511Reinforcement Steel

511.1General Description

This work consists of furnishing and placing bar reinforcement steel and superstructure reinforcement steel. 511.1.01 Definitions General Provisions 101 through 150. 511.1.02 Related References

QPL 12 QPL 19 ASTM A 615/A 615M ASTM A 153/A 153 M ASTM D 570 ASTM D 1248 Manual of Standard Practice prepared by the Concrete Reinforcing Steel Institute 511.1.03 Submittals

Furnish three copies of mill orders and shipping statements for fabricated reinforcement steel bars, both black and epoxy, to the Office of Materials and Testing. The purchase orders shall include the following: • Complete State Project number, including the name(s) of the county(ies) • Company name and order number of the Contractor • Name and address of the fabricator • Bar sizes and total weight

Furnish the Engineer with copies of the fabricator’s bar lists and calculated weights. The Engineer will compare these copies to the Plan quantity. 746 746 746 746 746 746

511.2Materials

Bar reinforcement shall meet the requirements of the following Specification, unless specified otherwise on the Plans or in the Special Provisions. For a list of bar support sources, see QPL 19. Material Section Steel Bars for Concrete Reinforcement 853.2.01

Make wire bar supports from one of the following materials:

ASTM A 153/A 153 M, Table 1, Class D, Weights of Zinc Coatings.

1) For nominal heights of 3-1/2 in. (90 mm) and under, the legs may be fabricated from cold-drawn, weldable, stainless steel wire containing at least 16 percent chromium. Ensure that the wire provides a minimum tensile strength of 85,000 psi (585 MPa) for bolsters and of 100,000 psi (690 MPa) for high chairs. 2) For nominal heights exceeding 3-1/2 in. (90 mm), the legs may be fabricated from cold-drawn, carbon steel wire (non-stainless steel) with stainless steel extensions attached to the bottom of each leg.

3/4 in. (20 mm) clear from a formed surface. Use the same wire sizes as that specified for galvanized wire in Subsection 511.2.A.1.a, Galvanized Wire above.

steel wire. Protect the wire with plastic and use only in these types of bar support configurations: SB, BB, JC, HC, BC, and CHC (see) 1) If using Plastisol for dipping, ensure that it meets the following criteria: • Tensile strength: 1,500 to 2,000 psi (10 to 13.5 MPa) • Shore A hardness: 80 to 100 durometers 2) If molding plastic legs of polyethylene to the top wire, use polyethylene that meets ASTM D 1248.

conduct electrical current.

molded into a configuration that does not restrict concrete flow and consolidation around and under the supports. The supports shall be able to withstand a load of 300 lbs. (135 kg) without exhibiting any breakage or visible deformation. When tested according to ASTM D 570, the water absorption shall not exceed 0.1%.

concrete sand with a 1:2 cement-sand ration and shall have wires cast into them for fastening to the steel. Support faces shall be approximately parallel and smooth. The blocks shall be moist cured for a minimum of three (3) days.

Use at least No. 16 gauge, black, soft iron wire to tie bar reinforcement steel. 747 747 747 747 747 747

Comply with the following requirements:

For nominal heights exceeding 3.5 in. (90 mm), attach stainless steel extensions to the bottom of each leg. Design the leg extensions so that no portion of the carbon steel wire will be unprotected closer than 3/4 in. (20 mm) from the form surface.

Apply plastic protection by dipping the bar support in plastic or by molding legs to the top wire. 1) Apply a plastic coat at least 3/32 in. (2.4 mm) thick at points of contact with the form. 2) Extend the plastic upward on the wire to a point at least 1/2 in. (13 mm) above the form. 3) Turn up all legs on wire bar supports at least 1/8 in. (3 mm).

Apply an epoxy powder coat at least 0.006 in. (0.15 mm) thick. 748 748 748 748 748 748

Table 1—Bar Support Designation Requirements Symbol Bar Support Illustration Type of Support Nominal Height Minimum Wire Sizes (Type of Steel) Remarks Carbon Stainless Top Legs Runne r Legs SB * Slab Bolster All No. 4 Corrugated No. Ñ No. 8 Legs spaced 5 in (125 mm) on center. Vertical corrugations spaced 1 in. (25 mm) on center.** SBU * Slab Bolster Upper All No. 4 Corrugated No. No. 7 Same as SB BB * Beam Bolster Up to 1 ½ (40 mm) incl. Over 1 ½ – 2 in. (40 - 50 mm) incl. Over 2 – 3 ½ in. (50 - 90 mm) incl. Over 3 ½ in. (90 mm) No. 7 No. 7 No. 4 No. 4 No. No. No. No. No. 9 No. 8 No. 7 - Legs spaced 2 ½ in. (63 mm) on center.** BBU * Beam Bolster Upper Up to 2 in. (50 mm) incl. Over 2 in. 50 mm No. 7 No. 4 No. No. No. 7 No. 4 - No. 4 Same as BB. BC * Individual Bar Chair All No. No. 9 --**. 749 749 749 749 749 749

JC * Joist Chair All Ñ No. Ñ No. 9 --**. HC * Individual High Chair Up to 3 ½ in. (90 mm) incl. Over 3 ½ - 5 in. (90 - 125 mm) incl. Over 5 – 9 in. (125 - 225 mm) incl. Over 9 in. (225 mm) Ñ Ñ Ñ Ñ No. No. No. No. Ñ Ñ Ñ Ñ No. 7 - - - Legs at 20 degrees or less with vert. When height exceeds 12 in (300 mm) legs are reinf. with welded crosswires or encircling wires.*** HCM * High Chair for Metal Deck 2 – 5 in. (50 - 125 mm) incl. Over 5 – 9 in. (125 - 225 mm) incl. Over 9 in. (225 mm) Ñ Ñ Ñ No. Ñ Ñ Ñ - - - Sane as HC. The longest leg will govern the size of wire to be used.*** CHC * Continuo us High Chair 2 – 3 ½ (50 - 90 mm) incl. Over 3 ½ - 5 in. (90 - 125 mm) incl. Over 5 – 9 in. (125 - 225 mm) incl. Over 9 in. (225 mm) No. 2 No. 2 No. 2 No. 2 No. No. No. No. Ñ Ñ- Ñ Ñ No. 7 - - - Legs at 20 deg. or less with vert. All legs 8 ¼ in. (206 mm) on center max., with leg within 4 in. (100 mm) of end of chair, and spread between legs not less than 50% nominal height. CHCU * Continuo us High Chair Upper 2 – 5 in. (50 - 125 mm) incl. Over 5 – 9 in. (125 - 225 mm) incl. Over 9 in. (225 mm) No. 2 No. 2 No. 2 No. No. No. No. - - - 750 750 750 750 750 750

No. No. CHCM * Continuo us High Chair for Metal Deck Up to 2 in. (50 mm) incl. Up to 2 in. (50 mm) incl. Over 2 – 5 in. (50 - 125 mm) incl. No. 4 No. 2 No. 2 No. No. No. No. No. No. No. 4 top wire: maximum leg spacing 5 in. (125 mm) on center. No. 2 top wire: maximum is 10 in. (250 mm) on center.**** UJC * Upper Joist Chair -1 to + 3 ½ in. ( -25 to +90 mm) incl. (measured from form to top of middle portion of saddle bar) in. ¼ in. (6 mm) increments No. 13 Bar or 1/2 in. (13 mm) No. Ñ - Legs spaced 14 in. (350 mm) on center. CS * Continuo us Support 1 ½ - 5 in. (40 - 125 mm) incl. Over 5 – 7 ½ in. (125 - 190 mm) incl. Over 7 ½ - 12 in. (190 - 300 mm) incl. No. 8 No. 6 No. 4 No. No. No. No. No. No. - Legs spaced 6 in. (150 mm) on center, 4 in. (100 mm) on center at bend point. Middle runner used with heights over 7 in. (175 mm). “Zig Zag” width: 8 in. (200 mm) min. If the top wire on continuous supports are not designated as corrugated, the Manufacturer may use either straight or corrugated wire. * Refer to the Manual of Standard Practice prepared by the Concrete Reinforcing Steel Institute and the Western Concrete Reinforcing Steel Institute for bar support illustrations. ** To provide adequate stability against overturning, make the leg spread measured between points of support on the minor axis of the support at least 70 percent of the nominal height. *** To provide adequate stability against overturning, make the leg spread measured between points of support on the minor axis of the support at least 55 percent of the nominal height. **** To provide adequate stability against overturning and to provide adequate load capacity, make the leg spread measured between points of support on the minor axis of the support be between the minimum and maximum percentages of the nominal height, as shown: 751 751 751 751 751 751

Nominal Height, in. (mm) Distance Between Supports, % of Nominal Height Under 4 in. (100) 4 in. (100) 6 in. (150) 8 in. (200) 10 in. (250) 12 in. (300) Over 12 in. (300) Minimum 70 70 65 60 55 50 50 Maximum No limit 95 90 85 80 75 75 752 752 752 752 752 752

tolerances specified in the Fabrication Tolerances illustration (Figure 1). Bar dimensions shown on the Plans are out-to-out unless otherwise noted on the Plans. The maximum allowable deviations out of the design plane are as follows: Bar Size Allowable Deviation No. 7 (22 m) bars and under 1/2 in. (13 mm) No. 8 (25 m) bars and over 1 in. (25 mm) Bend the reinforcement steel to the shapes and dimensions specified on the Plans. Do not rebend and use bars that have been rejected. Hooks and bends shall comply with the Manual of Standard Practice, prepared by the Concrete Reinforcing Steel Institute and the Western Concrete Reinforcing Steel Institute, unless otherwise shown on the Plans. FIGURE 1—FABRICATION TOLERANCES 753 753 753 753 753 753

If using Plastisol, test the tensile strength of 1,500 to 2,000 psi (10 to 13.5 MPa) and the Shore A hardness of 80 to 100 durometers.

percent solution) for one hour.

Standard Practices. Ensure that the plastic does not deform permanently when heated to 170 °F (77 °C).

Reject any plastic on the fabricated unit that chips, cracks, or peels under ordinary job conditions.

General Provisions 101 through 150. 511.2.01 Delivery, Storage, and Handling After reinforcement steel is fabricated by one of the steel fabricators listed on QPL 12, handle and store it as follows: • Load, transport, unload, and handle reinforcement steel in a way that prevents damage. • Block unloaded reinforcement steel off the ground and store it in piles separated by size and type.

• Protect reinforcement steel from the weather if prolonged exposure is expected and the Engineer requires the

protection.

511.3Construction Requirements

511.3.01 Personnel

General Provisions 101 through 150.

511.3.02 Equipment

General Provisions 101 through 150.

511.3.03 Preparation

Before placing reinforcement, clean off loose mill scale, rust scale, and coatings that will destroy or materially reduce

the bond.

511.3.04 Fabrication

See Subsection 511.2.B, Fabrication and Subsection 853.2.01.B, Fabrication.

511.3.05 Construction

Bar schedules are shown on the Plans as a service. The Contractor is responsible for conforming to the Plan details. If

there is a discrepancy between Plan details and bar schedules, the Plan details take precedence.

Space reinforcement steel within permissible tolerances. Tie and support the reinforcement steel so it cannot move

during concrete placement.

Twist bar ties at least two full turns. The Engineer may require double bar ties if single bar ties do not keep the bar

reinforcing steel secure under construction traffic.

Tie epoxy-coated reinforcement steel with the epoxy-coated or plastic-coated tie wire specified in Section 853.

Use the following placing requirements: 754754754754754754

mat.

(100 mm x 100 mm) Plan clearance. Fasten the precast blocks with cast-in wires.

Steel may be supported by other satisfactory means approved by the Engineer. Do not use rocks or random

pieces of broken concrete to support steel.

in. (25 mm) from the side clearance. Do not deviate more than 1 in. (25 mm) from the location indicated on the

Plans as seen in the Plan view.

the location the Plan specifies.

1/4 in. (6 mm) on the side clearance.

2 in. x Plan clearance (50 mm x 50 mm). Fasten the blocks with cast-in wires.

not deviate more than 1/4 in. (5 mm) on the side form clearance.

(6 mm) on the side form clearance.

(50 mm x 50 mm). Fasten the blocks with cast-in wires.

that the spacing devices provide enough space between steel mats according to the Plans.

accumulate causing an omission of bars. Do not deviate more than 1/4 in. (6 mm) on the side form clearance.

Shift bars more than the tolerance only when necessary to clear a fixture. Do not reduce the number of bars

specified for the pour. Place any remaining bars on either side of the fixture to the spacing specified on the

Plans and to the tolerance specified in the previous paragraph.

755755755755755755

maximum dimensions of 2 in. x 2 in. x Plan clearance (50 mm x 50 mm). Fasten the blocks with cast-in

wires.

clearance (50 mm x 50 mm). Fasten the blocks with cast-in wires.

Designation Requirements (Table 1).

the lower layers with upper beam bolsters placed directly over lower supports. Refer to symbol “SBU” on

the Table of Bar Support Designation Requirements (Table 1).

be required at a maximum spacing of 4 ft. (1.2 m).

within 1/4 in. (6 mm) of the Plan vertical dimension for that layer. Do not deviate more than 1/2 in. (15 mm) on

side form clearance.

Place each stirrup within 1 in. (25 mm) of its specified location.

If transverse spacing is not specified on the Plans, ensure that the main steel in beams and in tops and

bottom of caps has at least 2 in. (50 mm) horizontal clearance between bars.

Wall Reinforcement Steel.

requirements for footings in Subsection 511.3.05.A, Footing Reinforcement Steel.

If more than one mat of steel is required by the Plans, support the top mat from the bottom mat using

upper beam bolsters (SBU) or other satisfactory means approved by the Engineer.

• Continuous high chairs placed near each end of the top bends of truss bars. Refer to symbol

“CHC” on the Table of Bar Support Designation Requirements (Table 1).

• Individual high chairs at a maximum longitudinal spacing of 4 ft. (1.2 m). Refer to symbol “HC” on

the Table of Bar Support Designation Requirements (Table 1).

Support the bottom mat steel of top slabs as follows:

1) Use slab bolsters spaced approximately 12 in. (300 mm) from the inside faces of walls.

Refer to symbol “SB” on the Table of Bar Support Designation Requirements (Table 1)

2) Additional bolsters will be required along the length of the slab at a maximum spacing of

approximately 4 ft. (1.2 m) to maintain the bottom clearance. 756756756756756756

3) The Contractor may support bottom mats using precast blocks spaced approximately

4 ft. (1.2 m) (maximum) in any direction.

Blocks shall have maximum dimensions of 2 in. x 2 in. x Plan clearance (50 mm x 50

mm). Fasten the blocks with cast-in wires.

If the Engineer determines that precast blocks do not provide proper support and

maintain bottom clearances, use slab bolsters. Refer to symbol “SB” on the Table of Bar

Support Designation Requirements (Table 1).

in Subsection 511.3.05.D.2, Wall Bar Tolerances.

Place top and bottom slab reinforcing bar mats according to the tolerances specified in Subsection

511.3.05.G.6, Bridge Deck Slab Tolerances.

locations:

• Each intersection on the outer edges

• Every third intersection within the mat

with slab bolsters as follows:

Requirements (Table 1).

the beam edges.

bolsters parallel to and in between the lines of bolsters so the maximum spacing between the lines of

bolsters does not exceed 4 ft. (1.2 m).

additional row of bolsters approximately 4 in. (100 mm) from the end of the reinforcement.

discontinuous ends of cutoff transverse bars using slab bolsters. Refer to symbol “SB” on the Table of

Bar Support Designation Requirements (Table 1). Place bolsters parallel to skew and as close to the cut

ends of bars as possible.

reinforcing in the panels between beams using precast blocks instead of slab bolsters as follows:

Subsection 511.3.05.G.1, Bridge Deck Slab Bottom Mat Support—Slab Bolsters, steps c, d, and e.

on the Table of Bar Support Designation Requirements (Table 1). 757757757757757757

Support top mat reinforcing steel with continuous high chairs as follows, except as noted in Alternate 1 and

Alternate 2. Refer to symbol “CHC” on the Table of Bar Support Designation Requirements (Table 1).

Designation Requirements (Table 1).

rows of continuous high chairs so the maximum spacing between the lines of continuous high chairs does

not exceed 4 f.t (1.2 m). Refer to symbol “CHC” on the Table of Bar Support Designation Requirements

(Table 1).

reinforcing, support top mat steel using individual high chairs as follows:

to symbol “HC” on the Table of Bar Support Designation Requirements (Table 1).

Maximum spacing for individual high chairs is 3 ft. (1 m) longitudinally and 4 ft. (1.2 m) transversely.

transverse reinforcing, support top mat steel using continuous high chairs upper as follows:

that support the bottom mat steel. Refer to symbols “CHCU” and “SB” on the Table of Bar Support

Designation Requirements (Table 1).

discontinuous ends of cutoff transverse bars using continuous high chairs (CHC) placed parallel to skew

as close to the cut ends of bars as possible.

skew for the full deck width and as close as possible to the deck joint. Securely tie this bar to the

following to maintain correct bar mat location:

• The underside of the top mat of reinforcing steel

• The forms

• The supports (beams)

• Both forms and supports (beams)

shear bar and pick-up loop in the panels. This keeps the top bar reinforcing mat in the correct vertical

position.

(6 mm) of the dimension shown on the Plans. Clearances for reinforcement steel mats shall be within 1/8

in (3mm) of dimension shown on the Plans at the time of the final screed setting check.

Do not deviate horizontal spacing or end and edge clearances of the mats more than 1/2 in. (15 mm) from

the spacing shown on the Plans.

dimension.

Plans. Do not deviate from the bottom clearance specified on the Plans.

steel is coated with epoxy. 758758758758758758

steel is coated with epoxy.

Furnish reinforcement steel in the full lengths shown on Plans. Splice as shown on the Plans. Do not make other

splices unless approved by the Engineer.

Place bars in continuous contact on lapped splices. Wire the bars together to maintain a clearance not less than

the minimum clear distance to other bars and to the surface of the concrete.

Splice length shall be at least 12 in (300 mm) on No. 4 (13M) longitudinal bars for cast-in-place box culverts,

unless indicated otherwise on the Plans.

Weld reinforcement steel only where shown on Plans.

The minimum spacing limitations are as follows unless shown otherwise on the Plans

Clear Distance Between Parallel Bars

(Shall be at least the largest measurement listed)

Cast-in-Place Concrete Precast Concrete Manufactured Under Plant Control

Conditions

1.5 bar diameters 1 bar diameter

1.5 times the maximum size of the coarse

aggregate

1-1/3 times the maximum size of the coarse aggregate

1-1/2 in. (40 mm) 1 in. (25 mm)

511.3.06 Quality Acceptance

Place reinforcement steel and have it inspected and approved by the Engineer before placing concrete.

If this requirement is violated, the Engineer may reject the concrete and require the Contractor to remove it.

511.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

511.4Measurement

This work is measured for payment as an accepted lump quantity or in pounds (kilograms) of accepted bar

reinforcement steel, whichever is shown on the Plans. The Department reserves the right to revise bar reinforcement

steel quantities to correct errors and reflect changes on the Plans.

• Payment Per Lump Sum

The quantity of bar reinforcing steel measured for payment per Lump Sum basis shall conform to the Plan

details and will include reinforcement in concrete handrailings, concrete parapets, and barriers.

• Payment Per Pound (Kilogram) 759759759759759759

The quantity of bar reinforcement steel measured for payment per pound (kilogram) in bridges and concrete

box culverts will be the algebraic sum of the base pay quantity and authorized quantity changes.

Reinforcement bar weight calculations will be made using the theoretical unit weight in pounds (kilograms) per

foot (meter) for deformed bars as shown in the table of Deformed Bar Designation Numbers, Units Weights,

and Nominal Dimensions (Table 2). This table is taken from ASTM A 615.

Lengths of bent bars will be the sum of the component sections of the bars as shown on the Plans.

Table 2—Deformed Bar Designation Numbers, Unit Weights, and Nominal Dimensions

Nominal Dimensions

Bar Designation No.* Unit Weight lb./

ft. (kg/m)

Diameter in.

(mm)

Cross-sectional

Area, in.² (mm²)

Perimeter in. (mm)

3 (10M) 0.376 (0.560) 0.375 (9.5) 0.11 (71) 1.178 (29.9)

4 (13M) 0.668 (0.994) 0.500

(12.7)

0.20 (129) 1.571 (39.9)

5 (16M) 1.043 (1.552) 0.625

(15.9)

0.31 (199) 1.963 (49.9)

6 (19M) 1.502 (2.235) 0.750

(19.1)

0.44 (284) 2.356 (59.8)

7 (22M) 2.044 (3.042) 0.875

(22.2)

0.60 (387) 2.749 (69.8)

8 (25M) 2.670 (3.973) 1.000

(25.4)

0.79 (510) 3.142 (79.8)

9 (29M) 3.400 (5.060) 1.128

(28.7)

1.00 (645) 3.544 (90.0)

10 (32M) 4.303 (6.404) 1.270

(32.3)

1.27 (819) 3.990 (101.4)

11 (36M) 5.313 (7.907) 1.410

(35.8)

1.56 (1006) 4.43 (112.5)

14 (43M) 7.650 (11.38) 1.693

(43.0)

2.25 (1452) 5.32 (135.1)

18 (57M) 13.600 (20.24) 2.257

(57.3)

4.00 (2581) 7.09 (180.1)

*Bar numbers are based on the number of eighths-of-an-inch included in the nominal diameter of the bars. Metric

equivalents are rounded to the nearest whole millimeter. 760760760760760760

511.4.01 Limits

No separate measurement or payment will be made for the cost of bar reinforcement steel used in constructing

minor items.

Bar reinforcement steel in prestressed concrete bridge members will be considered a component part of the

members. The cost shall be included in the Contract Price for prestressed concrete bridge members.

Reinforcement steel in handrail end posts that are a part of the superstructure or substructure will be considered

part of the superstructure or substructure quantities.

Extra reinforcement steel in lap splices permitted for convenience at splices not shown on the Plans will not be

measured for payment.

511.5Payment

This work will be paid for at the Contract Price per Lump Sum or per pound (kilogram) of bar reinforcement steel, each

complete in place.

Payment will be made under:

Item No. 511 Superstructure Reinforcement Steel—Bridge No._____ Per lump sum

Item No. 511 Bar Reinforcement Steel Per pound (kilogram)

511.5.01 Adjustments

Assume the burden of proof for errors of commission or omission in the Plan quantities.

The Department will not consider requests for additional monies because of Plan errors unless they are submitted

with the bar lists and weights described in Subsection 511.1.03.B, “Bar Lists and Calculated Weights.” Projects

involving multiple bridges or non-skewed concrete box culverts will be considered on an individual basis.

Quantities for bridges and concrete box culverts shown on the Contract Plans (including Standard Plans) will

beconsidered the Base Pay Quantity. Calculated additions or deductions will be applied to the Base Pay Quantity

when quantity changes authorized by the Engineer are made. Changes include, but are not limited to, the

following:

• Raising or lowering foundations

• Lengthening or shortening concrete box culverts

• Correcting Plan quantity errors or placement details 761761761761761761

When authorized quantity changes in the bar reinforcement Plan Quantity are made, Lump Sum payments will be

adjusted on a pro-rata basis as follows:

than two percent, the Bridge Office will recalculate the plan quantity.

If the recalculated Plan Quantity differs by more than two percent from the original Plan Quantity, the Plan quantity

will be revised by the Bridge Office to equal the recalculated quantity or the Contractor’s quantity, whichever is

lower. The Lump Sum payment will be adjusted on a pro-rata basis.

When the Contractor exercises an optional feature of the Plans that results in the only increase or decrease to the

Base Pay Quantity, there will be no increase or decrease in payment. However, if the two percent variation is

being considered, the effects of the optional feature will favor the Department.

Payment for prestressed concrete deck panels will be 35 percent of the lump sum superstructure reinforcement

steel price. Payment will be made after panels are placed.

Payment for post-tensioned box girder bridges will be 35 percent of the lump sum superstructure reinforcement

steel price only for the reinforcement steel in the top slab of the box.. 762 762 762 762 762 762