1、Designation: D 3963/D 3963M 01Standard Specification forFabrication and Jobsite Handling of Epoxy-Coated SteelReinforcing Bars1This standard is issued under the fixed designation D 3963/D 3963M; the number immediately following the designation indicates theyear of original adoption or, in the case o
2、f revision, the year of last revision. A number in parentheses indicates the year of lastreapproval. A superscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This specification covers the fabrication and jobsiterequirements for deformed and plain stee
3、l reinforcing bars withprotective epoxy coating applied in accordance with Specifi-cation A 775/A 775M.1.2 This specification is applicable for orders in either SIunits (as Specification D 3963M) or inch-pound units (asSpecification D 3963).1.3 The values stated in either SI units or inch-pound unit
4、sare to be regarded separately as standard. Within the text, theinch-pound units are shown in brackets. The values stated ineach system are not exact equivalents; therefore, each systemmust be used independently of the other. Combining valuesfrom the two systems may result in nonconformance with the
5、specification.1.4 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2
6、. Referenced Documents2.1 ASTM Standards:A 775/A 775M Specification for Epoxy-Coated Reinforc-ing Steel Bars2B 117 Practice for Operating Salt Spray (Fog) Apparatus3D 374 Test Methods for Thickness of Solid Electrical Insu-lation4D 2967 Test Method for Edge Coverage of Coating Pow-ders5E 177 Practic
7、e for Use of the Terms Precision and Bias inASTM Test Methods6E 691 Practice for Conducting an Interlaboratory Study toDetermine the Precision of a Test Method6G 20 Test Method for Chemical Resistance of PipelineCoatings52.2 Federal Highway Administration ReportFHWA-RD-74-18 Nonmetallic Coatings for
8、 Concrete Rein-forcing Bars73. Coating Repair Materials3.1 The patching or repair material shall be compatible withthe coating, inert in concrete, and feasible for repairs at theapplicator, fabricator, or in the field. This material shall beapproved in accordance with Annex A1 prior to use.3.2 The m
9、anufacturer shall specify the method of metalsurface preparation, and the patching application procedures tobe used in the field.4. Handling and Identification4.1 Coated bars shall be transported and handled with care.All systems for handling coated bars shall have padded contactareas. All bundling
10、bands shall be padded, or suitable bandingshall be used to prevent damage to the coating. All bundles ofcoated bars shall be lifted with a strong back, spreader bar,multiple supports, or a platform bridge to prevent bar-to-barabrasion from sags in the bundles. The bars or bundles shall notbe dropped
11、 or dragged.4.2 The identification (including heat number, mill testresults, date and type of coating system used, etc.) of allreinforcing bars shall be maintained throughout the coating andfabrication processes to the point of shipment.5. Fabrication of Steel Reinforcing Bars After Coating5.1 The s
12、teel reinforcing bars to be fabricated after applica-tion of the coating shall meet the requirements of this specifi-cation.5.2 Handling and storage of coated bars at the fabricatorsfacility shall meet the requirements of Section 4 and 6.3.1This specification is under the jurisdiction of ASTM Commit
13、tee D04 on Roadand Paving Materials and is the direct responsibility of Subcommittee D04.32 onBridges and Structures.Current edition approved Jan. 10, 2001. Published March 2001. Originallypublished as D 3963 81. Last previous edition D 3963/D 3963M 00a.2Annual Book of ASTM Standards, Vol 01.04.3Ann
14、ual Book of ASTM Standards, Vol 03.02.4Annual Book of ASTM Standards, Vol 10.01.5Annual Book of ASTM Standards, Vol 06.02.6Annual Book of ASTM Standards, Vol 14.02.7Available from National Technical Information Service, 5285 Port Royal,Springfield, VA 22161.51Copyright ASTM International, 100 Barr H
15、arbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.5.3 Drive rolls on shear beds, and back-up barrels onbenders shall be protected with a suitable covering to minimizedamage during the fabrication process.6. Storage, Handling and Placement at the Jobsite6.1 The finished, insta
16、lled coated steel reinforcing bars to beused in the construction shall meet the requirements of thisspecification.6.2 All systems for handling the coated bars at the jobsiteshall have padded contact areas. Coated bars or bundles shallnot be dropped or dragged.6.3 Coated steel reinforcing bars shall
17、be off-loaded as closeas possible to their points of placement or under the crane sothat the bars can be hoisted to the area of placement tominimize rehandling.6.4 Coated bars or bundles shall be stored above the groundon wooden or padded supports with timbers placed betweenbundles when stacking is
18、necessary. Space the supports suffi-ciently to prevent sags in the bundles.6.5 Coated and uncoated steel reinforcing bars shall bestored separately.6.6 Long-term storage shall be minimized and materialdelivery scheduled to suit construction progress.6.7 Coated bars shall be tied with tie wire coated
19、 withepoxy, plastic, nylon or other non-conductive material that willnot damage or cut the coating.6.8 Bar supports and spacers shall be coated with or made ofa non-conductive material compatible with concrete.6.9 Placed coated bars shall be covered with opaque poly-ethylene or other suitable protec
20、tive material if cumulativeenvironmental exposure of the coated bars, including previousuncovered storage time, of greater than two months prior toconcrete embedment is expected. Provisions shall be made foradequate ventilation to minimize condensation under the cover.NOTE 1Extended storage of the b
21、ars at the job site should be avoided.It is recommended that coated bars be covered immediately upon arrivalat the job site.6.10 After placing, walking on coated steel reinforcing barsshall be minimized. The placement of mobile equipment shallbe planned to avoid damage to the coated bars.NOTE 2Resea
22、rch has shown that steel-headed vibrators cause damageto epoxy-coated steel reinforcing bars when used to consolidate concrete.When consolidating concrete reinforced with epoxy-coated bars, it isrecommended that vibrators with heads made of rubber or other resilientmaterial approved for concrete con
23、solidation be used.7. Repairs7.1 Repair of Damage Incurred During Fabrication:7.1.1 All coating damage due to fabrication or handling atthe fabricators facility shall be repaired with patching materialmeeting the requirements of 3.1. The patching shall be per-formed in accordance with the written re
24、commendations of thepatching material manufacturer.7.1.2 Visible cracks, including hairline cracks without bondloss (the coating cannot be easily removed with a peelingaction by the fingers of the inspector), and damage to thecoating within each fabricated area of the reinforcing bar shallbe repaire
25、d. All disbonded areas of coating shall be removed,cleaned and repaired. The cleaning shall remove loose ordeleterious material, or both. In cases where rust is present, therust shall be removed by a thorough cleaning prior to the repair.This cleaning shall be done by blast cleaning, filing, powerbr
26、ushing or other method recommended by the patchingmaterial manufacturer and approved by the purchaser in amanner that minimizes damage to the sound coating.7.1.3 When coated bars are sheared, saw-cut or cut by othermeans during the fabrication process, the cut ends shall bepatched.7.1.4 The repairs
27、shall be performed as soon as possible andbefore visible oxidation appears on the steel surface and priorto shipment to the jobsite.7.1.5 The fabricator shall be responsible for repair to thecoating due to damage during fabrication and handling at thefabricators facility.7.2 Repair of Damage Incurre
28、d During Shipment and Han-dling at the Jobsite:7.2.1 Coating damage, visible to a person with normal orcorrected vision, incurred during shipment, storage or place-ment of epoxy-coated bars at the jobsite shall be repaired withpatching material meeting the requirements of 3.1.7.2.2 The contractor sh
29、all be responsible for repair to thecoating due to damage during shipment, storage, or placementat the jobsite.7.2.3 The patching shall be performed in accordance withthe written recommendations of the patching material manu-facturer. The patching material shall be dry to the touch priorto concrete
30、placement.7.3 The total damaged surface area (prior to repair withpatching material), shall not exceed 2 % in any given 0.3 m 1ft section of coated reinforcement. The total bar surface areacovered by patching material shall not exceed 5 % in any given0.3 m 1 ft section of coated reinforcement. This
31、limit ondamaged and repaired area shall not include sheared or cutends.8. Rejection8.1 Coated bars that do not meet the requirements of thisspecification shall be rejected.9. Field Sampling9.1 The purchaser or their representative shall have the rightto select samples of the coated reinforcement to
32、be used in theproject at the jobsite for testing on site or at the purchasersfacility.10. Keywords10.1 coating requirements; concrete reinforcement; corro-sion resistance; epoxy coating; fabrication repair; field repair;steel barsD 3963/D 3963M 012ANNEX(Mandatory Information)A1. QUALIFICATION OF PAT
33、CHING MATERIAL USED TO REPAIR ORGANIC COATINGS FOR STEEL REINFORCINGBARSA1.1 ScopeA1.1.1 This specification covers qualification requirementsfor patching materials used to repair barrier organic coatingssuch as epoxy powder coatings used for protecting steelreinforcing bars from corrosion.A1.2 Coati
34、ng Patching MaterialA1.2.1 A minimum of 0.5 L 1 pt of patching material,compatible with the coating and inert in concrete, shall besubmitted to the testing agency. The material shall be feasiblefor repairs to the coated reinforcing bars damaged by handling.The product name and a description of the p
35、atching materialshall be given in the test report. A complete list of powdercoating materials (product names and manufacturers) for whichthe patching material has been approved for use with shall beprovided and included in the test report.A1.3 Test SpecimensA1.3.1 The following test specimens shall
36、be submitted as aminimum for test:A1.3.1.1 Four free films of coating patching material with athickness within 6 25 m 6 1 mil of the patching materialmanufacturers minimum recommended patching materialcoating application thickness.A1.3.1.2 Six 75 by 150 mm 3 by 6 in. by 3 mm 1/8 in.flat panels that
37、have been blast cleaned and coated on bothsides with 175 to 300 m 7 to 12 mils of epoxy powdercoating in accordance with the powder coating manufacturerswritten instructions. The hanger marks on the panels shall besealed with silicone or other suitable sealant.A1.3.2 A description of the sample prep
38、aration process forthe free films and flat panel samples (for example, the numberof coats of patch material applied to the intentional coatingdefect to achieve the minimum required coating thickness),used in this prequalification evaluation shall be provided in thetest report. The patching material
39、manufacturer shall specifythe minimum recommended patching material coating appli-cation thickness to be used. In addition, the patching materialmanufacturer shall specify the method of metal surface prepa-ration and the patching application procedures. These proce-dures and minimum thickness shall
40、be followed by the testingagency to prepare the coated metal specimens for test and shallbe listed in the test report.A1.4 Patching Material RequirementsA1.4.1 Chloride PermeabilityThe chloride permeabilitycharacteristics of the patching material shall be measured ontwo test films and a control film
41、 at 24 6 2C 75 6 3.6F for45 days. The permeability cells shall be of the type shown inFig. 1. Films selected for testing shall be carefully handled andexamined for any defects prior to installation in the cell. Thecell shall consist of two glass compartments separated by acoating film sandwiched bet
42、ween two glass plates, each havinga centered 25-mm 1-in. hole. One compartment shall contain175 mL 5.3 oz. of 3M NaCl and the other 115 mL 3.5 oz ofdistilled water. The activity of chloride ions passing throughthe film shall be measured using a specific ion meter equippedwith a chloride electrode an
43、d a double junction electrode.Activity measurements shall be converted into concentrationvalues of mole per L M with a conversion diagram, con-structed by plotting measured chloride ion activities versusknown chloride ion concentrations. The accumulative concen-tration of chloride ions permeating th
44、rough the film shall beless than 1 3 104M.A1.4.2 Salt Spray ResistanceThe resistance of the patch-ing material to a hot, wet corrosive environment shall beevaluated in accordance with Practice B 117. Three coated 75by 150 mm 3 by 6 in. by 3 mm 1/8 in. flat panels, withintentional defects repaired wi
45、th the patching material, shall beexposed to 35 6 2C 95 6 3.6F salt spray comprised of 5%NaCl by mass dissolved in distilled water for 400 6 10 h. Eachintentional defect shall be an area of 12 by 25 mm 12 by 1 in.removed from the center of one side of the coated panel usinga grinding wheel or other
46、suitable method. Dust and loosematerial shall be removed from the intentional defect site witha clean cloth after the coatings removal. The patching materialshall be prepared for application in accordance with the writteninstructions of the patching material manufacturer. The patch-ing material shal
47、l be applied with a new paint brush to theFIG. 1 Chloride Permeability Test Equipment ConfigurationPermeability Cell ComponentsA = Compartment containing distilled water.B = Epoxy film sandwiched between two glass plates, eachhaving centered one-inch diameter holes.C = Component containing 3M NaCl.D
48、 3963/D 3963M 013intentional defect to form a patched area of 25 by 37 mm 1 by1.5 in. fully covering the intentional defect. The coated panelshall be lying flat on a table during the patching materialapplication and shall remain in such a position until the coatinghas cured according to the manufact
49、urers instructions. Thepatching operation and the patched panels shall be maintainedat a temperature of 24 6 2C 75 6 3.6F. The patched areacoating thickness shall be within 6 25 m 6 1 mil of thepatching material manufacturers minimum recommendedpatching material coating application thickness. The patchedpanels shall be allowed to cure for a minimum of three daysbefore placement in the salt spray apparatus. Upon examina-tion after completion of the test, the patched areas on each ofthe three coated panels shall not be obse
