Rebar Procesing

Rebar Processing Solutions

Process & Benefits

Copyright © 2010 Jindal Steel & Power Ltd.3

EMERGING TRENDS IN CONSTRUCTION PRACTICES IN INDIA

• Non-availability of cheap manual labor employed at site for cutting, bending, tying and Fixing of Re-bars.

• Lack of Space at project sites.

• Increased awareness about speed, quality & safety of Construction.

• Cost pressures on Construction Co.’s : Find ways & means to reduce pilferage and wastage at site

Ready to use cut & bent

Rebars take lead in

shaping the Indian

Construction market

Copyright © 2010 Jindal Steel & Power Ltd.

REBAR PROCESSING SOLUTIONS

STRAIGHT LENGTHCOILS

StraighteningCutting to required length

Bending to required Shapes

AssemblyMesh Coupler

TMT

Stirrups


PRODUCTS

Shear line

Single Bender Manual Bender

Rebars

Radial Bender

Coils

Poly Bender

Stirrups Simple 2D Shapes Radial Shapes 3D Shapes


FINISHED GOOD RANGE


This Solution will bring a cascading improvement in the way project is executed

1. Reliability of Steel supplies

2. Improvement in Quality

3. Timeliness : Compress project schedules

4. Improvement in Quality of construction

Customer

Customers to focus on their core job – CONSTRUCTION


Advantages of Processed Rebar solutions

Project design Materials

procurementConstruction Construction

ManagerCompany's

margins

Traditional System

Minimize wasteAssess steel consumption(5 a 7%),yields (40 a 60 hh/t).

Get Steel price quotation.Cut and Bend Serviceprice quotation.Purchase planning at least5 weeks ahead of requirement.

Insure qualified bar benders.Plan adequateequipmentplan space for storageand processing(120 m2).

High level quality controlis necessary.Production capacity islimited by labor andequipment availability.Ensure yields and waste within budget.

Uncertain consumptionand yields until completionof work.

JSPL Processed Rebar solution

Bar formingShape makingStirrup making

Weldmesh weldingWeldmesh making

Prepare Cut and BendBlueprints.

Price quotation of steeland service.

Program deliveries according toconcreting program.

Possibility to accelerateor slow down the pace ofconstruction by simplyreprogramming deliveries.

Knowledge of processedsteel real cost from thevery first day.

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• Lower production costs: The Cut and Bend process, traditionally performed at the construction site, requires between 40 - 60 man hour/t, around 60 % of steel value. By using processed Rebars, the cost of processing decreases by approximately 30 % of steel value, depending on the type of construction and diameters mix. Moreover, lower indirect costs are obtained through shorter construction time.

• Zero waste: There is usually a certain amount of waste generated, which varies around 5 to10 % (a mean value of 7% can be estimated). With the processed Rebars, customer pays for the theoretical blueprint weight only, and saves on waste, processing or freight.



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• Lower financial cost: Normally the bars are kept in storage for three weeks before using them. Add to this one week for procurement and one additional week for processing at the construction site, Total lead time is 5 weeks. On the other hand, when buying processed Rebars, lead time is considerably shorter as the time required for the delivery of material at construction site is lesser, (5 weeks later than when buying the bars at the plant and bending at construction site.)

• Elimination of storage: Material is ordered when needed and partial deliveries are programmed according to the concreting schedule. This results in lower financial cost, since the material gets to construction site ready to be assembled. Lesser space is also needed at the site, since no storage space is required for bars (60 m2), nor for the cut and bend process (120m2).



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• Simple, safe and operational: Since the whole cut and bend process is limited to ordering the material according to blueprints, handling of 12 m bars is eliminated, and neatness is improved, thus decreasing the risk of accidents as well as the eternal problem of bar thefts.

• Greater response capacity and delivery flexibility:You can speed-up the pace of your construction to comply with certification deadlines, or slow it down -e.g. in case of rain- simply by programming delivery dates with our Rebar processing plants at Patratu/ Nalwa. You can also decrease the construction time of the Reinforced Concrete structure.

Facilities @ plant


JSPL facilities – automatic shaping centre

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JSPL Facilities

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JSPL Facilities – shear line

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JSPL facilities

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JSPL facilities

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JSPL facilities

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Welded mesh -• The longitudinal and transverse reinforcement bars are welded into concrete wire

mesh. The concrete meshes have a more dense spacing of the steel bar. Concrete wire mesh is also named welded steel fabric.

• Application: concrete wire mesh is used for coal mine tunnel network protection or reinforcement, concrete pavement, bridge deck pavement, airport runway, tunnel lining, housing floor, roof, wall, floor, concrete pipes and so on.

• Advantages: concrete wire mesh for a new, efficient and high-quality steel reinforced concrete structures can be reinforced to reduce the installation of a large number of working hours, less than banding employment nearly approached net 50% - 70%. Concrete wire mesh can help to prevent the emergence of concrete cracks and development, roads, floors, Floor welding network configuration can reduce the surface of concrete about 75 percent split.

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Weld mesh plant

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Weld mesh plant

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Weld mesh plant

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JSPL Facilities – welded wire mesh

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Practical Advantage of Weld Mesh:Greater ability to work to achieve increased output with exact steel areas and spacing. Simplified drawings with easy checking without errors.

For Site Supervisors:Simple design enables the placement and checking of steel.Avoid wastage and scrap.

For Contractors:Faster work and finish the task within deadline.Reduced steel scrap generation.Easy to read drawings and cross checking.Achieve greater accuracy with less manpower.


Welded mesh machine

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Machine specifications

Speed of production

Up to 120 strokes/ min

Width 1200-3200 mm

Length 2000-6000 mm

Long. Step 50-200 mm

Cross step 50-250 mm

Long. overhang 50-200 mm

Cross overhang 25-150 mm


Welded mesh - advantages– Concrete Reinforcement Advantages of Welded Wire Fabric Higher characteristic Design

Strength WWF with Fe500 grade results in savings in steel area or steel weight required to the tune of 13.55% vis-a-vis HYSD bars of Fe415 grade

– Vastly Superior Bonding Behavior As against the peripheral surface area which is responsible for bonding to concrete in the case of individual bars, the right mechanical interconnections by means of welds to cross wires are primarily responsible for stress transfer from concrete to steel and vice-versa in the case of WWF. Each of the rigid welds capable of resisting up to 210 N/mm2 ensure quick and complete stress transfer within 2 welded joints from the critical section.

– Better and Economic Crack Resistance with Thinner Wires and Closer Spacing WWF usage affords the possibility of using thinner wires at closer spacing. This serves most effectively in countering the non-load phenomena or strain induced stresses due to Shrinkage and Temperature changes. The close spacing of thinner wires and the two way behavior of WWF minimizes the crack widths and preserves structural integrity of the slab.

– Savings of Labor, Time and Binding Wire The most obvious and clinching advantage in the use of WWF is the immediate and positive savings in labor and time. It is complete freedom from all the mundane filter's jobs. There is no cutting of bars, no marking and spacing them out, and above all no laborious tying of binding wires

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Welded mesh - advantages– The only feasible and Essential Reinforcement for ground slabs WWF usage provides the only

practical and easy solution for reinforcing slabs on ground. A plain concrete slab under construction of sub-soil erosion or movements or due to temperature changes coupled with heavy traffic loading will develop cracks which collapse concrete of the surface. The tendency to use extra high strength concrete or extra thickness of concrete to minimize cracking does not solve any problems since the strains induced by the drying shrinkage or temperature contraction do not appreciably change with thickness. Cost of a WWF reinforced slab is also more or less similar to that of a slightly thicker unreinforced slab. Usage of WWF serves to control cracking and crack width in both directions. It ensures that even if a crack develops the cracked faces are held together and the aggregate interlock is maintained.

– Flexibility of Handling and Placing The usage of thinner wire lends the fabric as extremely flexible in handling. Coupled with the availability in long lengths in roll form, WWF provides the ideal and convenient solution for all kinds of repair work by Re-plastering or Guniting. The same aspect makes WWF indispensable in thin elements such as Precast partitions, shelves, fins, ferro-cements or ferrocate products such as ferrocate water tanks etc. WWF is the only solution for the thin and tough spine of thin and efficient structural elements such as folded plate roofs, folded plate precast roof girders or hyperbolic paraboloid shells

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Thank you

Rebar Procesing

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