Rebar cage quick reference card
📏 KEY DIMENSIONS
MAIN BODY: 8' long × 2' deep × 3' tall
├─ Seat: 2' tall (bottom section)
└─ Parapet: 1' tall (top section)
WINGS: 4.33' extension × 2.4' span × 3' tall
├─ Angle: 29° from main body
├─ Location: APPROACH SIDE (both wings)
└─ Connection: Expansion joints
DRAINAGE: 2× 4" PVC pipes
├─ Slope: 2% (approach to creek)
└─ Cages: 8 bars around each pipe
BEARING PLATES: 2 locations
├─ Positions: Y = +30" and Y = -30"
└─ Extra reinforcement: 10 stirrups each
🔧 MATERIAL LIST
| Item | Quantity | Cost |
|---|---|---|
| #4 Grade 60 rebar @ 10’ | 50 bars | $400 |
| 16ga tie wire | 80 lbs | $40 |
| 3” rebar chairs | 200 pcs | $60 |
| Expansion joint kit | 1 set | $87 |
| 4” PVC pipe + fittings | 6 ft | $38 |
| TOTAL | $625 |
📊 REBAR SCHEDULE AT-A-GLANCE
| Mark | Description | Qty | Length | Where |
|---|---|---|---|---|
| R1 | Base longitudinal | 8 | 9’ | Bottom, Y-direction |
| R2 | Base transverse | 2 | 3’ | Bottom, X-direction |
| R3 | Seat verticals | 16 | 3’ | Through seat walls |
| R4 | Seat horizontals | 24 | 3’ | 3 levels of ties |
| R5 | Back parapet verts | 8 | 2’ | Top of back wall |
| R6 | Side parapet verts | 4 | 2’ | Top of ends |
| R7 | Bearing stirrups | 20 | 3’ | U-shape at bearings |
| R8 | Corner diagonals | 8 | 2’ | 45° at corners |
| R9 | Wing verticals | 16 | 3.5’ | Wing walls |
| R10 | Wing horizontals | 24 | 2’ | Wing ties |
| R11 | Expansion dowels | 12 | 2’ | ⚠️ SMOOTH - half wrapped |
| R12 | Drainage cages | 16 | 1.5’ | Around pipes |
| 450 ft total |
⚙️ CODE REQUIREMENTS
✓ REBAR: #4 Grade 60 (fy = 60 ksi)
✓ CONCRETE: f'c = 3,000 psi
✓ COVER: 3" minimum all faces
✓ SPACING: 12" on center
✓ LAP SPLICES: 24" tension, 12" compression
✓ HOOKS: 90° with 3" extension (6×db)
✓ STANDARD: ACI 318-19
📅 11-PHASE ASSEMBLY SEQUENCE
WEEK 1: Fabrication
- Day 1: Workspace setup (plywood, sawhorses, tools)
- Days 2-3: Cut all bars, bend all bars, organize by type
WEEK 2: Main Body
- Day 4 AM: Assemble base grid (R1 + R2)
- Day 4 PM: Install seat verticals (R3)
- Day 5 AM: Complete seat cage (R4, R5, R6)
- Day 5 PM: Bearing plates (R7), corners (R8)
WEEK 3: Wings & Special Items
- Day 6: Assemble both wing cages (R9, R10)
- Day 6 PM: Prepare expansion dowels (R11) - SMOOTH!
- Day 7 AM: Drainage pipe cages (R12)
WEEK 4: Final
- Day 7 PM: Quality control inspection
- Day 8: Installation in forms
⚠️ CRITICAL ITEMS - DON’T MESS THESE UP!
1. CONCRETE COVER = 3” EVERYWHERE
- Use correct chair height
- Measure from rebar to form surface
- Inspector WILL check this
2. BEARING PLATE LOCATIONS
- Y = +30” and Y = -30” EXACTLY
- Elevation = 24” (top of seat)
- Mark with paint
- 10 extra stirrups each location
3. EXPANSION JOINT DOWELS (R11)
- 12 bars, 2’ long each
- Half wrapped in plastic (NO BOND)
- Mark “NO BOND” end clearly
- Coat with form oil before wrapping
- CRITICAL: Allows wings to settle independently
4. ALL INTERSECTIONS TIED
- Use wire tier (faster than manual)
- Twist 3-4 times
- Bend twisted end flat
- NO EXCEPTIONS
5. LAP SPLICES = 24” MINIMUM
- R3 laps 6” into base
- R5 laps 6” onto R3
- Offset lap locations (stagger)
✅ QUALITY CHECKS
Every 5 Bars:
- Length ±1/4”
- Hooks 90° ±5°
- Hook extension 3” ±1/4”
- No cracks at bends
After Assembly:
- Dimensions correct ±1/4”
- Diagonals equal (square)
- All intersections tied
- 3” cover achievable
- Bearing locations marked
- Cage rigid (doesn’t rack)
Before Pour:
- Inspector approved
- Rebar clean (no rust/oil)
- Chairs in place
- Expansion dowels wrapped
- Drainage pipes sloped
- Photos taken
🔨 ESSENTIAL TOOLS
Must Have:
- Rebar bender (manual)
- Angle grinder with cut-off wheel
- Automatic wire tier ($40 - saves hours!)
- 100’ tape measure
- 25’ tape measure
- 4’ level
- Chalk line
- Plywood work surface
- Sawhorses
- Safety glasses, gloves
Cutting Example: From 10’ bar → 3 pieces @ 3’ = 9’ used, 12” scrap
🎯 SUCCESS FORMULA
GOOD MATERIALS
+
ACCURATE MEASUREMENTS
+
COMPLETE TYING
+
PROPER COVER
+
INSPECTOR APPROVAL
=
SUCCESSFUL CAGE
📸 PHOTO CHECKLIST
Take photos of:
- Organized rebar (labeled by type)
- First bent bars (quality check)
- Base grid complete
- Verticals installed
- Complete seat cage (4 sides)
- Bearing plate locations (with tape measure!)
- Wing cages
- Expansion dowels (show wrapping)
- Drainage pipes
- Complete assembly (multiple angles)
- In forms before pour
Include tape measure in photos to show dimensions!
🚨 WHEN TO STOP & ASK
Stop work immediately if:
- Measurements don’t match
- Bars don’t fit together
- Unsure about any step
- Safety concern
- Inspector has questions
Better to ask than to rebuild!
📞 EMERGENCY CONTACTS
Project Engineer: _______
Inspector: _______
Material Supplier: _______
Safety Officer: _______
💡 PRO TIPS
- Work at waist height - Use sawhorses, save your back
- Cut all bars first - Assembly line efficiency
- Practice bending - Use 2-3 extra bars to perfect technique
- Tie as you go - Don’t wait until end
- Keep rebar clean - Inspector will reject dirty rebar
- Label everything - Confusion = mistakes
- Measure twice, cut once - Classic for a reason
- Take breaks - Heavy work, stay safe
- Photos are proof - Document everything
- Ask questions - No stupid questions in construction
⏱️ TIME ESTIMATE
Fabrication: 16 hours (2 days × 8 hrs)
Assembly: 24 hours (3 days × 8 hrs)
Installation: 8 hours (1 day)
TOTAL: 48 hours (6 working days)
🎓 WHAT YOU’LL LEARN
- Reading structural drawings
- ACI code requirements
- Rebar fabrication techniques
- Quality control procedures
- Working with inspectors
- Real-world construction
- Problem-solving skills
- Professional documentation
Resume Line:
“Fabricated and assembled 450 linear feet of reinforced concrete cage for agricultural bridge abutment per ACI 318-19 specifications”
✅ FINAL CHECKLIST
Before Starting:
- Read full specification
- Understand all 12 bar types
- Materials on site
- Tools ready
- Workspace prepared
- Safety equipment
During Work:
- Follow sequence
- Quality checks
- Take photos
- Keep site clean
- Stay safe
Before Installation:
- Complete inspection
- All checks passed
- Inspector notified
- Ready for concrete
🌟 YOU’VE GOT THIS!
This is a well-designed, code-compliant cage. Follow the spec, measure carefully, tie every intersection, and you’ll build something that lasts 50+ years.
Questions? → Ask before proceeding
Problems? → Stop and get help
Success? → Take pride in professional work
Good luck! 🏗️