SECTION 811 STEEL REINFORCEMENT
811.01 CLASSIFICATION AND CONDITION. This specification covers bars,
welded steel wire fabrics, bar mats, steel wi re, prestressing strands, and load transfer assemblies. Ensure that these materials, when incorporated into the work, are reasonably free from dirt, paint, oil, grease, loose-thick rust, or other foreign substance and, when deemed necessary, are cleaned to the satisfactio n of the Engineer. The Department will not require cleaning when these materials exhibit tight, thin, or powdery rust. Reject reinforcement rusted sufficiently to cause it to fail specified physical properties or prestressing strands displaying pits visible to the naked eye.
811.02 BARS. For all bar reinforcement use Grade 60 deformed bars except as indicated
for the following items:
A.JPC Pavement Tie Bars, Paved Ditches, St eps, Flume Inlets, Integral Curb, Right- of-Way Markers, Transverse Bars for Bar Mats, Piles, Cribbing, Small Drainage Structures, Pipe Headwalls, or Manhole Tops. Use Grade 40, 50, or 60 deformed bars.
B.Steel Piling Encasement and Spiral Reinforcement for Precast (non-prestressed) Piling. Use Grade 40, 50 or 60 plain or deformed bars.
C.Spiral Reinforcement (excluding piles). Use Grade 60 deformed or plain bars.
811.02.01 Requirements. Furnish bar reinforcement for bridges, cast-in-place
culverts, and cast-in-place retaining walls that conforms to ASTM A 615 (billet) or ASTM A 996 (rail). ASTM A 706 steel is acceptable with prior approval of the Division of Materials. Do not weld any steel bar reinforcement unless it is ASTM A 706 rebar. The Engineer will accept anrail steel bar reinforcement in straight lengths only. Do not use rail steel reinforcement where field bending is allowed or required. Furnish bar reinforcement for other uses that conform to either ASTM A 706 (weldable), ASTM A 615 (billet), ASTM A 996 (rail), or ASTM A 617 (axel).
811.02.02 Testing and Acceptance. Identify all shipments of steel reinforcement by
the producer’s heat or test identification numbers. Obtain bar reinforcement from manufacturers included on the Department’s List of Approved Materials. To be included on this list, Fabricators shall conform to KM 64-101 and shall participate in the National Transportation Product Evaluation Program (NTPEP) for Reinforcing Steel. Current data must be posted in NTPEP DataMine.
811.03 HOOK BOLTS AND ANCHOR BOLTS. Conform to the design and
dimensions provided in the Standard Drawings. Furnish hook tie-bolts that, when assembled as a unit, are capable of sustai ning an axial load of 14,000 pounds or greater.
811.04 PLAIN WELDED WIRE REINFORCEMENT (WWR). Conform to ASTM
A 1064.
811.05 DEFORMED WELDED WIRE REINFORCEMENT. Conform to ASTM A
1064.
811.06 BAR MATS. Conform to ASTM A 184 and fabricate by welding deformed
Grade 60 weldable bars.
811.07 STEEL WIRE. Conform to AASHTO M 32.
811.08 PRESTRESSING STRANDS. Ensure that Uncoated Seven-Wire Stress
Relieved Strand for Prestressed Concrete conforms to AASHTO M 203, Grade 270 or low 811-1 relaxation strand Grade 270 as specified.
811.09 Load Transfer Assemblies (Contraction and Expansion).
The Department will approve the design of assemblies before delivery to the project. The Department will approve assemblies incorporating the typical features depicted by the Standard Drawings. The Department will reject assemblies at any time that deviate from previously approved designs and manufacturing procedures. Shop fabricate all assemblies. Where chair bars fit over ends of dowel bars , form them to obtain a snug fit over the end of the dowel bar not welded to the chair bar. Control welding to prevent a significant reduction in the areas of the dowel bars or the wires. Modify the load-transfer assemblies fu rnished for slip form construction to allow for approximately 4 inches of clearance between the assemblies and the slip forms. Accomplish this by welding the outer leg of the chair at an angle of approximately 90 degrees with the upper and lower spacer bars.
811.09.01 Chair, Spacer, Aligning Bars, and Upper Tie Bars. Furnish steel for
these items that conforms to AASHTO M 32.
811.09.02 Dowel Bars. Furnish dowel bars that are plain round bars conforming to
ASTM A 706, A 615, A 996, or A 617 with respect to mechanical properties only. Provide either Grade 40, 50 or 60 steel. Saw cut the free ends of the dowels and ensure that they are free of burrs or projections. Broken or sheared ends are acceptable with prior approval of the Division of Materials. Coat dowel bars according to AASHTO M 254 with the following exceptions for Type B coatings:
1.ensure that the thickness is 12 3 mils,
2.subject the coated dowel bars to a bend test (KM 64-102),
3.use a bond breaker from the Department’s List of Approved Materials for load transfer assemblies,
4.the maximum pull-out load shall not exceed 2,500 pounds,
5.loose dowel bar ends that have been saw cut (broken or sheared if permitted) shall be epoxy coated. Use any Type B Coatings that are on the Department’s List of Approved Materials for epoxy coating materials, and apply them (except for thickness) according to Subsections
811.10.03 and 811.10.04.
The Department will inspect and accept dowel bars with Type B coatings as specified in Subsection 811.10.06. Obtain a Certificat e of Compliance as specified in Subsection
811.10 07.
811.09.03 Dowel Bar Sleeves. Furnish a sleeve for each dowel bar used with
expansion joints. Place these sleeves on alternate and opposite ends of the dowels. Furnish sleeves manufactured from sheet metal or metal tubing having a minimum thickness of .010 inch, 32 gage. Ensure that they are of such length as to cover no less than 2 inches nor more than 3 inches of the dowel, have a closed end, fit the dowel bar snugly, and are of such design as to provide an unobstructed expansion space of no less than one inch to allow movement of the dowel bar.
811.09.04 Fabrication Tolerance. Ensure that the longitudinal alignment of dowel
bars in load transfer assemblies is within 1/4 inch in 18 inches of the specified alignment. When checked along the total length of the dowels, allow the deviation to be 0 1/4 inch for assemblies on a zero degree skew, and 3 1/4 inch for assemblies on a 9.5 degree skew.
811.10 EPOXY COATED STEEL REINFORCEMENT. Conform to ASTM A 775.
811-2
811.10.01 Uncoated Bars. Ensure that the deformed steel bars conform to the
applicable requirements of Subsections 811.01 and 811.02. In addition, blast clean all surfaces of the steel bars to a near-white surface finish according to SSPC-SP 10. Blast clean to produce a surface having a profile no greater than 3 mils. Immediately before application of the coating, ensure that the blast cleaned surface corresponds with either pictorial standard A SP 10, B SP 10, or C SP 10 of SSPC-Vis 1, and the surfaces are free of all dust and grit.
811.10.02 Epoxy Coating Material. Select the epoxy coating material for reinforcing
steel from the Department’s List of Approved Materials. Ensure that the coating material conforms to the prequalification requirements of ASTM A 775. Submit documentation in the form of test results from a private testing laboratory verifying that the coating material conforms to ASTM A 775 to the Division of Materials to gain approved list status. Select and furnish the powdered epoxy resin of the same material and quality as the resin which has been previously submitted for prequalification. Ensure that the resin manufacturer annually furnishes a written certif ication to the Division of Materials that attesting to the sameness of the powdered epoxy resin. Obtain the approval of the Engineer for epoxy material for touch-up and repair work. Ensure that the epoxy material furnished by the epoxy manufacturer is compatible with the coating material and inert in concrete, and is suitable for use in the field.
811.10.03 Application of Epoxy Coating Material. Ensure the epoxy application is
performed by an epoxy coater that is certified and participating in the CRSI (Concrete Reinforcing Steel Institute) certification program. Apply the powdered epoxy resin to the blast cleaned steel bars within 8 hours after blast cleaning and before any visible rusting of the near-white surfaces appears. Apply the resin as an electrostatically charged dry powder sprayed onto the grounded steel bars by electrostatic sprays. Ensure that the steel bars are at the temperature recommended by the powdered epoxy resin manufacturer at the time of the application of the coating. After coating the bars, give them the thermal treatment recommended by the manufacturer of the powdered epoxy resin to provide fully cured coating on the bars. Touch up all uncoated areas of electrical contact points as directed. Ensure that the epoxy coating applied to the bars is uniform and smooth with 90 percent of the film thickness measurements falling between 7 and 12 mils for bar sizes Nos. 3 to 5 and 7 to 16 mils for bar sizes Nos. 6 to 18 after curing, when checked according to KM 64-102. The Department will reject the coated bars for either an insufficient or excessive film thickness or a partially cured coating.
811.10.04 Properties of the Coated Bars. Ensure that the coated bars, after curing,
display a continuous, flexible, and abrasion resistant coating as determined by the following.
A.Continuity of Coating. After curing, check all bars visually for defects in the coating such as holes, voids, delaminations, contamination, and damaged areas. In addition, check for “holidays” (pinholes not visually discernible) according to KM 64-102. When any bar has more than 2 defects or “holidays” per linear foot or a total defective area exceeding 0.25 percent of the surface area per linear foot, repair the defects or “holidays” with the touch-up material. When any bar has more than 5 defects or “holidays” per linear foot or a total defective area exceeding 0.5 percent of the surface area per linear f oot, the Department will reject the bar.
B.Flexibility of Coating. The Department will evaluate the flexibility of the coating by bending tests according to KM 64-102. Ensure that the coated bars are capable of being bent to 180 degrees for bar sizes Nos. 3 to 11 and 90 degrees for bar sizes Nos. 14 to 18 (after rebound) over a mandrel, without any visible evidence of cracking the coating.
C.Recleaning. Do not remove the coating from rejected bars for the purpose of 811-3 recoating by any process involving temperatures higher than 500 F.
D.Color of Coating. For all epoxy coatings use a light color that will provide a distinct contrast with the color of cleaned steel, and the color of rusted steel.
811.10.05 Fabrication of Coated Bars. Fabricate the steel bars into the shapes and
lengths specified on the bridge plans either before or after coating. When performing fabrication after coating the bars, repair any damage to the coating. Repair the coating on straight portions of the bars when damaged or bare areas exceed 0.25 percent of the coated area per linear foot or when individual damaged areas are in the order of 0.063 square inch, 1/4 inch by 1/4 inch or larger. When repairing coating, clean and repair all damaged and bare areas on the straight portion of the bar. When the amount of repair in the straight portion of a bar exceeds 2 percent of the surf ace area per linear foot the Department will reject the bar. Repair coating within each bent area of the bar when bond loss and damage exceed 0.25 percent of the surface area within each bent area or when individual damaged areas are in the order of 0.063 square inch, 1/4 inch by 1/4 inch or larger. When repairing coating, clean and repair all damage within each bent area. When the amount of repair in a particular bent portion of a bar exceeds 2 percent of the surface area, the Department will reject the bar. It is not necessary to repair hairline cracks that do not have bond loss or other minor damage on fabrication bends. Do not allow the amount of touch-up area for repair of defects and necessary overlap to exceed 5 percent of the surface area of the bar per meter for straight bars. Do not allow the amount of touch-up area for repair of defects and necessary overlap to exceed 10 percent of the surface area of the ba r per linear foot for bent portions of bars. The Department will approve of all cleaning and repair methods and materials. Coat the ends of the coated bars cut during fabrication with the epoxy used for repairs. Repair the damaged areas and the coating of the ends of cut bars within 24 hours and before any visible rusting appears. Obtain the Department’s approval for any additional requested splices to accommodate lengths suitable for coating. Make requested additional splices at no additional expense to the Department. Coat all areas receiving touch-up material, including ends with a minimum thickness of 5 mils. The Department will allow a maximum thickness of 16 mils in repair of overlap areas. Extend touch-up material, applied to sheared or sawn bar ends to coat the resulting damaged area, up to a maximum of 7 inches from the end of the bar. When the sheared or sawn surface conforms to the specifications after touch-up, the Department will not count the bar end and first 7 inches from the bar end in determining the percent of repair area.
811.10.06 Inspection and Acceptance. Before subjecting them to blast cleaning and
coating with the powdered epoxy resin, confirm that uncoated steel bars are from a manufacturer on the Department’s List of Approved Materials for Reinforcing Steel Manufacturers. The Department may inspect and test all materials at the coating plant, and after delivery to the project. Use an epoxy coater to apply the coating that is on the Department’s List of Approved Materials. To be approved, epoxy coaters must conform to KM 64-101 and KM 64-102. If the Department’s inspection or testing indicates that material furnished to a Department project materially differs from the specification requirements, the Department will review and reconsider the approval of the epoxy coater’s quality control program.
811.10.07 Documentation. Ensure that each shipment of epoxy coated steel
reinforcement is accompanied by documentation prepared by the epoxy coater according to KM 64-101.
811.11 Acceptance Procedures for Non-Specification Rein-
FORCING STEEL. Ensure that all reinforcing steel conforms to the requirements of this section. However, when non-specification reinforcing steel is inadvertently incorporated into the work before completion of testing, the Department may accept the material with a reduction in pay, provided the failure is marginal and will not cause poor performance. 811-4 When the failure is excessive, then remove the reinforcing steel, and replace it unless the Engineer determines that the reinforcing steel can remain in place with a 100 percent reduction rate. The Department will apply the largest payment reduction when the material fails to meet more than one specification requirement. The Department will calculate the payment reduction on the invoice cost of the material delivered at the project site. The Department will reject reinforcing steel that fails and has not been incorporated into the work. YIELD STRENGTH % of Requirement 97% - 100% or more 91% - 96% 86% - 90% 85% or less Reduction Rate 0% 20% 50% (1) TENSILE STRENGTH % of Requirement 97% - 100% or more 91% - 96% 86% - 90% 85% or less Reduction Rate 0% 20% 50% (1) ELONGATION % of Requirement 97% - 100% or more 91% - 96% 86% - 90% 85% or less Reduction Rate 0% 20% 50% (1) WEIGHT PER FOOT % of Requirement 94% - 100% or more 89% - 93% 86% - 88% 85% or less Reduction Rate 0% 20% 50% (1) EPOXY COATING THICKNESS Thickness (mils) Nos. 3 to 5 7 - 13 14 - 15 0 – 6 Over 16 Nos. 6 to 18 7-16 17-18 0-6 Over 19 Reduction Rate 0% 25% (1)
1.Remove and replace the reinforcing steel unless the Engineer determines that the steel can remain in place at a 100% reduction rate. 811-5 SECTION 812 STRUCTURAL STEELS
812.01 Structural Steel Shapes, Plates, Bars, and Fasteners.
Conform to Charpy V-notch toughness requirements for structural steel for load carrying members in bridges when specified in the Plans.
812.01.01 Structural Steel, All Types . Conform to AASHTO M 270 (ASTM A 709),
Grades 36, 50 50W, 70W, HPS70Wand 100W. When the supplementary requirement of this specification are specified, they exceed the requirements of ASTM A 36, A 514, A 572, A 588, and ASTM A 852.
A.Structural Steel. Conform to AASHTO M 270 Grade 36, ASTM A 709 Grade 36, or ASTM A 36.
B.High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality. Conform to AASHTO M 270 Grade 50, or ASTM A 709 Grade 50, or ASTM A 572.
C.High-Strength Low-Alloy Structural Steel with Minimum Yield Point to 4 Inches Thick. Conform to AASHTO M 270 Grade 50W, ASTM A709 Grade 50W, or ASTM A 588.
D.Quenched and Tempered Low-Alloy Structural Steel Plate with 485 MPa Minimum Yield Strength to 4 Inches Thick. Conform to AASHTO M 270 Grade 70W, ASTM A 709 Grade 70W, or ASTM A 852.
E.High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding. Conform to AASHTO M 270 Grade 100/100W, ASTM A 709 Grade 100/100W, or ASTM A 514.
F.High-Strength Low-Alloy, Quenched and Tempered Structural Steel Plate. Conform to ASTM A 709 Grade HPS70W.
812.01.02 Hot-Rolled Carbon Steel Sheets a nd Strip of Structural Quality, Grade
33 (Corrugated Steel Plank for Bridge Floors). Conform to ASTM A 1011.
812.01.03 Cold Rolled Carbon Steel Sheet of Structural Quality, Grade “D” (40
ksi) (Corrugated Steel Plank for Bridge Floors). Conform to ASTM A 1008.
812.01.04 Steel Sheet Piling. Conform to AASHTO M 202 (ASTM A 328).
812.01.05 Frames and Grates (for Catch Ba sins, Inlets, Outlets, and Manholes).
Use steel in these items that conforms to A36 or A572 to the following properties: Yield Strength 36 ksi. minimum Tensile Strength 58 ksi minimum Elongation in 2-inch specimen 21 percent minimum
812.01.06 Hollow Structural Sections (HSS). Conform to ASTM A500.
812-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 583–587 of 718.