709REINFORCEMENT STEEL

709.1REINFORCEMENT BARS—As indicated, from a manufacturer listed in Bulletin 15, and conforming

to the following requirements:

40 is indicated (non-bridge items only), Grade 60 may be substituted on a bar-to-bar basis at no additional cost to the Department. If using deformed bent tie bars in pavement structures, use only Grade 40.

AASHTO M 31 (ASTM A615), Grades 40 or 60.

• Section 5. Materials Subsection 5.2. “Maintain the certification for the powder coating material at the applicator's site. Provide only a light colored coating that will reveal rusted or undercoated areas of steel .”

Subsection 5.2.1. Revise as follows: “Provide written certification in accordance with Pennsylvania Department of Transportation Publication 408, Section 709.5 that the powder supplied meets the requirements of Annex A1 of this specification.”

• Section 8. Requirements for Coated Steel Reinforcing Bars. Subsection 8.1.3. Revise the first sentence as follows: “For acceptance purposes, 90% of all recorded coating thickness measurements must not be less than the specified minimum thickness or more than the specified maximum thickness.”

Subsection 8.2.1. Add a second sentence as follows: For Department verification purposes, after shipment, a hand held 67.5V, 80 000 ohm, wet-sponge type direct current holiday detector or equivalent method will be used to test plant or project samples consisting of an approximate 4 ft. length of bar cut from a full production bar or cut from a bar shipped to a project.

Subsection 8.2.2. Add a third sentence as follows: For quality control and quality assurance purposes, the average applies to the full production length of a bar or to a Department verification sample consisting of an approximate 4 ft. length of bar cut from a full production length bar or cut from a bar shipped to a project.

2.a QC. Section 106.03(a)2. Submit a QC Plan to the CMD.

2.b Repair all sheared or cut ends and/or damaged areas with epoxy patching material according to the QC Plan and ASTM D3963, modified as follows:

• Section 3. Coating Repair Materials

• Subsection 3.1. Add the following sentences: “ Provide verification that the material has been tested and conforms to Annex 1. Certify each shipment of this material as specified in Pennsylvania Department of Transportation Publication 408, Section 106.03(b)3.”

• Section 7. Repairs Subsection 7.1.3 Coat sheared/cut ends with approved patch material to have a minimum coating thickness of 7 mils.

Control repair of damaged epoxy coating and sheared/cut ends according to ASTM A775, Section

in Bulletin 15. Furnish patching or repair material that is inert in concrete. F urnish patching or repair material that can be satisfactorily used at the coating application facility, at the bar fabrication facility or at a project location in the field.

The patching or repair material must be compatible with the coating, inert in concrete, and feasible for repairs at the applicator, fabricator, or in the field. Control repair of dama ged epoxy coating and sheared/cut ends according to ASTM A775, Section 11, modified as follows.

• Section 11. Permissible Amount of Damaged Coating and Repair of Damaged Coating Subsection 11.2. Furnis h patching or repair material that is compatible with the coating as approved and listed in Bulletin 15. Furnish patching or repair material that is inert in concrete. Furnish patching or repair material that can be satisfactorily used at the coating application facility, at the bar fabrication facility, or at a project location in the field.

Subsection 11.4. Coat sheared/cut ends with approved patch material to have a minimum coating thickness of 7 mils.

Handle and store coated bars at the fabricator’s facility according to the requirements of ASTM D3963.

coated reinforcement bars. Separate bundled pieces before pickling. Galvanize straight bars only in accordance with ASTM A 767. Where bent bars are indicated, bending may be performed only after galvanizing is performed. Provide a Class 1 coating weight conforming to the requirements given in Table 1. Ensure that each piece is completely galvanized. During galvanization, use methods that prevent bars from becoming stuck together . Immediately quench t he galvanized reinforcement bars in the chromate bath specified in ASTM A767. Repair all sheared or cut ends and/or damaged areas, as defined in ASTM A767, in accordance with ASTM A 780. Cracking, flaking, tears, or spikes in the zinc coating at bend areas is considered to be damaged. Test galvanized reinforcement bars for embrittl ement after galvanizing by bend testing samples of the galvanized reinforcement bars in accordance with ASTM A615. Reject any lots found to be embrittled.

stainless steel reinforcement bars in accordance with ASTM A955, Grade 60 meeting one of the following UNS Designations:

• S24100, S30400, S31653, or S31803

reinforcement bars may be substituted for epoxy coated reinforcement bars on a bar -to-bar basis. Substitutions other than on a bar -to-bar basis may only be pursued through the Value Engineering (VE) process for substructure units only, which includes the submission of a substructure design utilizing the higher strength available from uncoated, corrosion-resistant reinforcement bars. The VE must be approved

and accepted in writing by the Department before any substructure bar substitutions are allowed. Provide steel reinforcement bars conforming to AASHTO M 334, modified as follows:

• Section 13. Finish Subsection 13.2. “Seams and surface irregularities will not be cause for rejection provided the weight, dimensions, cross-sectional area, and tensile properties are not less than the requirements of this specification. Visible mill scale oxidation or corrosion deposits are cause for rejection.”

709.2BAR MATS—Steel Bars, Section 709.1, assembled into mats, as shown on the Standard Drawings,

by rigidly welding or clipping the bars at joints or points of intersection.

fracture in mat fabrication. For manual assembly, use No. 12 gage spring steel wire of high elastic limit, conforming to the following chemical analysis:

Percent Element Min. Max.

Carbon 0.45 0.70 Manganese 0.90 1.20 Sulfur 0.00 0.045 Phosphorus 0.00 0.045 Silicon 0.08 0.12

constant pressure. Assemble at the point of manufacture, using clips of acceptable design, and fasten by mechanical means. Use double-latching type clips for manual assembly. Use some form of locking device on the clips' free or latching ends so that when the clips are latched in place, no creeping occurs that would allow the bars to be easily moved from their necessary positions. Provide, approximately, a 1-inch spread of the clips at intersections for necessary leverage to hold bars at right angles. Latch each alternate clip at right angles to the adjacent clips, to ensure maximum rigidity. Use clips of a length so the material is not stressed beyond the elastic limit during the latching process. A minimum length of 3 1/2 inches is necessary for No. 3 to No. 10 bars. Other types of clips that ensure equal rigidity may be submitted for acceptance.

709.3STEEL WELDED WIRE FABRIC—ASTM A1064 Grade 70. From a manufacturer listed in Bulletin 15,

rigidly welded at joints and points of intersection to form a fabric reinforcement, and as shown on the Standard Drawings.

Coated Welded Wire Fabric. Galvanize in accordance with ASTM A123 with a coating grade consistent with the measured wire diameter of the fabric. Chromate in accordance with ASTM A767, Section 6.8.

709.4DEFORMED WELDED WIRE FABRIC —ASTM A1064 Grade 75 . From a manufacturer listed in

Bulletin 15 and as shown on the Standard Drawings.

Coated Deformed Wire Fabric. Galvanize according to ASTM A123 with a coating grade consistent with the measured wire diameter of the fabric. Chromate in accordance with ASTM A767, Section 6.8.

709.5CERTIFICATION —Certify as specified in Section 106.03(b)3 and conforming to the following

requirements.

• Identify the appropriate specification on the certification and include the grade of steel. Forward a copy to the project with the shipment of steel.

• Epoxy coaters or galvanizers of reinforcement steel must complete and maintain the original copy of Form CS-4171C in addition to the original CS -4171 and all component certifications at the epoxy coater’s or galvanizer’s location for a period of not less than 3 years from the date of the last shipment to a project, distributor, supplier, private label company, fabricator, or precast plant . Make files available for inspection and verification by a Department Representative. Submit a copy of Forms CS- 4171 and CS -4171C, with each shipment of epoxy coated or galvanized reinforcement steel to a project, distributor, supplier, private label company, fabricator, or precast plant. Form CS-4171C does not have to be c ompleted i f the fabrication of epoxy coated or galvanized reinforcement steel is performed at the same location as listed in Bulletin 15.

• Fabricators of epoxy coated or galvanized reinforcement steel must complete and maintain the original copy of Form CS-4171F in addition to the CS-4171C, when applicable, and all component certifications at the fabricator’s location for a period of not less than 3 years from the date of the last shipment to a project, distributor, supplier, private label company, or precast plant. Make files available for inspection and verification by a Department Representative. Submit a copy of Forms CS -4171 and CS -4171F, with each shipment of epoxy coated or galvanized reinforcement steel to a project, distributor, supplier, private label company, or precast plant.