1602 - EPOXY COATED STEEL FOR CONCRETE REINFORCEMENT
1600-5 Section 1602
EPOXY COATED STEEL FOR CONCRETE REINFORCEMENT 1602.1 DESCRIPTION This specification covers the requirements for epox y coated steel for concrete reinforcement. The protective epoxy coating is applied to the reinforcing steel by the electrostatic spray or th e electrostatic fluidized-bed method. 1602.2 REQUIREMENTS
a.General.
1.Appendices to the standards cited below that are identified as non-mandatory information in those standards, are to be considered mandatory information for the purposes of this specification. (2) Applicators must be certified under the Concre te Reinforcing Steel Institute (CRSI) Epoxy Coating Plant Certification program.
b.Epoxy Coated Steel Bars.
1.Unless shown otherwise in the Contract Docume nts, use uncoated steel bars that comply with SECTION 1601 for straight bars or SECTION 1604 for helical reinforcement.
2.Apply an epoxy coating that complies with ASTM A 775.
3.Fabricators must comply with the provisions of ASTM D 3963, “Standard Sp ecification for Fabrication and Jobsite Handling of Epoxy-Coated Reinforcing Steel Bars."
c.Epoxy Coated Steel Wi re and Welded Wire Fabric.
1.Unless shown otherwise on the Contract Documents, use material which complies with SECTION 1603 for welded wire fabric or SECTION 1604 for steel wire.
2.Apply an epoxy coating that complies with ASTM A 884, Type 1 with Class A coating thickness. Prestressed beams may utilize preformed welded wire fabric having an ASTM A 884, Type 2 coating. Do not re-bend after applying the Type 2 coating.
d.Dowel Bars and Straight Tie Bars* for Pavement.
1.Use steel bars that comply with SECTION 1601 .
2.Apply an epoxy coating that complies with ASTM A 775. (3) Coating or patching material need not be applied to the cut end faces of the bars. For dowel bars to be mounted in baskets, coating will not be required within 2 inches of the end that will be fixed in the supporting basket by welding. (4) Cut the bars by a method that minimizes heat input and surface da mage and results in no appreciable deformation of the ends. * Refers to straight bars that are not bent after being epoxy coated. For field straightened tie bars (delivered bent), provide uncoated Grade 40 st eel bars that comply with SECTION 1601 . Do not use epoxy co ated steel for field straightened tie bars. 1602.3 TEST METHODS As specified in the ASTM standards referenced above. 1602.4 PREQUALIFICATION
a.Applicators. Epoxy coating applicator plants supplying material to KDOT projects must be prequalified. Follow the instructions on CRSI’s website to participate in the Epoxy Coating Plant Certification program. Send a copy of the most r ecent yearly certification, gr ade sheets and inspection notes, as well as audit responses when applicable, to the Bureau of Construction and Materials for review. In order to maintain prequalified status, send copies of the yearly certification, grade sheets and inspection notes, as well as audit response when applicable, each year as soon as they are received from CRSI. Failure to 1602 - EPOXY COATED STEEL FOR CONCRETE REINFORCEMENT
1600-6 provide copies of this information may result in removal from prequalified status.
b.Organic Coatings. Organic coatings used for protection of reinforcing steel under this specification must be prequalified under ASTM A 775 or in the case of dowel bars or straight tie bars for pavement, ASTM A 934 if applicable. Manufacturers desiring to supply material should submit a certified test report by an independent laboratory regularly inspected by the Cement and Conc rete Reference Laboratory (CCRL) to the Bureau of Construction and Materials.
c.Patching Material for Organic Coatings . Patching material for organic coatings used for protection of reinforcing steel under this specification must be prequalified under ASTM D 3963. Manufacturers desiring to supply material should submit a certified test report by an independent laboratory regularly inspected by the Cement and Concrete Reference Laboratory (CCRL) to the Bureau of Construction and Materials.
d.Prequalified Lists. The Bureau of Construction and Materials will maintain lists of prequalified applicators, organic materials and patchi ng materials for use on KDOT projects. 1602.5 BASIS OF ACCEPTANCE Receipt and approval by the Regional Materials Labo ratory of the documents re quired for the uncoated reinforcing steel. Receipt and approval by the Regiona l Materials Laboratory of a certifi cation prepared by the Plant that applied the coating, stating that all bars have been coated in accordance with this specification. Provide this certification to the KDOT represen tative at the coating plant. Satisfactory results of bend tests (if applicable), coating thickness and continuity tests conducted on the coated material by re presentatives of KDOT. Visual inspection at destination fo r proper tagging of each bundle to enab le identification of each heat or lot, for condition and for other properties. 1603 - WELDED STEEL WIRE FABR IC FOR CONCRETE REINFORCEMENT
1600-7 Section 1603
WELDED STEEL WIRE FABRIC FOR CONCRETE REINFORCEMENT 1603.1 DESCRIPTION This specification governs the welded steel wire fabric for concrete re inforcement that is produced from deformed or non-deformed steel wire or a combination thereof. 1603.2 REQUIREMENTS
a.General .
1.Any plant producing welded steel wire fabric for concrete reinforcement through this specification must be currently prequalified. A plant is any facility that weld s the steel wire fabric from wire produced internally or obtained from an external source. (2) The fabric provided through this specification can be produced from deformed or non-deformed wire or a combination of both unle ss specified otherwise in the Contract Documents.
3.The fabric is to be produced to the dimensi ons and sizes as specified the Contract Documents. Deviations from this requirement must have the doc umented approval of the Engineer’s representative.
b.Material Specifications. Non-deformed steel wi re ................................................................................ AASHTO M 32 Deformed steel wire ....................................................................................... AASHTO M 225 Fabric produced from non-deforme d steel wire ............................................. AASHTO M 55 Fabric produced from deformed wire or a combination of deformed and non-deformed wire .................................................................................. AASHTO M 221 1603.3 TEST METHODS Conduct all tests as specified in subsection1603.2b . 1603.4 PREQUALIFICATION Follow the instructions on the AASHTO National Transportation Product Evaluation Program’s (NTPEP) website to participate in the welded wire producing mill audit program. Forward an official copy of the initial (and latest) NTPEP audit report, including split sample results, to the Bureau Chief of Construction & Materials for evaluati on. Producing mills that have successfully met the requirements of the audit (including test results that comply with subsection 1603.2b. ) and are listed on the NTPEP website as compliant will be prequalified. In order to maintain prequalified status, send a copy of the annual NTPEP certifi cate of compliance as soon as it is received. Producing mills th at have been removed from the NTPEP website listing will be removed from prequalified status. For producing mills that attain “provisional” status on the NTPE P website, immediately forward a description of the failing material (sizes, grade, and h eat) to the Bureau Chief of Construction & Materials. Producing mills that fail to provide the annual certificate of compliance or descriptions of failing material associated with a “provisional” NTPEP status, or are no longer in compliance with the audit requirements may be removed from prequalified status. 1603.5 PREQUALIFICATION (Alternate Method)
a.General. Contact the Bureau Chief of Construction and Materials to arrange for the required sampling, observation of testing procedures and review of the plant quality control program. The plant is to absorb all the Engi neer’s representative’s expenses asso ciated with the inspection. This includes travel, subsistence and lodging, and the expenses of shipping the selected wire and fabric specimens to the KDOT Materials and Research Center for comparison testing. 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:
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 750–753 of 978.