Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 1 - ROADS, Second Edition 2020)

TEEL

AWS

American Welding Society;

AWS - D1.4/

American Welding Society - Structural Welding Code

– Reinforcing Steel;

D1.4M:2011

British Standards;

BS EN

European Standards;

CRSI

Concrete Reinforcing Steel Institute;

CRSI’s

Manual of Standard Practice, 2009;

ICC-ES

International Code Council Evaluation Service;

IBC

International Building Code;

ISO

International Organization for Standardization;

ISO 9001:2015

Quality management systems

– Requirements.

Table 5-1 and Table 5-2 identify a set of American Association of State Highway and Transportation
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), and European
(BS EN) Standards that support the manufacture and use of reinforcement steel.

Table 5-1: Designations and titles for AASHTO and ASTM standards that apply to

reinforcing steel works

AASHTO

Designation

ASTM

Designation

Title

AASHTO M

284M/M 284-09

ASTM A 775/A

775M-07b

Standard Specification for Epoxy-Coated Reinforcing
Bars: Materials and Coating Requirements

AASHTO M

317M/M 317-03

(2007)

ASTM D3963 /

D3963M -

01(2007)

Standard Specification for Fabrication and Jobsite
Handling of Epoxy-Coated Steel Reinforcing Bars

ASTM A82 /

A82M - 07

Standard Specification for Steel Wire, Plain, for Concrete
Reinforcement

ASTM A934 /

A934M - 07

Standard Specification for Epoxy-Coated Prefabricated
Steel Reinforcing Bars

ASTM A884 /

A884M - 12

Standard Specification for Epoxy-Coated Steel Wire and
Welded Wire Reinforcement

AASHTO M

31M/M 31-10

(2011)

ASTM A615 /

A615M - 12

Standard Specification for Deformed and Plain Carbon-
Steel Bars for Concrete Reinforcement

ASTM A706 /

A706M - 09b

Standard Specification for Low-Alloy Steel Deformed
and Plain Bars for Concrete Reinforcement

AASHTO M

225M/M 225-09

ASTM A496 /

A496M - 07

Standard Specification for Steel Wire, Deformed, for
Concrete Reinforcement

AASHTO M

55M/M 55-09

ASTM A185 /

A185M - 07

Standard

Specification

for

Steel

Welded

Wire

Reinforcement, Plain, for Concrete

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AASHTO

Designation

ASTM

Designation

Title

AASHTO M

221M/M 221-09

ASTM A497 /

A497M - 07

Standard

Specification

for

Steel

Welded

Wire

Reinforcement, Deformed, for Concrete

ASTM A955 /

A955M - 12e1

Standard Specification for Deformed and Plain
Stainless-Steel Bars for Concrete Reinforcement

ASTM A1035 /

A1035M - 11

Standard Specification for Deformed and Plain, Low-
carbon,

Chromium,

Steel

Bars

for

Concrete

Reinforcement

AASHTO MP

18M/MP 18-09

(2010)

Standard Specification for Uncoated, Corrosion-
Resistant, Deformed and Plain Alloy, Billet-Steel Bars for
Concrete Reinforcement and Dowels

ASTM A493 - 09

Standard Specification for Stainless Steel Wire and Wire
Rods for Cold Heading and Cold Forging

ASTM A580 /

A580M - 12a

Standard Specification for Stainless Steel Wire

AASHTO T

68M/T68-09

ASTM E8 / E8M -

Standard Method of Test for Tension Testing of Metallic
Materials

ASTM G12 - 07

Standard Test Method for Nondestructive Measurement
of Film Thickness of Pipeline Coatings on Steel

ASTM A370 - 12a

Standard Test Methods and Definitions for Mechanical
Testing of Steel Products

Table 5-2: Designations and titles for BS, and BS EN standards that apply to reinforcing

steel works

BS Designation

BS EN

Designation

Title

4449:2005+A2:20

Steel  for  the  reinforcement  of  concrete.  Weldable
reinforcing  steel.  Bar,  coil  and  decoiled  product.
Specification

6744:2001+A2:20

Stainless steel bars for the reinforcement of and use in
concrete. Requirements and test methods

BS EN 10088-

3:2005

Stainless steels. Technical delivery conditions for semi-
finished products, bars, rods, wire, sections and bright
products of corrosion resisting steels for general purposes

BS 8666:2005

Scheduling, dimensioning, bending and cutting of steel
reinforcement for concrete . Specification

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BS Designation

BS EN

Designation

Title

BS EN 1011-

1:2009

Welding. Recommendations for welding of metallic
materials. General guidance for arc welding

BS EN 1011-

2:2001

Welding. Recommendations for welding of metallic
materials. Arc welding of ferritic steels

5.3

Materials

All reinforcing steel and related materials for which the Contract documents do not define specific
requirements shall comply with the requirements for applicable materials that are outlined in this
section.

5.3.1

Uncoated Reinforcement

Uncoated reinforcing steel shall conform to one of the following specifications, as applicable:

•

Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

(AASHTO M 31M/M 31-10 (2011))

(ASTM A615 / A615M - 12)

Deformed and plain steel

bars for concrete reinforcement shall be grade 60 (grade 420) unless otherwise specified in
the Contract documents.

•

Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete

Reinforcement (ASTM A706 / A706M - 09b).

•

Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement (AASHTO M

225M/M 225-09) or (ASTM A496 / A496M - 07).

•

Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete (ASTM

A185 / A185M - 07) or (AASHTO M 55M/M 55-09).

•

Standard Specification for Steel Wire, Plain, for Concrete Reinforcement (ASTM A82 / A82M

- 07).

•

Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete

(AASHTO M 221M/M 221-09) or (ASTM A497 / A497M - 07).

•

Steel for the Reinforcement of Concrete - Weldable Reinforcing Steel - Bar, Coil and Decoiled

Product - Specification (BS 4449:2005+A2:2009).

5.3.2

Coated Reinforcement

Any reinforcing steel that is to be epoxy-coated shall conform to Section 5.3.1,

Uncoated

Reinforcement

. When reinforcing bars require epoxy coating, the coating materials, coating process,

fabrication,  handling,  identification  of  the  bars,  and  repair  of  damaged  coating  that  occurs  during
fabrication and handling through completion of the shipment to the job site shall conform  with the
requirements of  AASHTO  M 284M/M 284-09 (ASTM A 775/A 775M-07b) or AASHTO M 317M/M
317-03 (2007) (ASTM D3963 / D3963M - 01(2007)) or to ASTM A934 / A934M - 07, as specified in
the Contract documents.

Epoxy-coated wire and welded wire fabric shall conform to the Class A requirements outlined in
ASTM A884 / A884M - 12.

When epoxy coating is specified, only fusion bonded epoxy-coated reinforcement steel shall be
accepted. No other means of epoxy-coating shall be approved

Epoxy coated reinforcing bars shall be coated in a certified epoxy coating Applicator plant in
accordance with

Concrete Reinforcing Steel Institute

(CRSI) requirements, as outlined in

Voluntary

Certification Program for Fusion-Bonded Epoxy Coating Applicator Plants

, or an equivalent

standard.

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Coating material shall be epoxy resin powders as specified in ASTM A 775/A 775M-07b. Before
using epoxy resin powders that do not meet the above requirements, the Contractor shall have them
tested by an approved independent testing laboratory for acceptance by the Engineer.

The Contractor shall supply a representative 1.0 kg sample of the coating material from each batch
of material. Such samples shall be packaged in an airtight container and identified by the batch
number.

Patching material, which shall be furnished by the epoxy coating manufacturer, shall be as approved
by the Engineer, compatible with the coating, and inert in concrete. Such material shall be suitable
for repairs that the Contractor or the coating Applicator might make to coated reinforcing bars at the
Project site.

Reinforcement steel bars that are to be coated shall be clean and free from rust, scale, oil, grease,
and similar contaminants. The surface of the steel bars shall be cleaned by abrasive blast cleaning.
The Contractor shall apply the coating to the cleaned surface as soon as possible after cleaning,
before any visible oxidation to the surface occurs, and not more than eight hours after cleaning. If
reinforcement steel bars to be coated have surface defects that prohibit proper coating, the Engineer
shall reject them.

To apply coating to cleaned steel reinforcing bars, the Contractor shall apply the electrostatic spray
method and fully cure the bars in accordance with the recommendations of the

coating material’s

manufacturer.

Epoxy coating film shall be cured and/or post cured to a fully cured condition. The epoxy coating
Applicator shall check a representative portion of each production lot, using the method most
effective for measuring cure, to ensure that the entire production lot of epoxy coating is fully cured.

Binding wire used for tying epoxy-coated steel reinforcement shall be PVC coated wires.

5.3.2.1

Requirements for Coated Bars at Coating Applicator's Plant

Coated bars shall meet the requirements outlined in this section before leaving the coating
A

pplicator’s plant.

a. Thickness of Coating

After curing, the

coating’s film thickness shall be 0.13 to 0.30 mm inclusive. The Applicator shall take

at least 15 evenly-spaced measurements along each side of the test bar. No less than 90% of these
measurements shall be within the specified limits. Thickness measurements below 0.13mm or more
0.30mm shall be considered cause for rejection of the coated bar. The limits on coating thickness
do not apply to repaired areas of damaged coating.

The thickness of the coating film shall be measured in accordance with ASTM G12 - 07, SSPC-PA
2 (Procedure for Determining Conformance to Dry Coating Thickness Requirements) or another
equivalent thickness measuring method.

The thickness of the coating film shall be measured on the body of the reinforcing bar between the
deformations or ribs on a straight length of bar.

b. Continuity of Coating

After  curing,  the  coating  shall  be  free  from  holes,  voids,  cracks,  and  damaged  areas  that  are
discernible  to  the  unaided  eye.  There  shall  not  be  more  than  two  holidays  (pinholes  that  are  not
discernible to the unaided eye) in any 300 mm of the coated bar, except at the point of manufacturer's
bar markings, where holidays may be more frequent. For example, a coated bar that is 12 meters
long shall not have more than 80 holidays, excluding the exceptions at point where the bar has a
manufacturer’s markings.

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Patching of holidays is not required unless a bar has more than two holidays per 300 mm. As directed
by the Engineer, the Contractor shall either clean and recoat or replace bars with three or more
holidays per 300 mm.

To check holidays, the Contractor shall use a 67.5 volt D.C. holiday detector.

c. Adhesion of Coating

For epoxy-coated bars, the Contractor shall evaluate the adhesion and flexibility of the epoxy coating
on test bars that have been coated with each production lot. The Contractor shall furnish such test
bars in addition to the bars to meet the Contract and the Project requirements. The Contractor shall
supply either six meters of test bars or one percent of the total length of all epoxy coated bars for the
Project, whichever is less. Test bars may be in one length or multiple lengths, as long as there is
one test bar of each size for each production lot.

To evaluate the epoxy-coated test bars, the Contractor shall bend them 120 degrees (after rebound)
around a mandrel of a diameter corresponding to size of bar indicated in Table 5-3. Each bend shall
be made at a uniform rate and may take as long as 1.5 minutes to complete. The bend test shall be
conducted at room temperature (20-30° C.) after the specimen has been exposed to room
temperature for a sufficient time to ensure that it has reached thermal equilibrium. No cracking or
disbonding of the epoxy coating shall be visible to the unaided eye on the outside radius of the bent
bar.

Table 5-3: Mandrel diameters for evaluation of epoxy-coated test bars

Bar Diameter (mm)

Diameter of Mandrel (mm)

111

127

143

159

175

191

198

206

222

238

254

270

286

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Bar Diameter (mm)

Diameter of Mandrel (mm)

302

318

357

Fractures or partial failures of the steel reinforcing bar do not indicate that the coating failed to
adhere. Neither do visible cracking or disbonding that is caused by imperfections in the bar surface.
In all such cases, however, the Contractor shall test two additional samples. These two samples
shall then meet all adhesion test requirements.

Evidence of cracking or disbonding of the coating shall be considered cause of rejection of the coated
bars represented by the sample subject to conducting 2 re-tests.

Before shipment from the manufacturer’s plant, coated bars shall meet all of the requirements
outlined in this section.

5.3.2.2

Inspection

The Owner, the Engineer, or the Engineer

’s representative reserve the right to access to the epoxy

coating Applicator's plant to witness epoxy coating processes for the Project work and to obtain
example test bars for any tests.

Unless the Project specifies that they do otherwise, the coating Applicator shall conduct all tests at
their plant, before shipment, in such a way as to avoid unnecessary interference with the coating
operation.

5.3.2.3

Rejection

The Owner or the Engineer shall reject coated bars that do not meet the requirements of this
specification. The coating Applicator has an option to either replace bars with defective coating or
strip the coating from such bars of coating, clean them, and coat them again in accordance with the
requirements of this specification.

5.3.2.4

Certification

Each shipment of epoxy coated reinforcing steel shall have a Certificate of Compliance that has
been signed by the Applicator of the coating. Such documentation shall certify that the epoxy coated
reinforcing bars were cleaned, coated, and tested in accordance with the requirements of these
specifications and that they conform as appropriate to the requirements of the following standards:

•

Standard Specification for Epoxy-Coated Reinforcing Bars: Handling Requirements for

Fabrication and Job Site (AASHTO M 317M/M 317-03 (2007))

•

Standard Specification for Fabrication and Jobsite Handling of Epoxy-Coated Steel

Reinforcing Bars (ASTM D3963 / D3963M - 01(2007))

•

Standard Specification for Epoxy-Coated Reinforcing Bars: Materials and Coating

Requirements (AASHTO M 284M/M 284-09)

•

Standard Specification for Epoxy-Coated Steel Reinforcing Bars (ASTM A 775/A 775M-07b)

•

Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars (ASTM A934

/ A934M - 07)

•

Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Reinforcement

(ASTM

A884 / A884M - 12), Class A (for epoxy-coated wire or welded wire fabric)

The Contractor shall retain such test results for seven years and shall make them available to the
Engineer upon request.

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Furthermore, the Contractor shall have the coating Applicator regularly and frequently visit the
Contractor's steel storage, bending facilities, handling facilities, and construction site to ensure
procedural compliance.

5.3.3

Stainless Steel Reinforcing Bars

When specified in the Contract document, deformed or plain stainless steel reinforcing bars shall
conform to the requirements

outlined in ASTM’s Standard Specification for Deformed and Plain

Stainless-Steel Bars for Concrete Reinforcement (ASTM A955 / A955M - 12e1), AISI 316 or 316LN
(depending on bar diameter) or BS 6744:2001+A2:2009 type 316 (S31 or S33). The geometrical
classification for the bars shall be Type 2.

Because of the very long term performance expected from the stainless steel reinforcement, the
Contractor shall ensure at the time of arrival of the steel on the Project site that it meets all Project
specification requirements and that all the factors important for long-term performance are checked
carefully. Damaged or contaminated stainless steel shall not be accepted.

All stainless steel reinforcement shall be supplied by a mill approved by the Owner. In addition,
fabrication (cutting, bending, shaping, making spirals) of the steel shall be by a firm approved by the
Engineer. If the steel has been supplied, or fabricated by a company that is not approved, the steel
shall not be acceptable for use.

5.3.3.1

Binding Wire

Binding wire used for tying stainless steel reinforcement shall be 16 or 18 gauge (1.6mm or 1.2mm
diameter) stainless steel wire to ASTM A580 / A580M - 12a or BS EN 10088-3:2005.

5.3.3.2

Certificates and Tags

Stainless  steel  that  arrives  on  the  Project  site  shall  be  tagged,  indicating  the  mill  and  Fabricator,
stainless steel type and grade, and bar mark number including stainless designation. The steel shall
be  accompanied  by  a  "mill  certificate"  verifying  that  the  bars  conform  to  these  standard
specifications, and the Contract documents where applicable, including the stainless steel type and
name; chemical composition; finish; tensile properties and bend test results. The mill certificate shall
be checked by the Contractor to make sure it includes all the information required by the Contract
documents.

5.3.3.3

Bar Markings and Appearance

The bars shall be marked with a symbol that indicates which mill they are from. The marking shall
match the paper work (e.g. tag, mill certificate). Marks shall be made on the steel when it is rolled
into  bars,  so  these  markings  are  permanent  and  are  a  part  of  the  bar.  Bars  shall  be  marked
approximately  every  1  to  1.5  m,  and  the  marks  shall  appear  as  a  raised  area  of  steel  with  a
recognizable “picture” such as a letter of the alphabet or a shape like an empty box. Each mill shall
have a special mark that only that mill uses; the Contractor shall supply the Owner or the Engineer
with this information when they are approved for use.

If the marking on the bar does not match one of the common markings or markings used by currently-
approved mills, the steel should not go in the Project work unless it can be confirmed in writing that
the steel is from an approved source. This confirmation shall be from the supplier of the steel, not
just the Contractor or Fabricator.

The surface “colour” of stainless steel does not always look exactly the same. The surface shall be
uniformly silver-grey in colour, but it may be quite bright or it can be dull in appearance, and still be
of acceptable quality. However, if the steel does not look grey and looks discoloured

or has a “brown”

appearance, or has irregularities on the surface, it shall not be acceptable and shall not be included
in the Project work.

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5.3.3.4

Surface Contamination and Mechanical Defects

Reinforcing stainless steel bars at the time the concrete is placed shall be free of mud, oil and other
contaminants that adversely affecting bonding strength, and deposits of iron and non-stainless steel.
Fabrication of reinforcing stainless steel bars shall be such that the bar surfaces are not
contaminated with deposits of iron and non-stainless steels, or damage due to straightening from
coil.

The Contractor shall use the proper bending equipment not to press the steel from the bending
equipment or the environment into the stainless steel surface to avoid rust contamination on the bar.
If the amount of rust contamination is excessive, or occurs frequently along the length of the bar, the
reinforcing bar shall be rejected.

During the pickling process, stainless steel bars could be contaminated due to excessive iron in rinse
water. Rinse water shall require periodic changing. If surface has dull appearance, the stainless steel
bar was not left in acid bath for the required minimum length of time, and shall be cause of rejection.

Stainless steel with excessive contamination by iron particles due to spray of metal particles from
adjacent black bar cutting operation shall not be acceptable.

The selection of the wrong equipment for straightening can damage the bar (flattening the
deformations, gouging the surface) and reduce the corrosion resistance of the stainless steel; it shall
be cause of rejection.

The reinforcing bar shall be rejected if:

a. any area of contamination of the stainless steel by iron exceeds 100 mm in length;
b. two or more areas of iron contamination greater than 25 mm in length occur along the

length of the reinforcing bar;

c. there are frequent small occurrences of rust contamination along the full length of the

bar.

If reinforcing bars have been rejected due to excessive iron contamination, it may be possible for the
Contractor to have the bar treated to remove the contamination. This can be accomplished by
mechanical cleaning with a (stainless steel) wire brush, by use of a polishing machine or even by
chemical treatment (pickling) if the contamination is excessive or other approved methods are not
successful.

5.3.4

Low-carbon, Chromium, Steel Reinforcing Bars

When specified in the Contract documents, deformed, low carbon, chromium, steel reinforcing bars
shall conform to the requirements

outlined in ASTM’s Standard Specification for Deformed and Plain,

Low-carbon, Chromium, Steel Bars for Concrete Reinforcement (ASTM A1035 / A1035M - 11) and
AASHTO’s Standard Specification for Uncoated, Corrosion-Resistant, Deformed and Plain Alloy,
Billet-Steel Bars for Concrete Reinforcement and Dowels (AASHTO MP 18M/MP 18-09 (2010)), with
a minimum chromium composition by weight of 9.2%. The steel reinforcing bars shall have the
minimum yield strength, as required by the Contract documents, and as measured by using the 0.2%
offset test method of ASTM A370 - 12a.

5.3.4.1

Acceptance Requirements

The Manufacturer of deformed low-carbon chromium steel reinforcing bars shall submit to the Owner
and the Engineer the following documents for review, evaluation, and acceptance or rejection.

a.  Trade license
b.  Complete product description and specifications
c.  Brief description of manufacturing process
d.  Copy of the quality manual (Controlled copy)
e.  Description of quality assurance laboratory
f.  Evaluation report

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g.  Test reports by independent testing laboratories
h.  Vicinity map and factory layout
i.  Valid certification to ISO 9001:2015 (If available)
j.  List of personnel and their designation

a. Evaluation Report

The Manufacturer shall submit evaluation report issued by the International Code Council Evaluation
Service (ICC-ES), under the 2012 and 2009 International Building Code (IBC), recognizing the
deformed low-carbon chromium steel reinforcing bars. The basis of recognition shall be IBC Section
104.11.

b. Quality Management System

The Manufacturer of reinforcing steel bars shall have a Quality Management System that is aligned
to the requirements of ISO 9001:2015 standard.

c. Quality Assurance Laboratory

The Manufacturer of reinforcing steel bars shall have a quality assurance laboratory to carry out
factory production control testing to ensure that the reinforcing steel bars comply with the
requirements of these Standard Specifications.

As a minimum requirement, the laboratory shall have the following testing equipment:

•

Calipers and other linear measuring test equipments

•

Weighing Scale (with an accuracy of 100 grams)

•

Chemical Analyzer

•

Tensile Test Equipment

•

Bend Test Equipment

5.3.4.2

Identification

Bundled reinforcing bars shall have an attached tag identifying the Manufacture

r’s name, heat

number and roll number. The tag shall also bear the ICC-ES evaluation report number. Individual
reinforcing bars shall be identified by a distinguishing set of marks, rolled into the surface of one side
of the bar, denoting point of origin, size designation and minimum yield strength designation in
accordance with ASTM A1035 / A1035M

– 11 or AASHTO MP 18M/MP 18-09 (2010). Illustrations

of the bars highlighting the identifying marks shall be submitted for reproduction in the evaluation
report.

5.3.4.3

Independent Testing Laboratories

Independent testing laboratories shall comply with the ICC-ES Acceptance Criteria for Test Reports
(AC85) and Section 4.2 of the ICC-ES Rules of Procedure for Evaluation Reports, and shall be
approved by the Owner. The cost of the independent testing shall be borne by the Manufacturer.

5.3.4.4

Test Reports

Test reports shall comply with AC85. In addition, the test reports shall include sampling procedures,
test specimen preparation, test procedures, and results of all tests. Where indicated, photographs
shall be included in the report.

5.3.4.5

Product Sampling

Sampling of the reinforcing bars for tests shall comply with Sections 3.1, 3.3 and 3.4 of AC85.

Three sets of samples per size per grade shall be taken randomly. The first set shall be tested in the
plant supervised by the Engineer, the second set shall be sent to independent testing laboratory.
The third set will be kept by the Manufacturer as reference for future use.

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The test sample(s) for independent test shall be identified and signed in the presence of the Engineer
and shall be submitted to the approved independent testing laboratory.

Number of samples for testing shall be at least 10 pieces by one meter length per size per grade.

5.3.4.6

Product Evaluation

Independent test shall only be conducted if the result of the in-plant test shows satisfactory result. If
the result of the test conducted by the independent testing laboratory shows non- conformance, the
retest shall be carried out on the reference sample kept by the Manufacturer or on new samples
collected by the Owner/Engineer, on which full testing shall be carried out, if necessary. If the retest
passed, the initial product assessment is considered conforming to product specification, otherwise
the product shall be rejected.

5.3.4.7

Mechanical Properties

Testing for tensile and bending properties of reinforcing bars shall be in accordance with ASTM
A1035 / A1035M

– 11 or AASHTO MP 18M/MP 18-09 (2010). Each reinforcing bar size shall be

tested.

Conditions of acceptance are as set forth in ASTM A1035 / A1035M

– 11 or AASHTO MP 18M/MP

18-09 (2010).

5.3.4.8

Dimensions

The following dimensions shall be determined and reported by the testing laboratory for each
reinforcing bar size: weight, kg/m; diameter, mm; cross-sectional area, mm

; perimeter, mm;

deformation pattern, spacing and height, mm; and finish.

Deformations shall be determined based on procedures in Section 8 of ASTM A1035 / A1035M

– 11

or AASHTO MP 18M/MP 18-09 (2010).

Conditions of acceptance are as noted in ASTM A1035 / A1035M

– 11 or AASHTO MP 18M/MP 18-

09 (2010).

5.3.4.9

Chemical Composition

The chemical analysis of a heat shall be determined in accordance with Section 7 of ASTM A1035 /
A1035M

– 11 or AASHTO MP 18M/MP 18-09 (2010).

Conditions of Acceptance are as noted in Section 7 of ASTM A1035 / A1035M

– 11 or AASHTO MP

18M/MP 18-09 (2010).

5.3.4.10

Quality Control

a. The reinforcing bars shall be produced under a quality control program demonstrating

compliance with ASTM A1035 / A1035M

– 11 or AASHTO MP 18M/MP 18-09 (2010).

b. Mechanical splices shall be produced under a quality control program in accordance

with ICC-ES Acceptance Criteria (AC133).

c. Quality documentation complying with the ICC-ES Acceptance Criteria for Quality

Documentation (AC10) shall be submitted for each facility manufacturing or labelling
products that are recognized in the ICC-ES evaluation report.

d. A qualifying inspection shall be conducted at each manufacturing facility in

accordance with the requirements of the ICC-ES Acceptance Criteria for Inspections
and Inspection Agencies (AC304).

e. An annual inspection shall be conducted at each manufacturing facility in accordance

with AC304.

f. Special inspections for reinforcing bars and mechanical connectors shall comply with

IBC Section 1704.4. The evaluation report shall describe the special

inspector’s

duties.

TEEL

5.3.5

Bar Lists and Bending Diagrams

When the Contract documents do not include detailed bar lists and bending diagrams, the Contractor
shall provide such lists and diagrams to the Engineer for review and approval. Fabrication of material
shall not begin until the Engineer has approved such lists. The Engineer

’s approval of bar lists and

bending diagrams, however, shall in no way relieve the Contractor of responsibility for the
correctness of such lists and diagrams. The Contractor shall bear any expenses incurred for the
revision of material furnished in accordance with such lists and diagrams to make them comply with
design drawings.

5.4

Fabrication

Fabrication methods for steel to be used on the Project shall conform to the standards and
specifications outlined in this section.

5.4.1

Cutting and Bending

Bar reinforcement shall be cut and bent to the shapes shown in the Contract documents. Tolerances
shall be in accordance with the standards of the American Concrete Institute (ACI) Detailing Manual,
as documented in the details and detailing of concrete reinforcement (ACI 315-99). All bars shall be
bent cold in accordance with BS 8666:2005 unless otherwise permitted.

All cutting and bending of reinforcement bars shall be done by competent workmen using equipment
that has been approved by the Engineer. Cutting and bending by the application of heat is not
allowed (flame cutting). Unless shown otherwise on the Contract plans or unless written approval is
obtained from the Engineer, fabricators shall cut and bend all reinforcement bars in an on-site
fabrication shop. Bars that will be partially embedded in concrete shall not be bent by fabricators in
the field, except as specified in the Contract documents.

Unless otherwise provided on the plans or with written authorization from the Engineer, the minimum
pin diameter (D) around which a bar (with a diameter d) may be bent shall be as follows:

•

D = 6d for 5 to 22 mm bar sizes

•

D = 8d for 24 to 28 mm bar sizes

If coated reinforcement is specified, bent reinforcement steel bars shall be coated after bending. On-
site cut and bent of epoxy-coated reinforcing bars s

hall not be permitted, it shall be in the fabricator’s

shop. The Engineer shall reject any steel with visible cracks in the coating on the outside of a bend
or damage to coating that causes debonding of the coating. Fabricators may shear or saw bars that
are shorter than 7.6 meters after coating, as long as resulting damage to the coating does not extend
more than 12 mm back and fabricators patch the cut ends before any visible oxidation appears. The
Owner and the Engineer do not permit flame cutting.

Deformed  low-carbon  chromium  steel  reinforcing  bars  shall  be  accurately  fabricated  to  the
dimensions  shown  in  the  Contract  documents,  within  the  tolerances  shown  in  the  ACI  315-99  or
CRSI Manual of Standard Practice. Bends shall conform to the dimensions and details in accordance
with ACI 315-99, ACI SP-66(04) and/or CRSI Manual of Standard Practice, unless otherwise shown
in the Contract documents. Bars shall be bent cold, and shall not be bent or straightened in a manner
that  will  injure  the  material.  Heating  of  the  bars  shall  not  be  permitted.  Bar  cutting  shall  be
accomplished  by  shearing  or  with  a  fluid-cooled  saw,  and  flame  cutting  shall  not  be  permitted.
Reinforcing bars partially embedded in concrete shall not be field bent. Fabricated bent bars shall
not be straightened or rebent in the field.

5.4.2

Hooks and Bend Dimensions

Hook dimensions and bend diameters on the inside of each bar shall be as shown in the Contract
documents. When the Contract documents do not show the dimensions of hooks or the diameter of
bends, such measurements shall meet the specifications of Section 5.4.1 of these standard

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specifications, Section 5.10.2 of the latest AASHTO LRFD Bridge Design Specifications or ACI

’s

Building Code Requirements for Structural Concrete and Commentary (ACI 318-08).

5.4.3

Mill Test Reports

When uncoated steel reinforcing bars are to be spliced by welding or when otherwise requested, the
Contractor shall provide a certified copy of the mill test report showing physical and chemical analysis
for each heat or lot of reinforcing bars to the Engineer. Bars that conform to

ASTM’s Standard

Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement (ASTM A706
/ A706M - 09b) are exempt from this requirement. However, welding of steel reinforcement shall be
upon a specific approval of the Engineer.

For deformed low-carbon chromium steel reinforcing bars, a certified copy of a mill certification report
showing physical and chemical analysis for each heat of reinforcing bars shall be provided to the
Engineer upon request.

5.4.4

Identification

The Contractor shall ship reinforcement bars in standard bundles, after tagging and marking the bars
in accordance with Concrete Reinforcing Steel Institute (CRSI) requirements, as outlined in their
Manual of Standard Practice.

If the coating Applicator is also the Supplier of the reinforced bars, each lot of bars delivered to the
Project site shall have both a tag for the coating Applicator and the original tag of the reinforcing
bars’ manufacturer or fabricator.

5.5

Application Methods

5.5.1

Handling and Storing Reinforcement Steel

5.5.1.1

Handling Uncoated Bars

Uncoated reinforcement steel shall be stored above the ground on platforms, skids, or other supports
and shall be protected from  conditions that can cause mechanical damage, surface deterioration,
and  rust. When placed into a construction work, reinforcement  steel shall be free from dirt, loose
rust,  loose  scale,  mortar,  paint,  grease,  oil,  and  any  non-metallic  coatings  that  can  reduce  bond.
Reinforcement steel shall be free from defects such as cracks and laminations.  The Engineer will
not reject reinforcement steel with discoloration as long as the minimum dimensions, cross-sectional
area, and tensile properties of a hand wire-brushed specimen meet the physical requirements for
the specified size and grade of steel.

5.5.1.2

Handling Epoxy-coated Bars

Epoxy-coated reinforcing steel shall be handled and stored by methods that shall not damage the
epoxy coating. All systems for handling epoxy-coated reinforcement shall have adequately padded
contact areas. All bundling bands shall be padded and all bundles shall be lifted with a strong back,
multiple supports, or Platform Bridge so as to prevent bar-to-bar or wire-to-wire abrasion from sags
in the bundles. Bars or bundles shall not be dropped or dragged. Epoxy-coated reinforcing steel shall
be transported and stored on wooden or padded supports.

The Contractor shall immediately cover bundled epoxy-coated reinforcing steel with dense black
plastic or other suitable lightproof material to protect the steel from sunlight, salt spray, and weather
exposure. The Contractor shall ensure that air can circulate sufficiently around the protected
reinforcement to minimize condensation under the protective covering.

Bars shall not be dragged out from the bundles. Rather, the Contractor shall lift bars vertically to
avoid damaging the coating on deformations. The Contractor shall ensure that each bar is properly
supported as it is fed into the cutting or bending machine. An ideal method to provide this support

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involves threading a PVC pipe onto a rebar frame to function as a soft roller. The Contractor shall
handle bars carefully at all times to avoid dropping or otherwise damaging them with tools, heavy
footwear, or wheelbarrows.

5.5.2

Placing and Fastening Reinforcement Steel

The Contractor shall accurately place reinforcement steel shall as shown in the Contract documents,
firmly holding bars in position during the placement and consolidation of concrete. Bars shall be tied
at all intersections around the perimeter of each mat and elsewhere at centres of no less than 600
mm or at every intersection, whichever is greater. Bundled bars shall be tied together at centres of
no more than 1.8 meters. Tie wire and metals clips used to fasten epoxy-coated reinforcement bars
shall be PVC coated wires. If uncoated welded wire fabric is shipped in rolls, the Contractor shall
straighten it into flat sheets before placing it. Unless the Engineer provides written approval for such
activity, the Contractor shall not weld crossing bars (a technique called tack welding) to assemble
reinforcement.

All chairs and other devices used in supporting, securing, or fastening epoxy coated reinforcement
steel shall be made of or coated with a dielectric material. The specific hardware that the Contractor
proposes shall be approved by the Engineer.

5.5.2.1

Support Systems for Reinforcing Steel

The Contractor shall use precast concrete blocks, wire bar supports, supplementary bars, or other
approved devices to support reinforcing steel bars in their proper positions. Such reinforcing supports
or devices shall be of such height and placed at sufficiently frequent intervals to maintain the distance
between the reinforcing steel and the formed surface or the top surface of deck slabs within 6 mm
of that indicated in the Contract documents.

Platforms that support workers and equipment during concrete placement shall be supported directly
on the forms and not on the reinforcing steel.

5.5.2.2

Precast Concrete Blocks

Precast concrete blocks shall have a compressive strength not less than that of the concrete in which
they are to be embedded. Block faces that contact forms for exposed surfaces shall not exceed 50
mm × 50 mm and shall have a colour and texture that matches the concrete surface. When used on
vertical or sloping surfaces, each such block shall have an embedded wire to secure the block to the
reinforcing steel. Such concrete blocks, when used in slabs, shall have a tie wire, unless the weight
of the reinforcement is sufficient to firmly hold the blocks in place, in which a groove in the top of the
block is sufficient. For epoxy-coated bars, such tie wires shall be PVC coated wires.

5.5.2.3

Wire Bar Supports

Wire bar supports, such as ferrous metal chairs and bolsters, shall conform to industry practice as
described in the

CRSI’s Manual of Standard Practice. Such chairs or bolsters which bear against the

forms for exposed surfaces shall be either Class 1-Maximum Protection (Plastic Protected) or Class
2, Type B-Moderate Protection (Stainless Steel Tipped) for which the stainless steel is type 430 as
defined in ASTM’s Standard Specification for Stainless Steel Wire and Wire Rods for Cold Heading
and Cold Forging (ASTM A493 - 09). All wire bar supports and bar clips for epoxy-coated
reinforcement shall be PVC coated wires.

5.5.2.4

Adjustments

The Contractor shall adjust or relocate all non-prestressed reinforcement bars that support post-
tensioned concrete during the installation of prestressing ducts or tendons, as required to provide
planned clearances for the prestressing tendons, anchorages, and stressing equipment and as
approved by the Engineer.

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5.5.2.5

Repairing Damaged Epoxy Coating

All reinforcing bars that require epoxy coating shall comply with the specifications in Section 5.3.2,
Coated Reinforcement. In addition, the Contractor shall repair all damaged coating on epoxy-coated
reinforcing steel that occurs during shipment, handling, and placement. If damage to any 300 mm
segment of rebar exceeds one percent of that total area, the Contractor shall remove and replace
that bar with an appropriate and acceptably undamaged epoxy-coated replacement bar. Therefore,
the Contractor shall only repair bars with damaged areas that do not exceed more than one percent
of any 300 mm segment. This restriction to bar repair does not include sheared or cut ends that are
coated with patching material. Repairs to any single rebar throughout all of the P

roject’s work stages

shall not exceed five percent of the total surface area of any bar; no single bar shall have patching
material on a greater area than five percent of its total surface. Patching material shall be pre-
qualified as required for the coating material and shall be either identified on the container as meeting
the following requirements:

•

Annex A1 of the Standard Specification for Fabrication and Jobsite Handling of Epoxy-

Coated Steel Reinforcing Bars (AASHTO M 317M/M 317-03 (2007))

•

Annex A1 of the Standard Specification for Fabrication and Jobsite Handling of Epoxy-

Coated Steel Reinforcing Bars (ASTM D3963 / D3963M - 01(2007))

•

Standard Specification for Epoxy-Coated Reinforcing Bars: Materials and Coating

Requirements (AASHTO M 284M/M 284-09)

•

Standard Specification for Epoxy-Coated Steel Reinforcing Bars (ASTM A 775/A 775M-07b)

•

Annex A1 of the Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing

Bars (ASTM A934 / A934M - 07)

When submitting patching material to the Engineer for pre-qualification, the Contractor shall also
provide a Certificate of Compliance that certifies that the material meets the requirements of the
appropriate standards. The Contractor shall patch damaged areas of rebar in accordance with the
patching material manufacturer's recommendations. The Contractor shall also allow all patches to
cure fully before placing concrete over the coated bars.

Before the Contractor lowers reinforcement steel bars into place and places concrete, the Engineer
shall inspect coated bars for damage to their epoxy coating. Using the specified patching and repair
materials, the Contractor shall repair any bars with sheared ends, scars, or minor defects.

If the bent portion of a fabricated bar has only hairline cracking and its coating has no discernible
loss of bond (loss of adhesion), repairs are not mandatory. When the bent portion of a bar has
disbondment, however, the Contractor shall remove the disbonded coating, clean the affected areas,
and repair the bar with patching material.

In addition to meeting the requirements outlined above, the Contractor shall, as approved by the
Engineer, suitably wrap and protect any partially embedded bars that will be left temporarily exposed
to prevent mechanical or environmental damage to the

bars’ coating before they are fully embedded

in concrete. Dowels shall project a minimum of 40 bar diameter unless otherwise indicated in the
Contract plans.

5.5.3

Minimum Test Procurement

The Contractor shall take one sample of every 100 tons or a fracture of 100 tons of reinforcing bars
of each size and test them for the following properties:

•

Tensile strength

•

Yield point

•

Elongation after fracture

•

Behaviour in the bend test

•

Behaviour in the re-bend test

•

Deviation from cross section

•

Bond test

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•

Chemical composition

•

Thickness of coating

•

Continuity of coating

•

Adhesion of coating

Testing shall

comply with the requirements outlined in AASHTO’s

Standard Method of Test for

Tension Testing of Metallic Material

s (AASHTO T 68M/T68-09

) or ASTM’s

Standard Test Methods

for Tension Testing of Metallic Materials

(ASTM E8 / E8M - 11). For bars with areas that vary from

the nominal bar area by six percent or more, testers shall use the measured bar area to calculate
unit stress.

All the testing shall be performed at no cost to the Owner and is solely borne by the Contractor.

If a reinforcing steel sample under test fails to meet the specification requirements at any time, if the
Engineer considers that the samples presented for test are not truly representative, or if reinforcing
steel that was not approved have been used on the Project works, the Engineer may instruct the
Contractor to break out and completely remove all such constructed sections that may include such
suspect reinforcement steel.

5.5.4

Splicing of Bars

The Contractor shall furnish all reinforcement bars in their full lengths, as specified in the Contract
documents, unless otherwise permitted. Except for splices that are specified in the Contract
documents and splices for bars with diameters of 16 mm diameter or smaller, the Contractor shall
not splice bars without written approval from the Engineer. When the Engineer permits splices, the
Contractor shall stagger them as far as possible.

5.5.4.1

Lap Splices

Lap splices shall be of the lengths specified in the Contract documents. If the Contract documents
do not specify lap splice lengths, the Contractor shall adhere to Sections 5.11.5.3.1 and 5.11.5.5.1
of the AASHTO LRFD Bridge Design Specifications or approved directions from the Engineer.

In lap splices, the Contractor shall place and tie bars in a manner that maintains the minimum
distance from the surface of the concrete, as specified in the Contract documents. The Contractor
shall not use lap splices for bars with diameters from 40 mm to 50 mm, except as provided in either
Section 5.11.5.2.1 or Section 5.11.5.5.1 of the

AASHTO LRFD Bridge Design Specifications

Lap splices for coated bars shall match those for uncoated bars except that tension lap lengths for
coated bars shall be 50% longer than those for uncoated bars or as required by the

AASHTO LRFD

Bridge Design Specifications

5.5.4.2

Welded Splices

The Contractor shall only use welded splices for reinforcing bars if the Contract details such work or
if the Engineer provides written authorization. Welding shall conform to the Contract documents and
American Welding Society (AWS) specifications as outlined in Section 1.4 of the Structural Welding
Code - Reinforcing Steel (AWS - D1.4/D1.4M:2011) or BS EN 1011-1:2009 and BS EN 1011-2:2001.
Only approved welders shall be employed. Tensile testing is required for all welded splices and must
be performed in accordance with

ASTM’s Standard Test Methods and Definitions for Mechanical

Testing of Steel Products (ASTM A370 - 12a) and California Test 670 (Method of Tests for
Mechanical and Welded Reinforcing Steel Splices).

The Contractor shall not use welded splices on epoxy-coated reinforcing bars. To avoid heating their
coating, the Contractor shall not perform welding in close proximity to epoxy-coated bars.

The Contractor shall not use welded splices on all stainless steel reinforcing bars because welding
may detrimentally affect the physical characteristics of the material.

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The Contractor shall not use welded splices for deformed low-carbon chromium steel reinforcing
bars that conform to

ASTM’s

Standard Specification for Deformed and Plain, Low-carbon,

Chromium, Steel Bars for Concrete Reinforcement (

ASTM A1035 / A1035M - 11)

or AASHTO’s

Standard Specification for Uncoated, Corrosion-Resistant, Deformed and Plain Alloy, Billet-Steel
Bars for Concrete Reinforcement and Dowels

(AASHTO MP 18M/MP 18-09 (2010)).

5.5.4.3

Mechanical Splices

The Contractor shall use mechanical splices only if the Contract documents specify such work or if
the Engineer provides written authorization. Such mechanical splices shall develop in tension or
compression, as required, at least one hundred and twenty-five percent (125%) of the specified yield
strength of the bar being spliced.

When requested by the Engineer, the Contractor shall remove as many as two field splices out of
each 100 placed in the work, chosen at random by the Engineer, for testing by the Engineer to verify
that they have 125% of the yield strength specified for the bars being spliced. Slip test is also required
for all mechanical splices and must be performed in accordance with California Test 670 (

Method of

Tests for Mechanical and Welded Reinforcing Steel Splices

Mechanical connectors for deformed low-carbon chromium steel reinforcing bars shall comply with
Section 12.14.3 of ACI 318 and shall be either Type 1 or Type 2 in compliance with the ICC-ES

Acceptance Criteria for Mechanical Connector Systems for Steel Reinforcing Bars

(AC133), except

the testing shall demonstrate 125% of the full tensile strength and full elongation of the actual tested
reinforcing bars at failure. Verification of compliance, in the form of test results, shall be provided.

5.5.4.4

Splicing of Welded Wire Fabric

Sheets of welded wire fabric shall be spliced by overlapping each other sufficiently to maintain a
uniform strength and shall be securely fastened at the ends and edges. The edge lap shall not be
less than 50 mm more than the width of a single mesh.

5.5.5

Substitutions

The  Contractor  may  substitute  different  size  reinforcing  bars  only  when  so  authorized  by  the
Engineer.  Substituted  bars  shall  have  an  area  equivalent  to  the  design  area  or  larger,  and  shall
comply  with  the  specifications  outlined  in  Section  5.7.3.4  of  the  AASHTO  LRFD  Bridge  Design
Specifications.

When substituting bars of different sizes, the total number of substitute bars may also be different.
In such cases, although the number of bars may differ, the substitute bars must provide the same
total area per unit spacing. Substitution of millimetre bars for bar sizes not readily available from the
Contractor's source may be made on the same basis. All bar substitutions shall be approved in
writing by the Engineer. Table 5-4 shows the minimum size, weight, and area required for reinforcing
bars, as indicated on the Contract plans.

5.5.6

Calculated Weights

To compute the weight (mass) of reinforcing bars and wire reinforcement, the Contractor shall refer
to Table 5-4 and Table 5-5.

Table 5-4: Reinforcing bars - nominal weights and areas

Bar

Designation

Nominal Diameter

Nominal Area

Nominal Weight

kg/m

Dia. 6

0.222

Dia. 8

0.395

Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 1 - ROADS, Second Edition 2020) - page 29