SECTION 03210

EPOXY COATED CONCRETE REINFORCEMENT

PART 1 - GENERAL

1.1 DESCRIPTION OF WORK

A. Epoxy coated steel reinforcement shall be used for concrete structures in

accordance with requirements in specification Section 03200.

B. 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.

C. Related Work:

1. Section 03100: Concrete Formwork

2. Section 03200: Concrete Reinforcement
3. Section 03300: Cast-In-Place Concrete
4. Section 03400: Precast Concrete

1.2 QUALITY ASSURANCE

A. Codes and Standards: Comply with the provisions of the following codes,
specifications, and standards, except as otherwise shown or specified:

1. ACI 301 Specifications for Structural Concrete for Buildings.

2. ACI 315 Manual of Standard Practice for Detailing Reinforced

Concrete Structures.

3. ACI 318 Building Code Requirements for Reinforced Concrete.

4. ASTM A 615 Deformed and Plain Billet-Steel Bars for Concrete

Reinforcement.

5. CRSI Manual of Standard Practice.

6. SASO 2 Steel Bars for the Reinforcement of Concrete.

RCMYAS Guide Specs 03210-1 Contract No. ____________

Rev A, 29 Oct. 05
 7. ASTM A 775 Standard Specification for Epoxy-Coated Reinforcing Steel
Bars.

8. SSPC-SP10 Steel Structures Painting Council "Surface Preparation

Specification No. 10.

1.3 SUBMITTALS

A. 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 the Royal Commission 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 DELIVERY, HANDLING AND STORAGE

A. 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.

B. 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.

RCMYAS Guide Specs 03210-2 Contract No. ____________

Rev A, 29 Oct. 05
 C. Equipment for handling epoxy coated bars shall have padded contact areas.
Bundles shall be lifted with a strongback or have multiple supports to prevent
bar-to-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 paragraph 3.2.B.

PART 2 - PRODUCTS

2.1 MATERIALS

A. All reinforcing steel shall be deformed and shall comply with the requirements of
ASTM A 615 and as follows:

1. Provide Grade 60 bars, except as otherwise indicated.

B. Steel wires shall conform to ASTM A 82.

C. Column Spirals: Plain, cold-drawn wire, ASTM A 82, or hot-rolled rods for
spirals, ASTM A 615.

D. 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.

2. 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.

3. For abrasive-blasted or bush-hammered concrete, provide special

stainless bar supports (CRSI, Class E).

4. Over waterproofing membranes, use precast concrete chairs to prevent

penetration of the membrane.

2.2 EPOXY COATING

A. 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 the Royal Commission.

RCMYAS Guide Specs 03210-3 Contract No. ____________

Rev A, 29 Oct. 05
 2. 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.

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 2½, BSa 2½, or CSa 2½, as applicable.

b. 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.

2. Coating Application: The powdered epoxy resin coating shall be

electrostatically applied in accordance with ASTM A 775 Standard. The
epoxy coating may be applied before or after fabrication of the reinforcing
bars.

3. 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 G 12.

4. 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.

b. 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.

RCMYAS Guide Specs 03210-4 Contract No. ____________

Rev A, 29 Oct. 05
 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.

6. 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 thermal equilibrium between 20° and 30°C at the time of
testing.

b. No cracking of the coating shall be visible to the naked eye on the

outside radius of the bent bar.

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.

b. 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.

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.

3. Plant Inspection:

a. The Royal Commission reserves the right to have its authorized

representative observes 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.

RCMYAS Guide Specs 03210-5 Contract No. ____________

Rev A, 29 Oct. 05
2.3 FABRICATION

A. 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.

B. Unacceptable Materials: Reinforcement with any of the following defects will not
be permitted in the work:

1. Bar lengths, depths, and bends exceeding specified fabrication tolerances.

2. Bend or kinks not indicated on drawings or final shop drawings.

3. Bars with reduced cross-section due to excessive rusting or other cause.

4. Epoxy coating not meeting the requirements of article 2.2.

PART 3 - EXECUTION

3.1 INSTALLATION

A. 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.

B. Clean reinforcement to remove dirt and other materials which reduce or destroy
bond with concrete.

C. 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 bars supports and reinforcement together with
1.52 mm diameter coated wire (See paragraph 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.

D. 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.

RCMYAS Guide Specs 03210-6 Contract No. ____________

Rev A, 29 Oct. 05
 E. Splices: All splices in reinforcement shall be as shown on the drawings or as
directed by the Royal Commission. Minimum lap for bar splices shall be as noted
on the plans. 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 REPAIR OF COATED BARS

A. 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 + +

RCMYAS Guide Specs 03210-7 Contract No. ____________

Rev A, 29 Oct. 05