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Technical Note
CTN-G-2-10
Cover over reinforcing bars In some instances the damage may be too
severe, and replacing the damaged bars is most
Epoxy-coated reinforcing bars appropriate. Drilling into the concrete and install-
ing new adhesive grouted bars into the concrete
Properties of old reinforcing bars
substrate is one common repair. Alternately, if the
Bar support use & types base of the bar protruding from the concrete is
undamaged, it may be possible to couple onto
Tying of reinforcing bars the bar extension with a mechanical splice.
Availability and application of ASTM A706 Field repair situations become problematic
reinforcing bars where reinforcing bars have been fabricated and
then field re-bent or straightened. Often the con-
Given these general areas of inquiry, CRSI re- dition of the final bar configuration is not clear
sponds to the frequently asked questions (FAQ). and can leave questions about adequacy for the
Specific questions and responses are provided EOR. Fabricators are familiar with the properties
below. of reinforcing bars; they adhere to industry stan-
dards for minimum bend diameter, and generally
When and how is it acceptable to bend
do not rework previously bent bars. The yielding
steel reinforcing bars in the field?
and subsequent cold working of the bars may
The engineer of record (EOR) for the project compromise the performance and function of the
should specify and/or approve the acceptability steel, even where cracks or other indicators may
of field bending, straightening, or re-bending of not be visible.
reinforcing bars. Section 7.3.2 of the ACI 318
Building Code (2008) prohibits all reinforcement Section 8.4 of the CRSI Manual of Standard
partially embedded in concrete from being field Practice (2009) provides recommendations for
bent, unless specifically shown on the design the realignment of reinforcing bars partially em-
drawings or expressly permitted by the licensed bedded in concrete: #3 through #6 [#10 through
design professional. #19] bars can be field bent up to a 45 bend, #7
through #18 [#22 through #57] bars can be field
may need to be applied. Heating of the bar
should be controlled by temperature-indicat-
ing crayons or other suitable means. The
heated bars should not be artificially cooled
(with water or forced air) until after cooling to
at least 600 F.
When the reinforcement is exposed, or when the con- By providing an electrical insulating barrier between
crete cover is significantly less than required, additional the reinforcing steel and the elements, epoxy coating in-
measures should be taken to protect the steel from cor- creases the durability of the reinforcement and the struc-
roding. Measures frequently used include surface coat- ture. The trademark green or purple epoxy is one coating
ings, additional cladding, or chemical treatment of the material used to protect reinforcing bars from corrosion
concrete surface. In some cases, insurers or building of- in severe exposure. The epoxy material used is durable,
ficials may require added protection to meet the required and when handled with proper care, it can enhance the
fire resistance criteria of the structure. service life of the structure once the epoxy-coated bar
is encased in concrete. If the epoxy coating is chipped
As an example, Table 3 is based on Table 721.2.3(3) during fabrication or handling, and is not repaired, the ef-
from the International Building Code (2006), which lists fectiveness of the coating has been reduced. In addition,
the minimum concrete cover for reinforced concrete an excessive number of holidays (pinpoint holes) in the
beams, based on type of restraint, beam width, and fire- coating may impact the coating performance. Therefore,
resistance rating. care must be taken to repair coating damage before the
concrete is placed.
Section 721 of the IBC contains tables of minimum
concrete cover for slabs and beams, both cast-in-place How do I find out about vintage reinforcing
and precast, for different fire-resistance ratings. In addi- bars in an existing structure?
tion, IBC Section 721 provides minimum thicknesses of
From about 1911 through the 1960s, reinforc-
ing steel bars had to conform to specification
ASTM A15 (precursor to the current A615)
Table 3 Minimum Concrete Cover (in.) for
and were available in three grades: Structural
Cast-In-Place Beams, as per Required Fire-Rating*
Grade (fy = 33 ksi), Intermediate Grade (fy = 40
Beam ksi), and Hard Grade (fy = 50 ksi). These bars
Restrained or Fire-Resistance Rating (hr) could be round or square in cross-section, plain,
Width
Unrestrained deformed, or twisted. CRSIs out-of-print Engi-
(in.) 1 1-1/2 2 3 4
neering Data Report (EDR) No. 48, Evaluation
5 3/4 3/4 3/4 1 1-1/4 of Reinforcing Bars in Old Reinforced Con-
Restrained 7 3/4 3/4 3/4 3/4 3/4 crete Structures" (2001), presented information
10 3/4 3/4 3/4 3/4 3/4 such as allowable stresses from earlier Codes.
Table 4, which lists minimum yield and tensile
5 3/4 1 1-1/4 strength requirements from past and present
Unrestrained 7 3/4 3/4 3/4 1-3/4 3 ASTM specifications, is an updated version of
10 3/4 3/4 3/4 1 1-3/4 Table 1 from EDR No. 48.
The most effective way to identify the reinforcing bar lass 1 Maximum Protection. These wire bar sup-
C
yield strength is to excavate enough concrete around ports are intended for moderate to severe exposure
the bar to remove a sample for testing. Non-destructive and/or situations requiring light grinding/sandblasting
techniques, along with documentation about when and of the finished concrete surface. These supports are
how the structure was built, may provide sufficient in- either dipped in plastic or pre-molded plastic tips are
formation to make an educated assessment of current placed on the support legs.
structural capacity. Obviously, the reinforcing steel only
comprises one part of the structure, and the compres- lass 1A Maximum Protection for Use with Epoxy-
C
sive strength of the old concrete may be the deciding Coated Reinforcing Bars. These wire bar supports are
factor in determining overall structural capacity. intended for moderate to severe exposure, but with-
out any subsequent surface grinding/sandblasting.
What kinds of bar supports are used in They are generally used to support epoxy-coated re-
structures? inforcing bars. These supports are completely coated
with epoxy, vinyl, or other plastic compounds.
Chapter 3 of the CRSI Manual of Standard Practice
(2009) describes and includes sketches of different lass 2 Moderate Protection. These wire bar sup-
C
types of (1) wire, (2) all-plastic, and (3) precast concrete ports are intended for moderate exposure and/or
bar supports. The type of bar support used on a project light grinding/sandblasting of the finished concrete
is dependent on a number of factors, such as the type of surface. The legs of these supports are either manu-
exposure, concrete finish, and surface finish on the bar factured from stainless-steel wire or cold-drawn car-
(uncoated or coated). The different types of supports are bon steel with stainless-steel leg extensions attached
described in the following paragraphs: to the bottom of each leg.
Wire - Wire bar supports are classified in terms of here are two variations of Class 2 supports. Sub
T
method used to minimize potential visible rust spots on Type A bar supports have stainless-steel leg exten-
the concrete surface. The four classes are summarized sions inch long, while Type B bar supports have
below and various examples of wire bar supports are inch long stainless-steel leg extensions.
illustrated in Figure 2 (next page):
Element
ASTM
Spec. Condition Carbon Manganese Phosphorus Sulfur Silicon
(C) (Mn) (P) (S) (Si)
1 0.06%
A615
2 0.075%
1 0.30% 1.50% 0.035% 0.045% 0.50%
A706
2 0.33% 1.56% 0.043% 0.053% 0.55%
Conditions: 1 = Maximum allowable chemical content for each heat. 2 = Maximum allowable chemical content for finished bar.
portant to know how this type of reinforcing bar differs For A615 bars with an unknown C.E., the AWS D1.4
from ASTM A615 (2009a) carbon-steel bars. specification requires a preheat temperature of 500 F.
One important difference is the chemistry of A706 Another important difference between A706 and A615
bars. A706 bar chemistry is more tightly controlled bars is A706 has more stringent strength limits than A615.
than A615 bars in order to enhance the weldability of For A706 bars, the yield strength can be no more than
the steel. There is considerable increased control in the 18,000 psi above the minimum specified yield strength,
A706 specification with maximum limits on five chemi- and the tensile strength must be at least 1.25 times the
cal elements, while the A615 specification limits only one actual yield strength. In addition, there are minimum
element. Table 5 lists the specific chemistry limits for the elongation requirements for A706 bars that are higher
two bar types. than A615 bars, and the bend test requirements for A706
bars require a smaller pin diameter than A615 bars.
Another requirement of A706 is that the carbon equiv-
alent (C.E.) is specified as having a maximum limit of In summary, steel reinforcing bars produced to ASTM
0.55 percent. C.E. is a numerical value calculated from A706 have tighter controls on chemistry and metallurgi-
the chemical analysis of seven elements. The formula is: cal properties than that produced to ASTM A615. With
greater chemistry control, these A706 bars are weldable,
C.E. = %C + % Mn + %Cu +%Ni + %Cr %Mo %V have more reliable strength limits, and greater elonga-
6 40 20 10 50 10 tion and ductility.
The steels C.E. value is used in the AWS D1.4 (2005) Applications Because if its greater weldability than
specification to determine the preheat temperature re- A615 bars, A706 bars are well suited for those cases
quired before welding. According to Table 5.2 of AWS when a significant amount of welding is required for the
D1.4, little or no preheating is required for #3 to #11 [#10 project. Due to its tighter strength limits, A706 bars are
to #36] bars with a C.E. of under 0.55 percent. For #14 also well suited where greater ductility is needed in the
and #18 [#43 and #57] bars with a C.E. of 0.40 to 0.55 reinforcing steel, such as for blast-resistant and seismic-
percent, a preheat no greater than 200 F may be re- resistant structures. Chapter 21 of ACI 318 (2008) should
quired. Table 6 lists the minimum preheat temperatures be consulted for seismic information.
required by AWS D1.4, based on C.E. values.
Availability A recent survey conducted by CRSI of
mills producing reinforcing bars showed that 31 out of
35 mills that produce A615 bars can also produce or are
Table 6 Minimum Preheat Temperatures* producing A706 bars. There is a small premium for A706
bars, generally costing about 5 to 10 percent more than
C.E. Range Bar Sizes A615 bars.
(%) #3 to #6 #7 to #11 #14, #18
0.40 max. 50 F
0.41 to 0.45 50 F
0.46 to 0.55 50 F 200 F
0.56 to 0.65 100 F 200 F 300 F
0.66 to 0.75 300 F 400 F 400 F
Above 0.75 300 F 500 F 500 F
*Based on Table 5.2 of AWS D1.4 (2005)
ASTM International ASTM [2009a], Standard Speci- Concrete Reinforcing Steel Institute CRSI [2009], Man-
fication for Deformed and Plain Carbon-Steel Bars for ual of Standard Practice, 28th Edition, Concrete Rein-
Concrete Reinforcement, ASTM A615 / A615M - 09, forcing Steel Institute, Schaumburg, IL, 144 pp.
ASTM International, West Conshohocken, PA.
International Code Council ICC [2006], International
ASTM International ASTM [2009b], Standard Speci- Building Code, International Code Council, Washington,
fication for Low-Alloy Steel Deformed and Plain Bars D.C., 664 pp.
for Concrete Reinforcement, ASTM A706 / A706M - 09,
ASTM International, West Conshohocken, PA. Stecich, J.; Hanson, J.M.; and Rice, P.F. [1984], Bend-
ing and Straightening of Grade 60 Reinforcing Bars,
ASTM International ASTM [2009c], Standard Specifi- Concrete International: Design & Construction, V. 6,
cation for Zinc-Coated (Galvanized) Steel Bars for Con- No. 8, August, pp. 14-23.
crete Reinforcement, ASTM A767 / A767M - 09, ASTM
International, West Conshohocken, PA.
Contributors: The primary authors on this publication are John Turner and Anthony Felder, with
review by the CRSI Design Aids and Codes Committee.
Keywords: Frequently asked questions, FAQs, reinforcing bar, field bending, cutting, welding, rust,
epoxy-coating, bar support
Reference: Concrete Concrete Reinforcing Steel Institute - CRSI [2010], Frequently Asked Ques-
tions (FAQ) about Reinforcing Bars, CRSI Technical Note CTN-G-2-10, Concrete Reinforcing
Steel Institute, Schaumburg, Illinois, 8 pp.
933 North Plum Grove Rd.
Historical: Formerly CRSI EDR No. 44 Schaumburg, IL 60173-4758
p. 847-517-1200 f. 847-517-1206
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reproduced without the expressed written consent of CRSI.