1603 - WELDED STEEL WIRE FABR IC FOR CONCRETE REINFORCEMENT
1600-8 It is the option of the Bureau Chief of Construction and Materials to grant prequalified status to a plant
based upon the qualification test and inspection resu lts of the transportation agencies of other states. A plant will be notified by written documentation in th e event of any change in their prequalified status. The Bureau of Construction and Materials will maintain a list of all plants that are prequalified to provide fabric to KDOT projects.
b.Plant Quality Control Requirements. The plant must have a quality control section identified within its organization that is adequately staffed to perform the re quired lot by lot testing. The plant laboratory must have proper equipment, calibrated according to AASHTO T 67 (ASTM E 4) annua lly as a minimum, with which to adequately perform all testing required through subsection1603.3 . Provide a copy of the plant quality control plan the Engineer’s representative during the plant inspection.
c.Sampling and Testing Procedure. The Engineer’s representative will select the test samples, at random, at the plant. Provide access to all facilities necessary for the Enginee r’s representative to randomly select samples from all lots defined below. Provide plant personnel to cut and label the necessary specimens from the randomly selected wire and fabric.
1.Lot size. The reinforcing fabric and wire that is subject to sampling includes all sizes and production lots of fabric, and heats or lots of wire in stock. Re move the fabric samples from 10 different production lots. Remove 3 wire samples from each of 10 different lots, heats when available, of wire bein g utilized to produce fabric at the plant. Vary the size of the fabric and wire that is sampled to the greatest extent that availability permits. This is for the purpose of obtaining a representative cross-sec tion of the plant production. These sampling requirements apply unless exceptions are authorized by the Bureau Chief, Construction an d Materials, or their designated representative.
2.Fabric samples are to be contiguous sections, i.e. , all wires and welds intact, that are 6 longitudinal or ‘running’ wires in width by 10 transverse wires in le ngth. Wire tensile samples are to be 2 m in length.
3.Sample preparation. Assign each fabric and wire sample a unique identification number. Durably affix this number to each end of the wire tensile and fabric sa mples. For definition purposes , the length direction of a fabric sample is parallel to the longitudinal wires. Cut each fabric and wire sample into 2 equal length specimen preparation sections. This cut is perpendicular to the long itudinal wires for the fabric samples. Each wire section provides a tensile and bend test sp ecimen and each fabric section provides 4 weld shear test specimens. The specimens from one section are for testing by the plant and the specimens from the co mpanion section are for the comparison testing by the KDOT. Leave the KDOT’s speci men preparation sections in one piece. Conduct all sample preparation operations in the presen ce of the Engineer’s representative.
4.Specimen testing. Test the sp ecimens according to the procedures and requirements of the applicable AASHTO specification as referenced in subsection 1603.2b . For the purpose of comparing the plant and KDOT testing laboratories, one tensile and bend test set from each sample and one weld shear test specimen set from each sample is to be tested by each laboratory. Provide a ll the necessary facilities and test records required by the Engineer’s representative to witness the tests. The Engineer’s representative will witness all relevant testing performed by the producer. Record the plant test results onto a KDOT form and sign the form. Pr ovide these results to the E ngineer’s representative for submittal to the KDOT central laboratory. Submit the remaining companion s ections from each sample to the KD OT central laboratory. It is mandatory that these sections retain their unique identif ication number during shipment and when delivered to the central laboratory. (5) Comparison testing. The companion sections w ill each provide a tensile and bend test specimen set and a set of 4 weld shear test specimens th at will be tested by the KDOT central laboratory according to the procedures and subsection 1603.2b . The KDOT results will be compared to the parallel plant data from each heat or lot for variations and differences. These variations and di fferences may not exceed the following, based on the KDOT values as the reference where applicable: 1603 - WELDED STEEL WIRE FABR IC FOR CONCRETE REINFORCEMENT
1600-9 Table 1603-1: Welded Steel Wire Fabric Comparison Testing
Property Individual Specimen Test Results Average Test Results for the Heat or Lot Tensile Strength 10% 5% All variations and differences are absolute value based. A heat or lot that fails the comparison requirements may be resampled one time only, and on a 2 to 1 basis. It is preferable that the resample be removed from the same heat or lot that failed. The initial test results will be replaced by those of the resample specimens. A lot that fa ils the weld shear test requirements may be resampled in accordance with the procedures of subsection 1603.2b .
d.Plant Status.
1.Attainment of prequalified status. In order for a plant to be prequalified to provide welded wire fabric to KDOT projects, the following requirements must be complied with:
a.With the exceptions as noted in (b) and (c) to follow, no single heat of those tested is permitted to fail to comply with the appli cable requirements referenced in subsection 1603.2b .
b.No heat or lot tested by the KDOT may have any of the individual test results for yield strength, tensile strength, reduction of area (when applicable), or the average weld shear strength below the AASHTO specified minimum values without the deficiency also being identified by the plant quality control section.
c.It is permissible for one bend test specimen from 1 heat or lot only to fail the bend test. (d) The variations from the comparison testi ng are not to exceed the values stated in subsection 1603.5c(5) for any heat or lot of wire.
2.Renewal of prequalified status. Plants that have attained their initial prequalification status will remain prequalified unless the results of verification samples indicate quality control deviations, or there are significant changes in production methods or material characteristics. Any variations in production methods or material characteristics must be immediately broug ht to the attention of the Bureau Chief, Construction and Materials, to determine if a subsequent prequalification evaluation is required. A prequalified plant that becomes disqualified must comp ly with all the requirements that apply to a plant that is attempting the initial prequalification, with the fo llowing exception. The disqualified plant may petition for an immediate reevaluation provided it can be demonstrated to the Bureau Chief, Construction and Materials, that the disqualifying deficiencies have been corrected.
3.Disqualification. All prequalified plants that are currently providing welded steel wire fabric for KDOT projects will have their product quality monitored through the use of verification samples.
a.Verification samples. During the course of each calendar year, every KDOT District will randomly select a minimum of one verification sample from the fabric being provided by each prequalified plant for use on KDOT projects in th e District. These samples will be drawn from various shipments and heats and may be obtained at the project, fabrication, or warehouse locations or any other location approved by the En gineer’s representative. These samples will be submitted to the KDOT central laboratory fo r testing according to the procedures and requirements of subsection 1603.2b .
b.Verification sample testing. The verification samples are to comply with the minimum requirements of the appli cable AASHTO specification of subsection 1603.2b with the exceptions as noted in the following. It will not be permissible for the test results from any annual verification sample from a prequalified plant to be less than the following: 1603 - WELDED STEEL WIRE FABR IC FOR CONCRETE REINFORCEMENT
1600-10 Table 1603-2: Welded Steel Wire Fabric Verifi Cation Testing
Property Requirement Unit Weight, Deformed Wire only: 98% of the specified minimum Weld Shear Strength, Average 95% of the specified minimum Tensile Strength 95% of the specified minimum Reduction of Area,%, Non-deformed Wire only: Specified minimum minus 2 No annual verification sample from a prequalified plant will be permitted to fail the bend test. In the event that the verification sample fails to co mply with the preceding, the Engineer’s representative may resample the failing lot one time only on a two to one basis or reject the failing lot. The contractor is to replace the rejected lot at no add itional cost to the KDOT. The initial test results will be replaced by those of the resample specimens. Failure of the verification sample fabric from a plant to comply with the sample requirements of subsection 1603.5d(3)(b) will result in disqualification of the plant and remova l from the prequalified source list. In the event of disqualification, the plant is subject to subsection 1603.5 . A plant that fails to comply with subsection 1603.5d(3)(b) 2 times, consecutive or otherwise, will be permanently disqualified. 1603.6 BASIS OF ACCEPTANCE The plant must be currently prequalified. Receipt and approval of a Type C certification as specified in DIVISION 2600 . Single sections, bound sections or rolls, or otherwise grouped fabric must be tagged or otherwise marked in a durable manner. At a minimum, this identification must list the fabric manufacturers corporate identification and plant location, the heat, lot, job, or mill order number, and display a copy of the of the identification markings attached to the delivered materials. The final disposition of the fabric will be completed at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1604 - HELICAL REINFORCEMENT
1600-11 Section 1604
HELICAL REINFORCEMENT 1604.1 DESCRIPTION This specification covers steel wi re and steel bars intended for use in helical reinforced members. 1604.2 REQUIREMENTS Provide materials that comply with AASHTO M 32 fo r plain, uncoated wire, or AASHTO M 31 for carbon steel bars. 1604.3 TEST METHODS Test methods as cited in the AASHTO references. 1604.4 PREQUALIFICATION Manufacturers desiring to provide material under this specification must be prequalified under the provisions of: Steel bars ........................................................................................................ SECT ION 1601 Uncoated wire ................................................................................................ SECT ION 1603 Epoxy coated reinfor cement ........................................................................... SECTION 1602 1604.5 BASIS OF ACCEPTANCE Prequalification as required by subsection 1604.4 . Submit for approval a Type A certification ( certified mill test report), as specified in DIVISION 2600 , that governs the analysis of all bar or wire steel heats delivered to the project. Receipt and approval by the Engineer of a copy of the shipping orde rs or invoice sh owing the project number, heat or lot number, steel size and quantity in the shipment. Tag each bundle of helical reinforcement sent to the pr oject with a plastic or metal tag which lists the plant name and the heat or lot number, or other identification tyi ng the material to the certifica tions and invoices as stated above in this subsection. 1605 - REINFORCING STEEL SPLICES
1600-12 Section 1605
REINFORCING STEEL SPLICES 1605.1 DESCRIPTION This specification covers devices and systems for splicing steel bars for concrete reinforcement. Thermomechanical splices are produced by a process that introduces molten filler metal into an annular space around the bars created by a high strength st eel sleeve of larger diameter than the bars. Make the mechanical splices with any mechani cal device or system which will meet the physical requirements cited below. 1605.2 REQUIREMENTS When tested in tension, develop all splices to at least 125% of the minimum yield strength specified for the bars being spliced. After loading in tension to 30 ksi then relaxing to 3 ks i, the total slip of the bar within the splice sleeve shall not exceed 0.01 inch for #14 bars and smaller, and 0.03 inch for #18 size bars. Displacements will be measured between gage points clear of the splice sleeve. For those splicing systems to be prequalified in the “fatigue resistant” group, provide splices capable of withstanding a load range of 12 ksi (3 ksi to 15 ksi, tension) for a minimum of 1,000,000 cycles. Prepare and mount splices on bars in a fabricator's shop for ship ment to the project that meet SECTION 1601 including prequalified plant status. 1605.3 TEST METHODS Splicing devices or systems will be tension tested according to the procedures of AASHTO M 31, “Deformed and Plain Carbon Steel Bars for Concrete Reinforcement” and slip tested according to subsection 1605.2 . 1605.4 PREQUALIFICATION Prepare 3 fully assembled test specimens each for bar sizes number 4, 6 and 8, and forward them to the Engineer of Tests along with the following information: Name, address and telephone number of the manufactur er. Include the name of the preferred contact person. Brand name of the splice. Type and description of the splice. Information regarding recommended usage and splicing instructions. Material Safety Data Sheets (if applicable). For those splicing systems to be prequalified in the “fatigue resistant” group, submit test results from an independent testing laboratory demonstrating that the splice meets the fatigue requirements described above. Test splices for #4, #8, and # 11 size, Grade 60 reinforcing steel. These sizes represent the small, medium, and large sizes common in construction. Exceptions to the bar sizes specified above ma y be authorized by th e Engineer of Tests. The samples provided will be tested to destruction and test reports prepared. During testing, the Engineer of Tests will determine if operator prequalification is require d for field and/or fabricator shop splicing, and enter that information on the test reports. The test reports and the information supplied will be reviewed by the Bureau Chief of Construction and Materials. The manufacturer will be a dvised as to whether or not the product is prequalified. The Bureau of Construction and Materials will mainta in a list of prequalified splicing systems. Products will remain prequalified as long as the manufacturing pr ocesses remain unchanged, a nd field experience indicates that the product functions appropriately. Changes in manufacturing processes require new prequalification testing. Failure of the product to function appropriately in the fi eld will be cause for removal from prequalified status. Products removed from prequalified status will be consid ered for requalification if the manufacturer can provide
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 753–757 of 978.