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Doc No.: ES-V-DR-S008

CONSTRUCTION SPECIFICATION
CONCRETE REINFORCEMENT Issue No.: 3

CONSTRUCTION SPECIFICATION

FOR

CONCRETE REINFORCEMENT

IS S U E DATE PREPARED REVIEWED APPROVED PAGE DESCRIPTION

1 01/07/04 K.P. PAU C.Y. LOW TOM YU ALL NEW EDITION

2 01/09/04 K.P. PAU C.Y. LOW TOM YU ALL CHANGES OF

COMPANY’S NAME

3 10/12/04 K.P. PAU C.Y. LOW TOM YU ALL CHANGES OF

COMPANY’S NAME
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CONSTRUCTION SPECIFICATION
CONCRETE REINFORCEMENT Issue No.: 3

1.0 SCOPE
1.1 This specification covers fabrication, supply, placing, testing and inspection
of steel bar and welded wire fabric reinforcing for construction at Titan
Petrochemical & Polymers, Johor.

1.2 Other works related to this specification are Concrete Work (ES-V-DR-
S007), Concrete Formwork (ES-V-DR-S009) and Anchor Bolts &
Embedded Items (ES-V-DR-S010).

2.0 APPLICABLE CODES, SPECIFICATIONS AND REFERENCES

The latest edition of the following codes and standards shall apply, unless otherwise
specified:

2.1 BS – British Standards

a) 4449 Specification for Hot Rolled Steel Bars for the

Reinforcement of Concrete

b) 4466 Bending Dimensions and Scheduling of Bars for the

Reinforcement of Concrete

c) 4482 Hard Drawn Mild Steel Wire for the Reinforcement of

Concrete

d) 4483 Steel Fabric for the Reinforcement of Concrete

2.2 When applying the various codes, the following priorities shall be observed:

a) The Laws and Regulations of Malaysia shall be complied with under all
circumstances.

b) While observing any limitation outlined in (a) above, construction shall

be carried out strictly in accordance with Titan specification and
drawings. In the case of conflict between this specification, relevant
drawings and referenced codes and standards, Titan documents shall
prevail.
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c) In the case of conflict between referenced codes and standards, Titan

will establish the order of priority.

2.3 The use of other codes and standards, such as Malaysian, Japanese,
equivalent to those listed may be proposed. Titan’s approval is required.

3.0 MATERIALS

General

3.1 All materials shall be approved by Titan.

3.2 As far as possible use only one source of supply for each material and for the
entire project.

3.3 Use materials in the same sequence as they are received at the Site. Oldest
materials shall be used first.

Submittals

3.4 The following documents shall be submitted for approval:

1) Samples

a) Bar supports : One of each type and grade

b) Splice devices : One of each type

2) Mill Certificates

Manufacturer’s certificate of mill analysis of each heat of steel used,

tensile, and bend tests.

Material Delivery, Handling and Storage

3.5 General

a) Use all means to protect the materials of this specification before and
during installation and to protect the work and materials of all other
trades.
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CONSTRUCTION SPECIFICATION
CONCRETE REINFORCEMENT Issue No.: 3

b) Ensure sufficient and continuous supply of all necessary materials

throughout the whole project to avoid interruptions or delays in the
work.

3.6 Delivery

Deliver reinforcement to the job site bundled, tagged and marked. Use metal
tags indicating bar size, grade and lengths.

3.7 Storage and Handling

a) Handle and store materials in a manner to prevent damage and

accumulation of dirt and excessive rust.

b) Stack reinforcing steel on wooden plank so that it is kept completely

clear from the ground. Protect reinforcing steel from rain.

c) Do not unload materials by free fall from trailers or trucks.

d) Do not drag materials against the ground.

Product Characteristics

3.8 Reinforcing Bars

Deformed Bars : BS 4449, Grade 460

Round Bars : BS 4449, Grade 250

3.9 Steel Fabric

BS 4483 and BS 4482

3.10 Supports for Reinforcement

Bolsters, chairs, spaces and other devices for spacing, supporting and
fastening reinforcement in place:

1) Use wire bar type supports. Do not use wood, brick and other
unacceptable materials.

2) For slabs on grade, use concrete spacer block where base material will
not support chair legs.
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3) For exposed-to-view concrete surfaces, where legs of supports are in

contact with forms, provide supports with either hot-dip galvanized or
plastic protected legs.

4) Welding of reinforcing bars is not acceptable.

3.11 Tie Wire

Annealed steel wire shall be used.

4.0 WORKMANSHIP

Fabrication

4.1 Clean reinforcement to remove loose rust and mill scale, earth, grease,
coating and any oil products.

4.2 Fabric reinforcing bars to conform to required shapes and dimensions. In the
case of fabrication errors, do not rebend or straighten reinforcement in a
manner that will injure or weaken the material.

4.3 Prepare and submit shop drawings in which sizes and dimensions for
fabrication and placing of reinforcing steel and bar supports are shown.
Indicate bar schedules, stirrup spacing and diagrams of bend bars,
arrangement and assemblies.

4.4 Reinforcement with any of the following defects will be rejected:

1) Bar lengths, depths and bends exceeding specified fabrication

tolerances.

2) Bend or kinks not indicated on drawings or final shop drawings.

3) Bars with reduced cross-section due to excessive rusting or other cause.

4.5 Allowable Tolerance

1) Cut off length : ±25 mm

2) Depth of truss bar : +0 – 15 mm

3) Overall dimensions of stirrups, ties and spirals : ±15 mm

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CONSTRUCTION SPECIFICATION
CONCRETE REINFORCEMENT Issue No.: 3

Installation

4.6 Examine the substrate, formwork and the conditions under which concrete
reinforcement is to be placed, and correct conditions which would prevent
proper and timely completion of the work. Do not proceed with the work
until unsatisfactory conditions have been corrected.

4.7 Reinforcement, at the time concrete is placed, shall be free from oil or
grease, loose rust or scale, or other coatings that will impair the bond.

4.8 Position, support and secure reinforcement against displacement by

formwork construction, or concrete placement operations. Locate and
support reinforcing by metal chairs, runners, bolsters, spacers and hangers, as
required.

4.9 Place reinforcement to obtain the minimum cover for concrete protection.
Arrange, space and securely tie bars and bar supports together with 16 gage
wire to hold reinforcement accurately in position during concrete placement
operations. Set wire ties so that twisted ends are directed away from exposed
concrete surfaces.

4.10 Wire Fabric (Wire Mesh)

1) Install welded wire fabric in length as long lengths as practicable. Lap

adjoining pieces at least one full mesh.

2) Do not make end laps midway between supporting beams, or directly

over beams of continuous structures.

3) Offset end laps in adjacent widths to prevent continuous laps.

4.11 Provide sufficient numbers of supports to carry reinforcement. Do not use

supports as bases for runways for concrete conveying equipment and similar
construction loads.

4.12 Move within allowable tolerances to avoid interference with other

reinforcing steel, conduits or embedded items. Wherever adjustment exceeds
allowable tolerance, ask Titan’s representative for directives before concrete
is placed.
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4.13 Do not heat, or cut bars without Titan’s approval.

4.14 Do not bend bars partially embedded in concrete

4.15 Make and locate splices as called for on the drawings.

4.16 Provide standard reinforcement splices by lapping ends, placing bars in

contact, and tightly typing with wire.

4.17 Cover

1) The cover to reinforcement shall be measured as the minimum distance

between the outermost reinforcement bar and the nearest permanent
surface of the concrete members, excluding finishes.

2) Unless otherwise specified on the drawings, the following minimum

concrete cover shall be provided for reinforcement. The minimum
concrete cover on the outer reinforcement shall be as follows:

i) Concrete cast against earth : 75 mm

ii) Concrete in contact with the ground : 50 mm

iii) Concrete exposed to weather : 40 mm

iv) Concrete neither exposed to weather : 30 mm

nor in contact with the ground

v) Concrete paving : 40 mm

4.18 Allowance Tolerances for Placement

1) Clearance from formed surface : ±5 mm

2) Spacing between bars : ±10 mm

3) Top bars in slabs and beams

a) Members 200 mm deep or less : ±5 mm

b) Members more than 200 mm : ±10 mm

but not over 600 mm deep

c) Members more than 600 mm deep : ±12 mm

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4) Maximum bar movement to avoid : 1 bar diameter

interference with other reinforcing
steel, conduits, or embedded items

5.0 TESTING AND INSPECTION

Testing
5.1 An analysis of each heat of steel shall be made by the manufacturer from test
samples taken during the pouring of the heats.

5.2 For each size rolled from each heat, one tension test and one bend test shall
be made by the manufacturer.

5.3 Titan may required supplementary testing of reinforcement delivered to site

to verify correctness of manufacturer’s test results.

Inspection

5.4 Before Installation

1) Verify that reinforcement is free of loose scale or rust and contaminants

that would reduce the bond with concrete.

2) Check that reinforcement is of the proper grade, quantity, size and length.

5.5 During Installation

1) Verify that reinforcement is placed within allowable tolerances.

2) Verify that bar supports are used where needed to secure reinforcement.

3) Check that lap splices are securely tied, and that splicing devices are
installed according to manufacturer’s instructions.

4) See that wire fabric is overlapped one full mesh at adjoining section, and
splices laced with wire.

5) Assure that wire fabric is not lapped mid-way between supporting beams
or directly over beams of continuous structures.
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5.6 After Installation

1) Check that reinforcement is kept in proper position during placement of

concrete.