®
EPOXY INTEREST GROUP
USE AND INSTALLATION
Of Epoxy-Coated Reinforcing Bars
Epoxy-coated reinforcing steel has been used for more than 40 years to reduce expensive and disruptive repairs to
concrete structures caused by corrosion. Proper use and handling of these bars during the construction process will
optimize the corrosion-free life of concrete structures. In addition, efficient handling will reduce the amount of costly
touch-up work required prior to concrete placement. This document outlines jobsite, storage, placement, handling
and repair of epoxy-coated bars during the installation process.
INTRODUCTION
MANUFACTURE
Epoxy-coated reinforcing (ECR) steel was first used in 1973 on the Schuylkill
Bridge near Philadelphia, Pennsylvania, as a method to reduce the corrosion
damage to bridge structures. Since then, the material has been used in over
80,000 bridges nationwide covering an area of 900,000,000 sq. ft. Structures
built with ECR steel have longer lives than structures built with black steel.
The manufacture of the majority of
epoxy-coated reinforcing steel is
covered in ASTM A775 Standard
Specification for Epoxy-Coated Steel
Reinforcing Bars. This specification
requires that suppliers of coated bars
take steps to properly prepare the bars
prior to coating, that contaminants are
not present, and that the coatings are
fully cross-linked and bonded to the bar.
Epoxy-coated reinforcing steel can be used almost anywhere corrosion causes
damage. While the product is most commonly used on bridges, it can also be
used in continuous reinforced concrete pavement, parking garages,
piers and docks, water towers, columns and parapets.
The product may also be manufactured
to ASTM A884 Standard Specification
for Epoxy-Coated Steel Wire and
Welded Wire Fabric for Reinforcement
or ASTM A934 Standard Specification
for Epoxy-Coated Prefabricated Steel
Reinforcing Bars.
JOB SITE HANDLING AND STORAGE
Just like any material used on a jobsite, appropriate handling of epoxy-coated
reinforcing steel is required. These steps are aimed at reducing damage to the
coating that would negatively affect its corrosion protection performance.
Handling and storage requirements for epoxy-coated reinforcing steel may
be included in contract documents or within individual agency specifications.
Lifting: Bars should be lifted using a spreader bar or strong-back with multiple
pick-up points to minimize sag. During sagging, steel bars may rub on each
other, causing coating damage.
Carrying: At no time should coated steel bars be dragged.
Slings: Nylon or padded slings should be used and at no time should bare
chains or cables be permitted.
Unloading: Steel should be unloaded as close as possible to the point of
concrete placement to minimize rehandling.
Storage: Bundles of steel should be stored on suitable material, such as timber
cribbing. At no time should steel be stored directly on the ground. Coated and
uncoated steel should be stored separately.
Covering: If the steel bars are to be exposed outdoors for more than 30 days, they
should be covered with a suitable opaque material that minimizes condensation.
BAR PLACEMENT INTO FORMS
COATING REPAIR
Form preparation: In order to protect bars from oil contamination, forms
should be oiled prior to placement of the reinforcing bars. Bars should not be
dragged or placed directly on the forms as this may result in oil contamination
of the bar surface.
Damage repair: All coating damage
should be repaired using a two-part
epoxy approved by the coating
manufacturer.
Bar supports: Reinforcement should be placed on supports coated with
non-conductive material, such as epoxy or plastic bar supports, and these
should meet Class 1A, as defined in the CRSI Manual of Standard Practice.
Materials: Repair material should
conform to Annex A2 of ASTM A775
or A934. Repair materials from spray
cans are not recommended.
Tie wire: Reinforcement should be tied using a coated tie wire. This wire is
typically 16.5 gauge or heavier and black annealed. When used with epoxycoated reinforcing bars it is typically coated with PVC.
Cutting: Coated bars may be cut using power shears or chop saws and cut
ends should be repaired using a two-part epoxy. Bars MUST NOT be flame cut.
Bending: Bars may only be bent at the jobsite with the permission of the
engineer responsible for the particular project, and this should be documented.
If bending is to be conducted it must be conducted at ambient temperatures.
Welding: Bars should only be welded with the permission of the engineer
responsible for the particular project. After welding, all exposed steel should
be repaired using a two-part epoxy. At no time should stands or rails used for
concrete placement machines be welded to the epoxy-coated steel.
Surface Preparation: Areas to be
repaired should be prepared using a
small wire brush that removes rust
and other contaminants.
Application: Repairs should be
strictly conducted according to the
written instructions furnished by the
patching material manufacturer. Repair
materials should be mixed according
to the manufacturer’s directions and
should be used within the specified
pot life.
CONCRETE OPERATIONS
Allowable damage: If the coated bar
has more than 2% of coating damage
in any given 1 ft section, it should be
replaced.
Allowable patching: ASTM D3963
states that if the total bar surface area
covered by patching material exceeds
5% in any given 1 ft section, the bar
may be rejected. This limit does not
include sheared or cut ends.
Coating Cure: Repair materials
should be provided with sufficient
time to cure prior to concrete placement. Some repair materials require
eight hours and this time may be
increased in cold weather.
Pre-placement meeting: A pre-pour meeting may be beneficial with the
concrete contractor to ensure that bars are not damaged during concrete
placement.
Traffic: Minimize traffic over the epoxy-coated steel. Consider a runway if
necessary. Care should be taken to ensure that items such as unprotected
couplers for concrete delivery hoses are not dragged across the steel as
this may result in coating damage.
Concrete Placement: Care should be used to ensure that activities during
the concrete placement do not result in damage to the epoxy-coated steel.
Concrete pumps should be fitted with an “S” bend to prevent free fall of
concrete directly onto the coating.
Concrete Vibration: Plastic headed vibrators should be used to consolidate
concrete. Steel vibrators may cause coating damage.
UV Protection: Bars that are partially cast in concrete, and then exposed
for extended periods, should be protected against exposure to UV, salts
and condensation. It has been found that wrapping with plastic or individual
tubing is suitable for providing long-term protection.
BENEFITS
OUR MISSION
Epoxy-Coated Steel Reinforcing Bars
To promote the use and advance the
quality of Epoxy-Coated Reinforcing
Steel. Epoxy-coated steel is used
instead of conventional reinforcing
bars to strengthen the concrete and
protect against corrosion. The epoxy
coating is applied to the steel in a
factory prior to shipping.
• More than 40 Years of Improved Manufacturing and Coating Technologies
• Excellent Corrosion Protection
• Cost Effective Life-Cycle
• CRSI Certified Plants
IN
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CERTIFIED PLANT
Photos courtesy of FIGG, photographer Tim Davis.
• Sustainable
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• Readily Available
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• Lower Maintenance
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• Extended Service Life
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© 2014 EIG
EPOXY INTEREST GROUP
933 N Plum Grove Road n Schaumburg, IL 60173
Tel: 847.517.1200 n email: info@epoxy.crsi.org n www.epoxyinterestgroup.org