804.01 Description. This item shall consist of reinforcing steel
and miscellaneous accessories of the quality, type, size, and quantity designated, which shall be furnished and placed in concrete structures according to these specifications and in conformity with the details shown on the plans, or as directed.
804.02 Materials. (a) Bar Reinforcement. Bar reinforcement
for concrete in sizes up to and including #18 (No. 57) shall conform to the requirements of AASHTO M 31 or M 322 Type A. Mill test reports shall be submitted for reinforcing steel.
b.Wire and Wire Fabric. Wire, when used as reinforcement in concrete, shall conform to the requirements of A ASHTO M 32 or M 225. Wire fabric, when used as reinforcement in concrete , shall conform to the requirements of AASHTO M 55 or M 221 . All wire fabric shall meet the weld shear requirements for A ASHTO M 55. The type of wire fabric shall be approved by the En gineer.
c.Bar Mat Reinforcement. Bar mat reinforcement for concrete shall conform to the requirements of AASHT O M 54.
d.Epoxy Coating. When specified, reinforcing steel bars shall be coated according to ASTM A775 using a coating ma terial that meets the requirements of Annex A1 of ASTM A775. The Contractor shall supply to the Engineer a writt en certification that properly identifies the number of each batch o f coating material used in the order; the material, quantity represent ed, date of manufacture, and name and address of the manufactur er; and a 726 statement that the supplied coating material meets the requirements of Annex A1 of ASTM A775. Patching material, compatible with coating material , inert in concrete, and meeting the requirements of Annex A2 of ASTM A775, shall be provided by the epoxy coating manufa cturer.
804.03 Bar Lists and Bending Diagrams. All reinforcing steel
shall be fabricated to conform to the details shown on the plans. Pins used for bending reinforcing steel shall be eq ual to or larger than that shown on the plans. Bar lists and bendin g diagrams for reinforcing steel and bar supports will not be revi ewed or approved by the Engineer. The Contractor shall be responsib le for the accuracy of the fabricated reinforcing steel.
804.04 Fabrication. Bar reinforcement shall be bent to the
shapes shown on the plans. Bars shall be bent cold, unless otherwise permitted by the Engineer. No bars partially embedded in concrete s hall be field bent, except as shown on the plans or specifically permitted by the Engineer. Radii for bends shall be as shown on the plans. Wh en not shown on the plans, radii bends on the inside of bars sha ll be as specified below. Bar Number Minimum
U.S. Standard Metric (SI) Radii Stirrups and Ties 4 bar diameters 3, 4, 5, 6, 7, or 8 10, 13, 16, 19, 22, or 25 6 bar diameters 9, 10, or 11 29, 32, or 36 8 bar diameters 14 or 18 43 or 57 10 bar diameters The Engineer or his representative shall have free access to the shop for inspection, and every facility shall be ex tended to him for this purpose. On a random basis, samples of bars, other than the additional test bars, may be taken by the Engineer. Epoxy coating applicators shall be CRSI certified. The Contractor shall inform the Engineer, in writing, a t least 10 days 727 prior to performing any of the cleaning or coating operations. The Contractor shall furnish to the Engineer the coatin g applicator's certification certifying that all materials used, t he preparation of the bars, coating, and curing were done according to th ese specifications and that no bars contain more than six holidays per yard (meter). The certification shall include or have attached sp ecific results of tests of coating thickness and flexibility of coati ng.
804.05 Shipping, Handling, and Protection of Materi al. Bar
reinforcement shall be shipped in standard bundles, tagged and marked according to the Code of Standard Practice of the Concrete Reinforcement Steel Institute. Epoxy coated bars shall be prepared for shipment by use of excelsior or equivalent padded metal bands, or othe r methods that will prevent damage during shipment. Caution shall be used to avoid dragging or dropping the bundles. If bundled together for shipment, the bundles should be small, tightly band ed with padded bands, and should be lifted with a strong back, mul tiple supports, or a platform bridge to prevent bar to bar abrasion fr om sags in the bar bundle. Epoxy coated bars shall be stored on padde d and/or wooden supports. All systems for handling coated bars sha ll have padded contact areas. If, in the judgment of the Engineer , the coating is damaged to the extent that the coating no longer pr ovides the intended protection, the material shall be returned to the coating applicator for repair or replacement. Patching mat erials or any required repair of the coating shall be at no cost to the Department. Steel reinforcement shall be protected from damage. When placed in the work, it shall be free from dirt, det rimental rust or scale, paint, oil, or other foreign substance. Ste el reinforcement shall be stored above the ground on skids, platform s, or other supports. Epoxy coated reinforcing steel that is n ot incorporated into the work within 90 calendar days after deliver y to the project shall be protected from exposure to the sun. Epoxy coating damaged during fabrication, shipping, or installation shall be repaired according to ASTM A7 75. Damaged areas less than 0.10 square inch (65 sq mm) need no t be repaired but all areas larger than 0.10 square inch (65 sq mm) s hall be repaired. The maximum amount of damage shall not exceed 2% of the surface area of each bar. All damaged areas shall be repai red with the material specified in Subsection 804.02(d) and acco rding to the manufacturer's instructions. Repairs will be requi red on all sheared 728 or cut ends of bars, end areas left bare during the coating process, and any areas where the entire coating is removed. All repairs shall be completed as soon as practicable and, in the cas e of bare end areas and sheared ends, before visible oxidation of the surface occurs. Epoxy coated bars shall not be flame cut. The Contractor shall exercise caution when placing and vibrating concrete to prevent any damage to epoxy coated bars . In order to prevent the vibrator from damaging the coated bars, the head shall be covered with a sheet of rubber or a similar mate rial as approved by the Engineer.
804.06 Placing and Fastening. Steel reinforcement shall be
accurately placed in the positions shown on the pla ns and firmly held during the placing and setting of concrete. B ars shall be tied at all intersections except where spacing is less than 12" (300 mm) in each direction, in which case alternate intersectio ns shall be tied. Bundled bars shall be tied together at not more tha n 6' (2 m) centers. Bar positions or clearances from the forms shall be maintained by means of stays, ties, hangers, or other approved de vices. Reinforcing steel shall not be welded unless detail ed on the plans or authorized in writing by the Engineer. Any authori zed welding shall comply with Subsection 807.26. Metal bar supports that are in contact with the exterior surface of the concrete s hall have protection conforming with the CRSI Specifications, Class 1 for Plastic Protected Bar Supports or Class 2 for Stain less Steel Bar Supports, with the further provision that the plast ic protection may be applied either by a dipping operation or by the addition of premolded plastic tips to the legs of the supports. Epoxy Coated Bar Supports that are coated according to the provision s of CRSI “Manual of Standard Practice” with a minimum coatin g thickness of 5 mils (127 µm) may be substituted for Plastic Protected Bar Supports or Stainless Steel Bar Supports. All high chairs and bar bolsters shall be metal. Plastic bar supports shall not be used. When concrete is to rest on an excavated surface, l ayers of bars shall be supported above the surface by metal chair s or by precast mortar or concrete blocks. The use of rocks, piece s of stone or brick, pipe, wooden blocks, or chunks of concrete w ill not be permitted as bar supports or spacers. 729 Reinforcement shall be placed by the Contractor and inspected and approved by the Engineer before the placing of concrete begins. Concrete placed in violation of this provision may be rejected and removal required. Unless otherwise shown on the pl ans, the spacing of supports shall conform to the recommendations of CRSI. If fabric reinforcement is shipped in rolls, it sha ll be straightened into flat sheets before being placed. Epoxy coated bars shall be placed on plastic coated or epoxy coated metal supports and shall be held in place by use of plastic coated tie wires or molded plastic clips especially fabricated for this purpose. Bar supports for epoxy coated bars shall be fully coated metal supports. Epoxy coated bar supports shall be coated according to the provisions of CRSI “Manual of Stan dard Practice” and shall have a minimum coating thickness of 5 mil s (127 µm). In placing epoxy coated bars, care shall be maintained to prevent coated bars from being damaged. After the coated bars are secured to bar supports, a final visual inspection shall be made and all uncoated or damage d areas coated or repaired as required by the Engineer. Any bar supports that deform under foot traffic or other construction activities shall not be used. Reinforcing steel that is to be doweled into existi ng concrete shall be installed into drilled holes and secured using a n approved non- shrink grout or a resin anchoring system listed on the Department’s Qualified Products List. The diameter of the drille d holes and the installation procedures shall be as recommended by the grout manufacturer or the resin anchoring system manufact urer.
804.07 Splicing. Reinforcing steel shall be furnished in the full
lengths specified on the plans. Bars spliced as a result of unforeseen construction conditions or sequences will require t he written approval of the Engineer. Splices shall meet the r equirements of the current edition of the AASHTO Standard Specifications for Highway Bridges or AASHTO LRFD Bridge Design Specifications , as specified in the plans. Secondary reinforcing used for distribution of load s, such as longitudinal bars in box culverts, retaining walls, and slabs for steel girder spans, may be lapped 32 bar diameters minimu m if bars are #6 (No. 19) or smaller. Primary reinforcing for co lumns and 730 retaining walls which require splicing as a result of the lowering of footings shall be spliced at the upper end of the o riginal bars. Required lengths of splices for primary reinforcing will be determined by the Bridge Engineer. In lapped splices, the bars shall be placed in cont act and fastened together in such a manner as to maintain the minimu m distance to the surface of the concrete as shown on the plans. Welded or mechanical splices shall be made only if detailed o n the plans or authorized in writing by the Engineer. Welding sha ll comply with Subsection 807.26. Mechanical splices shall be lis ted on the QPL and shall be the type specified on the plans or app roved by the Engineer.
804.08 Lapping. Sheets of wire fabric or bar mat reinforcement
shall overlap each other sufficiently to maintain a uniform strength and shall be securely fastened at the ends and edge s. The lap shall be not less than one space of wire fabric or bar.
804.09 Substitutions. Bar size substitutions will be permitted
only with specific authorization by the Engineer. The substituted bars shall have an area equivalent to or larger tha n the design area.
804.10 Method of Measurement. Steel reinforcement properly
placed and tied will be measured in pounds (kilogra ms) based on the total computed weight for the sizes and lengths of bars, wire fabric, or mats shown on the plans or revised by the Engine er. Epoxy Coated Reinforcing Steel will be measured by the pound (kilogram), based on the theoretical number of poun ds (kilograms) calculated on the nominal weight before application of the epoxy coating materials. No allowance will be made for t he epoxy coating material, the coating process, accessories, or the testing required by the manufacturer or applicator as specified above. The weight of wire fabric will be computed from the theoretical weight of plain wire. If the weight per square foo t (square meter) is given on the plans, that weight will be used. 731 The weight of plain round bars and deformed bars wi ll be calculated using the following table:
U.S. STANDARD METRIC (SI) Bar No. Weight(lbs./ft) Bar No. Weight (kg/m) 3 0.376 10 0.560 4 0.668 13 0.994 5 1.043 16 1.552 6 1.502 19 2.235 7 2.044 22 3.042 8 2.670 25 3.973 9 3.400 29 5.060 10 4.303 32 6.404 11 5.313 36 7.907 14 7.65 43 11.38 18 13.60 57 20.24 The quantities shown on the plans will be considere d as the final quantities and no further measurement will be made unless, in the opinion of the Engineer or upon evidence furnished by the Contractor, substantial variations exist between qu antities shown on the plans and actual quantities due to changes in a lignment or dimensions or to apparent errors. If bars are substituted at the Contractor's request and as a result more steel is used than specified, only the amount specified will be measured for payment. When laps are made for splices other than those sho wn on the plans, for the convenience of the Contractor, the e xtra steel will not be measured for payment.
804.11 Basis of Payment. Work completed and accepted and
measured as provided above will be paid for at the contract unit price per pound (kilogram) bid for Reinforcing Stee l-Bridge, Reinforcing Steel-Roadway, or Epoxy Coated Reinforc ing Steel, which price shall be full compensation for furnishi ng, bending, fabricating, epoxy coating, and placing the reinfor cement; for accessories placed in concrete; and for all labor, equipment, tools, and incidentals necessary to complete the work. Cl ips, metal spacers, chairs, bar supports, ties, separators, wi re, and other 732 material used for fastening reinforcement in place will not be measured or paid for separately, but full compensat ion therefor will be considered included in the contract unit price b id for Reinforcing Steel. When included on the plans for separate payment, wi re fabric will be paid for under the applicable item of Reinf orcing Steel. Payment will be made under: Pay Item Pay Unit Reinforcing Steel-Bridge (Grade __) Pound (Kilogram ) Reinforcing Steel-Roadway (Grade __) Pound (Kilogra m) Epoxy Coated Reinforcing Steel (Grade __) Pound (Kilogram)
Source: , Edition.