SPECIFICATION 822

STEEL REINFORCEMENT
Copyright MAIN ROADS Western Australia

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Specification 822 Steel Reinforcement Document 04/10136 Issue 24/10/12

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SPECIFICATION 822 STEEL REINFORCEMENT REVISION REGISTER

Date Clause Number 822.06 Description of Revision Authorised By A/SDSE

24 Oct 12

Inclusion of ACRS Certification Complete review no change Complete revision of Issue 1.3 to new format

11 June 10

Whole document Whole document

A/SDSE

1 Aug 06

MCP

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CONTENTS
Clause Page No

GENERAL ........................................................................................................................ 4 822.01 SCOPE ......................................................................................................... 4 822.02 REFERENCES ............................................................................................. 4 822.03 CLEAR COVER REQUIREMENT ................................................................ 4 822.04 822.05 NOT USED...................................................................................... 4 PRODUCTS AND MATERIALS ...................................................................................... 4 822.06 STANDARDS................................................................................................ 4 822.07 BENDING AND CUTTING ............................................................................ 5 822.08 STORAGE .................................................................................................... 6 822.09 CLEANING ................................................................................................... 6 822.10 MECHANICAL SPLICES .............................................................................. 6 822.11 822.25 NOT USED...................................................................................... 6 OPERATIONS.................................................................................................................. 6 822.26 FIXING .......................................................................................................... 6 822.27 WELDING ..................................................................................................... 7 822.28 LAP SPLICES ............................................................................................... 7 822.29 TOLERANCES FOR FIXING ........................................................................ 7 822.30 822.70 NOT USED.................................................................................... 11 AS BUILT AND HANDOVER REQUIREMENTS........................................................... 11 822.71 822.90 822.91 822.99 NOT USED.................................................................................... 11 NOT USED.................................................................................... 11 CONTRACT SPECIFIC REQUIREMENTS .................................................................... 11

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SPECIFICATION 822 STEEL REINFORCEMENT

GENERAL
822.01 SCOPE

1. The work under this specification consists of the scheduling, supply, delivery and fixing of steel reinforcement to be cast into concrete. 822.02 REFERENCES

1. Australian Standards, MAIN ROADS Western Australia Standards and MAIN ROADS Western Australia Test Methods are referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA 123). For convenience, the full titles are given below: Australian/New Zealand Standards AS/NZS 1554.3 Structural Steel Welding Welding of Reinforcing Steel AS/NZS 4671 Steel Reinforcing Materials 822.03 CLEAR COVER REQUIREMENT

1. The minimum cover measured from the surface of the concrete to the face of any reinforcing steel shall be as shown on the Drawings. 822.04 822.05 NOT USED

PRODUCTS AND MATERIALS

822.06 1. 2. STANDARDS Reinforcement used in the Works shall comply with the Australian Standards listed in Table 822.1. Manufacturers and processors of steel reinforcing materials must hold a valid certificate of approval issued by the Australian Certification Authority for Reinforcing Steels Ltd (ACRS).

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TABLE 822.1

REINFORCEMENT USED IN WORKS Specification AS/NZS 4671 AS/NZS 4671 AS/NZS 4671

Reinforcement Grade 500N Hot Rolled Deformed Steel Reinforcing Bars for Concrete Reinforcing Wire Reinforcing Fabric/Welded Mesh Grade 500L

822.07

BENDING AND CUTTING Schedule

1. The Contractor shall prepare reinforcement bending schedules from the Drawings. 2. Reinforcement shall be accurately cut and bent to the dimensions and shapes shown on the Drawings. All bars shall be bent in accordance with Table 822.2 unless otherwise detailed on the Drawings. Pin diameters for bends shall be in accordance with Table 822.3 and hook and cog allowances in accordance with Table 822.4. 3. Reinforcement partially embedded in concrete shall not be field bent unless it is allowed for on the Drawings. Where field bending is required it shall be carried out by the application of a constant force using a pin diameter as specified in Table 822.3. 4. Heating of reinforcement shall not be permitted except where indicated on the Drawings and shall then only be carried out in accordance with the following requirements: a) The steel shall be heated uniformly for at least 100 mm each side of the portion to be bent. b) For grade 500 steel the heating shall be controlled such that the temperature does not exceed 450C and shall be measured with temperature indicating crayons. Steel heated beyond 450C shall be rejected. c) Grade 250N steel may be heated to a dull cherry red. d) Heated bars shall not be cooled rapidly by quenching or any other means. e) All heating shall be carried out in the presence of the Superintendent. 5. Prior to heating any reinforcement the Contractor shall supply to the Superintendent full details of the proposed heating procedure.

HOLD POINT

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822.08

STORAGE

1. Reinforcing steel shall be stored above ground level and shall be protected from damage and deterioration. 822.09 CLEANING

1. Reinforcement placed in the Works shall be clean and free from all loose rust and mill-scale and all dirt and grease and all other foreign substances. After being placed in position all reinforcement shall be maintained in a clean condition until it is embedded in the concrete. 822.10 MECHANICAL SPLICES

1. Mechanical splices shall be used only where shown on the Drawings. Alternative mechanical splices to the ones shown on the Drawings may be used provided that they are capable of developing at least 125% of the specified yield strength of the bar and meet the dimensional and clearance requirements shown on the Drawings. 822.11 822.25 NOT USED

OPERATIONS
822.26 FIXING

1. Reinforcing steel shall be accurately placed in the positions shown on the Drawings in accordance with the tolerances given in Table 822.5. 2. The reinforcement shall be secured in position so that it shall not be displaced during the placement of concrete and the Contractor shall ensure that there is no disturbance of the reinforcement in concrete that has already been placed. 3. Reinforcing bars intended to be in contact at points where they cross shall be bound together with 1.6mm annealed soft iron tie wire. Stirrups shall be wired securely to the bars they are intended to restrain so as to form an effective reinforcement cage. 4. All reinforcing steel supported off formwork where the resulting concrete surface will be exposed, shall be supported on special purpose bar spacers approved by the Superintendent. 5. Reinforcement not supported off formwork or where the resulting concrete surface will be concealed may alternatively be supported on concrete blocks or plastic chairs approved by the Superintendent.

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822.27

WELDING

1. Welding or tack welding of reinforcement shall not be permitted except where indicated on the Drawings and shall then comply with the following requirements: a) Welding shall be in accordance with AS/NZS 1554.3. b) Welding of grade 500 steel will not be permitted within 75mm of a bend. c) Welds shall not be broken out. 2. Prior to welding any reinforcement, the Contractor shall supply to the Superintendent documentation showing that welders to be employed on the Works are suitably qualified and that the qualification of welding procedures has been verified by testing in accordance with the requirements of AS/NZS 1554.3 822.28 LAP SPLICES HOLD POINT

1. Reinforcement shall only be spliced at locations shown on the Drawings. 2. The minimum length of lap shall be as indicated on the Drawings. 3. Welded steel wire fabric shall be lapped as detailed on the Drawings and where not detailed shall overlap by at least one complete mesh on all sides such that the end cross wire of one sheet overlaps with the second end wire of the adjacent sheet. Loose bars shall not be used in conjunction with fabric reinforcement except where shown on the Drawings. Loose small pieces of fabric shall only be used where they are essential for fitting into small confined parts of the Works. 822.29 1. 822.5. TOLERANCES FOR FIXING The tolerances for fixing of reinforcement are given in Table

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1 Condition
On each overall dimension, or on the overall dimension of each straight portion, or on that offset dimension, controlled by concrete cover at both ends for bars other than fitments.

2
Nominal length or Dimension L (mm)

3
Nominal size or Diameter of Bar (mm)

4
Tolerance (mm)

Up to 600 Up to 600 Over 600 Over 600 Up to 600 Up to 600 Over 600 Over 600

Up to 20 Over 20 Up to 20 Over 20 Up to 20 Over 20 Up to 20 Over 20

+0 -20 +0 -30 +0 -40 +0 -50

-0 +20 -0 -0 +30 +50 -0 +40

On that overall dimension controlled by cover at both ends, for fitments (ties, stirrups, helices, hoops, and the like) only. Up to 600 Up to 600 Over 600 Any Length Up to 600 Up to 600 Over 600 Any Length On the overall dimension, or on the overall dimension of each straight portion, or on that offset dimension, controlled by concrete cover at one end only or at neither end. Any length including allowances for laps. On the overall offset dimension of a cranked column bar Any offset Up to 20 -0 +10 Any size -0 +50 Up to 12 16 to 20 Up to 20 Over 20 Up to 12 16 to 20 Up to 20 Over 20 +0 -10 +0 -15 +0 -20 +0 -30 - 0 +10 -0 +15 -0 +20 -0 +30

On the deviation from square measured in relation to the end 300mm of the sawn or machined end of a a straight bar intended for use as an end bearing

Any bar length.

24 and over

TABLE 822.2

FABRICATION

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Case a) Reinforcement, other than that specified in items (b), (c) or (d) below. Fitments

Material All deformed bars Fabric Wire and fabric Grade 230R bars All deformed bars Size 16 mm or less Size 20 mm or 24 mm Size 28 mm or greater Size 16 mm or less Size 20 mm or greater

Diameter 5 db 3 db 3 db 3 db 4 db 4 db 5 db 6 db

b)

c)

Reinforcement in which the bend is intended to be subsequently straightened or re-bent

d)

Reinforcement which is epoxy-coated or galvanised, either before or after bending

5 db 8 db

NOTE: db is the diameter of the bar being bent. TABLE 822.3 PIN DIAMETERS FOR BENDS

Bar Diam (mm) Length Allowance (mm) (assumed pin diameter, 5 db) TABLE 822.4

6 120

10 140

12 160

16 180

20 220

24 260

28 300

32 340

36 380

HOOK AND COG ALLOWANCES FOR BENT BARS AND FITMENTS

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1 Case
1
Where concrete cover to the reinforcement is the controlling factor. 1a.

2 Condition
At the end of reinforcement.

3 Tolerance(mm)
Tolerances on Dimensions 'C' -0 +30

1b.

At the outside edge of reinforcement or fitment.

Tolerances on Dimension 'T' -0 +20 when compression face -0 +10 when tension face Tolerances on Dimension 'B' -0 +10 when tension face -0 +20 when compression face

Where cover is not controlling.

2a.

At the end of reinforcement.

Tolerance on Dimension 'L'. 50

(see Case 1) 2b. At the outside edge of reinforcement including fitments. Tolerances on Dimension 'E' 10

Lateral spacing of reinforcement.

3a. Beam or column type member.

Tolerance on Dimension 'S' +0.1S or 15mm whichever is greater. 3b. Slab or wall type member.

Bars in corners, crossing bars starter bars, etc.

Bars to be placed in configuration shown on the Drawings. Tolerances on location of an individual bar 15mm unless otherwise limited by cover requirements of case 1 above.

The tolerances given above are the maximum permissable, but it should be noted that in some circumstances, where reinforcement is fabricated to maximum tolerance, they may not be fully available.

NOTE: This table should be read in conjuction with Table 822.2

TABLE 822.5

TOLERANCES ON FIXING REINFORCEMENT

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822.30 822.70

NOT USED

AS BUILT AND HANDOVER REQUIREMENTS

822.71 822.90 NOT USED

CONTRACT SPECIFIC REQUIREMENTS

822.91 822.99 NOT USED

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SPECIFICATION 822 GUIDANCE NOTES

DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR REFERENCE All edits to downloaded TDP documents shall be tracked (most word processing software allows this to be done automatically). Deletions shall be struck through e.g. example. Insertions shall be in italics e.g. example. If all information relating to a clause is deleted then the clause number should be retained and the words "NOT USED" should be inserted.

The proposed documents with tracked changes shall be submitted to the Project Manager for review, prior to printing the final batch of documents. When this final printing is carried out, the tracked changes option is to be turned off. The Custodian of this specification is the Structures Design and Standards Engineer.

NO GUIDANCE NOTES OR CONTRACT SPECIFIC REQUIREMENTS AVAILABLE AT THIS TIME.

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CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE

The following clauses are to be placed under the CONTRACT SPECIFIC REQUIREMENTS as required.

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SPECIFICATION AMENDMENT CHECKLIST Specification Name: No: REINFORCEMENT Project Manager: Name: 822 Revision No: _______Title: STEEL

_______________Signature: ____________Date:______

Checked By: Name: _______________Signature: _______________Date:______ Contract No: ___________Contract Description: _______________________________ ITEM SIGN OFF All changes/amendments must be shown in Tracked Change mode until DESCRIPTION

Note: approved. 1. Project Manager has reviewed Specification and identified Additions and Amendments. 2. CONTRACT SPECIFIC REQUIREMENTS addressed? Contract specific materials/products/clauses added? (Refer Specification Guidance Notes for guidance). 3. Any unlisted Materials/Products proposed and approved by the Project Manager? if Yes provide details at 15. 4. Standard Clauses amended? MUST SEEK approval from MCP. 5. Clause deletions shown as NOT USED. 6. Appropriate INSPECTION & TESTING parameters included in Spec 201 (Test Methods, Minimum Testing Frequencies verified). 7. ANNEXURES completed (Refer Specification Guidance Notes). 8. HANDOVER and AS BUILT requirements addressed. 9. Main Roads QS has approved changes to SMM. 10. Project Manager certifies completed Specification reflects intent of the design. 11. Completed Specification independent verification arranged by Project Manager 12. Project Managers review completed. 13. SPECIFICATION GUIDANCE NOTES deleted. 14. TABLE OF CONTENTS updated. 15 Supporting information prepared and submitted to Project Manager. Further action necessary:

Signed:

(Project Manager)

Date: _______________

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