1、Designation: D 3963/D 3963M 01 (Reapproved 2007)Standard 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
2、 or, in the case of 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 defor
3、med and plain steel 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
4、or inch-pound unitsare 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 nonco
5、nformance with thespecification.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 limitati
6、ons prior to use.2. Referenced Documents2.1 ASTM Standards:2A 775/A 775M Specification for Epoxy-Coated Steel Rein-forcing BarsB117 Practice for Operating Salt Spray (Fog) ApparatusD 374 Test Methods for Thickness of Solid Electrical Insu-lationD 2967 Test Method for Corner Coverage of Powder Coat-i
7、ngsE 177 Practice for Use of the Terms Precision and Bias inASTM Test MethodsE 691 Practice for Conducting an Interlaboratory Study toDetermine the Precision of a Test MethodG20 Test Method for Chemical Resistance of PipelineCoatings2.2 Federal Highway Administration ReportFHWA-RD-74-18 Nonmetallic
8、Coatings for Concrete Rein-forcing Bars33. 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 u
9、se.3.2 The manufacturer 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. A
10、ll bundling 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 n
11、otbe dropped 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 Coat
12、ing5.1 The steel 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 6.3.5.3 Drive rolls on shear beds, and back-up barre
13、ls onbenders shall be protected with a suitable covering to minimizedamage during the fabrication process.1This specification is under the jurisdiction of ASTM Committee D04 on Roadand Paving Materials and is the direct responsibility of Subcommittee D04.32 onBridges and Structures.Current edition a
14、pproved Dec. 1, 2007. Published January 2008. Originallyapproved in 1981. Last previous edition approved in 2001 as D 3963/D 3963M 01.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume info
15、rmation, refer to the standards Document Summary page onthe ASTM website.3Available from National Technical Information Service (NTIS), 5285 PortRoyal Rd., Springfield, VA 22161, http:/www.ntis.gov.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, U
16、nited States.6. Storage, Handling and Placement at the Jobsite6.1 The finished, installed 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 ba
17、rs or bundles shallnot be dropped or dragged.6.3 Coated steel reinforcing bars shall 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 gr
18、oundon wooden or padded supports with timbers placed betweenbundles when stacking is 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 sched
19、uled to suit construction progress.6.7 Coated bars shall be tied with tie wire coated 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 P
20、laced coated bars shall be covered with opaque poly-ethylene or other suitable protective 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
21、 ventilation to minimize condensation under the cover.NOTE 1Extended storage of the bars 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 placeme
22、nt of mobile equipment shallbe planned to avoid damage to the coated bars.NOTE 2Research 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 vib
23、rators with heads made of rubber or other resilientmaterial approved for concrete consolidation 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 re
24、quirements of 3.1. The patching shall be per-formed in accordance with the written recommendations 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 da
25、mage to thecoating within each fabricated area of the reinforcing bar shallbe repaired. 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 cleani
26、ng prior to the repair.This cleaning shall be done by blast cleaning, filing, powerbrushing 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 other
27、means during the fabrication process, the cut ends shall bepatched.7.1.4 The repairs 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 du
28、ring fabrication and handling at thefabricators facility.7.2 Repair of Damage Incurred 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 r
29、epaired withpatching material meeting the requirements of 3.1.7.2.2 The contractor shall 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 mate
30、rial manu-facturer. The patching material shall be dry to the touch priorto concrete 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 materi
31、al shall not exceed 5 % in any given0.3 m 1 ft section of coated reinforcement. This 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
32、 representative shall have the rightto select samples of the coated reinforcement to 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 re
33、pair;steel barsD 3963/D 3963M 01 (2007)2ANNEX(Mandatory Information)A1. QUALIFICATION OF PATCHING 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
34、as epoxy powder coatings used for protecting steelreinforcing bars from corrosion.A1.2 Coating 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
35、 the coated reinforcing bars damaged by handling.The product name and a description of the patching 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 a
36、nd included in the test report.A1.3 Test SpecimensA1.3.1 The following test specimens shall be submitted as aminimum for test:A1.3.1.1 Four free films of coating patching material with athickness within 625 m 61 mil of the patching materialmanufacturers minimum recommended patching materialcoating a
37、pplication thickness.A1.3.1.2 Six 75 by 150 mm 3 by 6 in. by 3 mm 18 in. flatpanels that have been blast cleaned and coated on both sideswith 175 to 300 m 7 to 12 mils of epoxy powder coating inaccordance with the powder coating manufacturers writteninstructions. The hanger marks on the panels shall
38、 be sealedwith silicone or other suitable sealant.A1.3.2 A description of the sample preparation 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 thi
39、s prequalification evaluation shall be provided in thetest report. The patching material 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-ratio
40、n and the patching application procedures. These proce-dures and minimum thickness shall 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 permeabilitychara
41、cteristics of the patching material shall be measured ontwo test films and a control film 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.
42、Thecell shall consist of two glass compartments separated by acoating film sandwiched between 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 throught
43、he film shall be measured using a specific ion meter equippedwith a chloride electrode and 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 ch
44、loride ion concentrations. The accumulative concen-tration of chloride ions permeating through 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 B117. Three coated
45、 75by 150 mm 3 by 6 in. by 3 mm 18 in. flat panels, withintentional defects repaired with 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.Each intentional defect shall be an area of 12 by 25 mm 12 by1 in.
46、 removed from the center of one side of the coated panelusing a grinding wheel or other suitable method. Dust andloose material shall be removed from the intentional defect sitewith a clean cloth after the coatings removal. The patchingmaterial shall be prepared for application in accordance withthe
47、 written instructions of the patching material manufacturer.FIG. 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 co
48、ntaining 3M NaCl.D 3963/D 3963M 01 (2007)3The patching material shall be applied with a new paint brushto the intentional defect to form a patched area of 25 by 37 mm1 by 1.5 in. fully covering the intentional defect. The coatedpanel shall be lying flat on a table during the patching materialapplica
49、tion and shall remain in such a position until the coatinghas cured according to the manufacturers 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 625 m 61 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
