Grade 60 vs Grade 40 Steel: Which One Should You Use?
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Written by:
Icons Team
- Last updated: November 12, 2025
- Lifestyle
Grade 60 vs Grade 40 Steel Comparison — which one should you use for your next project?
That’s a question every builder in Pakistan faces before construction begins. The steel you choose decides your structure’s strength, durability, and cost.
Both grades are common in RCC projects, but they differ in tensile strength, flexibility, and price. Let’s break it down and see which one truly fits your build.
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What Is Steel Grade in Construction?
Before jumping into the comparison, let’s first understand what a “steel grade” really means.
The grade of steel refers to its tensile strength and yield strength — or simply, how much stress it can bear before it bends or breaks.
In reinforced concrete, steel reinforcement (rebars) works in conjunction with concrete to resist tensile forces. Stronger steel grades can withstand greater loads, making them ideal for multi-story or commercial projects.
In Pakistan, most steel bars are manufactured to follow ASTM standards (American Society for Testing and Materials) or Pakistan Standards (PSQCA). These standards define how much load a steel bar can safely carry.
So, when you see “Grade 40” or “Grade 60,” you’re actually looking at the strength rating of that rebar.
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Overview of Grade 40 Steel
Grade 40 steel type is commonly used in residential construction.
Strength and Composition
Grade 40 steel has a yield strength of 40,000 psi (pounds per square inch). Mild steel bends and welds easily because it has less carbon.
Key Properties
- Highly flexible
- Easy to cut, shape, and handle
- Affordable and widely available
Applications
Grade 40 is ideal for:
- Single-story or double-story houses
- Boundary walls
- Small foundations and floor slabs
- Non-heavy load structures
Advantages
- Budget-friendly: Ideal for small-scale projects where cost control is crucial.
- Easy handling: Contractors love its flexibility during construction.
- Suitable for basic structures: Meets the strength requirements for residential units.
Limitations
However, Grade 40 isn’t suited for high-rise or load-bearing projects. Its lower strength can make structures vulnerable under heavy stress or during earthquakes.
So, while it’s great for homes, it’s not the best pick for towers or bridges.
Overview of Grade 60 Steel
Now, let’s discuss Grade 60, the backbone of modern construction.
Strength and Composition
Grade 60 steel has a yield strength of 60,000 psi, which is 50% higher than Grade 40. It contains more carbon and alloy elements, making it denser and more challenging to work with.
Key Properties
- High tensile strength
- Less flexibility but more durability
- Superior resistance to stress and load
Applications
Grade 60 is widely used in:
- Multi-story buildings
- Bridges and flyovers
- Commercial plazas
- Industrial projects
- High-load structures
Advantages
- Stronger and safer: Can bear more load without bending.
- Long-lasting: Withstands environmental stress better.
- Ideal for large-scale construction: Preferred by structural engineers for high-rise safety.
Limitations
- Slightly more expensive than Grade 40
- Difficult to cut or weld due to rigidity
Still, most modern builders prefer Grade 60 for its performance and reliability.
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Key Differences Between Grade 40 and Grade 60 Steel
Let’s put both grades side by side for a quick comparison.
| Feature | Grade 40 Steel | Grade 60 Steel |
| Yield Strength | 40,000 psi | 60,000 psi |
| Flexibility | More flexible | Less flexible |
| Durability | Moderate | High |
| Cost | Lower | Higher |
| Best For | Residential buildings | Commercial and high-rise structures |
| Welding Ease | Easy | Slightly difficult |
| Load Capacity | Limited | Heavy-duty |
Grade 60 is tough and lasts longer. It’s best for big jobs like bridges and towers. The grade 40 bends more easily and costs less, so it’s great for houses and small buildings.
Which Grade Is Better for Your Project?
Choosing between the two depends on your project type, budget, and design requirements.
Let’s make it simple:
- For houses or small buildings: Grade 40 works perfectly. It’s flexible, affordable, and strong enough for residential loads.
- For high-rise or commercial projects: Grade 60 is a must. Its high tensile strength ensures safety and structural stability.
Key Factors to Consider
- Structural load: Heavy loads need higher-grade steel.
- Project height: Taller buildings face greater stress.
- Budget: Grade 60 costs more upfront but lasts longer.
- Local building codes: Some cities now recommend Grade 60 for safety.
Pro tip: Always consult your civil engineer before finalising the steel grade. It’s not just about price — it’s about safety, durability, and compliance.
Brand Comparisons in Pakistan
When choosing between grades, you also need to think about the steel brand. Not all steel is made equal — and quality varies by manufacturer.
Here are some of Pakistan’s top steel brands that produce both Grade 40 and Grade 60 rebars:
1. Amreli Steels
- Known for high-quality, heat-treated rebars.
- Strong corrosion resistance and international certifications (ASTM, ISO).
2. Mughal Steel
- Produces both Grade 40 and Grade 60 rebars with consistent strength.
- Trusted by contractors nationwide.
3. FF Steel
- Focused on Grade 60 production with precise control over composition.
- Certified by PSQCA and ASTM standards.
4. Agha Steel
- Advanced micro-alloy technology ensures superior durability.
- Ideal for mega infrastructure projects.
5. Ittefaq Steel
- One of the oldest brands in Pakistan.
- Reliable product quality and competitive pricing.
While all these brands meet standards, Amreli, Mughal, and FF Steel are often favored for large-scale commercial projects because of their consistent tensile strength and certification reliability.
Price Difference Between Grade 40 and Grade 60 Steel
Now, let’s talk numbers — because pricing matters.
In Pakistan, steel prices fluctuate due to variations in raw material costs, international market rates, and demand.
On average:
Grade 40 steel is approximately 8–12% less expensive than Grade 60. However, Grade 60’s higher strength often means you need less quantity for the same structural performance.
So, even if Grade 60 costs more per ton, the overall project cost difference may not be that big — and you get better durability and safety.
Quick Tip: Always buy from verified dealers and ask for a mill test certificate to confirm the grade and authenticity.
Common Myths and Misconceptions
There’s a lot of confusion when it comes to steel grades. Let’s clear the air.
Myth 1: Grade 60 is always better.
Not always. For small homes or low-load structures, Grade 40 is a more practical and affordable option.
Myth 2: Grade 40 is outdated.
Wrong again. Grade 40 is still widely used in boundary walls, residential slabs, and small foundations.
Myth 3: A Higher grade means heavier steel.
No. The weight per foot of steel remains almost the same — it’s the strength that differs, not the mass.
Myth 4: You can mix both grades in one structure.
That’s risky. Engineers design reinforcement based on uniform grade strength. Mixing grades can cause structural imbalance.
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Expert Opinion: Engineering Recommendation
Structural engineers often prefer Grade 60 for long-term projects because it offers safety margins, durability, and performance under stress.
For example:
A two-story house in Islamabad may safely use Grade 40. But a 10-story building in Karachi’s seismic zone must use Grade 60 for earthquake resistance.
Engineers also follow design codes such as:
- ACI 318 (American Concrete Institute)
- ASTM A615/A706 standards
- PSQCA regulations in Pakistan
These codes ensure that your structure stays within safe stress limits.
Pro insight: Don’t select steel only by price — select it by project requirements. The cost difference is slight, but the safety benefit is massive.
Conclusion
In summation,
- Grade 40 is perfect for light, residential, or low-load structures.
- Grade 60 is ideal for high-rise, commercial, and heavy-load projects.
If you’re building a long-term property, Grade 60 offers better safety, less maintenance, and higher resale value.
Need expert advice?
Contact our certified valuers and engineers at Icons.com.pk for a professional consultation on steel selection, property valuation, or construction cost estimation.
FAQs
Q1. What is the main difference between Grade 40 and Grade 60 steel?
Grade 60 has a higher yield strength (60,000 psi) than Grade 40 (40,000 psi), making it stronger and more durable.
Q2. Can I use both grades in the same project?
No. Using different grades can cause uneven load distribution and structural issues.
Q3. Which grade is best for residential houses?
Grade 40 is suitable for single- or double-story homes.
Q4. Is Grade 60 worth the extra cost?
Yes. Its strength and durability make it ideal for long-term or high-rise construction.
Q5. How can I verify the steel grade before buying?
Ask your supplier for a Mill Test Certificate (MTC) and verify that the brand has a PSQCA or ASTM certification.
Final Takeaway:
When in doubt, go for quality over cost. Steel is the backbone of your building — choosing the right grade ensures safety, strength, and peace of mind for years to come.