Epoxy Coated Reinforcing Review Guidelines
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| State: | |
|---|---|
| Date: | |
| Review Participants: | |
| Project Information: | |
| Name/Address of applicator and fabricator: | |
Attach a copy of your State's current specifications.
- Coating Materials
- What are the prequalification requirements (if any) for the coating material?
- Who approves the coating material and how is this documented? Is the material approved prior to its use?
- Has the patching material been tested and approved? Is it approved prior to use?
- Is a written certification required for each batch of coating material certifying that the material is the same as that prequalified? (Required by AASHTO M284)
- Does the State perform independent testing of the coating material to verify its composition?
- Coating Applicator Shop
- Comment on the cleanliness of the reinforcing steel prior to coating. (Cleanliness can be observed by wiping a hand or cloth across a few bars after the blasting operation.)
- What is the time period between blasting and coating?
- What is the required thermal cure time? Does the production line speed allow for the proper cure time prior to quenching?
- After curing are coated bars free from holes, voids, contamination, cracks, and damaged areas detectable with the unaided eye? If not, what happens to them?
- Shop Inspection / Testing:
- Describe the State's inspection practices at the shop.
- Are periodic random bar samples taken for testing and evaluation of chemical and physical properties? Are the samples checked for cleanliness?
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Describe the testing performed at the shop for each of the following. Include a discussion of equipment and methods used, specification limits, and frequency.
Heat:
Holidays: (less than 2/ft)
Film Thickness: (ASTM D3963 requires 90% of film thickness measurements to be between 7 and 12 mils after curing. AASHTO M284 requires 90% between 8 and 12 mils after cure.)
Adhesion:
- Describe the shop's quality control practices.
- Are padded bundling bars or nylon straps used during handling of the coated bars?
- Are bundled bars moved in such a way as to prevent bar-to-bar abrasion due to sagging?
- Are coated bars stored above the ground on wooden or padded supports? If coated bars are stored outside, are they covered?
- Do the specifications include time limitations on length of outdoor storage? If so, what are they? (a limit of 3 months total time is recommended)
- Describe how the bar identification is maintained throughout the coating process.
- Describe the criteria used to determine the need for repairs in the shop.
- Is there a minimum and/or maximum thickness of coating specified for repair areas? If yes, what is it?
- Is there a limit on the amount of bar surface area that can be covered by patching material and, if so, what is it?
- At the time of shipment, does the State require certification from the coater that the bars were cleaned, coated, and tested in accordance with the specifications?
- Do the specifications require that bending of bars be performed prior to coating?
- Is the plant certified under the CRSI Epoxy Coating Applicator Plant Certification Program? If so, check on how the plant is following their certification.
- Fabrication Shop
- Describe the shop's quality control practices.
- Describe the State's inspection practices.
- Are padded bundling bars or nylon straps used during handling of the coated bars?
- Are bundled bars moved in such a way as to prevent bar-to-bar abrasion due to sagging?
- Are drive rolls on shear beds and back-up barrels on benders protected with a suitable cover to minimize damage during fabrication?
- Are coated bars stored above the ground on wooden or padded supports? If coated bars are stored outside, are they covered?
- Describe how the bar identification is maintained throughout the fabrication process.
- Describe the criteria used to determine the need for repairs in the shop.
- Do the specifications prohibit welding of coated bars?
- How are the bars cut? (should not be burned unless fully repaired)
- How is the epoxy coating repaired after the bars are cut?
- Project Site
- Describe the State's inspection practices at the project site.
- Are padded bundling bars or nylon straps used during handling of the coated bars?
- Are bundled bars moved in such a way as to prevent bar-to-bar abrasion due to sagging?
- Are coated bars stored above the ground on wooden or padded supports? If coated bars are stored outside, are they covered?
- Do the specifications include time limitations on length of outdoor storage? If so, what are they?
- Describe the criteria used to determine the need for repairs in the field.
- Do the specifications require the use of coated tie wire and supports? If so, what is the minimum thickness of coating required?
- Is there a limit on the amount of bar surface area that can be covered by patching material and, if so, what is it?