SECTION 03210 EPOXY COATED CONCRETE REINFORCEMENT

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK Epoxy coated steel reinforcement shall be used for concrete structures in accordance with requirements in specification Section 03200. The work of this Section includes furnishing, fabrication and placement of concrete reinforcement with protective epoxy coatings for cast-in-place concrete and precast concrete, including bars, ties and supports. The coatings shall be applied by the electrostatic spray method. Related Work: 1. 2. 3. 4. Section 03100: Concrete Formwork Section 03200: Concrete Reinforcement Section 03300: Cast-In-Place Concrete Section 03740: Concrete Repairs

B.

C.

1.2 A.

QUALITY ASSURANCE Codes and Standards: Comply with the provisions of the following codes, specifications, and standards, except as otherwise shown or specified: 1. 2. ACI 301 "Specifications for Structural Concrete for Buildings." ACI 315 "Manual of Standard Practice for Detailing Reinforced Concrete Structures." ACI 318 "Building Code Requirements for Reinforced Concrete." ASTM A615 "Deformed Reinforcement." and Plain Billet-Steel Bars for Concrete

3. 4.

5. 6. 7.

CRSI "Manual of Standard Practice." SASO 2 "Steel Bars for the Reinforcement of Concrete." ASTM A775 "Standard Specification for Epoxy-Coated Reinforcing Steel Bars".

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8.

SSPC-SP10 Steel Structures Painting Council "Surface Preparation Specification No. 10."

1.3 A.

SUBMITTALS Manufacturer's Data: 1. Submit copies of manufacturer's specifications and installation instructions for all proprietary materials and reinforcement accessories for approval.

B.

Mill Certificates: 1. Contractor shall furnish MARAFIQ copies of the manufacturer's records of chemical and physical properties of all heats of billet steel bars and copies of affidavit for materials stating that the material furnished meets the requirements for the steel reinforcement specified. Manufacturers' records shall include certificates of mill analysis, tensile strength test, and bend tests.

C.

Shop Drawings: 1. Submit shop drawings for fabrication bending, and placement of concrete reinforcement. Comply with ACI 315 "Manual of Standard Practice for Detailing Reinforced Concrete Structures." Show bar schedules, stirrup spacing, diagrams of bent, bars, arrangements and assemblies, as required for the fabrication and placement of epoxy coated concrete reinforcement.

1.4 A.

DELIVERY, HANDLING AND STORAGE Deliver epoxy coated concrete reinforcement to the project site bundled, tagged and marked. Use metal tags indicating bar size, lengths, and other information corresponding to markings shown on placement diagrams. Store epoxy coated concrete reinforcement materials at the site in protected racks above ground in an approved manner so as to avoid damage to the coating. Direct metal to coating contact shall be avoided wherever possible. Equipment for handling epoxy coated bars shall have padded contact areas. Bundles shall be lifted with a strongback or have multiple supports to prevent barto-bar abrasion from sags in the bundle. Bars or bundles shall not be dragged or dropped. Any coating damaged due to handling, shipment and placing shall be repaired as described in Section 3.2 B.

B.

C.

PART 2 - PRODUCTS A. All reinforcing steel shall be deformed and shall comply with the requirements of ASTM A615 and as follows: 1. B. Provide Grade 60 bars, except as otherwise indicated.

Steel Wires shall conform to ASTM A82.

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C.

Column Spirals: Plain, cold-drawn wire, ASTM A82, or hot-rolled rods for spirals, ASTM A615. Supports for Reinforcement: Bolsters, chairs, spacers and other devices for spacing, supporting and fastening reinforcement in place shall be coated with a dielectric material such as nylon, epoxy or plastic. 1. Use wire bar type supports complying with CRSI recommendations, unless otherwise indicated. Do not use wood, brick, and other unacceptable materials. The supports shall be used in such a manner that they will not be exposed or contribute to the discoloration or deterioration of the concrete. For abrasive-blasted or bush-hammered concrete, provide special stainless bar supports (CRSI, Class E). Over waterproofing membranes, use precast concrete chairs to prevent penetration of the membrane.

D.

2.

3.

4.

2.2 A.

EPOXY COATING Material: 1. The epoxy coating material shall be an organic, powdered epoxy resin that is applied by electrostatic methods. Epoxy coating materials shall be approved by MARAFIQ. Patching Material: Patching or repair materials shall be supplied by the epoxy-coating manufacturer. The patching material shall be compatible with the epoxy coating, inert in concrete, and shall be suitable for use in making field repairs.

2.

B.

Coating Application: 1. Surface Preparation: a) The surface of bars to be coated shall be blast cleaned to near-white metal in accordance with SSPC-SP 10. After blasting, the cleaned surface of the bar shall be defined by SSPC-Vis 1, Pictorial Standards ASa 2, BSa 2, or CSa 2, as applicable. The powdered epoxy resin coating shall be applied to the cleaned surface as soon as possible after cleaning and before visible oxidation occurs. In no case shall more than 8 hours elapse between cleaning and coating.

b)

2.

Coating Application: The powdered epoxy resin coating shall be electrostatically applied in accordance with ASTM A775 Standard. The epoxy coating may be applied before or after fabrication of the reinforcing bars.

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Coating Thickness: The epoxy coating shall be applied as a smooth, uniform coat. After curing, the coating thickness shall be 180 microns plus or minus 50 microns. Coating thickness shall be controlled by taking measurement on a representative number of bars from each production lot. Coating thickness measurements shall be conducted by the method outlined in ASTM G12. Continuity of Coating: a) The coating shall be checked visually after cure for continuity. It shall be free from holes, voids, contamination, cracks and damaged areas. The coating shall not have more than two holidays (pinholes not visible to naked eye) in any 300 mm length of the coated bar. A holiday detector shall be used in accordance with the manufacturer's instructions, to check the coating for holidays.

4.

b)

5.

Coating Cure: The coating applicator shall check each production lot to determine that the entire production lot of coated bars is in a fully-cured condition. Flexibility of Coating: a. The flexibility of coating shall be evaluated on a representative number of bars selected from each production lot. The coated bar shall be bent 120 degrees (after rebound) around a 150 mm diameter mandrel. The bend shall be done at a uniform rate and may take up to one minute to complete. The test specimens shall be at a thermal equilibrium between 20 and 30 degrees C at the time of testing. No cracking of the coating shall be visible to the naked eye on the outside radius of the bent bar.

6.

b.

C.

Testing and Sampling: 1. Lot Size: For test purposes, a production lot is the smallest number of reinforcing bars of the same type, heat and size as determined by the following requirements: a) A lot shall not exceed a single order, or delivered load, whichever is smaller. A lot shall consist of the number of bars as defined by the coating applicator except that it shall not exceed the number of reinforcing bars coated within a single working shift.

b)

2.

Quality Control: The coating applicator shall be responsible for quality control. This will include inspection for compliance with the requirements of coating thickness, continuity of coating, coating cure and the testing required under Flexibility of Coating.

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Plant Inspection: a. MARAFIQ reserves the right to have its authorized representative observe the preparation, coating and testing of the rein-forcing bars. The representative shall have free access to the plant and any work done when access has been denied shall be automatically rejected.

2.3 A.

FABRICATION General: Fabricate reinforcing bars to conform to required shapes and dimensions, with fabrication tolerances complying with CRSI "Manual of Standard Practice." In case of fabricating errors, do not re-bend or straighten reinforcement in a manner that will injure or weaken the material. Unacceptable Materials: Reinforcement with any of the following defects will not be permitted in the work: 1. 2. 3. 4. Bar lengths, depths, and bends exceeding specified fabrication tolerances. Bend or kinks not indicated on drawings or final shop drawings. Bars with reduced cross-section due to excessive rusting or other cause. Epoxy coating not meeting the requirements of Section 2.2.

B.

PART 3 - EXECUTION 3.1 A. INSTALLATION Comply with the Concrete Reinforcing Steel Institute (CRSI) recommended practice for placing reinforcing bars, for details and methods of reinforcement placement and supports, and as herein specified. Clean reinforcement to remove dirt and other materials which reduce or destroy bond with concrete. Unless otherwise shown on drawings or in other sections, all reinforcement including ties shall be placed to obtain a minimum concrete clear cover of 75mm. Arrange, space, and securely tie bar supports and reinforcement together with 1.52 mm diameter coated wire (See Section 2.1.B) to hold reinforcement accurately in position during concrete placement operations. Set wire ties so that twisted ends are directed away from exposed concrete surfaces. Provide sufficient numbers of supports and of strength to carry reinforcement. Do not place reinforcing bars more than 50 mm beyond the last leg of any continuous bar support. Do not use supports as bases for runways for concrete conveying equipment and similar construction loads. Splices: All splices in reinforcement shall be as shown on the drawings or as directed by MARAFIQ. Minimum lap for bar splices shall be as noted on the plans.

B.

C.

D.

E.

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Bar splices shall be made by lapping ends, placing bars in contact, and securely wiring together. Epoxy coated reinforcing steel shall not be welded. 3.2 A. REPAIR OF COATED BARS Epoxy coated reinforcement bars which do not meet the requirements for Coating Thickness, Continuity of Coating, Coating Cure or Flexibility of Coating shall not be repaired. Reinforcement bars with these defects shall be replaced or alternatively, stripped of epoxy coating, recleaned and recoated in accordance with the requirements of this specification. B. Coating breaks due to fabrication and handling shall be repaired with patching material. The repair of coating breaks shall be limited to bars on which the total of the defective coating areas does not exceed 5 percent of the surface area of the reinforcement bar. Bars with greater than 5 percent damage shall be replaced or alternatively, stripped of epoxy coating, recleaned and recoated in accordance with the requirements of the specification. + + END OF SECTION 03210 + +

P.O. Number : 7200018725