TORKARI HI GRADE STEEL TOR 55 GRADE STEEL

TORKARI - HI GRADE STEEL TOR – 55 GRADE STEEL ( Fe-550 grade)

TORKARI- THE WONDER BAR NEW GENERATION STEEL REINFORCEMENT FROM TORSTEEL GROUP. THE SPINE IN CONCRETE MEMBERS.

What is TORKARI IS A HIGH STRENGTH AND HIGH BOND REINFORCING STEEL CONFORMING TO Fe 550 Grade ( Tor 55) of IS 1786 -2008. TORKARI WAS INTRODUCED IN INDIA BY TRFI IN 1987. q. SMALLER q. STRONGER q. ECONOMICAL

The Company PROSTEEL INDUSTRIES üCommenced Operations in 1996. üFactory at SIPCOT COMPLEX, Gummidipoondi (45 kms from Chennai) üProduction Capacity: 1000 tons per month. üIn house testing facilities ( QC lab) üRegularly supplying to all the builders üManaged by technically qualified personnel

About TRFI The Parent Company viz. Tor-Isteg Steel Corporation of Luxemburg are the inventors of TOR STEEL BARS viz. Tor-40, Tor-50 -- TOR - STEEL, TOR-ALLOY Tor-55 – TOR. KARI TOR IS A REGISTERED BRAND NAME OF TRFI.

The Technology Superior and Latest BAUSTAHLGEWEBE Technology ( German) This technology permits the production of smaller diameter bars having superior strength and bond properties than even Torsteel ( Fe-415 and Fe 500 grade steel)

The Raw Material LOW CARBON STEEL WIRE ROD COILS – conforming to IS: 226, 2062, 7887, SWR 14, SAE 10101015 ( ASTM Standards) These WRC are locally available with RINL (VSP), JSW Steels, SAIL and Tisco. They are also imported from China, Turkey, Indonesia. MADE FROM 100% GENUINE BILLETS.

Manufacturing Process TORKARI IS MANUFACTURED BY SIMULTANEOUS COLD FLATENNING AND COLD RIBBING PROCESS.

Manufacture of Torkari steel by Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s). Drawing is usually performed at room temperature, thus classified as a cold working process.

Process Flow Chart - 1 Raw Material WRCoils DESCALAR MACHINE TORKARI DRAWING MACHINE BULL BLOCK TORKARI STEEL IN COIL FORM.

TORKARI COILS BEFORE STRAIGHTENING

Process Flow Chart - 2 BULL BLOCK TORKARI BUNDLES – 12. 15 mts ( 40 ft-U Bend) STRAIGHTENING AND CUTTING MACHINE BENDING AND BUNDLING

Sizes of Torkari 5 mm Dia 6 mm Dia 7 mm Dia 9 mm Dia

Torkari - Data Nominal Permitted nal Weight range of Dia weight Kg/m kg/m Mm 5. 0 0. 154 0. 142 to 0. 166 7. 0 0. 302 0. 278 to 0. 326 9. 0 0. 500 0. 459 to 0. 539 Range of Ast length Sq. m Mts/MT m 6007 to 7052 3065 to 3598 1854 to 2177 19. 63 38. 48 63. 62

BIS The Hi-tech Steel Advantage TORKARI CONFORMS TO ALL CHEMICAL AND PHYSICAL PROPERTIES FOR GRADE – 550 OF IS: 1786 – 2008.

TORKARI - STANDARDS TORKARI ALSO CONFORMS TO INTERNATIONAL STANDARDS LIKE • DIN – 488 ( GERMANY) • BS – 4483, 4449( UK) • ASTM – A 497 ( AMERICAN)

Chemical Properties of TORKARI Parameters IS Requirements Torkari specs Carbon 0. 30% Max Sulphur 0. 055% Max. 0. 050% Max Phosphorus 0. 050% Max. 0. 045% Max Sul+Phos 0. 10% Max. 0. 090% Max. 0. 20% Max

TORKARI WELDMESH v. Torkari Fe-550 grade steel will satisfy all the physical and chemical parameters as per IS 1786 -2008 for Fe-550 grade steel. v. We can also Torkari steel will also satisfy the requirements of grade B 500 A as per BS 4449: 2009 for yield strength of 500 mpa and tensile strength/yield ratio of 1. 02 for sizes below 8 mm and 1. 05 for sizes above 8 mm. The elongation will be min 14. 5% to satisfy the BIS earthquake code for ductile detailing. v. Torkari will satisfy the chemical requirement of B 500 A as per BS 4449: 2009 wherein the max carbon content is 0. 22% and carbon eq is 0. 42%. v. Our internal production process will limit the carbon content to 0. 18% hence ensuring fast and guaranteed weldability. v. The Weldmesh manufactured with the above specs will satisfy the requirement of BS 4483 for weld mesh and also relevant Indian standards. v. The available sizes of Torkari steel will be 5, 6, 7, 8, 9 mm and it will be supplied

Physical Properties of TORKARI Parameters IS Requirements Torkari specs 550 N/sq. mm (Min. ) Passes Ultimate Tensile Strength 585 N/sq. mm (Min. ) Or 1. 06 X Act P. S whichever is higher Passes Elongation 10% Min. Above 13% Bond Strength ( Extra Over Plain Round) 60% Min. over Mild Steel Above 100% Weight Tolerance + or – 7% + or - 4% 0. 2% Proof Stress (P. S)

Advantages of using TORKARI üThe Quality Advantage üThe Cost Advantage üThe Size Advantage

The Quality Advantage l. Superior Strength fy = 550 N/sq. mm. Ultimate = 585 N/sq. mm Over 30% when compared to Tor 40 or Fe-415 where fy=415 N/sq. mm viz. 550/415 = 1. 33 times.

The Quality Advantage l High Bond Properties Torkari is Tri-Ribbed viz. Rib on three sides. TMT and TOR-40 have ribs only on two sides. Even 5 mm TORKARI has ribs whereas 6 mm MS is plain. Bond strength is over 100%. LESSER CRACK WIDTH DUE TO HIGH BOND.

Rolling Tolerance q SINCE THE STRENGTH IS MORE , IT RESULTS IN LESS AREA OF REINFORCEMENT, THUS REDUCING CONGESTION OF REINFORCEMENT. q. AS PER IS CODE THE ACCEPTABLE ROLLING TOLERANCE IS 7%. IN TORKARI DUE TO ITS SUPERIOR TECHNOLOGY THE ROLLING TOLERANCE IS RESTRICTED TO 4%

Easily Weldable 100% Weldability As it is made from ØLow carbon mild steel with carbon less than 0. 20%, it can be welded by metal arc welding process with normal electrodes. Ø Most suitable for making fused weld mesh due to its low carbon content

Easily Weldable CTD, TMT ( local rerollers)bars and 6 mm MS are usually rerolled from scrap / ingots where the carbon content is not controlled. In fact the main reason for breakage during bending is due to rolling from scrap and high carbon content.

Other Quality Advantages l Better fatigue strength. l Advanced German Technology. l Built in high creep resistance through adequate cold working. l TRFI guidance and certification. l Well equipped QC lab at factory. Clients witness of testing can be arranged before despatch. l Can be used with any grade of Concrete

THE SIZE ADVANTAGE Smaller diameters from 5 mm onwards. � Available in 5 mm, 6 mm, 7 mm and 9 mm in Fe 550 grade � Custom sizes eg. 5. 25 mm, 6. 25 mm, 7. 25 mm can also be manufacterd as per grade B 500 A as per BS 4449 : 2009 � 5 mm TORKARI can be used in place of 6 mm MS. � 7 mm TORKARI can be used in place of 8 mm Tor-40. � 9 mm TORKARI can be used in place of 10 mm Tor-40. �

As minimum reinforcement l l l In slabs only 8 mm Fe-415/Fe-500 is used in most cases as it is the minimum dia available. As per IS the max. spacing is 3 d for main reinforcement and 5 d for distribution steel / temperature reinforcement. ( d – eff. Depth) Due to design conditions and slab thickness the max. spacing of 8 mm in slabs is restricted to 250 mm. The minimum reinforcement as per code is 0. 12% Ast whereas the above works out to 0. 17% Ast. If 7 mm Torkari is used the savings is nearly 30% in quantity of steel and it satisfies 0. 12% Ast.

5 mm in place of 8 mm Tor-40. Due to the poor quality of 6 mm MS which is rerolled from scrap most of the consultants recommend 8 mm Tor-40. In those areas where 6 mm MS would suffice but 8 mm Tor-40 is used we can implement 5 mm Torkari. In a 110 mm slab the spacing of 8 mm is limited to 250 mm since the max. spacing as per IS is 3 d.

USE OF TORKARI IN SLABS ü TORKARI CAN BE USED AS MAIN REINFORCEMENT IN SLABS. ü IT GOES WELL WITH ALL GRADES OF CONCRETE. ü BEING AVAILABE IN SMALLER SIZES IT CAN BE ECONOMICALLY USED AS DISTRIBUTION STEELS IN SLABS AT 0. 12% OF GROSS AREA OF CONCRETE.

USE OF TORKARI AS STIRRUPS IN BEAMS § TORKARI CAN BE USED AS STIRRUPS IN BEAMS § AS PER IS 456 FOR DESIGN OF SHEAR STIRRUPS THE DESIGN STRESS SHOULD BE LIMITED TO Fe 415. § HOWEVER CONSIDERING THAT SHEAR REINFORCEMENT IS STRESSED IN TENSION ONLY TO RESIST DIAGONAL TENSION IT SHOULD BE PERMITTED TO DESIGN SHEAR STIRRUPS UPTO 0. 2% PROOF STRESS VIZ. 550 FOR TORKARI. § DESIGN OF TORKARI STIRRUPS FROM Fe-415 STEEL AND 6 MM MS CAN BE EASILY CONVERTED AS PER THE SUBSTITUTION CHART. § 5, 7 AND 9 mm TORKARI CAN BE USED AS A DIRECT SUBSTITUTION FOR 6 mm MS, 8 AND 10 mm Tor-40 RESPECTIVELY.

OTHER USES OF TORKARI v RC Walls, Lift walls, Shear Walls, Waffle Slabs v Thermal Reinforcement in PT slabs , v LINTELS, SUNSHADES, LOFTS v PREFAB STRUCTURES. v PAVINGS v PRECAST SLABS v GROUND RESTING SLABS v SPIRAL AND LONGITUDIONAL REINFORCEMENTS IN RAILWAY SLEEPERS AND HUME PIPES. v WATER RETAINING STRUCTURES. v SKIN REINFORCEMENT IN BASEMENT WALLS, SUMPS, WATER RETAINING STRUCTURES. v TEMPERATURE REINFORCEMENT FOR CAR PARKS, RUNWAYS, FACTORY FLOORS, FINS etc

Savings in Steel SAVINGS IN STEEL CONSUMPTION BASED ON PROOF OR YIELD STRENGTH OF STEEL 1 MT OF TORKARI REPLACES 1. 33 MT OF TMT 1 MT OF TORKARI REPLACES 2. 42 MT OF MS ( Fe-250)

QUANTITY SAVINGS CHART SLABS TORKARI TMT 415/500 BASED ON PROOF OR YIELD STRENGHT 1 MT 1. 325 MT Slab Thickness Based on Min. Area of Steel , Min. dia available and Max. spacing permitted 100 mm 1 MT 1. 57 MT 120 mm 1 MT 1. 47 MT

Substitution Chart based on Strength Considerations. TMT TORKARI 8 mm @ spacing S mm 7 mm @ spacing S mm 10 mm @ spacing S mm 9 mm @ spacing 1. 07 Smm or 8. 5 mm @ spacing S mm. 12 mm @ spacing S mm 9 mm @ 0. 75 S mm 16 mm @ spacing S mm 9 mm @ 0. 42 S mm.

Substitution Chart for Distribution Steel in Slabs From Original Design with Convert to 8 mm Fe-415 7 mm TORKARI with no change in spacing 6 mm MS 5 mm TORKARI with no change in spacing

CONVERSION TO TORKARI STIRRUPS CONVERT FROM CONVERT TO TORKARI Grade of Steel Dia & spacing of stirrups Based on restricted Based on Actual Characteristic strength proof strength of of 415 N/sq. mm 550 N/sq. mm Fe-415 TMT/TOR 8 mm @ S mm c/c 7 mm @ 0. 77 S mm c/c 7 mm @ S mm c/c Fe-415 TMT / TOR 10 mm @ S mm c/c 9 mm @ 0. 8 S mm c/c 9 mm @ 1. 07 S mm c/c Fe-415 TMT / TOR 12 mm @ S mm c/c 9 mm @ 0. 56 S mm c/c 9 mm @ 0. 74 S mm c/c MS Fe-250 5, 6, 6. 5 or 7 mm @ S c/c 5 mm @ S mm c/c

CONVERSION TO COLUMN TIES From Original Design with Convert to Remarks 8 mm Fe-415 7 mm Torkari with no change in spacing 5 mm Torkari with no change in spacing This conversion ensures atleast same strength as with original design 7, 6. 5, 6 mm MS Fe-250

COST SAVINGS AS PER DESIGN BASED ON PROOF OR YIELD STRENGHT LANDED COST / TON COST SAVINGS PMT TORKARI TMT 415/500 1 MT 1. 325 MT 47000 40000 47000 53000 6000

DIRECT SUBSTITUTION Cost savings chart PRICE COMPARISON ( PRICES AS ON 23. 02. 2015) TORKARI Vs TMT ( Secondary quality ) 1 2 3 Details Dia Eqlnt. Noml. Length Qty Wt/mtr Mtr/ton Tons. TMT 10 9 8 7 6 5 0. 617 0. 485 0. 395 0. 302 0. 222 0. 154 TORKARI TMT TORKARI MS TORKARI 1621 2062 2532 3311 4505 6494 1. 272 1. 000 1. 308 1. 000 1. 442 1. 000 Landed Net Your Net Cost per % of Cost/MT for Savings ton excl Savings* equal qty per ton(Rs) octroi 40000 47000 41000 47000 39000 47000 50880 47000 53628 47000 56238 47000 3880 8. 26% 6628 14. 10% 9238 19. 66%

COST SAVINGS IN A TYPICAL 4 m X 4 m TWO WAY SLAB PANEL 7 mm Torkari vs 8 mm TMT Spacing as per design No of rods for 4 mt span Weight in kgs Landed cost per ton Total Cost in Rs. CONVENTIONAL DESIGN USING 8 mm TMT @200 mm c/c 168 66. 360 41000 2720. 76 DESIGN USING 7 mm TORKARI ( Fe-550) grade steel 7 mm Torkari @200 mm c/c 168 50. 736 47000 2384. 592 Savings 336. 168 %age Savings per ton in Rs 12. 36% 5, 065. 82

9 mm Torkari vs 10 mm TMT Spacing as per design No of rods for 4 mt span Weight in kgs Landed Cost pmt Total Cost in Rs. CONVENTIONAL DESIGN USING 10 mm TMT @200 mm c/c 168 103. 7 40000 4146. 24 DESIGN USING 9 mm TORKARI ( Fe-550) grade steel 9 mm Torkari @200 mm c/c 168 80. 64 47000 3790. 08 Savings %age Savings per ton in Rs 356. 16 8. 59% 3, 435. 98

COST SAVINGS

ADVANTAGES OF TORKARI RIBBED BAR WELDMESH VS TMT WELD MESH TORKARI TMT � Low carbon <0. 18 � Carbon content 0. 18 -0. 30 � Can be easily welded with min loss of tensile strength. Cost of welding low since low welding time reqd � Available in 5 mm, 6 mm, 7 mm and 9 mm in Fe-550 grade as per IS 1786. Cost savings can be optimized with standardized spacings Available from 8 mm onwards. Hence cost savings cannot be optimized since spacing is limited in design

TORKARI vs TMT weldmesh Torkari TMT � Customized dia like �TMT not possible 5. 25 mm, 6. 25 mm etc is possible for B 500 A as per BS 4449 standards � Cold drawn ribbed steel and hence most suitable for fusion bonded weldmesh � Can be supplied in coil form to minimize wastage at site. Additional cost savings �Hot rolled. Not suitable for fusion bonded weld mesh due to mill scales. �Coil form only from main producers where cost is higher

WELD MESH COST COMPARISION CHART PROJECT: TYPICAL 4 m X 4 m TWO WAY SLAB PANEL 1. SAVINGS DUE TO MATERIAL. Spacing of weldmesh No of rods as for 4 mt span per design Weight in kgs Landed cost per ton Total Cost in Rs. CONVENTIONAL DESIGN USING 8 mm HD wire 8 mm plain @200 mm c/c 168 66. 36 50000 3318 DESIGN USING 7 mm TORKARI ( Fe-550) grade steel 7 mm Torkari @200 mm c/c 168 50. 736 56000 2841. 216 Savings %age Savings per ton in Rs 476. 784 14. 37% 7, 184. 81

L&T – SERENE COUNTY, HYDERABAD

PROJECT CASE STUDY – GREEN ACRES ( 2005) S. No Tor-40 Wt/Mtr Qty. mt Rate/mt Amount 1 6 mm MS 0. 250 8. 25 25480 204600 2 8 mm 0. 395 33. 50 26000 871000 3 10 mm 0. 617 2. 5 25600 64000 TOTAL 44. 250 11, 39, 600 4 5 mm Tk 0. 154 5. 082 30100 152968 5 7 mm Tk 0. 302 25. 613 29400 753012 6 8 mm Tk 0. 500 2. 026 29400 59562 TOTAL 32. 721 9, 65, 542 TOTAL SAVINGS PER BLOCK 1, 74, 057 SAVINGS FOR 21 BLOCKS 36. 50 lakhs

A FEW OTHER PRESTIGOUS PROJECTS Ø Ø Ø Ø Opaline Project of M/s Olympia Infra Tech. OMR, Chennai ( On going) M/s Eden Park – South City Project, OMR, Chennai. ( On going) Polaris Software Lab. (Phase I and Phase II) at Navallur, OMR, Chennai Dalmia Cements expansion project at Dalmiapuram, Tiruchy. Mass Housing project ( 6087 flats) for MMRDA at Mankhurd, Mumbai. L&T – Mantri @ Commerce Job at Bangalore. BMS College of Engineering, Bangalore. Golden City Project for Kalki Bhagwan Trust. TADA, AP. Taj Hotel Project at Bangalore. SAP labs project at Bangalore. Jains Inselli Park at Padur, OMR, Chennai. ( On going) Tsunami Rehab project for Tamilnadu housing board at Ennore, Chennai. M/s L&T – Infotec II at Manapakkam, Chennai. M/s L&T-EDRC building and Centenary building project at Chennai.

IN A NUTSHELL Ø 6 mm MS, 8 mm and 10 mm Tor-40 can be totally eliminated and can be substituted by 5 mm, 7 mm and 9 mm TORKARI. Ø The above can be adopted at any stage of the project even if the designs are prepared with Tor-40 since Only direct substitution is needed. Ø THE ABOVE CAN BE ADOPTED IRRESPECTIVE OF THE AREA OF USAGE, GRADE OF CONCRETE, THICKENESS OF MEMBER.

CONCLUSION v. BY USING TORKARI STEEL RODS v. QUANTITY SAVINGS OF 20 -30%. v. COST SAVINGS OF 8 -12%

Torkari – Design Handbook