Journey to TMT Bars

Dr.G.S.Suresh
Professor &Head
Civil Engineering Department
The National Institute of Engineering
Mysore
 Introduction
• Reinforcement(Rebar)strengthens
concrete
• Concrete contracts and grips
rebar-Bond
• Rebars are rolled from billets that are obtained from a furnace.
• Rebars are generally rolled in round section.
• Ribs are indented on the surface of the deformed rebars or wires during
the process of rolling.
• The prime objective of such deformation is the enhancement of bonding
with concrete by mechanical interlocking.
• Plain mild steel (MS) rebars of grade Fe-250 were used widely till about
1967
• Square twisted bars (deformed bars) were first introduced in India in 1965.
 Introduction Contd.
• The concept of reinforced concrete (RC) was
first initiated by Jean Louis Lambot in 1850
through his rowboat
• The earliest civilian reinforced concrete
buildings were probably built in Bombay.
• In the suburb of Byculla a four-storey students
hostel built in 1907 for the Victoria Jubilee
Technical Institute is described as the «earliest
reinforced concrete structure in India
 Introduction Contd.
• The Indian Cement Company was the first to start
producing cement, in 1914 at a factory in Porbander on
the Gujarat coast.
• In 1914 India manufactured 945 tons of cement and
imported 150,530 tons and the demand was such that
London agents were buying Germancement to re-export
to India
• The steel reinforcement was initially imported from the
UK though agents in Bombay and Calcutta
• Tata were the principle manufacturer of reinforcement in
India from 1914
 Introduction Contd.
•  In 1918, soon after the war, Indian Iron and Steel Company
(IISCO) was formed.
• The then Mysore government also decided to start an iron works
at Bhadravati.
• While IISCO started producing pig iron at Burnpur in 1922, the
Mysore Iron and Steel Works took about 18 years to start its
plant.
• Meanwhile, the Bengal Iron Works went into liquidation and
merged with IISCO.
• The Steel Corporation of Bengal (SCOB) formed in 1937, started
making steel in its Asansol plant. Later in 1953, SCOB merged
with IISCO.
 Introduction Contd.
•  By the end of the second world war, deformed high
strength rebars started gaining momentum around the
world
• Cold twisted and hot rolled deformed rebars of proof
strength about 420 N/mm2 came out for wide usage
• However,in the Indian context, till about 1965, the
classical plain mild steel rebars of yield strength 250
N/mm2 constituted the reinforcement for the concrete
construction industry
• Winds of change were seen in this domain only after
1965.
 Types of Rebars
•  Mild Steel Bars
• Medium tensile steel
• Hot rolled deformed bars
• High yield strength deformed (HYSD)bars or
Cold twisted deformed bars (CTD)
• Thermo Mechanically treated bars
All bars have E= 200 kN/mm2
 LIST OF BUREAU OF INDIAN STANDARD
CODE FOR REBARS
432 : Mild Steel and medium tensile steel bars and hard drawn
steel wire for concrete.
1786: Specifications for HYSD bars and wires for reinforcement.
1566: Hard drawn steel wire fabrics for concrete reinforcement.
2502: Code of Practice for bending and fixing of bars for concrete
reinforcement.
2751: Recommended practice for welding of mild steel
reinforcement
1139 : Hot rolled deformed bars.
 History of Rebars in India
 Introduction of square twisted rebars
• For the first time in India, on a small scale, square twisted rebars with
chamfered corners, Fig 2, were brought in to market by IRC Steels, West
Bengal with the collaboration of BRC, UK. Since production of such
rebars was quite an involved process and since the rebars were not
efficient enough, they were phased out from the Indian market in a very
short period.
 History of Rebars in India Contd.
 Production of cold twisted circular rebars
• In 1967, Tor Isteg Steel Corporation of Luxumberg
introduced, in India, ‘cold twisted deformed circular
rebars’ of proof stress 420 N/mm2, which subsequently
became popular as Tor 40 rebars. The manufacturing
process essentially comprised of three stages:
(i) production of quality billets
(ii) passing the reheated billets through stands, to get
deformed rebars of desired diameters ; and
(iii) cold twisting the deformed rebars to the desired
Pitch.
 History of Rebars in India Contd.
 Production of cold twisted circular rebars
• Agarwal Hardwares, Kolkata; Mukund Steel, Mumbai, Rathi Steels, Delhi;
ISRM, Chennai were the first to produce these rebars in the country in
1967. Hindustan Steels, (Presently SAIL) followed soon after. By about
1970, these Tor 40 rebars (grade Fe 415) replaced the classical plain mild
steel rebars by about 50 percent in the country,
Fig 3.
 History of Rebars in India Contd.
 Production of cold twisted circular rebars
• In view of the simplicity in production, significant
savings in the consumption of rebars in
constructions and aggressive technical marketing
by the manufacturers and TOR ISTEG Steel
Corporation, classical plain mild steel rebars were
virtually replaced by these, by about 1975.
 History of Rebars in India Contd.
 Production of cold twisted circular rebars
• By about 1978, the industry decided to bring in
Fe 500 cold twisted rebars in consonance with
the trend in Europe. As a result, Tor 50 and
Tiscon 50 (grade Fe 500) were pushed in the
market
• Several major constructions came up around the
country with these higher grade rebars.
 History of Rebars in India Contd.
Production of hot rolled rebars
• During the period when cold-twisted rebars were
being introduced, a few industrialists decided to
produce hot-rolled alloy rebars as well in our
country
 History of Rebars in India Contd.
Production of hot rolled rebars
• It was by about 1968, that for the first time these
rebars were produced by Tata Steel and were
branded as Tistrong rebars
• Tata Steel, subsequently brought out cold twisted
deformed rebars with indigenous technical back
up, branding them Tiscon rebars
 History of Rebars in India Contd.
Production of hot rolled rebars
• It was by about 1968, that for the first time these rebars
were produced by Tata Steel and were branded as
Tistrong rebars
• Tata Steel, subsequently brought out cold twisted
deformed rebars with indigenous technical back up,
branding them Tiscon rebars
• It was at this juncture that Tor Isteg Steel Corporation
handed over the mantle of ensuring production of
quality rebars to Torsteel Research Foundation.
 History of Rebars in India Contd.
Torkari rebars
In contrast to the cold twisting and thermo processing, a
new procedure for manufacturing high strength
deformed rebars was developed by Germans, branded as
Torkari rebars. The manufacturing procedure essentially
comprises of simultaneous cold reduction and cold
ribbing of wire rods. This process results in production of
rebars of proof strength upto 550 N/mm2. However, the
process is restricted to diameters up to 11 mm.
 History of Rebars in India Contd.
Introduction of thermo processed (TMT) rebars
• In addition to Torsteel and Tiscon, several secondary
steel units, in the unorganised sector, also started
production of Fe-415 rebars, popularly termed as CTD
rebars.
• Between 1980 and 1985, new type of rebars termed
TMT rebars were developed around the world, for the
benefit of RC constructions. Notable amongst them
were Torsid from France, Tempcore from Belgium and
Thermex from East Germany.
 History of Rebars in India Contd.
Introduction of thermo processed (TMT) rebars
• In addition to Torsteel and Tiscon, several secondary
steel units, in the unorganised sector, also started
production of Fe-415 rebars, popularly termed as CTD
rebars.
• Between 1980 and 1985, new type of rebars termed
TMT rebars were developed around the world, for the
benefit of RC constructions. Notable amongst them
were Torsid from France, Tempcore from Belgium and
Thermex from East Germany.
 History of Rebars in India Contd.
Introduction of thermo processed (TMT) rebars
• The manufacturing process essentially comprised of
controlled quenching of rebars.
• The rebars heated up to a temperature of about 900o C, when
passed through quenching tubes — wherein the volume and
temperature of cooling water is controlled — get quenched to
a temperature of about 450oC in a few seconds, This process
results in enhancement of the strength level of rebars, subject
to precise control of all parameters.
• These are essentially ‘dual phase rebars’, with tempered
martensite periphery and ferrite-pearlite core.
History of Rebars in India Contd.

Manufacturing Process of TMT Bars

 History of Rebars in India Contd.
•In the initial years, the production
was restricted to rebars having
diameter higher than about 16 mm.
With experience and with the advent
of refinements in technology, smaller
diameters could be produced.
History of Rebars in India Contd.
 History of Rebars in India Contd.
Other Development in Rebars
•Corrosion resistant rebars (CRS)
Modifications in chemical composition of the billets.
Manufactured by TATA, Vizag Steel and SAIL.
•Stainless steel rebars
Austenitic stainless steel rebars –expensive
Ferritic stainless steel rebars, - chromium content of 11 to 12%
both cost effective and corrosion resistant.
 History of Rebars in India Contd.
Provisions in standards
A few prominent standards which cover the requirements
are:
Indian Standards – IS 1786
British Standards – BS 4449
American Standards – ASTM A615M and ASTM A706M
Euro norms – EN10080
and Asian Model Code 1999.
 Provisions in standards

Standard Grade Yield UTS %Elongation

Strength(N/mm2) (N/mm2) min-mix
min

IS:1786-2008 Fe 415 450 540 18-22

IS:1786-2008 Fe 500 530 610 16-21

IS:1786-2008 Fe 550 580 640 16-20

 Chemical Requirements
Maximum Limits as per IS1786-2008
Percent, Maximum
Constituent Fe Fe Fe Fe
Fe 500 Fe 550 Fe 600
415 415D 500D 550D
Carbon 0.3 0.25 0.3 0.25 0.3 0.25 0.3

Sulphur 0.060 0.045 0.055 0.040 0.055 0.040 0.040

Phosphorus 0.060 0.045 0.055 0.040 0.050 0.040 0.040

Sulphur &
0.11 0.085 0.105 0.075 0.100 0.075 0.075
Phosphorus

Note: The figures following Fe indicate the specified minimum 0.2% proof
stress or yield stress in N/mm2
The letter D following the strength grade indicates the category
with same specified minimum 0.2% proof stress/ yield stress but with
enhanced specified minimum percentage elongation
 Requirements of Bond (IS:2770 part 1)
For high strength deformed bars/ wires, the mean
area of ribs (in mm2) per unit length (in mm) above the core
of the bar/wire, projected in on a plane normal to the axis
shall not be less than following values:

0.12φ For φ ≤ 10 mm
For φ more than 10mm and ≤
0.15φ
16mm
0.17φ For φ > 16mm
The mean projected area of transverse rib alone shall
be not less than one-third of the values given above.
When subjected to pullout testing in accordance with
IS 2770 part1, the bond strength calculated from the load at
measured slip of 0.025mm and 0.25mm for deformed bars/
wires shall exceed that of a plain round bar of the same
size by 40% and 80 % respectively.
 History of Rebars in India Contd.
Sub-standard reinforcing bars
Inspite of the overall developments in the reinforcement field, the
construction industry is faced with the problem of substandard
reinforcements in the market which exhibit the following lacunae:
(i) brittle rebars with high carbon content,
(ii) low strength rebars with low carbon content,
(iii) bars marketed as TMT rebars, not being quenched at all; and
(iv) bars with inadequate quenching resulting in lower strength
 History of Rebars in India Contd.
The defects which are generally observed in rebars from
the market are:
(i) underweight
(ii) defective geometry (over sized ribs and lugs or worn
out ribs and lugs)
(iii) rolling defects
(iv) twisting defects, and
(v) defects due to production from defective raw material
(pipings and inclusions).
 History of Rebars in India Contd.
In the course of last two and a half years, about
18,000 rebar samples, sent by various consumers,
have been tested in Torsteel laboratories at
Bangalore, Chennai and Hyderabad in accordance
with stipulations in Indian Standards — IS 1608: 1995
and IS 1786 : 1985 (reaffirmed 2000). The physical and
chemical properties assessed included:
(i) 0.2 percent proof stress,
(ii) tensile strength
(iii) percentage elongation
(iv) type of fracture, and
(v) carbon content.
 History of Rebars in India Contd.
The sub-standard rebars that were tested can be classified
into six specific categories. These categories are:
(i) TMT rebars with low carbon content
(ii) TMT rebars (?) quenched in water tank
(iii) TMT rebars with inadequate quenching in cooling tubes
(iv) TMT rebars (?) with no quenching at all
(v) CTD rebars – hot twisted, and
(vi) CTD rebars with high carbon content.
History of Rebars in India Contd.

CLOSE-UP OF TWO SUB STANDARD REBARS TESTED

 History of Rebars in India Contd.

TMT REBARS QUENCHED IN WATER TANK: TYPICAL BRITTLE FRACTURE

History of Rebars in India Contd.

TMT REBARS THAT ARE INADEQUATELY QUENCHED

History of Rebars in India Contd.

TMT REBARS THAT ARE INADEQUATELY QUENCHED

History of Rebars in India Contd.

TMT REBARS WITH VERY LOW TENSILE STRENGTH

 History of Rebars in India Contd.

STRESS-STRAIN DIAGRAM OF NORMAL AND SUBSTANDARD TMT BARS

Field test for Checking TMT bars
1. Concrete and Rebars are the two vital
components in any reinforced concrete
construction.
2. Safety and durability of such constructions is
directly dependent on the quality of Concrete
and / or Rebars.
3. The main problem in India today, is defective,
substandard and fake rebars in the market.
 The cursory test – outline of test
Whenever a rebar under a high temp is
quenched under controlled conditions and
cooled in air subsequently, due to metallurgical
transformation, two distinct phases (shades)
show out.
Tempered martensite in the form of a ring
with definite width forms the outer case (ring),
whereas the inner core remains pearlite / ferrite.
The outer case (ring) and inner core are
distinctly visible, when the cross-section of
rebar is etched.
 C/s of a sample before Tempered martensite (outer
Pearlite / ferrite case)
controlledquenching (inner core)

Rebar before and after Thermo-Processing

The Cursory Field Test - test procedure
Following are the steps for carrying out the test;

1.Cut ‘small length samples’ from a few randomly

selected TMT rebars of any lot, preferably in a
cutting machine, if not, by hack-saw cutting.

2.Cross-sections of test samples shall be mirror

finished with any suitable polishing device.

An ideal polishing device is a unit with rpm of

about 3000, wherein an emery sheet can be
mounted on the rotating circular disc.

Polishing of cross-sections shall be done for

atleast about 10 minutes.
Contd/….
 The cursory field test – Test procedure (Contd/…..)

3. The c/s shall be smeared (etched) with drops of

‘Nitrol Solution’.
It is nothing but a synthesis of ’10 % of Conc.
Nitric Acid’ and ‘90 % of Ethyl Alcohol’.

Soon after etching, two distinct phases

(Shades) with uniform thickness are clearly visible
on the c/s, if the rebars are ‘Genuine TMT Rebars’.

If the two phases are not distinct, the rebars

are either ‘Substandard’ or ‘Fake’ TMT rebars.

Note: It is essential that the c/s be examined soon

after etching. In case of delay, etching to be redone.
Appearance of Genuine Thermo-processed
(TMT) rebars after etching with Nitrol
Appearance of Fake Thermo-processed
(TMT) rebars after etching with Nitrol
 Appearance of (inadequately / inappropriately
quenched) Thermo-processed (TMT) rebars after
etching with Nitrol
Chemical properties of Geniune Thermo-Processed
(TMT) Rebars

Ultimate Elongation
0.2% Proof Tensile over a gauge
Diameter Stress Strength length of ‘5
% Carbon
(mm) (N/sq.mm) (N/sq.mm) dia’ (%)

12 0.174 602 696 20

16 0.152 567 685 24

25 0.160 513 629 23

Note: The test results satisfy the requirements of

IS:1786-2008 for rebars.
 Chemical Properties of Fake Thermo-Processed (TMT)
Rebars
Ultimate Elongation
0.2% Proof Tensile over a gauge
Diameter % Carbon Stress
Strength length of ‘5
(mm) (N/sq.mm)
(N/sq.mm) dia’ (%)

12 0.204 353 552 32

16 0.186 314 520 35

20 0.198 390 556 29

Note: The test results do not satisfy the requirements of

rebars as per IS:1786-2008
Twisting operation is not involved in the production of the TMT steel bar,so no residual
stresses involved in that , which in turn increases the corrosion resistance.

Rust and Corrosion Resistance :

The main reason for failure in any reinforcement concrete structure is due to corrosion of
TOR Steel in the concrete, where this steel corrodes in existence of chloride ions. TMT Bars,
due to its Thermo- mechanical treatment are very highly rust and corrosion resistant and is
best suited in the humid and coastal states like West Bengal and Orissa.

Uses:
TMT Bars are much superior to conventional TOR Steel by virtue of their various engineering
properties and can be used for Residential Buildings, Bridges, Drums, Industrial
Establishment and all types of concrete reinforcement purposes.

TMT Bars:
Grade - Fe 415
IS: 1786

Note:
The project designers use thermo mechanically treated bars (TMT) in place of torsteel and
even in TMT, the choice is increasingly focussed on that with higher tensile strength ( Fe-500
in lieu of Fe-415) and high corrosion resistant TMT (HCRM) which is specially meant for use in
coastal areas.