tmt bars every thing
TRANSCRIPT
REQUIREMENT OF HIGH STRENGTH BARS
Reinforced cement concrete (RCC) today has become an integral part of every structure, be it
a multi-storeyed building, a tunnel, a flyover, a TV tower, a bridge, a nuclear reactor, an
industrial unit or a residential apartment.
With RCC so much coming under use, the engineers are constantly striving to devise ways
and means to reduce its cost and bring economy in construction. Among its constituent
materials, RCC has steel as the costliest material accounting for 30 to 40% of the cost of
RCC. Therefore, the focus has been more on steel than on any other constituent material.
The need for reduction in the steel used for concrete reinforcement has prompted most
countries to switch to reinforcement bars of higher yield strengths of say 500 and 550 MPa
(& even higher).
The direct benefits (to customers) of using high reinforcement bars are:
¶ Reduced total weight of reinforcement bars leading to reduced cost to the customer.
¶ Reduced manpower for reinforcement fabrication.
¶ Lower transportation costs
PROBLEMS ASSOCIATED WITH HIGH STRENGTH BARS
Reinforcement Steel can be in the form of mild steel, medium tensile steel, high tensile steel,
deformed bars, high tensile steel wires, hard-drawn steel wire fabric, twisted steel fabric and
so on but the mild steel and the deformed bars have remained under most common use.
In the last 15-20 years demand for higher strength deformed bars has been increasing. The
most common of these bars is of strength grade Fe 415. Strength grade means the value of
yield stress or the 0.2% proof stress.
You may here recall the definitions of yield stress & proof stress; which are as below :
Yield Stress: Stress (i.e load per unit cross-sectional area) at which elongation first occurs
in the test piece without increasing the load in tensile test. In case of steel with no definite
yield point, proof stress is applicable.
0.2% Proof Stress: The stress at which the non-proportional elongation equal to 0.2% of the
original gauge length takes place.
In India, deformed bars for concrete reinforcement are being produced for many years. The
main processes for their production are hot rolling or hot rolling followed by cold twisting.
The increased yield strength was being first achieved by raising carbon & manganese and to
a great extent by cold twisting.
These cold twisted bars, though in extensive use at present, continue to have inherent
problem of inferior ductility, weldability and increased rate of corrosion due to presence of
residual stresses and higher carbon content. Additionally, cold twisting being labour
intensive, enhances cost of production with limitation on production rates.
Increasingly varied & innovative applications have resulted in growing demand for larger
diameter bars with similar strength, elongation, weldability and bendability as the small size
bars. Along with this, there is also a need for these steel bars to be welded and fabricated on
the site easily. For this strength & ductility have to be achieved at the lowest possible carbon
content. The most challenging requirement is to achieve all these superior properties at
relatively lower cost.
TECHNOLOGICAL DEVELOPMENTS IN PRODUCTION
PROCESSES OF HIGH STRENGTH BARS
In recent past, there have been two major technological developments in processes for
production of High Strength Deformed Bars. These are:
(i) Micro-alloying &
(ii) (ii) TMT process; which are discussed below:
Micro-alloying with Nb, V, Ti & B, in combination or individually helps in meeting most of
these requirements and producing High strength reinforcement bars having yield strength of
500 and 550 MPa. Production of reinforcement bars by the addition of micro-alloys gives the
desired results of high strengths but at a cost, which is prohibitive. Moreover, the achieved
ductility is also low.
The need for cutting down the cost of production of high strength reinforcement bars
initiated the involvement of a more economical and competitive process -- the so called
Thermo Mechanical Treatment (TMT) Process. The Thermo Mechanically Treated bars are
generally called TMT bars. These bars owe their advantage to their composite micro-
structure, which is a soft and ductile ferrito-pearlitic core and a tough surface rim of
tempered martensite.
The use of Thermo Mechanical Treatment process has not only helped produce
reinforcement bars of high yield strength but also having superior ductility, weldability,
bendability & better corrosion resisting properties.
COMPARISON OF DIFFERENT PROCESSES FOR PRODUCTION OF
HIGH STRENGTH REBARS
Comparative features of the three main processes for production of High Strength Deformed Bars viz
(i) Cold Twisting ,
(ii) Micro-alloying &
(iii) TMT process are tabulated below:
S. No. Production
process
Treatment Production
Costs
Mechanical Properties
Ductility Weld-ability
1 Cold Twisting Cold work
hardening by
means of:
¶Stretching
¶ Twisting
High (Due to
Manpower and
Equipment)
Poor Good
(deteriorating
due to heat
generated by
welding)
2 Micro- Alloying Addition of
alloying
elements as: C,
Mn, V, Nb etc.
High (Due to
alloying
elements and
equipment)
Good Poor (Due to
high carbon
equivalent)
3 TMT Process Rapid cooling
and controlled
cooling from
rolling heat
Low Excellent Excellent (Due
to low carbon
equivalent)
The TMT bars have virtually replaced the conventional cold twisted deformed bars as reinforcement
material all over the world. With the increasing availability of TMT bars here, India is also set to
change over to the use of TMT bars.
TMT BARS MANUFACTURING PROCESS
Under thermo mechanical treatment, the steel bars are passed through a specially designed
water-cooling system (TMT box) where they are kept till the outer surface of the bars
becomes colder while the core remains hot. This creates a temperature gradient in the bars.
After the intensive cooling, the bar is exposed to air and the core re-heats the quenched
surface layer by conduction, therefore tempering the external martensite. When the bars are
taken out of the cooling system, the heat flows from the core to the outer surface, further
tempering of the bars, which helps them attain a higher yield strength. The resulting heat-
treated structure imparts superior strength and toughness to the bars. Cooling process is
illustrated below:
The pre-determined cooling of the bar periphery transforms the peripheral structure to
martensite and then annealed through the heat available at the core. The peripheral and core
temperature difference finally equalises at around 600 0C and the resultant bar structure is of
tempered martensite at the periphery and of fine-grained ferrite-pearlite at the core.
Generally speaking, the resultant soft core forms about 65-75 per cent of the area (depending
upon the desired minimum yield strength) and the rest is the hardened periphery. The
equalizing temperature together with the final rolling temperature is the most important
parameter to achieve the required mechanical properties.
Finally, when the bar is discharged on to the Cooling Beds, the remaining austenite
transforms into a very fine-grained pearlite structure.
The figure below illustrates a typical TMT bar manufacturing process:
After this process of thermo mechanical treatment, a dark etched peripheral rim of tempered
martensite and a grey core of ferrite pearlite get formed. The tempered martensite surface
layer is very hard while the microstructure of the core is a very fine-grained ferrite and
pearlite which is quite soft. The result is a structure with a high yield strength combined with
high ductility.
Microstructure of TMT bar showing peripheral rim of
tempered martensite & core of ferrite pearlite get
formed.
Tempered Martensite Rim
Ferrite-Pearlite core
TMT bars are also known as 'Quenched and Tempered rebars', because of the quenching and
tempering processes involved in making the bars.
The production of quality TMT bar depends on three major factors - quality of raw materials,
a properly designed and automated mill, and a well-designed quenching and tempering
technology.
TMT bars having uniform and concentrated hardened periphery and the softer core will have
the desired tensile strengths coupled with high elongation as required in seismic zones.
Depending on the size and grade, rebars with hardened periphery of about 15 to 30 per cent
of the cross sectional area of the bar are ideal for civil constructions (constructions of houses,
offices, etc.)
TMT Box
Pinion Gear Box
The pinion gear box used here are manufactured by "AMT". These are manufactured by
using the tested steel plates procured from main steel producers of the country and are joined
by automatic welding equipment and stress relieved. The gears and pinions used are
manufactured out of tested engineering quality forged steel and duly machined and tooth cut
and grounded and hardened .The bearings used are double spherical roller bearings and
double oil seals are used to avoid leakage of oil and inbuilt oil lubrication system is fitted for
oil bath of gears and bearings. Air breathers are also fitted to allow vent and intake of fresh
air.
Technical Specifications:
3 Hi and 2 Hi Pinion Gear Boxes, Low Speed and High speed type.
4 Hi Gear Boxes for Cold Rolling Mills.
Speed Increaser cum Pinion gear Boxes.
Gear Boxes suitable for 200 HP to 2000 HP Drives.
Gear Boxes suitable for 150mm PCD to 600mm PCD Mills.
Speed Range 50 R.P.M. to 750 R.P.M.
Salient features:
Torsionally Rigid Steel Fabricated Body designed to Dampen vibrations.
Double Hellical Gears made of En-9, En-19, or En-24 quality Steel Forgings. Duly
Hardened and grounded.
Amply Rated Bearings to work efficiently at Peak Loads.
Double Oil Seals fitted on Shaft extensions.
Lubrication lines for Bearings and Oil Splash system for gears are provided.
ADVANTAGES AND APPLICATIONS OF TMT BARS
Advantages
i. Better Safety of structures: because of higher Strength combined with
higher Ductility.
ii. Easy working at site: owing to better Ductility and Bendability. Pre-welded
meshes can be made to eliminate manual binding at site. Reduces
construction and fabrication time.
iii. Resists fire: Unlike Tor steel/ CTD Reinforcement bars, TMT bars have high
thermal stability. They are the preferred choice when elevated temperatures
of 400-6000 C may be encountered (Chimneys, fires).
iv. Resists corrosion: The TMT process gives the bar superior strength and
anti-corrosive properties. Controlled water-cooling prevents the formation of
coarse carbides, which has been cited as the main cause for the corrosive
nature of common bar.
Another reason for better corrosion resistance is the absence of surface
stresses caused by the cold twisting process.
Figure above shows view of Platform during rainy season which clearly shows the difference
between quality of CTD & TMT Bars
v. Formability: Due to very high elongation values and consistent properties
throughout the length of bar, TMT rebars have excellent workability and
bendability.
vi. Earthquake resistance: The soft ferrite-pearlite core enables the bar to bear
dynamic and seismic loading. TMT bars have high fatigue resistance to
Dynamic/ Seismic loads due to its higher ductility quality. This makes them
most suitable for use in earthquake prone areas.
vii. Malleability: TMT bars are most preferred because of their flexible nature
viii. Fine welding features: TMT rebars (having low carbon content) can be
used for butt and other weld joints without reduction in strength at the weld
joints.
ix. Bonding strength: External ribs running across the entire length of the TMT
bar give superior bonding strength between the bar and the concrete. Fulfils
Bond requirements as per IS: 456/78 and IS: 1786/85.
x. Cost-effective: A high tensile strength and better elongation value gives you
great savings, Reduced Transportation Costs. .
Applications
TMT bars find wide applications in different spheres:
i. General purpose concrete re-enforcement structures
ii. Bridges
iii. Flyovers
iv. Dams
v. High rise buildings
vi. Industrial structures
vii. Concrete roads
viii. Underground structures