STORMWATER & SUBSOIL DRAINAGE SYSTEMS VOLUME IV- TECHNICAL SPECIFICATIONS

2 CONCRETE REINFORCEMENT (SECTION

03200)
2.1 Part 1 General
2.1.1 Scope
A. This section of the specification gives the requirements for concrete
reinforcement, fabrication and placing

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2.1.2 Related Documents
Section 01300-Submittals

Section 01400-Quality Control

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Section 01600-Materials and equipment

2.1.3 Standards
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All activities relating to this section of the specification shall comply with the
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following or approved equal standard

ASTM A615 Standard Specification for Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement.

BS 4449 Specification for carbon steel bars for the reinforcement of

concrete.

BS 4483 Steel fabric for the reinforcement of concrete.

BS 8666 Specification for scheduling, dimensioning, bending and

cutting of steel reinforcement for concrete.

BS 7123 Metal arc welding of steel for concrete reinforcement.

BS 7973 Spacers and chairs for steel reinforcement.

BS 5135 Arc welding of carbon and manganese steel.

BS EN 1992 Design of Concrete Structures.

ISO 9000 Quality management system

2.1.4 Submittals
A. Method statements.

The Contractor shall submit method statements to the Engineer for approval four

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weeks in advance of commencing the site activity in accordance with Section

01600 of t h e specification. These shall comprise but not necessarily be limited
to:

1. Proposals for cleaning reinforcement from any deleterious material before

fabrication commences.

2. Proposals for welding connections between reinforcing bars including epoxy

coated bars where specified. Certificates for welders shall be provided and
verified by a recognized authority.

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B. Drawings

The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with Section 01300 of the

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specification. These shall comprise but not necessarily be limited to:

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Detailed fabrication and placement drawings for all reinforcement indicating:
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a. Layout of the individual panels.

b. Plans and sections showing bar sizes, spacing, splicing locations,

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position of construction joints and control joints.

c. Quantities of reinforcing steel and wire fabric, bending and cutting

schedules in accordance with BS 8666.

d. Supporting and spacing devices and notes to reinforcement erector

showing size and location of embedded conduits, pipes and sleeves.

C. Samples

Representative samples, as agreed with the Engineer, must be submitted for all
reinforcement that the Contractor proposes to use in the Works, at the same
time as the particulars are submitted.

2.1.5 Quality Control

A. Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the opportunity
to inspect and test the product and / or material prior to delivery in accordance with
Section 01400 of the specification.

B. Products and materials shall be from a manufacturer/supplier that operates a

quality system, which is registered to ISO 9000 series, or approved equal.

C. To allow the Engineer to inspect the Works, the Contractor shall give the Engineer

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a minimum 24-hour notice to carrying out the following activities on site:

1. Commencement of fixing of steel reinforcement to allow inspection of

formwork.

2. Completion of fixing of steel reinforcement for final approval by the

Engineer prior to concreting

D. The Engineer shall have access to the fabrication plant for inspection and
verification of length, size and bending of steel reinforcement as indicated in the
bending schedules. Advance notice of the date of commencement and duration of

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shop fabrication shall be provided by the Contractor.

E. The Engineer reserves the right to sample and test each batch of reinforcement
upon its arrival at the work site.
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1.
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The following tests shall be carried out for each delivery of
reinforcement, to the procedures and frequencies given in BS 4449 unless
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otherwise directed by the Engineer.

a. Mass per unit length.

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b. Ultimate tensile strength.

c. Yield stress.

d. Elongation.

e. Bend and rebend test.

2. Test results for each bar diameter shall be submitted to the Engineer three
weeks before concrete works commences on site. Reinforcement not
meeting the required standards shall be removed from site at the
Contractor’s expense.

3. Further tests may be called for, at the Contractor’s expense, if the source
of supply of reinforcement changes.

2.1.6 Delivery, Storage, and Handlin

A. Delivery, storage and handling of products and materials shall be in accordance
with the manufacturer’s recommendations, Section 01300 of the specification and
the following provisions:

1. Every delivery of steel reinforcement shall be legibly tagged by the

manufacturer.

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a. The tag shall show the manufacturers test number, batch number
and other applicable data that will identify the material with the
corresponding certificate issued for that batch of steel.

b. Steel reinforcement shall be delivered clean and free of rust.

2. Store steel reinforcement at all stages on suitable supports a minimum of

200mm above the ground surface or as directed by the Engineer and in such
a manner that permits easy access for inspection and identification.

3. All steel reinforcement shall be covered with suitable canvas tarpaulins.

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Plastic sheeting is not allowed.

4. Steel reinforcement shall not be rough handled, dropped from a height or

subject to shock loading or mechanical damage.

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5. Equipment handling for epoxy coated reinforcement if specified shall be
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adequately padded to prevent damage to coating and the reinforcement shall
be adequately supported to prevent bar to bar abrasion from sags in the
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bundle when lifting.
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6. Provide tags for all bundles of reinforcement and include bar schedule and
bar mark reference after bending. The bundle tag shall be traceable back to
the manufacturer’s consignment.

2.2 Part 2 Products

2.2.1 Reinforcement Bars
A. All steel reinforcement shall conform to the requirements of the specifications for
type 500B to BS 4449, unless otherwise shown on the drawings or specified by
the engineer.

B. Deformed high yield bars shall have yield strength of 460N/mm2 and shall be
classified as Type 2 unless otherwise specified.

C. The mill test report for three different samples shall be furnished to the Engineer
for each consignment of steel reinforcement bars proposed for use on the project.

D. The bars in each consignment shall be legibly tagged in accordance with CARES
requirements (or similar international certification organisation) by the
manufacturer and/or fabricator before being offered for inspection. The tag shall
show the manufacturer's test number and consignment number and other
applicable data that will identify the material with the certificate issued for that

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consignment of steel.

E. The fabricator shall furnish copies of a certification which shows the heat number
or numbers from which each size of bar in the shipment was fabricated.

F. The Contractor shall provide certificates confirming that samples taken from the
bars delivered to the Works pass all the tests required in BS 4449. The frequency
of sampling and the method of quality control shall be in accordance with BS
4449. The Engineer reserves the right to inspect, sample and instruct testing of
the reinforcement steel upon its arrival at the work site, in accordance with clause

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B of BS 4449. All such sampling and associated testing costs shall be borne by
the Contractor.

G. All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,

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paint, grease, oil or other foreign substance, fins, or tears. There shall be no

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evidence of visual flaws in the bars, test specimens or on the sheared ends of the
bars.
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H. All reinforcement shall be cleaned before use to remove rust, oil, grease, salt and
other deleterious materials. Where pitting has occurred, the bars shall be rejected.
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Blasting may be required when the reinforcement is in position, or partially cast in.
Partially set concrete adhering to exposed bars during concreting operations shall
be removed.

I. Water cleaning of reinforcement to remove chloride contamination shall be carried

out prior to pouring of concrete. Cleaning water shall be the same quality as
mixing water for concrete.

J. Where specified by drawings/Engineer, epoxy coating to steel reinforcement shall

be in accordance with ASTM A775.

1. The coating shall be applied by the electrostatic spray method at a

factory approved by the Engineer.
2. The film thickness of the coating after curing shall be at least 0.15mm and
shall not exceed 0.25mm over the complete periphery including
deformations and ribs. The bond classification of coated bars to concrete
determined in bond performance tests shall not be less than that of
uncoated bars.
K. The minimum thickness of concrete cover to reinforcement shall be as shown on
the drawings. Only approved spacers shall be used.

2.2.2 Welded Wire Fabric

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A. Welded wire fabric to be used for the reinforcement of concrete shall conform to
the following requirements.

B. Welded steel wire fabric reinforcement shall have yield strength of 460N/mm2 and
shall be classified as Type 2 unless otherwise specified.

C. Dimensions: Welded steel wire fabric shall conform to the size and dimensions
shown on the Drawings.

D. Properties: Wire fabric furnished under this Specification shall conform to both BS
4483 and BS 4449.

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2.2.3 Spacer Blocks
A. Spacers as approved by the Engineer shall be of such material and design as will
be durable, not lead to corrosion of the reinforcement and not cause spilling of the
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concrete cover.
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B. Spacer blocks made from cement, sand and small aggregate shall match the mix
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proportions of the surrounding concrete so far as is practicable be comparable in
strength, durability and appearance. Their surface shall be roughened to ensure
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satisfactory bond with the surrounding concrete.

2.2.4 Mechanical Couplers for Reinforcement

A. Couplers are only to be supplied from a manufacturer with a QA/QC system
accredited by an internationally recognized accreditation agency.

B. The contractor is to furnish three (3) copies of all test certificates for each size and
type of coupler proposed, demonstrating their compliance with the requirements
of relevant British Standards, and the particular performance requirements of this
specification.

C. The performance criteria for couplers for each representative gauge length
assembly comprising of reinforcement the size, grade and profile to be used and
a couple of the precise type to be used the following minimum criteria must be
attained.

D. The strength of the coupled bar in both tension and compression must exceed
125 percent of the yield strength of the bar (1.15fy) for grade 250 and 500A and
500B reinforcement or 95 percent of the ultimate actual tensile strength of the
reinforcement bars.

E. The couplers in each consignment shall be legibly tagged by the manufacturer

and/or fabricator before being offered for inspection. The tag shall show the

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manufacturer's test number and consignment number and other applicable data
that will identify each coupler with the certificate issued for that consignment.

F. The Contractor shall provide certificates confirming that samples taken from the
couplers delivered to the Works pass all the tests required by this specification.
The frequency of sampling and the method of quality control shall be in
accordance with British Standards and agreed with the Engineer prior to
commencing.

G. The minimum on site testing requirements are as follows:

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1. Prior to installation in the permanent works, 3 tests of each coupler size and
type to be used are to be completed by an approved independent testing
laboratory with results submitted for review and approval by the Engineer.

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Failure of any one of these tests will result in the immediate testing of no less

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than 25 couplers from the failed batch to determine if manufacturing defects
exist.
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2. Once initial testing is successfully completed and couplers are approved for
use in the permanent works 1 sample for every 200 couplers of each coupler
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type. If one coupler test fails 25 from the failed batch must be tested
immediately to determine if a manufacturing defect exists in the current
delivery. The subsequent rate of testing will then be reassessed.

H. The Engineer reserves the right to inspect, sample and instruct testing of the
coupler assemblies upon its arrival at the work site. All such sampling and
associated testing costs shall be borne by the Contractor.

2.2.5 Accessories
A. Tie wires shall be 1.6mm diameter soft annealed steel wires. For epoxy-coated
reinforcement, this shall be PVC coated.

B. Steel chairs, bolsters and bar supports shall be of sufficient size, shape and
strength to provide adequate support to steel reinforcement during placement
of concrete.

C. Spacers shall be made of concrete, plastic or other material as approved by the

Engineer. Concrete spacers shall have the same or greater strength as the
surrounding concrete and have an embedded plastic coated tie wire.

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2.3 Part 3 Execution

2.3.1 Reinforcement
A. Bar Schedules and Shop Drawings
1. The contractor shall schedule the reinforcement in accordance with BS 8110
and BS 8666 and the information on the drawings, this specification and
subsequent instructions.
2. The contractor shall include for all necessary supports, chairs and spacers,
and his price and rates for reinforcement thus shown shall include for these.

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3. The contractor shall prepare reinforcement detail drawings and other
relevant shop drawings to the following scales:

a. Walls and slabs 1:50

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b. Beams and column elevations 1:20
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c. Beam and column sections 1:20 or 1:10
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4. hop drawings shall show all openings for services, up stands or plinths for
equipment and cast-in items and be fully coordinated with relevant trades.
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5. Reinforcement details drawings shall be in accordance with the Standard

Method of Detailing Structural Concrete published by the Institution of
Structural Engineers/Concrete Society. Sketches will not be acceptable.
6. Bar bending schedules and coordinated shop drawings shall be submitted
for the Engineer's approval. An average of 21 days shall be allowed for the
Engineer’s review of this documentation.
7. The Contractor shall correct these schedules incorporating the Engineer’s
comments and resubmit as reasonably required to ensure a high standard of
work. He shall programme his work and submit schedules for approval
allowing time for such verification, rectification and resubmission as
necessary. Such approval shall not relieve the Contractor of his contractual
responsibility.
8. No concreting shall be allowed to proceed until such a time that the shop
drawings and bending schedules for that particular section of works are
approved.
B. Bar Cutting and Bending
1. Reinforcement shall be cut and bent in accordance with BS 8666. Cutting or
bending by the application of heat is not permitted. Welding of reinforcement
shall only be permitted when approved in writing by the Engineer. If such
approval is given then the workmanship shall be in accordance with BS

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5135. The Contractor shall submit full technical details of his proposed
procedures prior to seeking approval
2. Hot rolled high yield bars shall not be straightened or bent again, having
once been bent. If the Engineer gives approval to bend mild steel
reinforcement projecting from the concrete, the internal radius of bend shall
not be less than four times the nominal size of the bar.
C. Placing and Fixing Reinforcement
1. Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar

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intersections shall be tied together using 1.2mm diameter steel wire and the
ends of the tying wire shall be turned into the main body of the concrete
2. Spacer blocks or other supports approved by the Engineer, shall be provided

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and used to retain the reinforcement at proper distances from the forms. The

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contractor shall secure the cage/reinforcement by providing adequate
supports. All reinforcement shall be so rigidly supported and fastened that
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displacement will not occur during construction. Reinforcing steel shall be
inspected in place and must be approved by the Engineer before any
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concrete is deposited.
3. No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.
4. Reinforcement temporarily left projecting from the concrete at construction or
other joints shall not be bent out of position during the periods in which
concreting is suspended, except with the approval of the Engineer.
5. Minimum lap lengths are as follows unless otherwise noted in the contract
drawings.
Table 2-1: Minimum Lap Lengths
Lap Length (mm) Diameter (mm) Lap Length (mm)
Diameter (mm)
400 20 1000
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500 25 1250
10
600 32 1600
12
800 40 2000
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6. The minimum lap length for deformed high yield bars and welded steel wire
fabric reinforcement shall comply with BS EN 1992 C.3.12.8.
D. Electrical Continuity of Reinforcement
1. The Contractor shall provide and ensure the electrical continuity of all
reinforcing steel.

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2.3.2 Placement
A. All steel reinforcement shall be securely and accurately fixed in position as shown
on the drawings and supported to ensure that the reinforcement cage as a whole
shall retain its shape and correct position in the forms during the process of
depositing and compacting the concrete.

B. Maintain concrete cover around reinforcement to within + or - 5mm of the values

given in Table 2-2 below.
Table 2-2: - concrete cover to reinforcement

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Concrete cover to Reinforcement Minimum cover

External work, work against earth faces 75mm

and in liquid retaining structures.

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External work in a tidal environment 75mm

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and concrete placed in or under water.

Internal work in non-liquid retaining

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structures.

Walls, beams and columns. 50mm to the nearest bar including

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links

Slab reinforcement. 30mm to all bars or diameter of the

largest bar whichever is the greater.

Distance between parallel bars. 25mm or the diameter of the largest

bar whichever is the greater.

C. Turn ends of tie wires into the main body of the concrete. Do not allow tie wire to
project towards the surface.

D. Place chairs, bolsters, or bar supports between parallel layers of steel reinforcement
in slabs.

E. Place spacers against steel reinforcement to separate layers of reinforcement from

concrete blinding and formwork.

F. Do not use shapes of steel reinforcement not shown on the drawings.

G. Where epoxy coated reinforcement is specified provide adequate scaffolding

system to ensure that the coating is not damaged during fixing and concreting.

H. Welding of steel reinforcement shall not be carried out unless authorized by the
Engineer.

I. Mechanical splices shall only be used as indicated on the drawings or as authorized

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by the Engineer.

J. Steel reinforcement shall be fixed so that it does not come into contact with other
non-ferrous or dissimilar metals.

K. Do not damage forms or linings when fixing steel reinforcement.

L. Do not fix reinforcement above membranes applied to blinding and other horizontal
surfaces until cement mortar screed protection has been applied.

M. Protect exposed steel reinforcement from all aggressive elements.

2.3.3 Cleaning and Adjustment of Reinforcement

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A. At the time of concreting, all steel reinforcement shall be thoroughly cleaned and
freed from all loose rust, loose mill scale, oil, grease, mud, paint and other

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deleterious material to the satisfaction of the Engineer including partially set

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concrete, which may have been deposited during the placing of a previous lift of
concrete.
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B. Immediately prior to concrete placing, all reinforcing steel shall be thoroughly
washed with high-pressure potable water jets and shall be free off and corrosion
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product.

C. Check position of steel reinforcement during concreting operations and if

movement is observed adjust to the satisfaction of the Engineer or stop concreting.

END OF SECTION

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