540Steel Reinforcement

540.1 Description

This Work consists of providing and placing steel reinforcemen t.

540.2 Materials

540.2.1 Bar Reinforcement

The Contractor shall provide deformed bars in accordance with A ASHTO M 31, Grade 60, or ASTM A706, Grade 60, at the nominal dimensions in accord ance with Table 540.2.1:1, “Nominal Dimensions of Reinforcement.” AASHTO M31 Grade 40 may be used for Reinforced Concrete for Minor Structures (Section 515 only). Table 540.2.1:1 Nominal Dimensions of Reinforcement Bar size Nominal Weight (lb/ft) Diameter (inch) No. 3 0.376 0.375 No. 4 0.668 0.500 No. 5 1.043 0.625 No. 6 1.502 0.750 No. 7 2.044 0.875 No. 8 2.670 1.000 No. 9 3.400 1.128 No. 10 4.303 1.270 No. 11 5.313 1.410 No. 14 7.650 1.693 No. 18 13.600 2.257

540.2.2 Welded Wire Fabric

The Contractor shall provide welded wire fabric in accordance w ith AASHTO M 55.

540.2.3 Spiral Reinforcement

The Contractor shall provide spiral reinforcement fabricated fr om steel bars in accordance with AASHTO M 31, or from cold drawn steel wire in accordance with the AASHTO M 32.

540.2.4 Reinforcing Wire

The Contractor shall provide reinforcing wire in accordance wit h AASHTO M 32.

540.2.5 Corrosion-resistant and Coated Reinforcing Bars

The Contractor may use one (1) of the following corrosion-resis tant or coated reinforcement systems for Bridge decks and other concrete components exposed to weather and Road salts: 1. Epoxy-coated reinforcement in accordance with ASTM A775 and from plants certified by the Concrete Reinf orcing Steel Institute (CRSI) fo r the coating and fabrication process; 2. Deformed stainless steel bars in accordance with ASTM A 955; Section 540: Steel Reinforcement Page 480 3. Stainless steel clad deformed steel bars in accordance with AASHTO M 329; 4. Uncoated low-carbon, chromium, steel bars in accordance with AASHTO MP 18 ; or 5. Hot-dipped galvanized reinforc ement in accordance with ASTM A767.

540.2.6 Coating and Patching Materials

The Contractor shall provide the following coating and patching Materials: 1. A fusion-bonded powdered epoxy resin coating Material that m eets the requirements of ASTM A 775. 2. A liquid, two (2) part epoxy patching Material formulated to be compatible with the fusion-bonded epoxy powder coating, to repair damaged or uncoat ed areas. The patch Material shall meet the requirements of ASTM A775 Annex A 2. 3. Zinc-rich paint with a minimum 65% zinc content in accordanc e with ASTM A780 for patching damaged and uncoated areas of hot-dip galvanizing.

540.2.7 Accessories

The Contractor shall provide plas tic-coated reinforcing tie wir e for tying epoxy-coated reinforcing bars, for deformed st ainless steel bars, for stainl ess steel clad deformed steel bars and for uncoated low-carbon, chromium, steel deformed bars. Th e Contractor shall provide galvanized, annealed wire tires fo r galvanized reinforcing bars . The Contractor shall provide c ontinuous chairs or supports whic h shall be one (1) of the following types of chairs, supports, and clips: 1. Steel, fully coated with pl astic or fusion-bonded epoxy. 2. Galvanized steel, with the cradle and the upper two (2) inch es of the chair, support, or clip, coated with fusion-bonded epoxy or plastic. 3. Galvanized metal chairs or other metal supports for reinforc ement that contacts the exposed concrete surfaces. 4. Galvanized, painted or epoxy- coated metal chairs or other co rrosion resistant metal supports for regular reinforcement. 5. Epoxy coated metal chairs or other corrosion resistant metal supports for epoxy- coated reinforcement. 6. Galvanized sand c hairs or other metal supports placed direct ly on the ground; or 7. Concrete blocks in place of sand chairs or other metal suppo rts placed directly on the ground. The Contractor shall not use uncoated black (ferrous) steel tie s, chairs, supports or clips in direct contact with stainless or galvanized reinforcing.

540.2.8 Certificates of Compliance

The Contractor shall provide Certificates of Compliance to the Project Manager with each reinforcing steel shipment. The Contractor shall show the Project number, the shipping invo ice number, name of the manufacturer, pounds shipped, heat numbers, Laboratory test rep orts, and grade of steel on the Certificates of Compliance. This requirement is the same f or each of the coating/cladding systems and the corrosion-resistant systems.

540.2.9 Epoxy-Coated Reinforcing Bar Certificates of Compliance

The Contractor shall submit evidence that the epoxy-coated rein forcing steel furnished for this Project was produced by a p lant that is currently Certifie d by the CRSI. The Contractor shall provide the Department’s Inspector three ( 3) copies of a Certificate of Compliance for each shipment of coated bars. The Contractor shall state on the certificate that the samples of the coated bars were tested and that the te st results were in accordance with ASTM A 775 and this specification. The Contractor shall show epoxy resin batc h numbers on the certificate. The Contractor shall provide coat ing test results to the Depart ment for inclusion in final inspection reports.

540.2.10 Epoxy-Coated Reinforcing Coating

Epoxy coating shall be applied by the electrostatic spray meth od or other organic coating methods that meet the requirements of ASTM A 775. The Contractor shall provide epoxy coated reinforcing steel th at is produced by a plant that is currently Certified by the CRSI.

540.2.11 Hot-Dip Galvanized Reinforcing Bars

The Contractor shall provide hot -dip galvanized reinforcing bar s in accordance with ASTM A 767. The Contractor shall galvanize bar after cutting a nd bending.

540.2.12 Galvanizing Material

The Contractor shall provide gal vanizing zinc in accordance wit h ASTM B6.

540.3 Construction Requirements

540.3.1 General

The Contractor shall measure di mensions from centerline of bar to centerline of bar. The Contractor shall store all reinforcing bars above ground o n platform skids or other supports. Reinforcing shall be k ept free from dirt, grease, an d other foreign matter. Reinforcing shall be kept free o f corrosion as far as practicab le.

540.3.1 1 Bar Lists and Bending Diagram

When the Contract documents do not include detail bar lists and bending diagrams, the Contractor shall provide such list and diagrams to the State Br idge Engineer for review and approval. The approval of bar lists and bending diagrams shall in no way relieve the Contractor of responsibility for correctness. The bar lists an d bending diagrams shall meet the requirements of the current edition of the Concrete Reinforcing Steel Institute’s (CRSI) publication Reinforcing Bar Detailing. The Contractor shall al low 30 Days for review of the submittal.

540.3.1 2 Bundling and Tagging

The Contractor shall tag and mark reinforcement bar shipments i n accordance with CRSI’s Code of Standard Practice . The Department will allow cold bending around a pin. The Contr actor shall not field bend Grade 60 bars, epoxy-coated bars or hot-dip galvanized bars. Unless otherwise directed, the Contractor shall ensure the bend diameter is in accordance with CRSI Manual of St andard Practice current editio n.

540.3.1 4 Splicing

The Contractor shall splice bars only in accordance with the Pl ans unless otherwise approved by the State Bridge Engineer. The Contractor shall place and tie bars in lapped splices to ma intain minimum reinforcing cover. The Contractor shall splice spiral reinforcement by lapping. T he Contractor shall ensure that laps are at least 48 bar or wire diameters, but not less t han one (1) ft with 90° hooks around longitudinal bars at ends. The Department will allow mechanical couplers for AASHTO M 31, Grade 60, and ASTM A706, Grade 60. Mechanical coupler splice strength must be gre ater than or equal to 125% of the yield strength of the spliced reinforcing bars and must dev elop the specified tensile strength of the bars. ACI 318 “Type 2” mechanical couplers mee t the above splice strength requirements. The Contractor shall submit coupler type (manufa cturer and model number) and certified test results from an approved testing agency show ing that the coupler meets these requirements. If the mechanical couplers are included in the Contract Documen ts, the method of payment for couplers shall be by the each. If the mechanical c ouplers are not included in the Contract Documents but are requested for the convenience of the Contractor, payment shall be incidental to the reinforcing bar pay item. If the mechanical couplers are not included in the Contract doc uments, the Contractor may submit documentation to the Project Manager for showing whe re mechanical couplers are proposed to be used. The Contractor shall show splice loca tions and coupler clearance dimensions in the request and subm it before fabricating the rei nforcing bars that will be coupled. The Contractor shall allow 14 Days for review and app roval of submittals. Unless otherwise specified, the Contractor shall ensure that we lded wire fabric and bar- mat reinforcement overlap is at least one (1) spacing of cross wires plus two (2) inches when measured between the outer-most cross wires of each sheet.

540.3.1 5 Field Cutting

Bars may be cut to length in the field by shearing or sawing. Flame cutting will not be permitted. The ends of coated or c lad bars cut in the field sh all be patched with suitable patching Material.

540.3.1 5.1 Reinforcing Bar Placement

The Contractor shall place reinforcing bars as shown in the Con tract drawings, securely tied in position with wire not smaller than 16 gauge. The Cont ractor shall carefully place, support and tie reinforcing, and place and consolidate concrete around reinforcing with care to avoid any displacement and damage to the coatings. The Contractor shall tie all in tersections where bar spacing is greater than or equal to one

540.3.1 5.2 Reinforcing Bar Placement Tolerances

The Contractor shall ensure that the space between adjacent bar s does not vary more than the greater of ½ inch or 1 /2 4 of the spacing dimension sh own on the Plans. Except for slabs cast on the ground, the Contractor shall ensur e that the clear cover of reinforcement shall not vary more than the greater of either 1/ 4 inch or 1/8 of the dimension shown on the Plans. The Contractor shall ensure that the reinforcement clear cover in slabs cast on the ground does not vary more than minus 1/2 inch from the position shown on the Plans.

540.3.1 6 Cleaning Reinforcing Bars

Before placing concrete, the Contractor shall clean the reinfor cing bars of Materials that would reduce or destroy the bond. 540.3.1.7 Welding of Reinforcing Steel The Contractor shall weld reinforcing steel only if the Contrac t requires it or if the State Bridge Engineer authorizes it in writing. The Contractor shall weld in accordance with AWS Specification D1.4, Reinforci ng Steel Welding Code. Welding of bars other than ASTM A706 is allowed only upon approval of qualified welding procedures f or those bars that comply with AWS D1.4. The Contractor shall submit a Welding Procedure Spec ification, stamped by an AWS certified welding Ins pector for each procedure. Welding reinforcing to other steel added by the Contractor for stiffening, cage alignment, lifting, handling and other Contractor needs shall not be allow ed unless called for in the Plans.

540.3.1 8 Concrete Cover Requirements

Section 540: Steel Reinforcement Page 484 Concrete cover is the distance from the surface of concrete to the edge of the bar nearest to that surface. If cover dimensions are not specified in the Contract, the Contractor shall use the concrete cover dimensions in accordance with Table 540.3.1. 8:1, “Concrete Cover Requirements.” Table 540.3.1.8:1 Concrete Cover Requirements Location Minimum Cover (inch) Concrete cast against and permanently exposed to the ground 3 Concrete exposed to the ground or weather Principal reinforcement 2 Stirrups, ties and spirals 1 ½ Concrete Bridge slabs Top reinforcement 2 Bottom reinforcement 1 Concrete not exposed to weather or in contact with ground Principal reinforcement 1 ½ Stirrups, ties and spirals 1 Bar bundles 2a aOr equal to the diameter of a single bar of equivalent area, wh ichever is greater.

540.3.1 9 Final Inspection

The Contractor shall not place concrete until the Department in spects and accepts the reinforcing steel in place. Acceptance of the reinforcing steel does not relieve the Contra ctor of responsibility for the cover and position control of the steel.

540.3.2 Requirements for Epoxy-Coated Reinforcing Bars

540.3.2 1 Storage and Handling of Epoxy- Coated Reinforcing Bar s

The Contractor shall transport and store epoxy-coated reinforci ng steel on wooden or padded supports. The Contractor shall use devices with padded contact areas to handle epoxy-coated reinforcement bars and prevent bar-to-bar abrasion . The Contractor shall not drop or drag bars or bundles. The Contractor shall use spreade r beams and multiple pick points when hoisting bar bundles to prevent sagging. The Contr actor shall not store epoxy- coated reinforcing bars in sunlight for more than 30 Days. The Contractor shall use only non- metallic sleeved heads with immers ion-type vibrators when placi ng concrete around epoxy- coated reinforcing.

540.3.2 2 Repair of Damaged Epoxy-Coating

The Contractor shall repair visible damage before shipping. Th e Contractor shall ensure the total surface area of patched coating Material is not more than one percent (1%) of the total coated area in any one (1) foot section. The Department will reject bars shipped to the Project that show more than one percent (1%) patched coating Ma terial. Section 540: Steel Reinforcement Page 485 The Contractor shall patch sheared ends, cuts and exposed areas promptly before detrimental oxidation occurs. T he Contractor shall keep expose d areas free of contaminants before patching. The Contractor shall patch coating damage before placing concre te. The Contractor shall ensure that the total patched surface area does not excee d two percent (2%) of the coated area in any one (1) foot section. The Department will r eject any installed bars with more than two percent (2%) patching. The Contractor shall apply the patching Material in strict comp liance with the manufacturer’s instructions. The Contractor shall allow adequa te time for the patch to cure before placing concrete over the bars.

540.3.3 Requirements for Galvanized Reinforcing Bars

540.3.3 1 Galvanizing Bent Bars

Where galvanized bars are deta iled to be bent or have other typ es of cold-forming, the bars must be bent before galvanizing.

540.3.3 2 Surface Preparations

The Contractor shall prepare bar surfaces by removing dirt and grease with a hot alkaline solution. The Contractor shall use a diluted solution of sulfu ric acid to pickle. The Contractor shall use a solution of zinc ammonium chloride to flux. The Co ntractor shall ensure that the resulting surface condition is equal to SSPC-SP 10 as described by the SSPC.

540.3.3 3 Thickness of Galvanizing

The Contractor shall ensure that the galvanizing after drying w ith air, steam or wiping is from three (3) mils to 3.9 mils thick. The Contractor shall de termine the thickness with a magnetic thickness gage.

540.3.3 4 Chromating

The Contractor shall treat the gal vanized coating with chromate . This prevents a reaction between the bars and fresh Portland cement paste. The Departme nt will allow proprietary chromating treatment solutions of equivalent strength instead o f the generic chemical treatment in accordance with ASTM A 767, Section 5.3. Quenchin g of bent bars or bars to be bent is not allowed. Such bars must be chromated at ambient te mperature.

540.3.3 5 Finish and Adherence of Coating

The Contractor shall ensure that the zinc coating is free of ba re spots, blisters, flux spots or inclusions, dross, and acid or black spots. The Department will reject bars that stick together after galvanizing. A ma tte gray finish appearance is not, by itself, a cause for rejection. The Contractor shall ensure that the coating cannot be removed through normal handling.

540.3.3 6 Installation of Galvanized Reinforcing Bars

The Contractor shall transport an d store galvanized bars in a m anner to prevent damage to the galvanized coating. All systems for handling galvanized coated bars shall have padded Section 540: Steel Reinforcement Page 486 contact areas. All bundles of bar s shall be lifted using sprea der beams and multiple pick points or a platform Bridge to prevent bar-to-bar abrasion from sagging in the bar bundle. The bars and bundles shall not be dropped or dragged on the ground, platforms or other bars. Galvanized reinforcing bars shal l not be tied with black steel or left in contact with black steel. Galvanized reinforcing bars shall be left in contact on ly with galvanized, plastic-coated, or epoxy-coated surfaces.

540.3.3 7 Repair of Damaged Galvanizing

The Contractor shall patch sheared ends, cuts and exposed areas using a zinc-rich paint in accordance with ASTM A780. The Contractor shall prepare the surface to be patched so that it is clean, dry and free of oil, grease and corrosion pro ducts. The Contractor shall blast- clean the surface to near-white metal, in accordance with SSPC- SP10. The Contractor shall spray or brush-apply the paint con taining the zinc dust as reco mmended by the manufacturer in one (1) application of as many passes as required to achieve a dry film thickness of four (4) mils as determined using a magn etic or electromagnetic gage.

540.3.4 Repair of Stainless Steel Clad Deformed Steel Bars

The stainless steel clad deformed steel bars shall be shop bent as shown on the Contract documents using tools with non-ferrous surfaces that will not c ontaminate stainless steel cladding with ferrous particles. All ends of the bars where mi ld steel core is exposed shall be capped by one (1) of the following methods: 1. Heat shrink cap applied in accordance with the cap manufactu rer’s instructions. 2. Neoprene cap adhered with silicone or epoxy sealant. 3. Stainless steel cap epoxied in place. 4. Stainless steel seal weld. No field cutting or bending of stainless steel clad deformed s teel bars will be allowed.

540.4 Method of Measurement

The Department will measure reinforcing bar weight in accordanc e with Table 540.2.1:1, “Nominal Dimensions of Reinforc ement,” whether it is black stee l, epoxy-coated, galvanized, stainless steel, stainless steel c lad, or low-carbon, chrome st eel. The computed weights of reinforcing bars will be based on the nominal weights of the ba rs before application of the epoxy-coating, or gal vanizing of the bars. Lap splices shown i n the Contract documents shall be included in computing the weight of the bars for payment. F or CBC construction, lap splice weight shall be included in computing the weight of the bars fo r payment when phased construction is required by the C ontract documents and when max imum run lengths exceed 60 feet. When lap splices are unscheduled or are made for the convenience of the Contractor and are approved by the Project Manager at locations not shown in the Contract, the extra steel required for lap splices will not be included in computin g the weight of the bars for payment. Mechanical couplers that are shown in the Contract do cuments or are required for construction shall be paid for by “Each.” When mechanical coup lers are installed for the convenience of the Contractor and are approved by the State Bri dge Engineer at locations not shown in the Contract, the mechanical couplers will not be paid for.

540.5 Basis of Payment

Pay Item Pay Unit Reinforcing Bars, Grade ____ Pound Section 540: Steel Reinforcement Page 487 Epoxy-Coated Reinforcing Bars, Grade ____ Pound Galvanized Bars, Grade ____ Pound Uncoated Corrosion Resistant Reinforcing Bars, Grade ____ Pound Stainless Steel Reinforcing Bars, Grade ____ Pound Stainless Steel Clad Reinforcing Bars, Grade ____ Pound Mechanical Couplers E a c h

540.5.1 Work Included in Payment

The following Work and items will be considered as included in the payment for the main item(s) and will not be measured or paid for separately: 1. Clips, supports, wire, and othe r Material used for fastening reinforcement; 2. Samples and submittals; and 3. Mechanical couplers and reinforcing bar lap splices that are installed for the convenience of the Contractor. Section 541: Steel Structures Page 488