TORKARI: High Strength Reinforcing Steel Innovation by Torsteel Group
TORKARI is a high-grade steel reinforcing bar introduced in India in 1987 by TRFI, offering superior strength and bond properties conforming to Fe550 Grade (Tor-55). Manufactured using Baustahlgewebe technology, it outperforms traditional Torsteel with smaller diameters while being cost-effective. Prosteel Industries, established in 1996, produces TORKARI at its facility in Gummidipoondi with a monthly capacity of 1000 tons. The parent company Tor-Isteg Steel Corporation of Luxembourg is the inventor of TOR steel bars, including Tor-40, Tor-50, Tor-Alloy, and Tor-55. The manufacturing process involves simultaneous cold flattening and ribbing, as well as wire drawing to achieve the desired properties. Explore the wonders of TORKARI for your construction projects.
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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 TORKARI IS A HIGH STRENGTH AND HIGH BOND REINFORCING STEEL CONFORMING TO Fe550 Grade ( Tor- 55) of IS 1786-2008. TORKARI WAS INTRODUCED IN INDIA BY TRFI IN 1987. SMALLER STRONGER ECONOMICAL
The Company PROSTEEL INDUSTRIES Commenced Operations in 1996. Factory at SIPCOT COMPLEX, Gummidipoondi (45 kms from Chennai) Production Capacity: 1000 tons per month. In house testing facilities ( QC lab) Regularly supplying to all the builders Managed 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 1010- 1015 ( 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 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 DESCALAR MACHINE Raw Material WRCoils TORKARI DRAWING MACHINE BULL BLOCK TORKARI STEEL IN COIL FORM.
TORKARI COILS BEFORE STRAIGHTENING
Process Flow Chart - 2 BULL BLOCK STRAIGHTENING AND CUTTING MACHINE TORKARI BUNDLES 12.15mts ( 40 ft-U Bend) BENDING AND BUNDLING
Sizes of Torkari 5mm Dia 6mm Dia 7mm Dia 9mm Dia
Torkari - Data Nomi nal Dia Mm 5.0 Nominal Weight Kg/m Permitted range of weight kg/m 0.142 to 0.166 0.278 to 0.326 0.459 to 0.539 Range of length Mts/MT Ast Sq.m m 0.154 6007 to 7052 3065 to 3598 1854 to 2177 19.63 7.0 0.302 38.48 9.0 0.500 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 0.20% Max Sulphur 0.055% Max. 0.050% Max Phosphorus 0.050% Max. 0.045% Max Sul+Phos 0.10% Max. 0.090% Max.
Torkari Fe-550 grade steel will satisfy all the physical and chemical parameters as per IS 1786-2008 for Fe-550 grade steel. We can also Torkari steel will also satisfy the requirements of grade B500A as per BS 4449:2009 for yield strength of 500 mpa and tensile strength/yield ratio of 1.02 for sizes below 8mm and 1.05 for sizes above 8mm. The elongation will be min 14.5% to satisfy the BIS earthquake code for ductile detailing. Torkari will satisfy the chemical requirement of B500A as per BS 4449:2009 wherein the max carbon content is 0.22% and carbon eq is 0.42%. Our internal production process will limit the carbon content to 0.18% hence ensuring fast and guaranteed weldability. The Weldmesh manufactured with the above specs will satisfy the requirement of BS 4483 for weld mesh and also relevant Indian standards. The available sizes of Torkari steel will be 5,6,7,8,9 mm and it will be supplied
Physical Properties of TORKARI Parameters 0.2% Proof Stress (P.S) IS Requirements Torkari specs 550 N/sq.mm (Min.) Passes 585 N/sq.mm (Min.) Or 1.06 X Act P.S whichever is higher Ultimate Tensile Strength 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%
Advantages of using TORKARI The Quality Advantage The Cost Advantage The Size Advantage
The Quality Advantage 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 High Bond Properties Torkari is Tri-Ribbed viz. Rib on three sides. TMT and TOR-40 have ribs only on two sides. Even 5mm TORKARI has ribs whereas 6mm MS is plain. Bond strength is over 100%. LESSER CRACK WIDTH DUE TO HIGH BOND. LESSER CRACK WIDTH DUE TO HIGH BOND.
Rolling Tolerance SINCE THE STRENGTH IS MORE , IT RESULTS IN LESS AREA OF REINFORCEMENT, THUS REDUCING CONGESTION OF REINFORCEMENT. 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 Low carbon mild steel with carbon less than 0.20%, it can be welded by metal arc welding process with normal electrodes. Most suitable for making fused weld mesh due to its low carbon content
Easily Weldable CTD, TMT ( local rerollers)bars and 6mm 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 Better fatigue strength. Advanced German Technology. Built in high creep resistance through adequate cold working. TRFI guidance and certification. Well equipped QC lab at factory. Clients witness of testing can be arranged before despatch. Can be used with any grade of Concrete
THE SIZE ADVANTAGE Smaller diameters from 5mm onwards. Available in 5mm, 6mm,7mm and 9mm in Fe 550 grade Custom sizes eg. 5.25mm,6.25mm,7.25mm can also be manufacterd as per grade B500A as per BS 4449 :2009 5mm TORKARI can be used in place of 6mm MS. 7mm TORKARI can be used in place of 8mm Tor-40. 9mm TORKARI can be used in place of 10mm Tor-40.
As minimum reinforcement In slabs only 8mm Fe-415/Fe-500 is used in most cases as it is the minimum dia available. As per IS the max. spacing is 3d for main reinforcement and 5d for distribution steel / temperature reinforcement.( d eff. Depth) Due to design conditions and slab thickness the max. spacing of 8mm in slabs is restricted to 250mm. The minimum reinforcement as per code is 0.12% Ast whereas the above works out to 0.17% Ast. If 7mm Torkari is used the savings is nearly 30% in quantity of steel and it satisfies 0.12% Ast.
5mm in place of 8mm Tor-40. Due to the poor quality of 6mm MS which is rerolled from scrap most of the consultants recommend 8mm Tor-40. In those areas where 6mm MS would suffice but 8mm Tor-40 is used we can implement 5mm Torkari. In a 110mm slab the spacing of 8mm is limited to 250mm since the max. spacing as per IS is 3d.
USE OF TORKARI IN SLABS TORKARI CAN BE USED AS MAIN REINFORCEMENT IN SLABS. IT GOES WELL WITH ALL GRADES OF CONCRETE. 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 6MM MS CAN BE EASILY CONVERTED AS PER THE SUBSTITUTION CHART. 5,7 AND 9mm TORKARI CAN BE USED AS A DIRECT SUBSTITUTION FOR 6mm MS, 8 AND 10 mm Tor-40 RESPECTIVELY.
OTHER USES OF TORKARI RC Walls, Lift walls, Shear Walls, Waffle Slabs Thermal Reinforcement in PT slabs , LINTELS,SUNSHADES,LOFTS PREFAB STRUCTURES. PAVINGS PRECAST SLABS GROUND RESTING SLABS SPIRAL AND LONGITUDIONAL REINFORCEMENTS IN RAILWAY SLEEPERS AND HUME PIPES. WATER RETAINING STRUCTURES. SKIN REINFORCEMENT IN BASEMENT WALLS, SUMPS, WATER RETAINING STRUCTURES. 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 TORKARI TMT 415/500 SLABS 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 1 MT 1.57 MT 100 mm 120 mm 1 MT 1.47 MT
Substitution Chart based on Strength Considerations. TMT TORKARI 8mm @ spacing S mm 7mm @ spacing S mm 10mm @ spacing S mm 9mm @ spacing 1.07Smm or 8.5mm @ spacing S mm. 9mm @ 0.75 S mm 12mm @ spacing S mm 16mm @ spacing S mm 9mm @ 0.42 S mm.
Substitution Chart for Distribution Steel in Slabs From Original Design with Convert to 8mm Fe-415 7mm TORKARI with no change in spacing 6mm MS 5mm 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 Characteristic strength of 415N/sq.mm Based on Actual proof strength of 550 N/sq.mm Fe-415 TMT/TOR 8mm @ S mm c/c 7mm @ 0.77S mm c/c 7mm @ S mm c/c Fe-415 TMT / TOR 10mm @ S mm c/c 9mm @ 0.8 S mm c/c 9mm @ 1.07 S mm c/c Fe-415 TMT / TOR 12mm @ S mm c/c 9mm @ 0.56 S mm c/c 9mm @ 0.74 S mm c/c MS Fe-250 5, 6, 6.5 or 7mm @ S c/c 5mm @ S mm c/c 5mm @ S mm c/c
CONVERSION TO COLUMN TIES From Original Design with Convert to Remarks 8mm Fe-415 7mm Torkari with no change in spacing 5mm 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 TMT 415/500 TORKARI BASED ON PROOF OR YIELD STRENGHT 1 MT 1.325 MT LANDED COST / TON COST COST SAVINGS PMT 47000 40000 47000 53000 6000
DIRECT SUBSTITUTION Cost savings chart PRICE COMPARISON ( PRICES AS ON 23.02.2015) TORKARI Vs TMT ( Secondary quality ) Landed Cost per ton excl octroi Your Net Savings per ton(Rs) Noml. Wt/mtr Length Mtr/ton Eqlnt. Qty Tons. Net Cost/MT for equal qty % of Savings* Details Dia TMT TORKARI TMT TORKARI M S TORKARI 10 9 8 7 6 5 0.617 0.485 0.395 0.302 0.222 0.154 1621 2062 2532 3311 4505 6494 1.272 1.000 1.308 1.000 1.442 1.000 40000 47000 41000 47000 39000 47000 50880 47000 53628 47000 56238 47000 3880 8.26% 1 6628 14.10% 2 9238 19.66% 3
COST SAVINGS IN A TYPICAL 4m X 4m TWO WAY SLAB PANEL 7mm Torkari vs 8mm TMT Spacing as No of rods for 4 mt span per design in kgs Weight Landed cost per ton Total Cost in Rs. CONVENTIONAL DESIGN USING 8mm TMT 8mm TMT @200 mm c/c 168 66.360 41000 2720.76 DESIGN USING 7mm TORKARI ( Fe-550) grade steel 7mm Torkari @200mm c/c 168 50.736 47000 2384.592 Savings %age Savings Savings per ton in Rs 336.168 12.36% 5,065.82
9mm Torkari vs 10mm TMT Spacing as No of rods for 4 mt span per design in kgs Weight Landed Cost pmt Total Cost in Rs. CONVENTIONAL DESIGN USING 10mm TMT 10mm TMT @200 mm c/c 168 103.7 40000 4146.24 DESIGN USING 9mm TORKARI ( Fe-550) grade steel 9mm Torkari @200mm c/c 168 80.64 47000 3790.08 Savings %age Savings Savings per ton in Rs 356.16 8.59% 3,435.98
COST SAVINGS 2:SAVINGS DUE TO LABOUR Labour cost per ton Weight in kgs as per above Labour cost for above quantities Steel Used 8mm TMT 7mm TORKARI 5000 5000 66.36 50.736 331.80 253.68 Savings Percentage Savings Savings per ton in Rs. 78.12 23.54% 1,177.22
ADVANTAGES OF TORKARI RIBBED BAR WELDMESH VS TMT WELD MESH TMT TORKARI Low carbon <0.18 Can be easily welded with min loss of tensile strength. Cost of welding low since low welding time reqd Available in 5mm,6mm,7mm and 9mm in Fe-550 grade as per IS 1786. Cost savings can be optimized with standardized spacings Carbon content 0.18-0.30 Available from 8mm onwards. Hence cost savings cannot be optimized since spacing is limited in design
TORKARI vs TMT weldmesh TMT Torkari TMT not possible Customized dia like 5.25mm,6.25mm etc is possible for B500A 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 4m X 4m TWO WAY SLAB PANEL 1.SAVINGS DUE TO MATERIAL. Spacing of weldmesh as per design No of rods for 4 mt span Weight in kgs Landed cost per ton Total Cost in Rs. CONVENTIONAL DESIGN USING 8mm HD wire 168 66.36 50000 3318 8mm plain @200 mm c/c DESIGN USING 7mm TORKARI ( Fe-550) grade steel 7mm Torkari @200mm c/c 168 50.736 56000 2841.216 Savings %age Savings Savings per ton in Rs 476.784 14.37% 7,184.81
L&T SERENE COUNTY,HYDERABAD Estimation of Steel Quantities Co- efficient for 8mm Tor- 40(kg/m3) 65 Total quantity of 8mm tor-40 ( slab thickness = 115mm) 2402.84 Total Area G+ 14 X 10 towers 321450 Area per slab ( sq.ntr) 2143 1.SAVINGS DUE TO MATERIAL. Total Quantity in tons Landed cost per ton in Hyderabad in Rs. ( March 2008) Spacing as per design Total length in mts TOTAL COST 8y( Fe-415) @ 200mm c/c 2402.84 103706520 6083136.08 43160 7y ( TORKARI) @ 200mm c/c 1837.11 93334226 6083136.08 50805 TOTAL SAVINGS in Rs. PERCENTAGE SAVINGS 10372294 10% 4317 7930210 SAVINGS PER TON IN RS. TOTAL SAVINGS in Rs.
