509Concrete Reinforcement

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509.01 Description. This work consists of furnishing and placing supports, mechanical

connectors, tie wires, and uncoated (black), epoxy coated, galvanized, chromium, stainless steel and GFRP concrete reinforcement of the quality, type, size, and quantity designated, including steel dowels.

509.02 Materials. Furnish materials conforming to:

Epoxy coated reinforcing steel ......... 709.00 Reinforcing steel, deformed bars ..... 709.01, 709.03, 709.05 Spiral reinforcing steel ..... 709.01 or 709.08 Bar mats and wire fabric ............................. ............................ 709.09, 709.10, 709.12 Plastic supports ................................ 709.15 GFRP deformed bars........................ 705.28 Galvanized reinforcement ............... 709.16 Chromium reinforcement ................ 709.17 Stainless steel reinforcement .......... 709.18 Mechanical Splice Systems.............. 709.19 Do not substitute one type of reinforcement (uncoated, epoxy coated, galvanized, chromium, stainless steel or GFRP) for another except as noted in 709.16. The Department will randomly sample concrete reinforcement and mechanical splices for QA testing according to their respective material specifications. Provide sufficient additional concrete reinforcement to replace that removed by the Department for sampling. Replace random samples in the structures with additional reinforcement, spliced according to 509.07.

509.03 Care of Material. Upon delivery to the project and before use, place concrete

reinforcement on canvas tarps supported off the ground. Within 24 hours of delivery, cover reinforcement with canvas tarps or opaque polyethylene sheeting or other suitable opaque protective material to protect reinforcement from ultraviolet light. Keep the reinforcement covered and free from dirt, oil, grease, or avoidable rust. When handling reinforcement, use equipment that avoids damaging or abrading the reinforcement. Lift bundles of reinforcement with multiple pickup points. Do not drop or drag reinforcement. Prevent exposure of GFRP reinforcement to temperature above 120 ° F during storage. Before placing in the concrete, ensure the reinforcement is clean and free of dirt, oil, grease, and rust. Perform necessary repairs according to 509.10 for epoxy coated reinforcement, 711.02 for galvanized reinforcement and

509.11 for GFRP reinforcement.

509.04 Method of Placing. Place concrete reinforcement in the positions shown on the plans,

and firmly secure the reinforcement during the placing and setting of concrete. Tie bar s in the superstructure at all intersections, except tie bars at alternate intersections where bar spacing is less than 1 foot (0.3 m) in any direction. The Contractor may place up to 25 percent of the upper longitudinal bars in a bridge deck slab beneath the upper transverse bars to support the top mat. Do not drive or force concrete reinforcement into concrete after its initially set. Welding on reinforcing is prohibited, except as permitted by 709.10 and 709.12. The Engineer will allow the Contractor to fabricate reinforcing bar cages for prestressed beams if fabrication is done in a manner satisfactory to the Director. Install concrete reinforcement with the following clearances from the concrete surface:

509.05 Bending. Bend concrete reinforcement to the dimensions shown on the plans and in Table

509.05 1. Reject concrete reinforcement showing transverse cracks.

TABLE 509.05-1 STANDARD BENDS Bar A D Dimension % A D Dimension % A D Dimension % Nominal Dimensions 180 Bend 90 Bend 135 Bend Bar Diameter Area Weight D A D A D A Size in in² lb/ft in in in in in in 3 0.375 0.11 0.376 2 1/4 5 2 1/4 5 1 1/2 4 4 0.500 0.20 0.668 3 6 3 7 2 4 1/2 5 0.625 0.31 1.043 3 3/4 7 3 3/4 8 1/2 2 1/2 5 1/2 6 0.750 0.44 1.502 41/2 8 4 1/2 10 7 0.875 0.60 2.044 5 1/4 10 5 1/4 12 8 1.000 0.79 2.670 6 11 6 131/2 9 1.128 1.00 3.400 9 1/2 15 9 1/2 15 1/2 10 1.270 1.27 4.303 10 3/4 17 10 3/4 18 11 1.410 1.56 5.313 12 19 12 20 14 1.693 2.25 7.65 18 1/4 27 18 1/4 25 18 2.257 4.00 13.60 24 36 24 33 Tolerances: For diameter of bends, “D”, the tolerance may be plus or minus the diameter of the bar. Standard fabricating tolerances shall be in accordance with the CRSI Manual of Standard Practice. No weight allowances will be made for tolerances. Weight applies to steel only.

509.06 Approval of Placing. Before placing concrete, obtain the Engineer ’s acceptance of

concrete reinforcement in place.

509.07 Splicing. Splice reinforcement as specified in the Plans or determined by the Engineer .

Splice spiral reinforcement by lapping 1 1/2 turns. Splice Nos. 14 and larger reinforcing bars with mechanical splice systems. The Department will not permit lap splices for these size bars. Splice additional reinforcement used to replace random samples as follows: TABLE 509.07-1 - SPLICE LENGTHS FOR RANDOM SAMPLES Bar Size Weight (lb/ft) Lap Length (inches) Uncoated/ Galvanized/ Epoxy coated Stainless Steel Uncoated/ Galvanized/ Stainless Epoxy Coated Chromium GFRP 3 0.376 0.374 15 17 24 26 4 0.668 0.679 19 23 32 43 5 1.043 1.048 24 29 39 46 6 1.502 1.495 29 43 47 58 7 2.044 2.038 33 50 55 65 8 2.670 2.685 38 57 63 76 9 3.400 3.396 47 70 78 97 10 4.303 4.321 58 86 96 91 11 5.313 5.296 69 104 115 n/a 14 7.650 7.640 n/a n/a n/a n/a 18 13.600 13.590 n/a n/a n/a n/a 20 16.690 n/a n/a n/a n/a n/a The Department will not permit mechanical splices for GFRP reinforcement.

509.08 Supports. Use precast mortar blocks, epoxy coated, galvanized, stainless steel, or plastic

supports of adequate strength, of the proper depth, and in sufficient number to support concrete reinforcement. Use Table 509.08-1 to determine allowable support material for concrete reinforcement. Space supports for concrete reinforcement no more than 4 feet apart transversely and longitudinally. Supports shall have a shape that is easily enveloped by the concrete. TABLE 509.08-1 – ALLOWABLE SUPPORT MATERIAL Reinforcement Material Support Material Precast Mortar Epoxy Coated Galvanized Plastic Stainless Steel Uncoated X X X Epoxy Coated X X X X X Galvanized X X X X Chromium X X X Stainless X X X GFRP X X X X = Allowable Support Material Mortar blocks may only be used to support the lower mat of reinforcing steel in concrete that is cast directly against bedrock or soil.

509.09 Reinforcement Ties. Use Table 509.09 -1 to determine allowable reinforcement tie

material for concrete reinforcement. TABLE 509.09-1 – ALLOWABLE REINFORCEMENT TIE MATERIAL Reinforcement Material Reinforcement Tie Material Epoxy / PVC Coated Wire Galvanized Wire Plastic/ Nylon Zip Tie Stainless Steel Wire Thermo plastic Clips Uncoated X X Epoxy Coated X X X X Galvanized X X X Chromium X X Stainless X X GFRP X X X X = Allowable Tie Material

509.10 Epoxy Coated Steel Reinforcement. Use bar supports and reinforcement ties that

prevent electrical coupling between mats. Carefully handle and install bars to avoid coating damage that will require field repair. Repair all damaged coating areas where underlying steel surface is exposed. Surface rust is visual evidence of exposed steel surface. Where coating is damaged, use a wire brush or mechanical means to remove rust and loose epoxy. Repair using patching material of the same composition used or provided by the epoxy coating applicator meeting ASTM A775 except the Department will not allow aerosol spray applications. If repair is required, clean and repair the damaged areas and allow adequate cure time before placing concrete. The Engineer will approve the installation once patching has been done as outlined above.

509.11 GFRP Reinforcement. The maximum total unrepaired visible damage on each linear

foot of each GFRP bar shall not exceed 2% of the surface area in that linear foot of bar. The depth of the permissible damage shall not exceed 0.04 in. Replace the damaged bar or lap splice a new G FRP bar adjacent to the damaged portion with the appropriate lap length on either side of the damage. Do not field bend or straighten GFRP bars. Do not field cut GFRP reinforcement.

509.12 Galvanized Steel Reinforcement. Use bar supports and reinforcement ties that prevent

electrical coupling between mats. Carefully handle and install bars to avoid coating damage that will require field repair. Repair all damaged coating areas where underlying steel surface is exposed. Except for damage to due field fabrication, the maximum amount of repaired damaged coating shall not exceed one percent of the total surface area in each 1-ft of bar length. Surface rust is visual evidence of exposed steel surface. Where coating is damaged, repair according to 711.02.

509.13 Chromium Steel Reinforcement. Use bar supports and reinforcement ties that prevent

electrical coupling between mats.

509.14 Stainless Steel Reinforcement. Use bar supports and reinforcement ties that prevent

electrical coupling between mats.

509.15 Method of Measurement. The Department will measure Epoxy Coated Steel

Reinforcement, Galvanized Steel Reinforcement, Chromium Steel Reinforcement and Stainless Steel Reinforcement, by the number of pounds shown on the Plans . The Department will measure GFRP Reinforcement by the total length in feet for each bar size specified on the Plans. Additional measurements or calculations are not required. If the Contractor believes the pay weights or lengths, as shown on the Plans , are in error, the Contractor is responsible to prove this discrepancy by recalculating the total weight or length for the reference number involved. The Contractor shall submit its figures to the Engineer for review and approval. The number of pounds of respective steel reinforcement types shall be the actual number of pounds of the various sizes incorporated in the concrete as shown on the Plans, completed and accepted. The total length in feet for GFRP reinforcement shall be the actual number of feet of the various sizes incorporated in the concrete as shown on the Plans, completed and accepted. If the weight of respective steel reinforcement types is recalculated, determine the number of pounds from the number, length, and weight of the bars as shown on the concrete reinforcement list of the Plans, based on the weight per foot shown in the Table 509.07-1 with deductions for bars not used, and additions for extra bars used as directed by the Engineer . If the length of GFRP reinforcement is recalculated, determine the total length in feet from the number and length for each bar size as shown on the concrete reinforcement list of the Plans with deductions for bars not used, and additions for extra bars used as directed by the Engineer.

509.16 Basis of Payment. The Department will not include the supports, mechanical connectors,

and tie wires in the calculated weights or lengths but will consider them incidental to the price bid. The Department will pay for accepted quantities at the contract price as follows: Item Unit Description 509 Pounds Epoxy Coated Steel Reinforcement 509 Pounds Uncoated Steel Reinforcement 509 Feet No.__ Deformed GFRP Reinforcement 509 Pounds Galvanized Steel Reinforcement 509 Pounds Chromium Steel Reinforcement, Type __ 509 Pounds Stainless Steel Reinforcement

Concrete Reinforcement in other states

• Delaware 611 · CONCRETE REINFORCEMENT
• South Dakota 1010 · CONCRETE REINFORCEMENT
• Tennessee 907 · CONCRETE REINFORCEMENT