used, then
Structural member

If 'standards' used,
12 storeys are shown for 1.200m or 1.250m the overall metreage required, less the

as drawn (mtrs)

required on site
(mtrs) See Note 1

lengthSee Note 2
casing lengths, being representative of metreage of made-to-length 'specials'

FERBOX key
Note 1: common market options) equals wastage
The actual FERBOX
joint lengths Casing length (m) Casing length (m) Wastage (m) Wastage (m)
supplied were 1.200 Extn 1.250 Extn 1.200 % 1.250 %
generally less than Core B wall 1B Ⓐ 6.827 6.750 5 6 7.200 6 7.500 1 0.450 6.7% 0.750 11.1%
the concrete joint Core B wall 2B Ⓑ 3.305 3.150 3 3 3.600 3 3.750 1 0.450 14.3% 0.600 19.0%
lengths, at the Core B wall 2B Ⓒ 3.929 3.750 3 4 4.800 3 3.750 0 1.050 28.0% 0.000 0.0%
request of the Core B wall 3B Ⓓ 7.627 7.500 7 7 8.400 6 7.500 1 0.900 12.0% 0.000 0.0%
customer (to
Core B wall 4B Ⓔ 3.735 3.600 3 3 3.600 3 3.750 0 0.000 0.0% 0.150 4.2%
provide flexibility
Core B wall 4B Ⓕ 2.280 2.100 2 2 2.400 2 2.500 1 0.300 14.3% 0.400 19.0%
for the slip-form
Core B wall 5B Ⓖ 5.459 5.400 5 5 6.000 5 6.250 1 0.600 11.1% 0.850 15.7%
mechanism).
Core B wall 6B Ⓗ 3.176 3.000 2 3 3.600 3 3.750 1 0.600 20.0% 0.750 25.0%
Note 2: Core B wall 7B Ⓙ 4.600 4.500 4 4 4.800 4 5.000 1 0.300 6.7% 0.500 11.1%
At the request of Core B wall 8B Ⓚ 2.376 2.250 2 2 2.400 2 2.500 1 0.150 6.7% 0.250 11.1%
the customer, the Core B wall 9B Ⓛ 0.899 0.900 1 1 1.200 1 1.250 1 0.300 33.3% 0.350 38.9%
individual FERBOX Core B wall 10B Ⓜ 2.009 1.950 1 2 2.400 2 2.500 1 0.450 23.1% 0.550 28.2%
casing lengths were Core B wall 11B Ⓝ 1.450 1.350 1 2 2.400 2 2.500 1 1.050 77.8% 1.150 85.2%
manufactured Core B wall 12B Ⓟ 2.676 2.550 2 3 3.600 3 3.750 1 1.050 41.2% 1.200 47.1%
(where feasible in Core B wall 13B Ⓠ 0.888 0.900 1 1 1.200 1 1.250 1 0.300 33.3% 0.350 38.9%
accommodating lap Total per level 48.636 49.650 42 48 57.600 46 57.500 13 7.950 7.850
legs) to 1.200m or 16.0% 15.8%
Total per 12 levels 584 596 504 576 691 552 690 156 95.400 94.200
less (individual
casing lengths of up
to 2.400m are
ordinarily possible).
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’

Wastage impact analysed across both cores

+397m When the wasted material for Cores A and B is combined and then
Customer feedback added to the cost of wasted labour, using standards results in
The customer used in our project (20%) wasted
additional direct costs of £5,555. However, when variable indirect
example chose to use FERBOX 'standards'
costs such as waste disposal and remedial work are taken into
‘specials.’ account, the actual costs would be significantly higher.
The project manager explained, If FERBOX made-to-length specials are used (as they were in our
example project) the total length required is 1,998m. Where 1.25m
‘‘We hadn’t typically gone the
‘specials’ route before. But, by 1,998m standard case lengths are used, the total length required is 2,395m
of which 20% (397m) is cut off and wasted.
investing a little up-front time to FERBOX made-to-length 'specials'
schedule our FERBOX
The material wastage and direct costs when using standard length
requirements, we gained a
casings is very evident. Less evident, but equally compelling, is the
smooth supply and installation
avoidance of power tools (and the consequent health and safety
process - without wastage or
benefits) when using made-to-length specials.
complication - and exceeded the
programme demands of our slip-
formed cores.’’
Direct costs £ Cost
Adrian Paul, Project Manager
Up to 397m 'standards' material wastage (at nominal £12.50 per metre, but could be much more) £4,959
O’Keefe Construction (Greenwich)
Limited Labour to cut and seal 'standard' cases (596 cuts x 3 minutes/£1 each @ £20 hour) £596
Sub-total cost £5,555

Additional variable ‘unseen’ costs

Cost of waste disposal £,£££
Cost to drill and resin fix rebar (where applicable) £,£££
Cost of remedial couplers (where applicable) £,£££
Cost of project delay £,£££
Real Unaccounted Cost of Using ‘Standards’ >£5,555
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’
Shape 21 variants

Our range
FERBOX comes in 19 shape options Shape 21 Shape 21D Shape 21R
across 5 shape families. These 19
different bar shape configurations Shape 11 variants
are highly variable to application
requirements, in bar diameters 10,
12 and 16mm.

Choose the appropriate FERBOX Shape 11 Shape 11A Shape 11B Shape 11C Shape 11X
shape for your project using our All
Shapes Scheduling Form. Shape 00 variants

Accessories
Straightening tools are available,
which have a specially shaped end
and an internal diameter only
Shape 00 Shape 00A Shape 00B Shape 00C
slightly greater than the diameter
of the bar to be straightened. Both
of these simple features help to Shape 13 variants
ensure suitable straightness at the
concrete joint interface.

Shape 13D Shape 13S Shape 13X

Pull-out ‘link’ variants

Shape 44 Shape 51 Shape 77 Shape 100

 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’

1. Maintains structural integrity

• No cutting of case lengths is required, which compromises lap-lengths when
rebar is cut short. The specified reinforcement design can normally be met
(achieving correct anchorage, lap and concrete cover) by simply varying
Specials are our standard ‘H’, ‘L’ & ‘W’ shape dimensions to suit.
For good reasons, over 90% of • Product performance requirements are met. All FERBOX manufacture is
FERBOX reinforcement continuity endorsed by CARES Technical Approval, which also complies with
strip is made-to-measure, which requirements of the National Structural Concrete Specification (NSCS).
has many efficiency advantages for
concrete frame construction (see
2. Improves heath and safety
right). • No need to run power and operate power-tools, which improves safety on site
and eliminates the need for designated cutting areas (hot works).
Our manufacturing scope is
unrivalled in this product sector, so • In congested site working conditions, installation is 'de-hassled' by transferring
engineers and contractors benefit avoidable operations off-site and into factory controlled conditions.
from bespoke fabrication to
application specific dimensions, 3. Reduces on site labour
without need for site modification. • No labour and associated costs required for cutting and re-sealing cases,
drilling and resin-fixing rebar, or attaching remedial couplers. FERBOX arrives
FERBOX customers and ready to install.
stakeholders can therefore be
confident that design intent and
quality assurance will be met, as
well as timely delivery and ease of 4. Decreases expenditure and material wastage
installation. • By having correctly sized casing lengths, the unplanned and expensive cost of
remedial couplers is eliminated.
• Significantly reduces material loss, site storage and transfer of steel to be
recycled. Only the front covers of FERBOX are removed for recycling.

5. Increases efficiency
• Deliveries can be scheduled on a just-in-time basis, minimising site storage
requirements and making the location-labelled FERBOX easy to find and
position.
 Reinforcement Continuity Strip: Why use ‘specials’?

Information

ICL/FER/SPECIALS/02/0619
A comparison study of ‘specials’ v ‘standards’

Conclusion
This report identifies that concrete reinforcement in the UK is uniquely specified and required to be CARES approved, to ensure
design integrity and to avoid wastage. However, these standard practices are not always applied to reinforcement continuity
strip. Consequently, where ‘standard’ (and sometimes unapproved) reinforcement continuity strip is used, the ‘one size fits all’
About Invisible Connections approach to anchorage, lap and casing length often does little to address the needs of reinforcement design and also proves
Apart from being specialist wasteful in application.
manufacturers of the FERBOX®
reinforcement continuity system, This report establishes that selection of structurally and mechanically tested CARES approved reinforcement continuity systems,
we also supply the concrete combined with an application-specific approach to fabrication, ensures that 'specials' contribute to structural design integrity,
construction industry with ‘unseen’ satisfy stakeholder demands for quality assurance and comply with National Structural Concrete Specification
telescopic connection systems for (NSCS) requirements.
precast stair landings, beams and
columns. Analysis of reinforcement continuity strip and labour for a real (and typical) construction project concluded
that material wastage is higher (by 20%) when 'standards' are used. Not only is more material required
All our products meet industry and wasted, but additional man hours are needed for installation on site. Alternatively, using made-
demands for improved safety, to-measure 'specials' such as FERBOX results in less material and less labour wastage. If indirect
construction efficiency and cost costs such as waste disposal, remedial works and project delay are also taken into account, then
competitiveness. the savings delivered by 'specials’ are considerably more.

Our telescopic connection systems This report also points to the additional benefits of improved health and safety and increased
are endorsed by European construction efficiency as an outcome of using 'specials’. As 'specials' are purpose-manufactured
Technical Approvals (ETAs). They to application requirements, work is transferred off site, which makes for less congested working
comply with relevant Eurocode areas. Just-in-time (JIT) deliveries can be scheduled according to construction level or area,
standards and are individually CE minimising site storage requirements. Furthermore, since ‘specials’ do not require cutting, rapid
marked. installation can be achieved without the risks posed by power tools, thereby leading to a safer
site environment.

For technical or practical

Invisible Connections Ltd
Unit 6, Thame Forty advice, call us or go to
Jane Morbey Road
Thame, Oxfordshire OX9 3RR [Link]
+44 (0)1844 266000
sales@[Link]
[Link] This information is presented by Invisible Connections in good faith, for customers' evaluation and comment. Errors and omissions are excluded.