602FINAL 20181217

602.01 DESCRIPTION. Furnish and place steel for reinforcement of concrete. Furnish

bars, spirals, welded wire fabric, bar mat, or other specified reinforcement, of the quality, type, size, and quantity designated by the Contract.

602.02 Materials.

602.02.01 Steel Reinforcement. Conform to Section 811.

602.02.02 Epoxy Coating Material. Conform to Section 811.

602.02.03 Welded Steel Wire Reinforcement (WWR). Conform to Section 811.

602.03 Construction.

602.03.01 Protection of Material. Handle and store steel reinforcement to prevent

bending, excessive rusting, or contamination with objectionable substances.

602.03.02 Straightening. Before placing in the work, straighten reinforcement bent

during shipment or handling without injuring the steel. Do not heat the steel, or use steel with sharp kinks.

602.03.03 Bending. Bend reinforcement cold to the dimensions and shapes specified

in the Plans and to within tolerances designat ed in the CRSI Manual of Standard Practice. In bending, do not injure the steel. Bend bars in the shop before shipment, not in the field.

602.03.04 Placing and Fastening. Accurately place all steel reinforcement as shown,

and firmly hold in position while placing and during hardening of concrete. Hold in position to within a tolerance of  1/2 inch, and place to within a tolerance of  1/4 inch of specified clearance from the face of concrete, except for bridge deck reinforcement steel. Place steel reinforcement for bridge slabs to within the tolerances specified in Subsection 609.03.03. Dimensions shown from the face of concrete to bars are clear distances. Bar spacings are from center to center of bars. Tie bars at all intersections, except where spacing is less than one foot in both directions, then tie alternate intersections. Always pass vertical stirrups around the main tension members and securely attach them to the members. Use Engineer approved supports to maintain distances from forms and to accurately position reinforcement as necessary. Use precast blocks composed of mortar or Engineer approved supports for holding reinforcement from contact with the forms. Ensure that the tips of metal chair supports in contact with the surface of the concrete are plastic coated steel. When using plastic coated steel supports, provide a minimum of 1/8 inch thickness of the plastic material between the metal tips and the exposed surface of the concrete. The Engineer will accept metal supports as specified for epoxy coated bars. Securely tie down the steel placed in reinforced concrete slabs to prevent any possibility of steel rising above the specified elevation during placing, vibrating, and finishing the concrete as required by Subsection 609.03. Ensure that metal supports have a shape that will be easily enveloped by the concrete. Separate the top and bottom mats of bars with precast mortar blocks, Engineer approved supports or by other equally suitable de vices. Do not use pebbles, pieces of broken stone or brick, metal pipe, and wooden blocks as separators. Securely place reinforcement in any member, and then obtain the Engineer’s approval before placing concrete. The Engineer may reject concrete placed in violation of this provision. When using epoxy or non-epoxy adhesive or gr out to install steel reinforcing bars into existing concrete, provide an approved Type IV epoxy resin system conforming to Section 826 or if included in the proposal, the Special Note for Non-Epoxy Adhesives. Drill and install reinforcing to the embedment depth shown in the plans. Install epoxy or non- epoxy adhesive in accordance with the manufacturer’s recommendations including 602-1 hole size, drilling equipment and method, hole cleaning equipment and method, mixing and dispensing epoxy, and reinforcement insertion. Provide an embedment depth capable of developing the yield strength of the reinforcing bar based on the manufacturer’s literature for the epoxy materi al used if no resistance or embedment depth is shown in the plans. Do not alter the manufacturer’s mixing nozzle or dispenser. Post-installed reinforcement must be clean and free from grease, oil, or other foreign material. Furnish the adhe sive system manufacturer’s written recommendations for installation, cleaning, and use for approval . Demonstrate hole cleaning method to the Engineer for approval and continue the approved process for all post-installed reinforcement. Contact the Engineer 7 days in advance of the installation date to set up a testing schedule. After installation of the first 50 reinforcing bars, the Department will randomly select 5 and proof load the installed bars to 100% of the bars yield strength with zero slippage unless otherwise shown in the plans or approved by the Engineer. If any of the bars fail in bond, either revise the installation procedure, if applicable, or provide another adhesive that is capable of passing this test. The Engineer may require additional job site testing or may waive testing with the written approval of the Director, Division of Construction. .

602.03.05 Special Requirements for the Installation of Epoxy Coated Bars. Either

coat all tie wires, clips, chairs, bar supports, and other metallic materials used for the installation of the epoxy coated reinforcing bars with fusion bonded epoxy resin or with an approved vinyl type material, or make them of an approved non-metallic material. Use an epoxy material that provides a uniform continuous coating having a film thickness of 12  7 mils. Use vinyl-type material that is pliable and provides a uniform continuous coating having a thickness of 30  10 mils. Test installation devices coated with either material according to KM 64-106. Allow the Engineer to check the installation devices for flaking, chipping, or any other defects during the pre-pour inspection of the epoxy coated reinforcing bars, and repair or replace the devices as the Engineer deems necessary. Coat tie wires with a flexible plastic or vinyl material to a thickness of 12  7 mils. The Engineer will test the coating according to KM 64-106. Provide all systems for handling coated bars with padded contact areas for the bars whenever possible. Pad all bundling bands, and lift all bundles with a strong back, multiple supports, or a platform bridge so as to prevent bar-to-bar abrasion from sags in the bar bundle. Use nylon slings for direct epoxy bar contact. Use loading and unloading procedures and equipment that does not damage the coating. Unload and store the epoxy coated steel bars on the project site in a manner to avoid damage or contamination. Avoid extended outdoor storage of coated bars of over 2 months. If expecting the outdoor storage to exceed 2 months, cover the bars for protection against the elements and to prevent condensation from forming on the bars. Install the bars in the bridge deck according to applicable requirements of Section 609, except as provided in this section and as the Engineer deems necessary in order to protect and preserve the epoxy coating. Repair all cuts, nicks, and abrasions that exceed 0.25 percent of the surface area and the bar end with the epoxy repair material supplied by the powdered epoxy resin manufacturer. If the total surface area covered with patching material exceeds 2 percent in a one foot section, sheared ends not included, remove and replace them with acceptable bars. Also, repair any damaged metallic accessories with a suitable material. Make every reasonable effort to repair all damaged areas of the reinforcing steel and accessories before any rusting occurs. If infrequent and small damaged areas do rust, thoroughly remove the rust by sandblasting or other Engineer approved methods before repairing the areas. Ensure that the coated bars, when incorporated into the work, are reasonably free from dirt, paint, oil, grease, or other foreign substance, and, when deemed necessary, clean the bars to the satisfaction of the Engineer. Place concrete in the deck using methods and equipment that will not damage the coated materials. 602-2 Since the epoxy coating is flammable, do not expose the coated bars to any fire or flame. Do not cut coated bars by burning.

602.03.06 Splicing. Do not splice any reinforcement that is not of the type and at the

locations specified in the Plans without the Engineer’s written permission. The Department will allow the use of lapped splices, welded splices, mechanical couplers, or other positive connection splices specified in the Plans or designated by Engineer. Do not weld rail steel bar reinforcement used for bridges, cast- in-place culverts, and cast-in-place walls. Make all splices added in the field and not specified in the Plans as far from the point of maximum tensile stress in the member as practical, and stagger splice points 3 feet or more in adjacent bars, when possible. Do not use any splices which reduce the clear distance between the splice and the closest bar to less than the minimum clear distance required by the design specifications. Do not use mechanical couplers having a diameter of greater than 125 percent of the nominal diameter of the reinforcing bar in the top bars in beams, slabs, or girders in which the concrete under the top bars is 12 inches or more in depth. Make all splices with clean, sound materials properly affixed to the members being spliced and free of any substances that would weaken or contaminate the splice or concrete surrounding the splice. Provide lapped splices that have a length no less than that specified in the Plans. When using lapped splices in areas not specified in the Plans, conform to the AASHTO LRFD Bridge Design Specifications and obtain the Engineer’s approval. Splice bars by rigidly clamping or to otherwise wire together in a manner the Engineer approves. Make splices for spirals, where necessary, with a minimum lap of 1.5 turns of spiral. When welding splices, conform to the AWS Reinforcing Steel Welding Code. Butt together and weld bars to develop, in tension, at least 125 percent of the specified yield strength of the bars. Do not use welded splices unless specified in the Plans or as the Engineer approves. Use mechanical couplers primarily for bars required for compression only. Use only mechanical couplers or bars designed to carry critical tension or compression that are equivalent in strength to approved welded splices (125 percent of the specified bar yield strength). When the Engineer allows welded splices or mechanical couplers, prepare 2 test specimens of the spliced reinforcement for subm ittal to the Division of Materials for testing before incorporating the splices into the work, and submit one additional test specimen for each 100 splices made. Ensure that only personnel who are qualified in conformance with the AWS Reinforcing Steel Welding Code make the welded splices.

602.03.07 Welded Steel Wire Reinforcement(WWR). Overlap sheets of WWR by

40 or more times the nominal diameter of the longitudinal wires to maintain a uniform strength, and securely fasten the sheets at the ends and edges.

602.04 Measurement.

602.04.01 Steel Reinforcement. The Department will measure the quantity, including

bars used to replace test specimens, by the pound in the final work based on the theoretical number of pounds. The Department will not measure clips, wire, chairs, or other material used for fastening, supporting, or positioning reinforcement in place for payment and will consider them incidental to this item of work. The Department will not measure welded splicing for payment and will consider it incidental to this item of work. The Department will base quantities of materials furnished and placed on the calculated weights of the reinforcing steel actually placed. The Department will calculate the weights based upon the following table: 602-3

602.04.02 Steel Reinforcement, Epoxy Coated. The Department will measure the

quantity according to Subsection 602.04.01. The Department will not measure the epoxy coating or its application for payment and will consider it incidental to this item of work.

602.04.03 Mechanical Couplers. The Department will measure the quantity by each

individual unit installed in the completed structure. Test specimens submitted as per Section

602.03.06 will not be counted as a unit installed in the completed structure.

602.05 PAYMENT. The Department will make payment for the completed and accepted

quantities under the following: Code Pay Item Pay Unit 08150 Steel Reinforcement Pound 08151 Steel Reinforcement, Epoxy Coated Pound 08130-08139 Mechanical Reinforced Couplers, Size Each 08140, 08141 Mechanical Reinforced Couplers Epoxy Coated, Size Each The Department will consider payment as full compensation for all work required under this section. ASTM STANDARD REINFORCING BARS Bar Size Nominal Mass Nominal Dimensions - Round Sections English and (metric) pounds per foot Diameter inches Cross Section Area, sq. inches Perimeter inches #3 (10) 0.376 0.375 0.11 1.178 #4 (13) 0.668 0.500 0.20 1.571 #5 (16) 1.043 0.625 0.31 1.963 #6 (19) 1.502 0.750 0.44 2.356 #7 (22) 2.044 0.875 0.60 2.749 #8 (25) 2.670 1.000 0.79 3.142 #9 (29) 3.400 1.128 1.00 3.544 #10 (32) 4.303 1.270 1.27 3.990 #11 (36) 5.313 1.410 1.56 4.430 #14 (43) 7.650 1.693 2.25 5.320 #18 (57) 13.600 2.257 4.00 7.090 602-4 SECTION 603  FOUNDATION PREPARATION AND BACKFILL

603.01 DESCRIPTION. Excavate and backfill or dispose of all materials required for

the construction of bridges, box culverts, and other structures for which excavation is not otherwise provided.

603.02 MATERIALS AND EQUIPMENT. Use fabric wrapped backfill drains

conforming to Section 845.

603.03 CONSTRUCTION. Remove and dispose of all materials excavated for the

construction of the foundations for all structures, including the removal of existing structures. Place backfill to the original ground level and perform final cleaning up.

603.03.01 Classification. Perform structure excavation necessary for all bridge

foundations and culverts, except pipe culverts, as Structure Excavation Solid Rock or Structure Excavation Common. Perform structure excavation necessary in the construction of cribwalls and retaining walls as Structure Excavation Unclassified.

603.03.02 Channel Preservation. When any excavation or dredging is done at the

site of the structure, do not excavate outside of caissons, cofferdams, steel piling, or sheeting, and do not disturb the natural stream bed adjacent to the structure without the Engineer’s written permission.

603.03.03 Footing Excavation. Notify the Engineer at least 48 hours in advance of

beginning structure excavation. Excavate the foundation pits to allow placing of the full width and length of footings specified in the Plans with full horizontal beds. Do not use rounded or undercut corners and edges of footings. Ensure that all rock and other hard foundation material is free from all loose material, cleaned, and cut to a firm surface, either level, stepped, or roughened, as directed. Clean all seams and fill with concrete, mortar, crushed stone, or sand. When masonry is to rest on an excavated surface other than durable rock or durable shale (SDI equal to or greater than 95 according to KM 64-513), do not disturb the bottom of the excavation, and do not make the final removal of the foundation material to grade until just before the masonry is to be placed. When unsuitable foundation material is encountered, excavate and replace with acceptable material as the Engineer directs. Maintain the excavation free of standing water, insofar as is practical. When the Plans require the foundation for a bridge or culvert to be solid rock or shale, drill into the foundation material to confirm its suitability. The contractor shall drill test 603-1