Wisconsin WisDOT Standard Specifications (within FDM) — Section 505

Effective with the December 2018 Letting 241 2019 Standard Spec ifications Section 505 Steel Reinforcement

505.1Description

(1)This section describes furnishing and placing bar steel, high- strength bar steel or coated high-strength

bar steel.

505.2Materials

505.2.1 General

(1)Use deformed reinforcing bars unless the contract specifies ot herwise.

(2)Unless the plans show otherwise or the special provisions spec ify otherwise, use the deformed type

for all bar steel, all high-str ength bar steel, and all coated high-strength bar st eel reinforcement. If plain, round steel reinforcement is specified, conform to ASTM A675, grade 80.

(3)Use fabrication tolerances for straight and bent bars specifie d in Subsection 4.3, Tolerances, of the

American Concrete Institute Committee 315, in the American Concrete Institute Detailing Manual.

(4)Unless the contract specifies otherwise, submit a manufacturer 's certified report of test or analysis

showing the reinforcement confor ms to the specifications to the engineer before incorporating the reinforcement into the work. 505.2.2 Bar Steel Reinforcement

(1)Conform to AASHTO M31.

505.2.3 High-Strength Bar Steel Reinforcement

(1)Conform to AASHTO M31, grade 60.

505.2.4 Coated High-Strength Bar Steel Reinforcement 505.2.4.1 General

(1)Conform to AASHTO M31, grade 60. E nsure that the coating is ap plied in a CRSI certified epoxy

coating plant. Bend bars that require bending before coating, u nless the fabricator can bend the bar without damaging the coating.

(2)Do not weld epoxy-coated reinfo rcement except as the plans sho w.

505.2.4.2 Coating Material

(1)Coat reinforcement according to ASTM A775 with a fusion-bonded powder from the department's

APL. Provide written certification from the resin manufacturer that the coating material is the same formulation and quality as subm itted to the department for preq ualification testing.

(2)Furnish a two-part epoxy resin that meets ASTM A775 for field repairs and patching.

505.2.4.3 Surface Preparation

(1)Ensure the bar surface is cle an and free from rust, scale, oil , grease, and similar surface

contamination, and slivers, scabs and other surface defects det rimental to proper coating.

(2)Blast the surface to a near white No. 10 finish according to S SPC-SP 10. Provide an anchor pattern

with blast profile maximum roughness depth readings within the range of 1.6 mils to 4.0 mils. Determine the readings according to NACE RP-287, using replica tape.

(3)Remove all traces of grit and dust from the blasting before co ating.

(4)Apply the coating to the cleaned surface as soon as possible a fter cleaning and before visible

oxidation of the surface occurs . The contractor shall not wait to apply the coating more than 8 hours after cleaning, unless the e ngineer directs otherwise. 505.2.4.4 Coating Process

(1)Apply the coating as an electros tatically charged dry powders prayed onto the grounded steel bars

using an electrostatic spray gun. The contractor may apply the powder to either a hot or a cold bar. Give the coated bar the thermal treatment the epoxy resin manuf acturer recommends to provide a fully cured finished coating.

(2)Cure, post-cure, or cure and post-cure the coating film to a f ully cured condition. The coating

applicator shall check a represent ative proportion of each prod uction lot, using the method it finds most effective for measuring cure, to ensure the entire production lot of coating is fully cured. 505.2.4.5 Test Bar Conditioning

(1)Condition bars being tested for coating thickness, holidays (p inholes not visually discernible), coating

adhesion, and abrasion resistance at a temperature range of 68 F to 86 F. If disputed, conduct tests at 73 F +/- 4 F and 50 +/ - 5 percent relative humidity according to ASTM D3451 section 3.1.

Effective with the December 2018 Letting 242 2019 Standard Spec ifications 505.2.4.6 Coating Thickness

(1)Ensure the coating is smooth and uniform in thickness. After c uring is complete, ensure at least 90

percent of recorded thickness me asurements of the coating are 7 mils +/- 2 mils. Thickness measurements below 5 mils are ca use for rejection. The upper th ickness limit does not apply to repaired areas of damaged coating. Measure the film thickness o n a representativ e number of bars from each production lot according to ASTM D7091 for measuring film thickness of pipeline coatings on steel.

(2)Take an average of 3 individual readings on the body of a straight length of bar between 3 consecutive

deformations to obtain a single recorded thickness measurement. Obtain a minimum of 5 recorded measurements, evenly spacedal ong 2 sides of the test bar for a minimum of 10 recorded measurements per bar.

(3)The contractor may use pull off and fixed probe gauges. Do not use pencil-type pull off gauges that

require the operator to observe the reading at the instant the magnet is pulled from the surface. Follow the thickness gauge manufacturer’ s recommendations for its cali bration and use. 505.2.4.7 Coating Continuity

(1)Check the coating on a represent ative number of bars selected from each production lot after cure for

continuity of coating and ensure it is free from holes, voids, contamination, cracks, and damaged areas. Additionally, ensure tha t no more than an average of 2 holidays exist in any linear foot of coated bar. Base the average on the bar’s full production lengt h.

(2)Use a 67 1/2 volt holiday det ector at the manufacturer's plant to check the coating.

505.2.4.8 Coating Flexibility

(1)Evaluate the coating flexib ility based on a representative number of bars selected from each

production lot. Evaluate coating adhesion according to ASTM A775. 505.2.4.9 Abrasion Resistance

(1)Determine the coating’s resistance to abrasion on a representa tive number of bars selected from each

production lot, according to ASTM D4060 using CS-10 wheels and a 1000 gram load per wheel, and ensure that the weigh t loss does not exceed 10 0 megagrams per 1 000 cycles. 505.2.4.10 Inspection

(1)Furnish a certificate of compliance for the surface preparatio n, coating material, and process. The

coating applicator shall retain te st results and make them available for not less than 7 years. 505.2.4.11 Damage Repair and Rejection

(1)The contractor shall not repai r epoxy-coated high-strength bar steel reinforcement that does not

conform to the requirements for coating thickness, continuity of coating, coating cure, or flexibility of coating. Replace the reinforcement or strip, reclean, and recoa t epoxy-coated high-strength bar steel reinforcement with one or more of these defects.

(2)If using coated high-strength bar steel reinforcement in bridges, the department requires patching on

circumferential areas with damaged coating, on sheared or cut ends, on end areas left bare during the coating process, and on any ar eas that the entire coating is re moved.

(3)If using coated high-strength bar steel reinforcement in concr ete pavement and miscellaneous

concrete construction bid items in 415 or 416, the department requires patching on circumferential areas with damaged coating or removed coating. The department w ill not require patching on sawed ends, cut ends, coated damaged ends, or end areas left bare during the coating process.

(4)Patch with the material specified in 505.2.4.2(2) according to ASTM D3963 and manufacturer

instructions.

(5)Complete required repairs befor e visible oxidation of the steel surface occurs.

(6)The engineer will reject bars having total damage greater than 2 percent of the total circumferential

area of the bar length. Consider the entire loss of the coating at the specific area on the bar as total damage. 505.2.5 Welded Steel Wire Fabr ic for Concrete Reinforcement

(1)Use a fabric of the weight and de sign the plans show and conform to ASTM A1064.

Effective with the December 2018 Letting 243 2019 Standard Spec ifications 505.2.6 Dowel Bars and Tie Bars Revise 505.2.6 to add subsections for tubular dowels a nd alternate high performance dowels. This change was implemented in ASP 6 effective with the March 2018 letting. 505.2.6.1 General

(1)Furnish bars coated in a plant certified by the Concrete Reinforcing Steel Institute. For dowel bars and

straight tie bars, there is no requirement for bend tests. Ensure that the bars are the specified diameter and length the plans show.

(2)The contractor need not coat or patch sawed ends, sheared ends , cut ends, ends left bare during the

coating process, or ends with damaged coating.

(3)The contractor need not repair circumferential coating damage from shipping, handling, or installation,

if the following conditions are met:

1.The damaged area is 1/4 inch square or smaller.

2.The total damaged area in any one-foot length does not exceed 2 percent of the circumferential area in

that length.

(4)Repair areas of damaged circum ferential coating larger than 1/ 4 inch square. Reject bars with total

damage greater than 2 percent of the bar's ci rcumferential area . 505.2.6.2 Dowel Bars 505.2.6.2.1 General

(1)Ensure that the bars are straight, round, smooth, and free from burrs or other deformations detrimental

to the free movement of the bar in the concrete.

(2)Saw bars to the required length . For solid bars, the departmen t will allow shearing if no damage

occurs to the coating and sheari ng distortions do not exceed th e following:

1.No distorted diameter is m ore than 0.04 inches greater than the true diameter.

2.No distortion extends more than 0.40 inches from the sheare d end.

(3)Apply a surface treatment to loose dowels, or furnish manufactu rer-treated bars in dowel bar baskets ,

capable of preventing bond between the epoxy-coated bars and th e concrete. Apply field surface treatments when loading bars in the dowel bar magazine. 505.2.6.2.2 Solid Dowel Bars

(1)Furnish coated bars conforming to AASHTO M31 grade 40 or 60. Alternatively the contractor may

furnish dowel bars conforming to AASHTO M227 grade 70-80. Coat with a thermosetting epoxy conforming to AASHTO M254, type B. 505.2.6.2.3 Tubular Dowel Bars

(1)Furnish welded steel tubular bars conforming to ASTM A513 fabricated from plain carbon steel with a

minimum tensile yield strength of 60 ksi and sized as follows: SOLID BAR MINIMUM REQUIRED MINIMUM BASE METAL SPECIFIED DIAMETER OUTSIDE DIAMETER WALL THICKNESS 1 1/4-inch 1 5/16 inches 0.120 inch 1 1/2-inch 1 5/8 inches 0.120 inch

(2)Cap bar ends to prevent intrusi on of concrete or other materials. Ensure that tubing is galvanized on

the exterior and interior according to ASTM A653 with a G40 zinc coating and apply 7-13 mils of epoxy to the galvanized exte rior according to AASHTO M254, Type B. 505.2.6.2.4 High Performance Dowel Bars

(1)As an alternate the contractor m ay furnish high performance dowel bars from the department's APL.

505.2.6.3 Tie Bars

(1)Furnish coated bars conforming to AASHTO M31 grade 40 or 60. Coat tie bars as specified in 505.2.4

for coated high-strength steel reinforcement. Ensure that the t ie bars are the shape the plans show.

(2)Repair, with compatible coating material, the bend location of field-straightened coated tie bars.

505.3Construction

505.3.1 General

(1)Store reinforcement above grou nd on platforms, skids, or other supports. Protect from mechanical

injury and deterioration from ex posure. Store epoxy-coated rein forcement on wooden cribbing and handle without dragging or dropping using padded or non-metalli c slings.

Effective with the December 2018 Letting 244 2019 Standard Spec ifications Revise 505.3.1(2) to clarify that cu mulative exposure to sunlight for epoxy coated rebar is limited to 2 months.

(2)Cover epoxy-coated bars in sto rage, or placed in a bridge deck mat, with an opa que engineer-

approved material to prevent cum ulative exposure to sunlight fo r more than 2 months before being embedded in concrete . Include portions of partially embedded ba rs left exposed between construction stages.

(3)Mark reinforcement to facilitate inspection and checking. Ensu re reinforcement is free from detrimental

dirt, dust, paint, oil, or other fo reign material when placed i n the work. The engineer will not reject reinforcement with rust, seams, s urface irregularities, or mill scale if the weight, dimensions, cross- sectional areas, and tensile properties of a hand wire-brushed test specimen conform to AASHTO M31.

(4)The contractor may field cut rei nforcement by sawing, using ab rasive cut-off blades, or flame cutting.

Do not flame cut epoxy-coated reinforcement. 505.3.2 Bending

(1)Use bent bar reinforcement cold bent to the shapes the planss how, and unless the plans show

otherwise or the engineer directs otherwise, conform to Recomme nded Hooks All Grades and Recommended Sizes for Stirrup and Tie Hooks, of the American Co ncrete Institute Committee 315. Ensure all bending dimensions are out-to-out of the bar. 505.3.3 Splicing 505.3.3.1 General

(1)Furnish bar steel reinforcement in the full lengths the plans show. Except where the plans show, do

not splice reinforcement withou t the engineer’s written approva l. The department will allow lapped splices, welded splices, mechanical couplers, or other connecti ons the plans show or the engineer approves in writing. To the ext ent practicable, stagger splices in adjacent bars and locate splices as far as possible from the point o f maximum tensile stress. The e ngineer will not allow splices at points that do not offer a minimum distance of 2 inches between the splice and the nearest adjacent bar, or design concrete cover the plans show at the splice location.

(2)Overlap the sheets of welded st eel wire fabric to maintain uni form strength, and securely fasten at the

ends and edges. Ensure the edge lap is at least one mesh wide. 505.3.3.2 Lapped Splices

(1)Ensure that lapped splices conform to plan requirements, are placed in contact with each other, and

wired together to hold the bars in position for the full length of the splice. 505.3.3.3 Welded Splices

(1)The contractor may weld uncoated reinforcement only if the pla ns show welded splices or the engineer

approves welded splices in writi ng. Do not splice epoxy-coated reinforcement by welding. Use welded butt splices conforming to the AWS D 1.4, Structural Welding Co de - Reinforcing Steel. Use electrodes conforming to AWS D 1.5 and submi t electrode acceptance reports according to AWS D 1.5.

(2)Use AWS D 1.4 certified welders to perform all welding. If wel der certification tests are required, a

department-approved i ndependent testing agenc y shall perform th e testing. The engineer may require qualification tests according to AWS D 1.4.

(3)Test 4 percent of the total number of splices per each bar size, but not less than 4 splices. For both

qualification samples and producti on splices, conform to AWS ra diographic methods and provide test results prepared by an inspecto r qualified under AWS to perform radiographic interpretation. 505.3.3.4 Bar Couplers 505.3.3.4.1 General

(1)Provide threaded bar couplers unless the engineer approves an alternate coupler system in writing as

allowed under 505.3.3.4.3 .

(2)If splicing epoxy-coated bars, clean and coat couplers and exp osed threads with epoxy. Couplers may

be coated with epoxy before or a fter installation. Use epoxy th at is compatible with the touchup epoxy used on coated reinforcing bars. 505.3.3.4.2 Threaded Bar Couplers

(1)Ensure that the threaded bar coupler material is capable of de veloping 125 percent of the yield

strength of the bar being spliced. Provide a manufacturer-certi fied report of tests, based on a minimum of 3 tests, showing the thr eaded bar coupler capacity.

Effective with the December 2018 Letting 245 2019 Standard Spec ifications 505.3.3.4.3 Alternate Bar Coupler System

(1)Do not install alternate bar co upler systems before department proof testing and without the engineer's

written approval. Provide 3 sample splices to the department for testing. Conform to the manufacturer's installation inst ructions and provide a copy of those instructions to the engineer. 505.3.4 Placing and Fastening

(1)Place steel reinforcement precisely in the position the plans show and hold firmly during the concrete

placing and setting by using spacer strips, stays, recycled pla stic chairs, metal chairs, or other engineer-approved devices or supp orts. The contractor may use recycled plastic supports for a bottom layer of steel reinforcement whi ch in turn supports upper layers on continuous bar chairs; but do not use individual plastic chairs to directly support upper layers. Unless the contract provides otherwise, use coated high-strengt h bar steel reinforcement in the top layer of reinforcement in the concrete deck.

(2)Make metal chairs from stainle ss steel, steel that is zinc coa ted or epoxy coated after fabrication, or

from uncoated steel with engineer-approved plastic tipped legs, or with at least 1/2 inch of the bottom of the legs hot dip zinc coated or plastic-coated. Furnish epox y-coated metal chairs or recycled plastic chairs to support coated high-stre ngth bar steel reinforcement, subject to the plastic chair restriction stated above. The epoxy coating thickness shall conform to 505.2.4.6 .

(3)Use recycled plastic chairs manuf actured from recycled plastic obtained from post consumer products.

Ensure they are chemically inert in concrete and are molded in a shape that does not restrict concrete flow and consolidation ar ound and under the chairs.

(4)For recycled plastic chairs conform to the following requireme nts within a temperature range of 20 F to

150 F: PROPERTY VALUE ASTM TEST Minimum shear strength 5000 psi ASTM D732 Minimum compressive strength 10,000 psi ASTM D695 Maximum water absor ption 0.1 percent ASTM D570

(5)Support bar steel reinforcemen t in the concrete decks and slab spans as follows:

1.For all decks and slab spa ns, support bottom transverse bar s with continuous bar c hairs spaced 4 foot on

centers or closer. Support the ends of the bars with a line of chairs near each deck or slab edge.

2.On decks less than 12 inches thick, support top longitudinal bars with continuous bar chairs spaced 4 foot

on centers or closer. Provide a row of continuous bar chairs di rectly under each ro w of transverse bar splices.

3.On decks and slab spans 12 in ches thick or thicker, support top transverse bars with individual supports

spaced approximately 3 foot on c enters or closer in both directions. Use either individual bar chairs setting on the form floor or bent reinfor cement bars supported off the bottom mat. Support bars near the edge of the deck or slab with individual supports spaced 3 foot on centers or closer.

4.On decks with prestressed wi de flange girders, place bar ch airs with continuous bottom runners between

the top and bottom l ongitudinal reinforcement layers at a maxim um 4 foot spacing over the girder flange.

(6)The contractor may use precas t concrete bricks or other engineer-approved bricks or blocking in

structures to support reinforcem ent in footings or slabs placed on grade; however, the bricks or blocking shall not contact the re inforcement over a distance gr eater than the depth of a standard concrete brick. Tie the upper layer of reinforcement for bridge decks securely to the girders or forms at a longitudinal spacing not greater than 8 feet. For decks of slab span bridges, the ties shall have a transverse spacing no t to exceed 8 feet, and for decks over gir ders, secure the ties to or next to each longitudinal line of girders.

(7)Tie the bars securely at intersections except if spacing is le ss than one foot in each direction, if

alternate intersections are tied. The contractor shall not use tack welding to tie steel. Before placing any concrete in a unit or section, obtain the engineer's approval of the reinforcement placing and securing in that unit or section.

(8)Tie coated bars using a procedure, equipment, and materials that will not damage or cut the coating.

Tie coated reinforcement with one of the following:

1.Ties made from an engineer- approved plastic or nonmetallic material.

2.Stainless steel wire.

3.Nylon, epoxy, or plastic-coated wire.

505.4Measurement

(1)The department will measure the Ba r Steel Reinforcement bid items by the pound acceptably

completed. The department will compute the bar weight from the nominal weights for corresponding sizes for deformed bars in AASH TO M31. The department will not measure the extra metal used if the

Effective with the December 2018 Letting 246 2019 Standard Spec ifications contractor chooses to substitut e bars larger than those specified, the extra metal necessary for splices the plans do not show, or the we ight of any devices used to sup port or fasten the steel in its correct position.

(2)The department will measure the Ba r Couplers bid items as each individual coupler acceptably

completed.

505.5Payment

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

505.0100 Bar Steel Reinforcement Structures LB

505.0400 Bar Steel Reinforcement HS Structures LB

505.0600 Bar Steel Reinforcement HS Coated Structures LB

505.0900-0919 Bar Couplers (size) EACH

(2)Payment for the Bar Steel Reinf orcement bid items is full comp ensation for providing, transporting,

and placing reinforcement including supports. Where the planss pecify bar couplers , the department will pay for the length of bars as detailed with no deduction o r increase for installation of the coupler.

(3)Payment for Bar Steel Reinforcement HS Coated Structures includes coating, including epoxy-coated

metal chair supports.

(4)Payment for the Bar Couplers bi d items is full compensation for providing couplers, including bar steel

that is part of the coupler and not detailed in the plan; for t hreading reinforcing bars; for installing and coating the splice; and for supplying and testing 3 couplers.

Effective with the December 2018 Letting 247 2019 Standard Spec ifications Section 506 Steel Bridges

506.1Description

(1)This section describes fabricating, furnishing, casting, machi ning or preparing otherwise, delivering,

and erecting the steel and miscella neous metals required for st eel bridges, or metal parts of other bridges.

506.2Materials

506.2.1 General

(1)Furnish materials conforming to the specifications for the sev eral parts of the completed structure.

506.2.2 Structural Steel 506.2.2.1 General

(1)Furnish structural steel for highway structures conforming to the ASTM specifications the plans show.

For material that the plans do not indicate the ASTM specifications, furnish structural carbon steel conforming to ASTM A709 grade 36. Revise 506.2.2.1(2) to prohibit shearing or punched holes in members requiring Charpy testing.

(2)Ensure that girder flange plates, girder web plates, flange sp lice plates, hanger bars, links, rolled

beams, flange cover plates, and plates and angles connecting fl oor beams to girders conform to zone 2 toughness requirements for longi tudinal Charpy V-Notch tests specified in ASTM A709 . Sample and test according to ASTM A673. Use the (H) frequency of testing. Do not shear cut or punch full-sized holes in members requiring Charpy V-Notch testing.

(3)Ensure that structural steel members included in the structural design capacity, and that will be

welded, have a maximum carbon equivalent (CE) of 0.48. Steels c onforming to ASTM A709 HPS 50 or 70 with carbon contents 0.10 per cent or less are exempted fr om this rule. The engineer may allow steels with up to CE 0.58 only i f the contractor uses an engineer-approved adjusted welding procedure. Submit steel mill cert ifications indicating the comp osition of the steel provided under the contract. The engineer will calculate the carbon equivalent as follows: CE= C + (Mn+Si)/6 + (C r+Mo+V)/5 + (Ni+Cu)/15 506.2.2.2 Structural Carbon Steel

(1)For structural carbon steel 4 inches thick or thinner, conform to ASTM A709 grade 36. For structural

carbon steel over 4 inches thick, conform to ASTM A36 . 506.2.2.3 High-Strength Structural Steel

(1)Use high-strength structurals teel conforming to ASTM as follo ws:

HSLA columbium-vanadium steels of structural quality: 50 ksi minimum yield poi nt to 4 inches thick .................. ............................................. ASTM A709 , grade 50 HSLA weathering steel: 50 ksi minimum yield poi nt to 4 inches thick .................. .......................................... ASTM A709 , grade 50W High-yield-strength quenched and tempered alloy steel plate: Martensitic ................................................................................................... ASTM A709 , grade 100 or 100W Non-martens itic ............................................... ......................................................... ASTM A709 , grade 70W High Performance Steels: Up to 4 inches thick .......................................... .......................................... ASTM A709 HPS, grade 50 or 70 506.2.3 Miscellaneous Metals 506.2.3.1 Steel Castings

(1)If using carbon steel castings for bridges and general use, co nform to class 70 , 90, 120 of AASHTO

M192 and the following:

1.Furnish the specific class o f steel castings the plans show or are specified in the contract.

2.The plans will specify the nondestructive tests to perform and their extent.

3.Use steel castings that are true to pattern in form and dim ensions and free from def ects affecting strength

or service life.

4.The contractor may weld def ects using an engineer-approved process. Perform weld repairs before

annealing the ca sting. If the engineer requires, re-anneal castings after welding.

5.If the engineer requires, the c ontractor shall test castings by radiography or ultrasonic testing to determine

the presence of cracks, flaws, or other defects.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 250–255 of 601.

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504 Culverts, Retaining Walls, and Endwalls

506 Steel Bridges