1002REINFORCEMENT BARS

1002.1DESCRIPTION —This work is the furnishing and placement of reinforcement bars for cement

concrete construction.

1002.2MATERIAL—

reinforcement bars as specified in Section 709.1(c). Galvanized reinforcement bars as specified in Section 709.1(e) may be substituted for epoxy -coated reinforcement bars . As indicated, provide stainless steel reinforcement bars as specified in Section 709.1(f). Uncoated, corrosion-resistant steel reinforcement bars may be substituted for epoxy-coated reinforcement bars as specified in Section 709.1(g). When uncoated, corrosion-resistant steel reinforcement bars are utilized, the Representative will select, for ea ch size of reinforcement bar used, one sample (comprised of three increments, where each increment is collected from separate reinforcement steel bars of the same size and lot). Provide samples 48 inches in length. Immediately package and deliver the samples to the Representative. The Representative will submit the field verification samples (Sample Class FV) to LTS for testing to determine conformance to the specified requirements.

• Annealed Iron Wire. ASTM A684 as described in Section 1002.3(d)1.

• Cement. Section 701

• Water. Section 720.1

• Welding Material. Section 1105.02(t)

physical requirements:

• Ultimate tensile strength of mechanical splice system 90% of specified ultimate tensile strength of reinforcement bars, minimum

• Allowable slip See Table A

• Yield strength of mechanical splice system 100% of specified yield strength of reinforcement bars, minimum

• Fatigue resistance, allowable slip (California Test No. 670, +25 kips per square inch to - 25 kips per square inch for 10,000 cycles) 0.05-inch, maximum

Table A Reinforcing Bar Number Total Slip (inch), Maximum 3 0.010 4 0.010 5 0.010 6 0.010 7 0.014 8 0.014 9 0.014 10 0.018 11 0.018 14 0.024 18 0.030

Provide an epoxy-coated mechanical splice system to splice epoxy coated reinforcement bars. Apply a minimum coating thickness of 7 mils to repaired areas but not exceeding the manufacturer’s recommendations, and repair according to the following sections of ASTM A775:

• Scope. Section 1

• Referenced Documents. Section 2

• Terminology. Section 3

• Powder Coating. Section 5.2

• Patching Material. Section 5.4

• Surface Preparation. Section 6

• Coating Application. Section 7

• Coating Thickness Testing. Sections 8.1.3 and 8.1.4

• Coating Adhesion. Section 8.4

• Retests. Section 10

• Repair of Damaged Coating. Sections 11.2, 11.3 and 11.5

Provide a galvanized mechanical splice system to splice galvanized reinforcement bars. Thread reinforcement bar ends before galvanization. Remove all grease, oils, or other contaminants that would adversely affect the bond before galvanization. Galvanize the mechanical splice system according to ASTM A153 with a minimum thickness of 2 mils or 1.2 ounce per square foot. Tap the splice system oversize according to ASTM A563, Section 7.4. Chromate according to ASTM A767, Section 4.3. Provide a stainless steel mechanical splice system to splice stainless steel reinforcement bars compatible with one of the UNS designations listed in Section 709.1(f) for stainless steel reinforcement bars. The Representative will select, for each size of reinforcement bar used, four splices, either sample or actual. Three are to be assembled for testing to verify the physical properties and one is to remain unassembled for testing of coating thickness or verification of reinforcement bar strength in case of a failing test result . Assemble samples or actual splices in the presence of the Representative according to the manufacturer's recommendations and Section 1002.3(e). All samples must have a minimum of 30 inches of reinforcement bar extending from each end of the coupler body. Immediately package and deliver the samples to the Representative. The Representative will submit the field verification samples (Sample Class FV) to the LTS for testing and conformance to the specified requirements.

Certify as specified in Section 106.03(b)3.

1002.3CONSTRUCTION—

Provide reinforcement bars free from frost, dirt, oil, grease, paint, mortar, loose rust, mill scale, and other materials that would reduce bond. The Department will not reject reinforcement bars for bonded rust, surface seams, surface irregularities, or mill scale provided the minimum dimensions, cross -sectional area, and tensile properties of a hand wire brushed specimen meet the physical requirements for the size and grade of steel indicated. Remove loose, scaly, or thick rust. A light powdery coating of rust, formed during project storage, does not require cleaning. The Representative will reject reinforcement bars with rusting that has caused detectable reduction in cross -sectional area. Obtain the Representative’s acceptance of in- place reinforcement bars before concrete is placed. Maintain the reinforcement bars in the correct position. Verify the compatibility of the bar schedule with the structure plans and details. Adjust the bar schedule, including reinforcement bar details and quantities, and obtain the Representative’s acceptance before fabrication. The Department will not grant additional Contract time as a result of adjustments to the bar schedule or to reinforcement bars. With each shipment of reinforcement bars delivered to the project, have the material supplier furnish a bill of lading that provides an itemized listing, as shown on the bar schedule for individual structural units, of all bars in the shipment by quantity, size, length, mark, type, weight, and bending dimensions, as indicated. Include general project identification information as well as any appropriate remarks and plan references (drawing number, description, etc.) on the bill of lading. Submit bills of lading to the Representative to verify and document field quantities and for the Department’s project records.

Store reinforcement bars off the ground on platforms, skids, or other supports, and protect the reinforcement bars from mechanical injury and surface deterioration caused by exposure to conditions producing rust. Keep reinforcement bars free from frost, dirt, oil, grease, paint, mortar, loose rust, mill scale, and other materials that would reduce bond. Handle and store epoxy-coated reinforcement bars by methods that will not damage the epoxy coating. Furnish all systems for handling epoxy-coated reinforcement bars with adequately padded contact areas if possible. Pad all bundling bands and lift all bundles with a strong back, multiple supports, or platform bridge to prevent bar-to-bar abrasion from sags in the bar bundle. Do not drop or drag bars or bundles. Transport and store epoxy -coated reinforc ement bars on wooden or padded supports. For additional storage and handling requirements for epoxy-coated reinforcement bars see Section 1002.3(g)1. Follow additional storage requirements for stainless steel reinforcement as specified in Section 1002.3(i)3. Follow additional storage and handling requirement for galvanized reinforcement bars, as specified in Section 1002.3(h)2. Follow additional storage requirements for uncoated, corrosion-resistant steel reinforcement as specified in Section 1002.3(j)3.

to make minor adjustments when approved by the Representative. If field bending or straightening is required, see Table B. Do not field bend rail or axle steel. Field bend uncoated, corrosion- resistant steel reinforcement bars at ambient temperature and do not bend or straighten bars in a manner that will damage the material. Heating of the uncoated, corrosion- resistant steel reinforcement bars to facilitate bending is not allowed. Cut uncoated, corrosion-resistant steel reinforcement bars by shearing or with a flui d-cooled say. Torch cutting of uncoated, corrosion-resistant steel reinforcement bars is not allowed.

TABLE B Bend and Straightening Requirements (1) (2) Bar Size Carbon Equivalent Bend Temp. F Straighten Temp. F Bar Size Dia. of Former Inches Min. 4 through 7 Unknown 1400-1500 1400-1500 4

0.55 or less and A 706 or 1400-1500 or 1400-1500

8 Any 1400-1500 1400-1500 8 8 >8 Bending and straightening not recommended

• 450F to 600F • 1800F and greater

Note: A. Apply heat to sufficient area to encompass bend area.

placing and settling of concrete using metal chairs or acceptable supports. Do not allow bar spacing to vary from the design spacing by more than 1/2 inch. Do not allow the distance from the surface of the formwork to the bars to vary more than 1/4 inch from the design distance. Do not place reinforcement bars closer than 1.5 times the maximum nominal size of the aggregate used in the concrete mix design. Firmly tie bars with annealed iron wire or secure the bars with acceptable metal clips. Tie bars at all perimeter intersections and at all intersections on the top mat of bridge decks and in bridge barriers. For other intersections, when bar spacing is greater than or equal to 12 inches, tie all intersections; when bar spacing is less than 12 inches, either tie all intersections or tie alternate intersections in each direction to provide a staggered tie layout. Tie bundled bars together at not more than 6- foot centers. When reinforcement bars are tied together and lifted into place as a unit, ensure stability of the unit and maintain proper bar alignment during lifting and placement operations. For epoxy-coated reinforcement bars and galvanized reinforcement bars , provide plastic -coated tie wire, epoxy-coated tie wire, metal clips, or plastic clips. When tying stainless steel reinforcement bars together, provide tie wire meeting one of the UNS designations as specified in Section 709.1(f) for stainless steel reinforcement bars. When attaching stainless steel reinforcement bars to any other dissimilar metals, provide 1/8-inch thick (minimum) nylon, polyvinylchloride, or polyethylene spacers or sheathing to ensure no contact between the reinforcement bars a minimum of 1 inch extending beyond the point of intersection in all directions. Use nylon or plastic coated wire ties to bind the spacers and/or reinforcement. When attaching uncoated, corrosion- resistant steel reinforcement bars to other uncoated, corrosion- resistant steel reinforcement bars use nylon or plastic coated wire ties. When uncoated corrosion-resistant steel reinforcement bars are attached to or may come in contact with any dissimilar metals, provide 1/8 inch thick (minimum) nylon, polyvinylchloride, or polyethylene spacers or sheathing to ensure no contact between the reinforcement bars for a minimum of 1 inch extending beyond the point of int ersection in all directions. Use nylon or plastic coated wire ties to bind the spacers and/or reinforcement. If fabric reinforcement is shipped in rolls, straighten it into flat sheets before placing it. Do not weld cross bars (tack weld) for assembly of reinforcement bars unless authorized in writing by the Representative.

bar supports, supplementary bars, or other devices. Supply such devices of proper height and at sufficiently frequent intervals to maintain the distance between the reinforc ement bars and the formed surface or the top surface of deck slabs within 1/4 inch of that indicated. Support platforms, supporting personnel and equipment during concrete placement, directly on the forms and not on the reinforcement bars. For uncoated, c orrosion-resistant steel reinforcement bars, provide pl astic supports as specified in Section 1002.3(d)2.c or steel bar supports as specified in Section 709.1(g). Use corrosion-resistant supports with plastic coated feet above steel beams or metal stay in place forms.

2.a Mortar Block Supports . Furnish mortar blocks of the same class as the concrete in which they are to be embedded. Use either a tie wire or, if the gravitational force of the reinforc ement bars is sufficient to firmly hold the blocks in place, a groove in the top of the block. For epoxy-coated reinforcement bars or galvanized reinforcement bars , use plastic -coated or epoxy -coated tie wires. Do not use mortar blocks on vertical surfaces.

2.b Wire Supports. Furnish wire bar supports, such as ferrous metal chairs and bolsters conforming to industry practice as described in the Manual of Standard Practice of the CRSI. Ensure that chairs or bolsters that bear against the forms for exposed surfaces are either Class 1 - Maximum Protection (Plastic Protected) or Class 2, Type B - Moderate Protection (Stainless Steel Tipped) for which the stainless steel conforms to ASTM A 493, Type 430. For epoxy -coated reinforcement bars or galvanized reinforcement bars, provide plastic -coated, epoxy -coated, or galvanized wire bar supports and bar clips. For stainless steel reinforcement bars, provide plastic supports as specified in Section 1002.3(d)2.c or stainless steel bar supports meeting one of the UNS designations as specified in Section 709.1(f) for stainless steel reinforcement bars. Use stainless steel supports with plastic coated feet above steel beams or metal stay in place forms.

2.c Plastic Supports. Use chairs and bolsters that do not deflect more than 1/4 inch under the minimum point load requirement of 350 pounds -force as described in PTM No. 430. Use supports molded in a configuration that does not restrict concrete flow.

installation of prestressing ducts or tendons, as required to provide planned clearances to the prestressing tendons, anchorages, and stressing equipment, as approved by the Representative.

allowed by the Representative. Do not splice bars, except as indicated or directed. If splicing is allowed, lap the reinforcement bars as shown on the Standard Drawings and as indicated, and wire together securely. Do not substitute alternate bars unless allowed by the Representative. Stagger splices as far as possible. In lapped splices, place and wire the bars maintaining the minimum distance to the surface of the concrete as indicated. Do not use lapped splices for Nos. 14 and 18 bars, except as provided in Articles 5.11.5.2.1 and 5.11.5.5.1 of the AASHTO LRFD Specification. As indicated, use welded splices or mechanical splice systems. For welded splices, use butt splices only. Stagger welded splices or mechanical splice system connections if possible. Do not weld uncoated, corrosion-resistant steel reinforcement bars. Only use welded splices if indicated or if the Chief Bridge Engineer gives written authorization to do so. Ensure that welding conforms to the Structural Welding Code, Reinforcing Steel, AWS D1.4. Do not use welded splices on epoxy-coated reinforcement bars or galvanized reinforcement bars. Do not weld so close to epoxy-coated reinforcement bars to cause any heating of the coating. Do not use welded splices on uncoated, corrosion-resistant steel reinforcement bars. Do not weld close to uncoated, corrosion-resistant steel reinforcement bars to prevent any heating of those reinforcement bars. Assemble all mechanical splice systems according to the manufacturer’s recommendations. Furnish a copy of the manufacturer's recommendations to the Representative. Mark reinforcing bars with scribe marks or indelible ink before splice attachment to ensure equal embedment. When epoxy coated or galvanized mechanical splice systems are used, clean, assemble and repair any visible damage to the coating with an acceptable repair material according to the manufacturer's

recommendations. For epoxy coated mechanical splice systems, seal off the epoxy coated rebar at the point of entry into the mechanical coupler using an acceptable epoxy repair material. Use a mechanical splice system manufactured from uncoated, corrosion- resistant steel as specified in Section 709.1(g) to splice uncoated, c orrosion-resistant steel reinforcement bars as specified in Section 709.1(g). Do not encase mechanical splices in concrete until visual examination and required testing have been completed and approved.

during fabrication, epoxy -coat the exposed portion of the bars. Wire brush the bars before applying the epoxy coating. If epoxy -coated stirrups are expected to be exposed for more than 6 months, cover with opaque polyethylene, or other suitable material, to prevent ultra-violet damage to the epoxy coating.

using epoxy-coated reinforcement bars:

bars at the jobsite for more than 2 months. If field storage on site is expected to exceed 2 months, cover the epoxy-coated reinforcement bars or bundles with opaque polyethylene or other protective material. Provide ventilation to prevent condensation from forming under the covering. Store, handle, and place epoxy -coated reinforcement bars at the jobsite according to ASTM D3963. Inspect the bars before placement. If the epoxy coating is damaged and the damages do not exceed 2% of the surface area in any 1-foot section of the epoxy-coated reinforcement bars, repair all visible damage according to ASTM D3963 before bar placement. Replace epoxy-coated reinforcement bars if damage to the surface area exceeds 2% in any 1-foot section. Do not apply heat to bend or straighten bars. After placement, inspect the epoxy-coated reinforcement bars again and repair areas damaged during placement.

with a minimum coating thickness of 5 mils according to CRSI Manual of Standard Practice section 3.2. 6. Provide galvanized appurtenances according to ASTM A123 Table 1 with a coating grade consistent with the measured wire diameter or thickness.

galvanized reinforcement bars:

at the jobsite for more than 30 days. Store as specified in Section 1002.3(b) to allow air circulation to prevent the formation of wet storage stain. If field storage is expected to exceed 30 days, cover bars with opaque polyethylene or other protective material. Provide galvanized reinforcement bars having uniform appearance. Do not use reinforcement bars with visible corrosion deposits, uncoated spots, spikes, or acid, flux or black spots. During galvanization, use methods that prevent bars from becoming stuck together. Do not field bend galvanized reinforcement bars except to make minor adjustments when approved by the Representative. Do not apply heat to bend or straighten galvanized reinforcement bars. Do not place or store galvanized reinforcement bars in contact with uncoated reinforcement bars or other uncoated steel or stainless steel. Before and a fter placement, inspect the galvanized reinforcement bars and repair areas damaged during placement according to ASTM A780 using paints containing at least 92% zinc dust in the dry film to a minimum final coating thickness of 3.1 mils (cured). Prepared damaged areas according to SSPC-SP 11 and feather at least 1 inch of the surrounding undamaged galvanized coating before painting.

with a minimum coating thickness of 5 mils according to CRSI Manual of Standard Practice section 3.2.6. Provide galvanized appurtenances according to ASTM A123 Table 1 with a coating grade consistent with the measured wire diameter or thickness.

using stainless steel reinforcement bars:

sleeves around bending pins and contact points during the bending operation to prevent contamination.

reinforcing bars to non-stainless steel reinforcement bars or other dissimilar metals. Do not store non- stainless steel reinforcement bars or other dissimilar metals above stainless steel reinforcement bars unless adequate protection has been provided to prevent contamination. Provide stainless steel reinforcement bars having a uniform appearance. Do not use stainless steel reinforcement bars with visible surface oxidation or corrosion deposits. Do not field bend except to make minor adjustments when approved by the Representative. When field bending is required, do not allow non-stainless steel bending equipment to come in direct contact with the stainless steel reinforcement. After placement, inspect the stainless steel reinforcement to ensure the no contact and tying requirements as specified in Section 1002.3(d) have been met.

requirements apply if using uncoated, corrosion-resistant steel reinforcement bars:

sleeves around bending pins and contact points during the bending operation to prevent contamination.

corrosion-resistant steel reinforcing bars to reinforcement bars or other metallic items manufactured from any dissimilar metals. Do not store uncoated, corrosion-resistant steel reinforcement bars uncovered at the jobsite for more than 2 months. If field storage on site is expected to exceed 2 months, cover the bars or bundles with protective material. Provide ventilation to prevent condensation form forming under the covering. Do not store uncoated, corrosion-resistant steel reinforcement bars below or in contact with reinforcement bars manufactured from any dissimilar metals unless adequate protection has been provided to prevent contamination. Provide uncoated, corrosion-resistant steel reinforcement bars having a uniform appearance. Do not use uncoated, corrosion-resistant steel reinforcement bars with visible surface oxidation or corrosion deposits. Do not field bend except to make minor adjustments when approved by the Representative. When field bending is required, do not allow uncoated, corrosion-resistant steel reinforcement to come i n direct contact with bending equipment manufactured form any other dissimilar metals. After placement, inspect the uncoated, corrosion-resistant steel reinforcement to ensure the no contact and tying requirements as specified in Section 1002.3(d) have been met.

1002.4MEASUREMENT AND PAYMENT—

As indicated for the type specified. Galvanized coating weight is incidental to the weight of the reinforcement bar.

Annealed iron wire, chairs, ties, spacers, and sheathing are incidental to the weight of the reinforcement bar.

As indicated for the type specified. Painting the uncoated threads and/or repairing the epoxy coating of the splice area after assembly is incidental, if epoxy-coated reinforcement bars and mechanical splice systems are used.