PART 1 GENERAL 1.01 DESCRIPTION SECTION 03200 CONCRETE REINFORCEMENT A. The work specified in this Section consists of furnishing and installing reinforcement for concrete structures. All reinforcement shall be galvanized unless noted otherwise on the Drawings. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 01400: Quality Requirements. C. Section 03300: Cast-in-Place Concrete. D. Section 03400 Precast Concrete Panels 1.03 REFERENCES A. American Concrete Institute (ACI): 1. ACI 315; Details and Detailing of Concrete Reinforcement. 2. ACI 318; Building Code Requirements for Structural Concrete and Commentary. B. American Welding Society (AWS): 1. AWS D1.4: Structural Welding Code Reinforcing Steel. 2. AWS WZC/D19.0: Welding Zinc-Coated Steels C. ASTM International (ASTM): 1. ASTM A82: Standard Specification for Steel Wire, Plain, for Concrete Reinforcement. 2. ASTM A123: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 3. ASTM A185: Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete. 4. ASTM A496; Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement. Concrete Reinforcement 03200-1
5. ASTM A615: Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement. 6. ASTM A641: Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire. 7. ASTM A663: Standard Specification for Steel Bars, Carbon, Merchant Quality, Mechanical Properties. 8. ASTM A767: Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement. 9. ASTM A775: Standard Specification for Epoxy-Coated Steel Reinforcing Bars D. Concrete Reinforcing Steel Institute (CRSI): 1.04 SUBMITTALS 1. CRSI Manual of Standard Practice. A. Shop Drawings and Product Data: 1. Prepare shop drawings of concrete reinforcement in accordance with ACI 315. 2. Provide drawings showing all fabrication dimensions and locations for placing reinforcement and bar supports; indicate bending diagrams, splicing and lap of rods, shapes, dimensions, and details of bar reinforcing and accessories. 3. Product Data: Submit manufacturer s descriptive product data and current specification for each product specified herein, include installation instructions. B. Test Reports: 1. Submit copies of reports showing the results of tests, conducted in accordance with ASTM Specifications. 2. Test Requirements may be waived based upon certified copies of mill test reports. 1.05 DELIVERY, STORAGE, AND HANDLING A. Storage of Materials: 1. Store reinforcing materials in a manner to prevent excessive rusting and fouling with dirt, grease, and other bond-breaking coatings. Concrete Reinforcement 03200-2
a. Store the reinforcement and accessories aboveground on platforms, skids, or other supports. b. Cover reinforcement and accessories. 2. Identify bundles of reinforcing steel with tags wired to steel. 3. Protect reinforcement from deforming, bending, kinking, and other injury. 1.06 PROJECT CONDITIONS A. Protection: Protect in-place reinforcement from excessive construction traffic and other work. PART 2 PRODUCTS 2.01 MATERIALS A. Reinforcing Steel: 1. Reinforcement Bars: ASTM A615, Grade 60, deformed steel with Zinc-coating conforming to ASTM A767. a. Damaged zinc coating shall be repaired with a zinc-rich formulation conforming to ASTM A767. 2. Reinforcement Bars: ASTM A615, Grade 60, deformed steel with epoxy coating conforming to ASTM A775. a. Damaged epoxy coating shall be repaired in conformance with ASTM A775. 3. Wire: ASTM A82, Zinc coated. 4. Welded Wire Fabric: ASTM A185, with Zinc coating conforming to ASTM A641, for cold-worked wire, or ASTM A123, for hot-dipped galvanizing of welded wire sheets/mats. 5. Metal Accessories: CRSI Manual of Standard Practice. B. Rebar Splicing Coupler: A two-piece splicing system manufactured from ASTM A615 Grade 60 deformed rebar. A dowel bar splicer with integral nailing flange shall be threaded for a threaded down-in rebar such that the completed splice exceeds the tensile requirements of ACI 318. Concrete Reinforcement 03200-3
1. Provide Zinc coated system. 2. Internal Coupler Protector: Provide coupler manufacturer's plastic internal coupler protector where couplers are provided for anticipated future additions. 3. Bar End Protectors: Plastic solid sleeve for placement over bar ends to protect threading from damage, contamination, and rust. 4. Use Rebar Splicing Coupler only where shown on Drawings or where approved by the SEPTA Project Manager. 5. Acceptable Manufacturers: a. Dayton Superior Corp. b. Or approved equal. C. Slab Joint Dowel System for Expansion and Contraction Joints: 1. Two-piece system consisting of a closed end plastic sleeve and smooth dowel bar, size as indicated on drawings. a. Dowel Bar: 1) Plain round bar confirming to requirements of ASTM A663, Grade 70, 75, or 80 which is not burred, roughened, or deformed out-of-round so slippage is not hindered. 2) Provide Zinc coated Dowel Bar. b. Acceptable Manufacturers: 1) Greenstreak: Speed Dowel System 2) Or approved equal. 2. Dowel Bar with Bondless Surface: a. Plain round bar conforming to requirements of ASTM A663, Grade 70, 75, or 80 which is not burred, roughened, or deformed out-of-round to slippage is not hindered. b. Provide Zinc coated Dowel Bar. c. Coat with curing compound to render surface bondless. 1) Curing compound: Section 03300. Concrete Reinforcement 03200-4
D. Deformed Bar Anchors: Deformed anchor conforming to ASTM A496 with minimum yield strength of 70 ksi and minimum ultimate tensile strength of 80 ksi. Bar anchor shall be low carbon steel with the following properties C -0.23 max, Mn 0.90 max, P 0.040 max, and S 0.050 max. 1. Anchors shall be similar to Nelson, flux-filled deformed bar anchor, Type D2L, by Nelson Stud Welding or equal. 2. Provide Zinc coated Deformed Bar Anchor. E. Fiber Concrete Reinforcement: First quality, 100% virgin polypropylene fibers containing no reprocessed olefin materials such as Fibermesh as manufactured by SI Concrete Systems, or equal. 1. Fiber material shall be mixed at rate of 1.5 pounds of fiber to 1 cubic yard of concrete. 2. Add fibrous reinforcement to concrete material at the time concrete is batched. Mix concrete in strict accordance with fiber reinforcement manufacturer s instructions in order to achieve uniform three-dimensional distribution. 3. Fiber reinforcement to be provided in concrete sidewalks. F. Metal Accessories: 2.02 FABRICATION 1. Provide Zinc Coated metal accessories in accordance with the requirements of the CRSI Manual of Standard Practice. A. General: Fabricate reinforcement to the dimensions indicated on the Drawings and within the tolerances given in ACI 315. Perform bending of steel reinforcement by the cold bending method. 1. Do not use bars with kinks or bends not indicated on Drawings. 2. Perform bar shape fabrication in a manner that will not injure the material or lessen the member strength. 3. Use a designed bending machine, either hand- or power-operated. 4. Do not field bend bars partially embedded in concrete unless approved by the SEPTA Project Manager. 2.03 SOURCE QUALITY CONTROL A. Tests and Inspections: Concrete Reinforcement 03200-5
1. Materials specified in this Section require advance examination or laboratory testing according to the methods referenced herein. 2. The Independent Testing and Inspection Agency (Agency) will perform the source testing specified in this Paragraph, unless the testing is not required as specified. a. The tests specified in Subparagraphs 2.03.A.3 through 2.03.A.8 may be waived if certified copies of mill test reports are submitted showing complete compliance with the specified requirements. b. If the certified mill test reports are not submitted the Testing and Inspection Agency must perform the specified tests. 3. Deformed Steel Reinforcement Tests: a. Test Procedure: 1) The following properties of the deformed steel bar reinforcement will be determined using the methods specified in ASTM A615: a) The carbon, manganese, phosphorus, and sulfur content of the dowel bar material. b) The tensile strength, yield strength, and percentage elongation. 2) The bend test will be performed on the deformed steel bar reinforcement using the methods specified in ASTM A615. b. Acceptance Criteria: 1) Deformed steel bar reinforcement that exhibit the chemical composition, tensile strength, yield strength, percent reduction of area, and weight (mass) per unit length within the ranges specified in ASTM A615, and that pass the bend test for the bar size, as specified in ASTM A615 are acceptable. 4. Steel Welded Wire Reinforcement Tests: a. Test Procedure: 1) The tensile strength, yield strength, and percent reduction of area will be determined, and the bend Concrete Reinforcement 03200-6
test for steel welded wire reinforcement will be performed in accordance with the methods specified in ASTM A185. b. Acceptance Criteria: 1) Steel wire used to fabricate the steel welded wire reinforcement that exhibits the tensile strength, yield strength, and percent reduction of area within the ranges specified, and that passes the bend test for the wire size as specified in ASTM A185 are acceptable. 5. Deformed Bar Anchor Tests: a. Test Procedure: 1) The tensile strength and yield strength will be determined, and the bend test for steel deformed bar anchors will be performed in accordance with the methods specified in ASTM A496. b. Acceptance Criteria: 1) Deformed bar anchors exhibiting the tensile strength and yield strength within the ranges specified in Subparagraph 2.01.E.1 are acceptable. 6. Rebar Splicing Coupler: a. Test Procedure: 1) The following properties of the dowel bar used to fabricate the rebar splicer components will be determined using the methods specified in ASTM A615: a) The carbon, manganese, phosphorus, and sulfur content of the dowel bar material. b) The tensile strength, yield strength, and percentage elongation. 2) The bend test will be performed on the dowel bar used to fabricate the dowel bar splicer components using the methods specified in ASTM A615. b. Acceptance Criteria: Concrete Reinforcement 03200-7
PART 3 EXECUTION 3.01 INSPECTION 1) Rebar splicer components that exhibit the chemical composition, tensile strength, yield strength, percent reduction of area, and weight (mass) per unit length within the ranges specified in ASTM A615, and pass the bend test for the bar size as specified in ASTM A615 are acceptable. 7. Slab Joint Dowel Bar Tests: a. Test Procedure: 1) The chemical composition, tensile strength, yield point, and percent elongation of slab joint dowel bars will be determined in accordance with the methods specified in ASTM A663. b. Acceptance Criteria: 1) Dowel bars exhibiting the tensile strengths, yield points, and percents elongation within the ranges as specified in ASTM A663 for the Grade of bar tested are acceptable. 8. Non-Conforming Work: a. Do not use concrete reinforcement that fails the testing. A. An Independent Testing and Inspection Agency (Agency) shall be engaged by the contractor to perform code-required testing. 1. Written reports on all tests and inspections shall be provided immediately after work is performed. The reports shall state test specimens either comply with requirements or deviate from them. The Agency shall submit reports directly to the SEPTA Project Manager. B. Inspections: 1. Notify the SEPTA Project Manager at least 10 days prior to scheduled concrete placement operations so the placement of reinforcement can be inspected. 2. Prior to placing concrete, inspect the reinforcement size, location, spacing, clear distance between bars and to the outside face of the Concrete Reinforcement 03200-8
3.02 INSTALLATION concrete, and the reinforcement will not be displaced during the placement of concrete. a. Verify the rebar splicer system is installed at the approved locations, is the correct type, and is installed in accordance with the manufacturer s guidelines. A. Placing Concrete Reinforcement: 1. Place metal concrete reinforcement accurately and in accordance with ACI 318. a. Do not lay metal reinforcement on formwork. b. Terminate reinforcement 2 inches from the face of expansion joints. c. Continue reinforcement across or through construction joints except for keyed control joints in slab-on-grade. d. Place additional concrete reinforcement around openings in slabs and walls as detailed on the Contract Drawings. e. Provide reinforcing accessories to securely brace the reinforcement against displacement outside of permitted tolerances. 2. Slab Reinforcement Placement: a. Install welded wire reinforcement (flat sheets or mats) as indicated, lapping joints eight inches with the overlap being measured between the outermost cross wires of each reinforcement sheet and securely wiring the joints together. b. Extend welded wire reinforcement to within 2 inches of sides and ends of slabs. c. To support slab reinforcement from the ground, place the reinforcement on concrete blocks of the correct height and having a compressive strength equal to or greater than the specified compressive strength of the concrete being placed. 1) Use concrete blocks not larger than 3 inches by 3 inches and of a height equal to required bottom steel cover. Concrete Reinforcement 03200-9
SEPTA Design GEC 14F-01 Media 90% Design Station Rock Cut reinforcement on bar chairs made of plastic or metal. 1) If the slab surface is exposed to view, provide supports with legs protected by plastic or stainless steel. B. Concrete Reinforcement Field Bends: 1. Do not field bend bars partially embedded in concrete. 2. When obstructions interfere with the placement of reinforcement, pass such obstructions by placing reinforcement around it. a. Do not bend the reinforcement to clear the obstructions. C. Shortening Concrete Reinforcement: 1. Shorten (trim) concrete reinforcement, if required, by shearing or sawing. 2. Shortening concrete reinforcement using an acetylene torch may be acceptable, but only if the location of the shortening is approved by the Engineer in writing in advance. 3. Cut ends of zinc coated bars shall be repaired with a zinc-rich formulation conforming to ASTM A767. D. Splicing Concrete Reinforcement: 1. Splice reinforcement in accordance with ACI 318 and as indicated on the Contract Drawings. 2. Secure reinforcement at intersections with not less than 16 gauge annealed wire or appropriately sized clips. a. Where bar spacing is less than 12 inches, tie alternate intersections. b. Do not tack-weld crossing bars. E. Slab Joint Dowel Bar Installation: 1. Install one-half the length of the coated bar dowel into the slab to be poured. F. Repair to Galvanized Coating: 1. Repair all visible damage (i.e., scratches, nicks, cracks) to the galvanized coating of the reinforcement steel and accessories, caused during shipment, storage or placement. Ends of reinforcement that have been sheared, sawed, or cut by other Concrete Reinforcement 03200-10
SEPTA Design GEC 14F-01 Media 90% Design Station Rock Cut means shall be coated. Repair with a zinc-rich formulation conforming to ASTM A767 in accordance with the material manufacturer s recommendations. 3.03 CLEANING A. Provide protection for concrete reinforcement during concrete pours in accordance with ACI 318, unless indicated otherwise on the Contract Drawings. 3.04 PROTECTION A. Provide protection for concrete reinforcement during concrete pours in accordance with ACI 318, unless indicated otherwise on the Contract Drawings. B. Protect in-place reinforcement from excessive construction traffic and other work. END OF SECTION Concrete Reinforcement 03200-11