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PATOQ

(Pre Activity Training &


Orientation on Quality)
Prepared by:
M.B. IDDARO
DCTC-PIC

Methodology of Rebar
Fabrication &
Installation

PURPOSE
The purpose of this method statement is to create awareness and
common tasks involved in executing the Rebar work (Reinforcements)
for concrete structures and to ensure the compliance of this activity with
the contract specifications and with EHS requirements.
This method statement shall be communicated and be understood by all
personnel associated with the task before commencing the activity.

SCOPE
This method statement deals with the (steel) rebar works in
building Foundations, Shear walls, Retaining walls, Columns &
Beams/Girders, Structural slabs, Concrete decks, staircases &
other applicable structural concrete elements of High Street South
Corporate Plaza Project. It includes preparation and fabrication of
reinforcements including bar bending and proper storing of
fabricated/un- fabricated items, hauling of fabricated items into
construction area, lifting, placing , installing & fixing of rebar ,
leveling and inspection of reinforcements.

RESPONSIBILITIES
Project Manager
Is responsible for the execution of this procedure.

Project In-charge
Is responsible for the site implementation of this procedure including
control and safety of the workers. He shall arrange Safe Working Plan,
and supervise the workforce so as to achieve the proper and
safe execution of work.

Site Engineer
Is responsible for site daily implementation and execution of this procedure.
He shall organize and manage all activities for the implementation of this
procedure. Protective measures and day-to-day activities.

QA / QC
Is responsible to manage the method statements, the progress,
distribution, and maintenance to the database.

General Foreman
Is responsible for site daily implementation and execution of
this
procedure. He shall organize and manage all activities in the
implementation of this procedure. Protective measures and
day-to-day
activities.

Safety Officer
Is responsible in the implementation of safe working
procedure and to
ensure all the health & safety precautions in place during
execution of
the job.

CUTTING LIST

Shop drawings and computations of rebar cut


length and bend taking into account a minimum
wastage on commercial length. Also considered as
value engineering. For shop drawings and
computations, it should be based on the approved For
Construction Drawings. It will be submitted for
correction/approval of the client/s and designers. In
these computations of rebar cutting lists, minimum
wastage is to be
considered from each commercial
length that will be used in
the project.

Only approved materials complying with the


standard specifications & requirements set by the
designer, duly noted by QA/QC inspector that it has
proper documentation
and passed a series of test
requirements indicating batch file numbers of
materials are to be use in the fabrication and
installation.

FABRICATION

Cut and fabricate reinforcement bars needed


for installation using the approved rebar cutting
list and staking plan as the basis. Prior to
fabrication, double check actual clear lengths
based on actual site condition with respect to the
approved cutting list, make adjustments as per
actual measurement if necessary.
The bar will be cut based on cut length from a
commercial length using a bar cutter. If the
bar needs to have a hook, it will be bended using
a bar bender until
the degree of bend will be
met. Note that each machine
has a maximum
bar diameter to be cut or bend. Bar
diameter
higher than the allowable diameter of the
machine should not be cut or bend on the machine

INSTALLATION

Haul fabricated bars from the fabrication area


to the site for installation. It will be assisted by a
mobile crane or a
tower crane. Hauling small
items such as ties and chair bars, an improvised
basket should be used.

Install necessary scaffoldings and lifelines


prior to installation of rebar especially at columns
and perimeter beams and girders. Use necessary
personal protective equipments such as safety
harnesses and gloves.

In installing reinforcement bars for mat


footings, bottoms
bars are to be installed first
then chair bars are to be position in place before
the top bars are installed.

The procedure of work for this Method Statement:


Foundation works (Footings)
A. Preparation
Check if the materials received at site coincides with Notice to deliver (NTD),
Fabrication Drawings/Lists and Stacking separators should be arranged precisely
with necessary tagging & numbering for materials fabricated off site.
Check that shop drawings (cutting list) & issued bar bending schedules has
been approved.
Check that all drawings are IFC & latest revision is available at site.
Fabricate re-bars as given in the approved drawings & schedules, then arrange
proper numbering/tagging with correct storage until deliver to construction place.

B. Execution

Provide work activity permit prior to start the activity.


Ensure that the area is ready for installation of the re-bars (lean concreted/with
gravel bedding and clean).
Layouts all column & wall positions on concrete & make ready for installation of
reinforcements.
Provide markings as per correct re-bar spacing prior to installation of bottom
bars.
Continue same procedure for every layer/set of re-bars to be installed with
necessary tie wires for fixing.
Provide chair bars as necessary in between bottom & top layers then start top
layer of reinforcements accordingly.

Install all starter bars for columns & walls composed on the said footing.
Follow the safe crane operations in loading & unloading of rebar on to the
foundation.
Check that necessary conduits, pipe sleeves & other embedded items have
been placed according to drawings & taken mechanical & electrical clearance (if
applicable).
Provide temporary access, clean outs in form works for easy rebar fixing &
tightening in the foundation.
In fixing, re-bars should be tied properly.

C. Inspection

Provide survey report.


Request for Inspection shall be submitted in advance as per approved Project
Quality Plan.
Any comment or minor changes must be rectified & re-inspection must follow
directly to attain the design & consultants
requirements.
Provide necessary checklist attached on request for inspection.

Verticals (Columns, Shear walls, Retaining walls, etc.


A. Preparation
Check if the steel received at site coincides with Notice to deliver (NTD),
Fabrication Drawings/Lists and Stacking separators should be arranged
precisely with necessary tagging & numbering (together with mill certificate).
Make sure that shop drawings (cutting list) & issued re-bar schedule has been
approved.
Check that all drawings are IFC & latest revision is available at site.
Fabricate re-bars as given in the approved drawings & schedules, then
arrange proper numbering /tagging with correct storage until deliver to
construction area.

B. Execution
Provide and check layouts making sure that the vertical structure is on its proper
location prior to installation of stirrups and splicing of verticals.
Scaffoldings and flat forms to be used must be inspected first to ensure safe
working condition especially in installation and fixing of stirrups and splicing bars.
Follow safe crane operations in lifting re-bars by tower crane.
Check size and no. of stirrups and splicing bars to be used as per approved shop
drawings.
Provide markings for correct spacing of stirrups prior to installation and fixing.
Make sure that diagonal bracing is provided before splicing of vertical bars.
Provide ties in all joints if necessary in fixing stirrups and splicing bars.
Align all vertical reinforcements, make sure verticality is obtained and provide
designated spacer blocks as required to maintain concrete covering.

Install all embed item if it requires as per drawings & obtain mechanical &
electrical clearance prior to inspection.

C. Inspection
Provide survey request/report.
Request for inspection must be submitted by QA/QC in advance as per
approved Project Quality Plan.
Provide necessary checklist attached to the request for inspection.
If has any comments or minor punch list it should be rectify directly to meet
correct design as per approved shop drawings and consultants requirements.

Standard & Tolerances


Tolerances in splicing of rebars & sleeve location (COLUMNS).
1. No pipe sleeve shall be allowed inside the column.
2.
Splicing shall be located at midspan. Or approved by the consultant a
nd designer.

Slabs & Beams/Girders

A. Preparation

Check if the steel received at site coincides with Notice to deliver (NTD),
Fabrication Drawings/Lists and Stacking separators should be arranged
precisely with necessary tagging & numbering (together with mill certificate).
Make sure that shop drawings (re-bar cutting lists) and re-bar schedule has
been approved.
Check that all drawings are IFC & latest revision is available at site.
Cut & bend re bars as given in drawings & schedules, then arrange proper
numbering /tagging with correct storage until deliver to construction area.

B. Execution
Check that necessary slab & beam form works, supports, level lines, Life lines
have been completed before installation of reinforcements on slab, beams and
girders.
Follow safe crane operations in lifting & unloading steel by tower crane. Also
follow the safety rules by making sure that scaffoldings, temporary access and
working flat forms are properly installed and have been inspected by EHS
supervisors.
Check for number of bars & bar sizes before installation.
Make sure that the number of main bars, extra bars, and stirrups are complete
before fixing prior to form closure.


Provide ties in all joints if necessary, chair bars on slab and make sure to put on
spacer blocks to maintain correct concrete covering.
Provide trimmer bars and diagonal bars on block outs, pipe sleeves, and slab
opening as required in consultant general specs.
Complete the reinforcement tying & joints, arranging cover blocks/ cover
spacers by laying the slab steel as per drawing & consultants requirement.

C. Inspection

Provide survey request/report.


Request for inspection must be submitted by QA/QC in advance as per
approved Project Quality Plan.
Provide necessary checklist attached to the request for inspection.
If has any comments or minor punch list it should be rectify directly to meet
correct design as per approved shop drawings and consultants requirements.

Standard & Tolerances


2.

No vertical sleeves nor pipe shall pass thru beams/girders.

3. Distance between two sleeves shall 4D.


D is the diameter of sleeve (larger sleeves govern).

Standard & Tolerances

4. Maximum diameter of sleeves shall be computed, 1/5 of beam depth.


5. No splicing at bottom shall (tension side) be located within 2D.
6. Splicing at top bar shall be located at the midspan.

Standard & Tolerances


Tolerances in splicing of rebars & sleeve location (BEAMS).
1. No pipe sleeve shall be allowed within the location of 2d.
-. D is depth of beam. And from the face of the support.

Standard & Tolerances


Reinforcing Steel Materials
1. Reinforcing Steel
-Shall be deformed bars bars for 10mm and above & around 8mm &
below.
- All reinforcing bars shall conform to grade 60 for diameter 12mm and
larger bars and grade 40 for the diameter and smaller bars.

Standard & Tolerances


2. Tie Wire (Galvanized)
- Gauge 18
double annealed wire.

3. Concrete Spacers
- see sample pictures.

Standard & Tolerances

Commercial sizes of steel reinforcements.


Size (diameter)

Unit wt.
(kg.)/meter

Length (meter)

10mm

.616

6,7.5, 9, 10.5, 12

12mm

.888

6,7.5, 9, 10.5, 12

16mm

1.579

6,7.5 ,9, 10.5, 12

20mm

2.466

6,7.5, 9, 10.5, 12

25mm

3.854

6,7.5, 9, 10.5, 12

28mm

4.833

6,7.5, 9, 10.5, 12

32mm

6.313

6,7.5,9, 10.5, 12

36mm

7.991

6,7.5,9, 10.5, 12

Standard & Tolerances


Sampling & Testing
General Notes: All steel bars must be properly identified as to heat number &
mill analysis.
1. All steel bars that cannot be identified by heat number and mill analysis
shall have one tensile and one bend test for each 2 tons thereof, each
size and kind of reinforcing steel.
2. Testing shall be yield and tensile stressing.

Equipment and Tools use in Rebarworks

Bar Cutter

Bar Bender

Steel Hook

Tower Crane

QUALITY
ASSURANCE

The fabrication and installation will be


strictly under the supervision of an
appointed rebar
supervisor/foreman/leadman to implement a
quality work. He will implement, monitor,
and check fabrication and installation
considering approved cutting lists, proper
housekeeping, and safety.
If there are comments by the management
on the work, it will be immediately be
rectified.

PARAMETERS

THE END