Questions You Should Know about Steel Reinforcement Suppliers

Concrete is one of the most common construction materials. Because of its durability, low maintenance requirements, fire resistance, and ease of use, people all over the world use concrete for many projects.

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But concrete has one potentially fatal flaw. If concrete is under a particular type of force, it will break'quickly.

Thankfully, there's a way to combat that fatal flaw: use reinforcement, such as rebar.

Here at Gra-Rock, we carry a full line of concrete reinforcement supplies, including rebar, because we understand how catastrophic it can be if your concreteisn't properly reinforced!

In this article, we'll explain why reinforcement is necessary and how to reinforce concrete using rebar.

Let's get started!

Why Does Concrete Require Rebar?

Most concrete requires some type of reinforcement.

Why?

While concrete is very strong in some ways, it also has a few devastating weaknesses. But to understand these weaknesses, we first need to understand the different types of stress that can be placed on objects.

1. Compressive stress. Compressive stress is a force that is placed upon an object that shortens or compresses the object. For example, if an elephant steps on your toe, you will experience compressive stress.

2. Shear stress. Shear stress occurs when forces are applied perpendicularly to one another. If you lock your fingers together and pull against yourself, you are experiencing shear stress.

3. Tensile stress. Tensile stress is a force exerted on an object that lengthens or stretches that object. When you swing on a rope swing and jump into a swimming hole, you exert tensile stress on the rope.

Concrete is very strong under compressive stress and shear stress, but it performs poorly under tensile strength. In fact, the tensile strength of concrete is only about 10-15% of its compressive strength.

Enter rebar.

Rebar is used primarily to increase the tensile strength of concrete.

(To learn more about concrete strength, read our related blog post: Understanding Concrete Strength: From PSI To Tips For Pouring Concrete)

What Is Concrete Rebar?

Rebar(short for reinforcing bar) is a steel rod used to strengthen concrete.

The rods come in various lengths and thicknesses and usually have ridges or bumps, so they bond well with the concrete.

Rebar is made from steel. Steel is very strong and expands and contracts in changingtemperatures at nearly the same rate as concrete.

What Does Rebar Do For Concrete?

As we already mentioned, concrete handles compressive stress well but does poorly under tensile strength.

Since almost every structure experiences more than one force acting on it, this is a problem.

Take, for example, the classic beam.

When a beam experiences compressive stress on the top, it bends. And when a beam bends from compressive stress on the top, the beam's bottom stretches.

That means the bottom of the beam experiences tensile stress.

So, since concrete doesn't do well with tensile stress, it doesn't always make a good structural material on its own.

But, when we add rebar, two things happen.

First: When rebar is placed in concrete, it creates a composite material. The concrete protects against compressive stress, and the rebar protects against tensile stress. This composite material is extremely strong.

In fact, concrete that includes rebar has a breaking point nearly double that of concrete without rebar.

Second: When rebar is placed in concrete, it gives warning signs before the concrete breaks apart completely.

Concrete without rebar is considered brittle. As the pressure increases on pure concrete, it will suddenly break without warning.

On the other hand, concrete that includes rebar is considered ductile. That means that as pressure increases, small fissures and cracks can be seen forming in the concrete.

This is positive in two ways:

• Concrete that contains rebar remains strong even with small cracks

• There is a warning signal before the concrete completely fails.

When is Rebar Necessary?

Does every single concrete job need rebar?

Not necessarily.

Concrete surfaces that support large trucks, heavy machinery, or steady traffic need concrete rebar reinforcement, and any structural concrete, like walls in buildings, should definitely include rebar.

But if you're pouring a concrete driveway as a place to park your family minivan, heavy reinforcement using rebar may be overkill.

When in doubt, though, use rebar. No matter how large or small the concrete pour is that you are doing, rebar will make your concrete stronger. At the very least, rebar will dramatically decrease the number of cracks in the concrete.

Bonus tip: If you are doing a small residential concrete bar and steel rebar rods feel like overkill, you can use welded wire fabric. Mesh is thinner than rebar, so it's not as strong, but it's also cheaper.

8 Main Types of Rebar

As we just discussed, welded wire fabric is a type of rebar ideal for certain applications.

Maybe you're wondering: Are there other types of rebar that are ideal for specific situations?

Yes, there are!

Here are some of the different types of rebar you may wish to use.

Carbon Steel Rebar: This is the most common type of rebar and is sometimes referred to as a "black bar." It's incredibly versatile but corrodes more easily than other types. This makes it less than ideal for areas that are subject to high humidity or in structures frequently exposed to water.

Welded Wire Fabric: Welded wire fabric (WWF) is made from a series of steel wires arranged at right angles and electrically welded at all steel wire crossings.

It is useful in slab-on-ground slabs where the ground has been well compacted. A heavier fabrication of welded wire fabric can be used in walls and structural floor slabs. This is commonly used in road pavement, box culverts, drainage structures, and small concrete canals.

Epoxy-Coated Rebar: Epoxy-coated rebars are simply rebars coated with a thin layer of epoxy. This makes them up to 1,700 more times resistant to corrosion than standard carbon steel rebars. As a result, they are often used in areas in contact with salt water or where a corrosion problem is imminent.

The only problem is that the coating can be very delicate, so bars should be ordered from a reputable supplier.

A particular concern with epoxy-coated rebars is that they can be susceptible to severe corrosion. If the epoxy is damaged in small spots, all the corrosion is concentrated in that one spot.

Galvanized Rebar: Galvanized rebars are 40 times more resistant to corrosion than carbon steel rebars, and they are much harder to damage than epoxy-coated rebars.

This makes it an excellent alternative to epoxy-coated rebars if you need something less prone to corrosion.

Unfortunately, galvanized rebar is about 40% more expensive than epoxy-coated rebar.

Sheet-Metal Reinforcing Bars:Sheet-metal reinforcement is commonly used in floor slabs, stairs, and roof construction. Sheet-metal reinforcing bars are composed of annealed sheet steel pieces bent into corrugations about one-sixteenth of an inch deep with holes punched at regular intervals.

European Rebar:The advantage of European rebar is its low cost. European rebar is made primarily of manganese, which makes it cheap and easy to bend.

This flexibility makes European rebar easy to work with, but it's generally not recommended for areas that experience earthquakes or for projects that require substantial structural integrity from its rebar.

Stainless Steel Rebar:Stainless steel rebar is quite expensive - about eight times the price of epoxy-coated rebar!

It is the highest quality rebar available for most projects. However, using stainless steel in all but the most unique of circumstances is often overkill, not to mention very expensive!

But, for those who have a reason to use it, stainless steel rebars are 1,500 times more resistant to corrosion than black bars. Stainless steel rebars can also be bent in the field, which is very convenient.

Are you interested in learning more about Steel Reinforcement Suppliers? Contact us today to secure an expert consultation!

Glass-Fiber-Reinforced-Polymer (GFRP) Rebar: Like carbon fiber, GFRP rebars will not corrode ' ever, under any conditions. But that feature comes at a significant cost. These rebars can run at ten times the cost of epoxy-coated rebars!

If you read over that list of rebar types and still have questions about which one is best for your project, that's ok. Reach out to a rebar manufacturer or local concrete provider to get advice on which kind of rebar you should be using.

Choosing the Right Size of Rebar

There aren't just different types of rebar; there are also different sizes of rebar!

The size of the rebar you'll use for a particular job depends on the amount of strength you need. When you need more strength, you'll use bigger pieces of rebar.

In the United States, rebar is categorized by a number reflecting the solid diameter of the rebar. The numbers range from # 3 (smallest) to # 18 (largest).

For example, The # 3 bar size is 3/8' diameter of the solid section, the # 4 bar size is 4/8' diameter of the solid section, and the # 5 bar size is 5/8' diameter of the solid section.

The three different sizes of rebar used for home projects are usually # 3, # 4 and # 5.

Rebar size # 3 is used for driveways and patios. For walls and columns, # 4 rebar is better, as these structures require more strength. For footers and foundations, it's best to use the # 5 rebar.

How to Place Rebar in Concrete

Once you know the type and size of rebar you need, it's time to place it in concrete!

There is no simple formula for placing rebar correctly. A lot depends on the variables of your particular build. For example, how much force will be exerted on the concrete? Will the concrete be freezing and thawing over the seasons?

If you are doing a simple pour around your home, talk to your local concrete contractor or some other knowledgeable person about how to place the rebar.

When it comes to bigger commercial pours, the rebar specifications should be detailed in the blueprints. An engineer has carefully figured out exactly how much rebar is needed and how it should be spaced, so follow the directions carefully.

Thought and care must be put into how the rebar is placed, or the concrete's structural integrity could be compromised.

For example, if the engineer calls for rebar spaced every 4 inches, you need to place three bars for every 12 inches of the form.

Bending and Cutting Rebar

Some rebar comes pre-bent, but in general, be prepared to cut and bend the rebar so you can place it properly.

If you have the right tools, the process is easy.

First, let's talk about cutting rebar. There are several tools to use for this task.

A hacksaw or bolt cutter is a good option if the rebar is thin enough and if you aren't cutting a large quantity. If you are doing a job of significant size, an angle cutter with a cutting wheel does a great job.

With all the tools listed, it's important to note that you don't need to cut through the entire rebar. You only need to cut through half of it, and you can break it in half easily. Use this little hack, and you'll end up saving yourself a lot of time.

Sometimes, rebar needs to be tied. That's a whole topic in itself, but if you'd like to learn more about tying rebar, your local concrete contractor is a great place to start.

Conclusion

Concrete is an essential material in construction. However, without rebar, concrete loses much of its value.

Thankfully, you don't need to be an engineering expert to be able to understand how to use rebar. Next time you want to pour concrete, you can be confident in choosing the correct type and size of rebar and installing the rebar.

If you are looking for rebar or a ready-mix concrete supplier in Northern Indiana, contact us at Gra-Rock for the concrete rebar that you need.

We have over 15 years of concrete experience, and we want to help you with whatever project you are working on!

We also offer:

• Supplies

• Advice

• Tools

• Ready-mixed concrete delivery

We've also written some helpful articles you may be interested in if you want to learn more about concrete projects.

• Concrete Pump Trucks: How They Save You Time & Money

• Everyone's Guide To Pouring Concrete in Any Weather

• 23 Tools Every Concrete Contractor Needs

• The Complete Guide to Crushed Stone & Gravel

• The Beginner's Guide to Ready-Mixed Concrete

• Pouring Concrete In Hard-to-Reach Places

We'd love to help you out'contact us today if you have any questions or would like to schedule your next concrete delivery!

Welded wire reinforcement is a prefabricated reinforcement for structural concrete comprised of orthogonally arranged high-strength steel wires.  Wires are cold-worked to incremental sizes up to and including 5/8' diameter (equivalent to a #5 rebar), then fused together using a machine-controlled electric resistance welding process that is governed by ASTM standards.  Modern welding equipment and production methods allow for a high level of customization during manufacture, with variability in wire size, spacing, and length possible on a given WWR mat to suit project-specific requirements.  Welded wire reinforcement mats can also be pre-bent by the manufacturer to conform to the spatial geometric form of particular structural elements. 

Welded wire reinforcement is an efficient, economical, and viable option for all large-scale concrete reinforcement applications.

No. Actually, welded wire reinforcement has been around since John Perry invented a machine to weld wires into large sheets in , at a time when he was looking for a way to make fencing. He started to advertise welded wire reinforcement as reinforcement for concrete in .

No. The design process is relatively the same as designing with conventional rebar and the main difference takes place once the design engineer calculates the required areas of steel and before the area of steel is converted into conventional reinforcing bars. At this point, the required areas of steel are then converted into the specified spacing and wire sizes used in a welded wire reinforcement sheet.

WWR is a mild steel, high-strength reinforcement for structural concrete that is recognized in code and design standards published by the American Concrete Institute (ACI), the American Association of State Highway and Transportation Officials (AASHTO), and the American Railway Engineering and Maintenance-of-Way Association (AREMA).

No. Welded wire reinforcement is a mild steel reinforcement required to conform to the ASTM A Standard Specification. All welded wire reinforcement manufacturers are all held to this common standard.
 
While it is feasible for one welded wire reinforcement producer to pursue different markets or applications than its competitors, or for one producer to have slightly different internal processes and/or automated welding equipment than its competitors, the reinforcement itself must always be compliant with the ASTM Specification's requirements, and this is confirmed through ASTM A certification and testing measures.
 
Welded wire reinforcement is a manufactured product in the same sense that rebar is, and as such should not be subject to unique proprietary-like scrutiny on the basis of its inherent pre-assembly.

Reinforcing bars are typically produced to eleven pre-defined sizes.  In contrast, the range of wire sizes used in welded wire reinforcement production is roughly 300, with wires produced in cross-sectional area increments of one-tenth of a square inch.  Combine this with the fact that the welded wire reinforcement mat geometries themselves are capable of being produced with varying lengths, widths, and wire spacings, and the result is a WWR product that is highly customizable to suit a project or application's specific needs. 

All manufacturers carry what are referred to as standard sheets, which are those configured to suit project applications that have longstanding construction industry demand. The range of standard sheets offered from one producer to the next will typically vary slightly, depending on regionally-driven demand.

With that said, because of the capabilities of modern welding equipment, the production of project-specific welded wire reinforcement sheet configurations is increasingly common for both precast and cast-in-place concrete applications. Designers are not limited to a standard sheet size or wire diameter.

If the structural design is relying upon welded intersections for the purposes of development or curtailment, then, yes, there exists a wire size relationship: the smaller wire must have a cross-sectional area at least 40% that of the larger wire per ASTM A. 

If the structural design does not rely upon welded intersections, then there is no wire size relationship requirement. Per ASTM A, the welded wire reinforcement producer is still required to verify that welded intersections exhibit a weld shear strength of 800 pounds. This is typically for basic transport, handling, and placing purposes.

The ACI 301 mandated support spacing does not guarantee conformance with a project's specified acceptable tolerance, nor does it allow for alternative support patterns or methods that would achieve conforming results.

Support spacing should be derived on a case-by-case basis with due consideration for attributes such as the reinforcement itself (type, size, and spacing), the intended function/performance of the reinforced concrete element, the selected chair/bolster type, and the substrate upon which the support rests, to name a few.

Pre-established tolerances - whether through a combination of ACI 318 and ACI 117 requirements or through a design professional's project-specific requirement - should govern placement of welded wire reinforcement fabric. Refer also to TF 702 in the WRI technical document library.

The WRI always encourages close collaboration between a project's contractor and design professional of record to ensure appropriate placement criteria and procedures.

Welding is carried out by automated welding machines using a controlled electrical fusion process.  Unlike manual stick welding characterized by the depositing of a consumable electrode, electrical fusion welding is predicated on welded parts (two wires) being pressed together to allow the flow of electricity across the contact interface, resulting in the material being fused together.  This process is acknowledged in ACI 318-19 Section R26.6.4.

Confirmation of weld integrity is carried out as part of the material's certification process during manufacture, with ASTM A as the governing material specification, which is also referenced in ACI 318-19.

Design codes do not recognize any two-way interaction that might exist as a result of orthogonally-arranged welded wire reinforcement. In structural engineering practice, reinforcement for each primary direction is essentially analyzed separately, independent of the presence of welds, with the only exception being those instances in which perpendicular perimeter/edge welded wires are depended upon for development or curtailment.

ASTM A welded wire reinforcement is permitted as transverse reinforcement in special moment frames and special structural walls per ACI 318-19 Table 20.2.2.4(a), but the welds themselves are not permitted to be relied upon for resistance to any stresses. As such, for welded wire reinforcement used in seismic applications, bond and anchorage of the reinforcement must be derived from wire surface deformations and hooked wire curtailments only, with any potential contribution by welded intersections ignored/disregarded.

The need for 'single-direction' welded deformed wire reinforcement mats is very common.

It is noteworthy that ACI 318-19 acknowledges treatment of welded deformed wire reinforcement in a manner identical to individual loose deformed bars and deformed wires when welded intersections are either absent or are not intentionally-positioned for tensile development or curtailment.  With this treatment established, and in light of modern welded wire manufacturing capabilities, it is difficult to find a technical justification for a broadly-applied prescriptive maximum spacing of welded intersections as is done in Section 20.2.1.7.3.   

ACI 318-19 Sections 25.4.6.4 and 25.5.3.1.1 outline the common scenario in which the absence of intentionally-positioned welded intersections in turn requires calculation of welded deformed wire reinforcement development length and lap splice length, respectively, to be based on the same equations that are used for individual (loose, non-welded) deformed bars and deformed wires.  In essence, these ACI 318 provisions direct the designer to disregard any contribution a welded intersection might make to bond and development, and have the designer instead base these attributes on the deformed wire surface's contribution alone. 

We encourage designers and contractors to continue to take advantage of the highly-customizable welded deformed wire reinforcement mat arrangements capable of being produced by modern automated welding equipment.  This includes 'single-direction' welded wire reinforcement mats characterized by structural deformed wires in one direction and perpendicular non-structural wire positioned as required in the other direction.

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