440Reinforcement for Concrete

2.1 Approved Mills . Before furnishing steel, producing mills of reinforcing steel for the Department must be

pre-approved in accordance with DMS -7320 , “Qualification Procedure for Reinforcing Steel Produc tion Mills,” by the Materials and Tests Division. The Department’s MPL includes approved producing mills. Reinforcing steel obtained from unapproved sources will not be accepted.

2.2 Deformed Steel Bar Reinforcement . Provide deformed reinforcing steel conforming to one of the following:

 ASTM A615, Grade 60 or 80;  ASTM A996, Type A, Grade 60;  ASTM A996, Type R, Grade 60, permitted in concrete pavement only (Furnish ASTM A996, Type R bars as straight bars only and do not bend them. Bend tests are not required.); or  ASTM A706, Grade 60 or 80. Provide the grade of reinforcing steel shown on the plans. Provide Grade 60 if no grade is shown. The nominal size, area, and weight of reinforcing steel bars this Item covers are shown in Table 1. Table 1 Size, Area, and Weight of Reinforcing Steel Bars Bar Size Number (in.) Diameter (in.) Area (sq. in.) Weight per Foot (lb.) 3 0.375 0.11 0.376 4 0.500 0.20 0.668 5 0.625 0.31 1.043 6 0.750 0.44 1.502 7 0.875 0.60 2.044 8 1.000 0.79 2.670 9 1.128 1.00 3.400 10 1.270 1.27 4.303 11 1.410 1.56 5.313 14 1.693 2.25 7.650 18 2.257 4.00 13.60

2.3 Smooth Steel Bar Reinforcement. Provide steel conforming to ASTM A615 or meet the physical

requirements of ASTM A36 for smooth bars that are larger than No. 3. Designate smooth bars by size number up to No. 4 and by diameter in inches above No. 4.

2.4 Spiral Reinforcement . Provide bars or wire for spiral reinforcement of the grade and minimum size or gauge

shown on the plans. Provide smooth or deformed wire conforming to ASTM A1064. Provide bars conforming to ASTM A615; ASTM A996, Type A; or ASTM A675, Grade 80, meeting dimensional requirements of ASTM A615. 637 2.5. Weldable Reinforcing Steel . Provide reinforcing steel conforming to ASTM A706 or with a maximum carbon equivalent (C.E.) of 0.55% if welding of reinforcing steel is required or desired. Provide a report showing the percentages of elements necessary to establish C.E. for reinforcing steel that does not meet ASTM A706, to be structurally welded. These requirements do not pertain to miscellaneous welds on reinforcing steel as defined in Section 448.4.2.1.1., “Miscellaneous Welding Applications.” Calculate C.E. using the following formula: Do not weld stainless reinforcing steel without permission from the Engineer. Provide stainless reinforcing steel suitable for welding, if required, and submit welding procedures and electrodes to the Engineer for approval. All welding operations must be performed before any required hot -dip galvanizing.

2.6 Welded Wire Reinfo rcement (WWR) . Provide WWR conforming to ASTM A1064. Observe the relations

shown in Table 2 among size number, diameter in inches, and area when ordering wire by size numbers, unless otherwise specified. Precede the size number for deformed wire with “D” and for smooth wire with “W.” Designate WWR as shown in the following example: 6 × 12 – W16 × W8 (indicating 6- in. longitudinal wire spacing and 12- in. transverse wire spacing with smooth No. 16 wire longitudinally and smooth No. 8 wire transversely). Table 2 Wire Size Number, Diameter, and Area Size No. (in.) Diameter (in.) Area (sq. in.) 31 0.628 0.310 30 0.618 0.300 28 0.597 0.280 26 0.575 0.260 24 0.553 0.240 22 0.529 0.220 20 0.505 0.200 18 0.479 0.180 16 0.451 0.160 14 0.422 0.140 12 0.391 0.120 10 0.357 0.100 8 0.319 0.080 7 0.299 0.070 6 0.276 0.060

5.5 0.265 0.055

5 0.252 0.050

4.5 0.239 0.045

4 0.226 0.040

3.5 0.211 0.035

2.9 0.192 0.029

2.5 0.178 0.025

2 0.160 0.020

1.4 0.134 0.014

1.2 0.124 0.012

0.5 0.080 0.005

Note —Size numbers (in.) are the nominal cross -sectional area of the wire in hundredths of a square inch. Fractional sizes between the sizes listed above are also available and acceptable for use. 6%% . .MnC E C+ = 638 2.7. Welded Deformed Bar Mat Reinforcement. Provide welded deformed bar mats in accordance with ASTM A184 except as otherwise noted in this Specification. Fabricate welded bar mats from deformed steel bars in accordance with ASTM A706 by securely connecting every intersection with a process of elect rical resistance welding that employs the principle of fusion combined with pressure. The bars must be assembled by automatic machines or by other suitable mechanical means that will assure accurate spacing and alignment of all bars of the finished product

2.8 Epoxy Coating. Provide epoxy -coated reinforcing steel as shown on the plans. Before furnishing

epoxy -coated reinforcing steel, an epoxy applicator must be pre- approved in accordance with DMS -7330 , “Qualification Procedure for Reinforcing Steel Epoxy Coating Applicators.” The Department’s MPL includes approved applicators. Furnish epoxy -coated reinforcing steel meeting the requirements in Table 3. Table 3 Epoxy Coating Requirements for Reinforcing Steel Material Specification Bar ASTM A775 or A934 Wire or WWR ASTM A884 Class A or B Mechanical couplers As shown on the plans Hardware As shown on the plans Use epoxy coating material and coating repair material that complies with DMS -8130 , “Epoxy Powder Coating for Reinforcing Steel.” Patch no more than 1/4- in. total length in any foot at the applicator’s plant. Maintain identification of all reinforcing steel throughout the coating and fabrication process and until delivery to the project site. Furnish one copy of a written certification verifying the epoxy -coated reinforcing steel meets the requirements of this Item and one copy of the manufacturer’s control tests.

2.9 Mechanical Couplers. Use couplers of the type specified in DMS -4510

, “Mechanical Couplers for Reinforcing Steel,” Article 4510.6.1, “General Requirements ,” when mechanical splices in reinforcing steel bars are shown on the plans. Furnish only couplers pre- qualified in accordance with DMS -4510 . Ensure sleeve- wedge type couplers are not used on coated reinforcing. Sample mechanical couplers in accordance with Tex-743-I for testing before use on individual projects. Test the mechanical couplers for every project in which mechanical couplers are used in accordance with Tex-744-I. Furnish couplers only at locations shown on the plans . Furnish couplers for stainless reinforcing steel with the same alloy designation as the reinforcing steel. Provide hot -dip or mechanically galvanized couplers when splicing galvanized reinforcing steel or CGR .

2.10 Fibers . Supply fibers conforming to DMS -4550 , “Fibe rs for Concrete,” at the minimum dosage listed in the

Department’s MPL, when shown on the plans. Use non- metallic fibers when shown on the plans.

2.11 Stainless Reinforcing Steel . Provide deformed steel bars of the types shown in Table 4 and conforming to

ASTM A955, Grade 60 or higher when stainless reinforcing steel is required on the plans. Table 4 Acceptable Types of Deformed Stainless Steel Bar Universal Numbering System designation S31653 S31803 S24100 S32304 AISI type 316LN 2205 XM-28 2304

2.12 Low-Carbon and Low -Chromium Reinforcing Steel . Provide deformed steel bars conforming to ASTM

A1035, Grade 100, Type CS when low carbon and low chromium reinforcing steel is required on the plans. Type CM will be permitted only if specifically allowed as shown on the plans . 639 2.13. Glass- Fiber Reinforced Polymer (GFRP) Bars . For reinforced concrete bridge decks, provide bars conforming to ASTM D7957/D7957M when GFRP bars are required on the plans . Provide GFRP bars with a minimum modulus of elasticity of 7,500 ksi when GFRP bars are required on the plans. Provide sample certification demonstrating the GFRP bar supplier has produced bar that meets the m aterial specifications 2 mo. before fabrication. Furnish certification upon shipment that the GFRP bar supplied meets these requirements.

2.14 Galvanized Reinforcement. Provide galvanized reinforcing steel conforming to one of the following as

shown on the plans:  zinc-coated, hot -dip galvanized Class I or II steel reinforcement conforming to ASTM A767, Grade 60 or 80; or  continuously hot -dip galvanized reinforcement (CGR) conforming to ASTM A1094 steel reinforcement, Grade 60 or 80.

3.1 Bending. Fabricate reinforcing steel bars in accordance with the CRSI Manual of Standard Practice to the

shapes and dimensions shown on the plans. Fabricate in the shop if possible. Field- fabricate, if permitted, using an approved method. Replace improperly fabricated, damaged, or broken bars at no additional expense to the Department. Repair damaged or broken bars embedded in a previous concrete placement using an approved method. Unless otherwise shown on the plans, the inside diameter of bar bends, in terms of the nominal bar diameter (d), must not be less than that s hown in Table 5. Table 5 Minimum Inside Diameter of Bar Bends Bend Bar Size N o. (in.) Diameter Bends of 90 ° and greater in stirrups, ties, and other secondary bars that enclose another bar in the bend 3, 4, 5 4d1 6, 7, 8 6d Bends in main bars and in secondary bars not covered above 3–8 6d 9, 10, 11 8d 14, 18 10d2 1. For Grade 80 bars, minimum finished diameter is 5.0db . 2. Do not ben d bars larger than No. 14 with grade designation of Grade 80 or higher Bend- test representative specimens as described for smaller bars in the applicable ASTM specification where bending No. 14 or No. 18 Grade 60 bars is required. Make the required 90° bend around a pin with a diameter of 10 times the nominal diameter of the bar. Bend stainless reinforcing steel in accordance with ASTM A955. Do not bend hot -dip galvanized reinforcement. Only minor positioning adjustments are permitted. Bending CGR is permitted after galvanizing.

3.2 Tolerances. Fabrication tolerances for bars are shown in Figure 1.

Figure 1 Fabrication Tolerances for B ars

3.3 Storage . Store reinforcement above the ground on platforms, skids, or other supports, and protect it from

damage and deterioration. Ensure reinforcement is free of dirt, paint, grease, oil, and other foreign materials when it is placed in the work. Use reinforcem ent free of defects such as cracks and delaminations. Rust, surface seams, surface irregularities, or mill scale will not be cause for rejection if the minimum cross - sectional area of a hand wire- brushed specimen meets the requirements for the size of steel specified. Do not allow stainless reinforcing steel to be in direct contact with uncoated reinforcing steel, or with galvanized reinforcing steel. This does not apply to stainless steel wires and ties. Store stainless reinforcing steel separately, off the ground on wooden supports.

3.4 Splices . Lap- splice, weld -splice, or mechanically splice bars as shown on the plans. Additional splices not

shown on the plans will require approval. Splices not shown on the plans will be permitted in slabs no more than 15 in. in thickness, columns, walls, and parapets. Do not splice bars less than 30 ft. in plan length unless otherwise approved. For bars exceeding 30 ft. in plan length, the distance center -to-center of splices must be at least 30 ft. minus one splice length, w ith no more than one individual bar length less than 10 ft. Make lap splices not shown on the plans, but otherwise permitted, in accordance with Table 6. Maintain the specified concrete cover and spacing at splices, and place the lap- spliced bars in contac t, securely tied together. Table 6 Minimum Lap Requirements for Steel Bar Sizes T hrough No. 11 Bar Size N o. (in.) Uncoated Lap Length Coated Lap Length 3 1 ft. 4 in. 1 ft. 7 in. 4 1 ft. 10 in. 2 ft. 8 in. 5 2 ft. 8 in. 4 ft. 0 in. 6 3 ft. 8 in. 5 ft. 6 in. 7 4 ft. 10 in. 7 ft. 2 in. 8 6 ft. 0 in. 9 ft. 0 in. 9 7 ft. 4 in. 11 ft. 0 in. 10 8 ft. 11 in. 13 ft. 4 in. 11 10 ft. 6 in. 15 ft. 9 in. 641 Do not lap No. 14 or No. 18 bars. Lap spiral steel at least one full turn. Splice WWR using a lap length that includes the overlap of at least two cross wires plus 2 in. on each sheet or roll. Splices using bars that develop equivalent strength and are lapped in accordance with Table 6 are permitted. Lap the existing longitudinal bars with the new bars as shown in Table 6 for box culvert extensions with less than 1 ft. of fill. Lap at least 1 ft. 0 in. for extensions with more than 1 ft. of fill. Ensure welded splices conform to the requirements shown on the plans and Item 448, “S tructural Field Welding.” Field- prepare ends of reinforcing bars if they will be butt -welded. Delivered bars must be long enough to permit weld preparation. Install mechanical coupling devices in conformance with the manufacturer’s recommendations at locat ions shown on the plans. Protect threaded male or female connections, and ensure the threaded connections are clean when making the connection. Do not repair damaged threads. Mechanical coupler alternate equivalent strength arrangements, to be accomplished by substituting larger bar sizes or more bars, will be considered if approved in writing before fabrication of the systems.

3.5 Placing . Place reinforcement as near as possible to the position shown on the plans. Do not vary bars from

plan placement by more t han 1/12 of the spacing between bars in the plane of the bar parallel to the nearest surface of concrete. Do not vary bars from plan placement by more than 1/4 in. in the plane of the bar perpendicular to the nearest surface of concrete. Provide a minimum 1 -in. clear cover of concrete to the nearest surface of bar unless otherwise shown on the plans . For bridge slabs, the clear cover tolerance for the top mat of reinforcement is - 0, +1/2 in. Locate the reinforcement accurately in the forms and hold it firml y in place before and during concrete placement by means of bar supports that are adequate in strength and number to prevent displacement and keep the reinforcement at the proper distance from the forms. Provide bar supports in accordance with the CRSI Manual of Standard Practice. Use Class 1 supports, approved plastic bar supports, precast mortar, or concrete blocks when supports are in contact with removable or stay -in-place forms. Use Class 3 supports in slab overlays on concrete panels or on existing concrete slabs. Bar supports in contact with soil or subgrade must be approved. Use Class 1A supports with epoxy -coated reinforcing steel . Use Class 1 or Class 1A supports with CGR . Provide epoxy - or plastic -coated tie wires and clips for use with epoxy -coated reinforcing steel. Use mortar or concrete with a minimum compressive strength of 5,000 psi for precast bar supports. Provide a suitable tie wire in each block for anchoring to the bar. Place individual bar supports in rows at 4- ft. maximum spacing i n each direction. Place continuous type bar supports at 4- ft. maximum spacing. Use continuous bar supports with permanent metal deck forms. The exposure of the ends of longitudinals, stirrups, and spacers used to position the reinforcement in concrete pipe and storm drains is not cause for rejection. Tie reinforcement for bridge slabs and top slabs of direct traffic culverts at all intersections, except tie only alternate intersections where spacing is less than 1 ft. in each direction. Tie the bars at enough intersections to provide a rigid cage of reinforcement for reinforcement cages for other structural members. Fasten mats of WWR securely at the ends and edges. 642 Clean mortar, mud, dirt, debris, oil, and other foreign material from the reinforcement befor e concrete placement. Do not place concrete until authorized. Stop placement until corrective measures are taken if reinforcement is not adequately supported or tied to resist settlement, reinforcement is floating upward, truss bars are overturning, or mov ement is detected in any direction during concrete placement.

3.6 Handling, Placing, and Repairing Epoxy -Coated Reinforcing Steel .

3.6.1 Handling. Provide systems for handling coated reinforcing steel with padded contact areas. Pad bundling

bands or use suitable banding to prevent damage to the coating. Lift bundles of coated reinforcement using a strongback, a spreader bar, multiple supports, or a platform bridge. Transport the bundled reinforcement carefully and store it on protective cribbing. Do not drop or drag the coated reinforcement.

3.6.2 Placing . Do not flame- cut coated reinforcement. Saw - or shear -cut only when approved. Coat cut ends in

accordance with Section 440.3.6.3., “Repairing Coating.” Do not weld or mechanically couple coated reinforcing steel except where specifically shown on the plans. Remove the epoxy coating at least 6 in. beyond the weld limits before welding and 2 in. beyond the limits of the coupler before assembly. Clean the steel of oil, grease, moisture, dirt, welding contamination (slag or acid residue), and rust to a near -white finish after welding or coupling. Check the existing epoxy for damage. Remove any damaged or loose epoxy back to sound epoxy coating. Coat the splice area after cleaning with epoxy repair material to a thickness of 7– 17 mils after curing. Apply a second application of repair material to the bar and coupler interface to ensure complete sealing of the joint.

3.6.3 Repairing Coating. Use material that complies with the requirements of this Item and ASTM D3963 for

repairing of the coating. Make repairs in conformance with procedures recommended by the manufacturer of the epoxy coating powder. Apply at least the same coating thickness as required for the original coating for areas to be patched. Repair all visible damage to the coat ing. Repair sawed and sheared ends, cuts, breaks, and other damage promptly before additional oxidation occurs. Clean areas to be repaired to ensure they are free of surface contaminants. Make repairs in the shop or field as required.

3.7 Repair of Galvanized Reinforcing Steel . Repair damaged galvanized surfaces in accordance with

Section 445.3.4.2. “Repair Processes.”

3.8 Handling and Placing Stainless Reinforcing Steel . Handle, cut, and place stainless reinforcing steel bar

using tools that are not used on carbon steel. Do not use carbon steel tools, chains, or slings when handling stainless steel. Use only nylon or polypropylene slings. Cut stainless steel reinforcing using shears, saws, abrasive cutoff wheels, or torches. Remove any thermal oxidation using pickl ing paste. Do not field bend stainless steel reinforcing without approval. Use 16- gauge fully annealed stainless steel tie wire conforming to the material properties listed in Section 440.2.11 ., “Stainless Reinforcing Steel.” Support all stainless reinforc ing steel on solid plastic, stainless steel, or epoxy -coated steel chairs. Do not use uncoated carbon steel chairs in contact with stainless reinforcing steel.

3.9 Bending, Handling, Repairing, and Placing GFRP Bars . Fabricate, handle, repair, and place GFRP bars

in accordance with the AASHTO LRFD Bridge Design Guide Specifications for GFRP -Reinforced Concrete, Section 6, “Construction Specifications. ” 643 4. MEASUREMENT AND PAYMENT The work performed, materials furnished, equipment, labor, tools, and incidentals will not be measured or paid for directly , but will be subsidiary to pertinent Items.