ECA-1400-Green Polymer Corporation Oxyplast EL-704-P-9 Fuller-O'Brien South San Francisco, California DK-0548 Dexter Hysol Corp. ECA-1440-3 Polymer Corporation The powdered epoxy resin selected by the Contractor and furnished by the manufacturer shall be of the same material and quality as the resins listed above. Prequalification of new products will be in accordance with Federal Highway Administration Notice 5080.48 (Available from the contracting officer). The approved powders are based on specific reinforcing steel preparation and powder application and curing methods and these identical methods shall be followed during fabrication. 559.03 General Requirements Certification: The coating manufacturer shall supply the purchaser with a certification which properly identified the batch and/or lot number, material, quantity of batch, date of manufacture, name and address of manufacturer and a statement that the material is the same composition as the initial sample prequalified for use. A statement shall also be submitted regarding the fact that production bars and prequalification bars have been identically prepared and applied with epoxy powders. Material for Repair: Patching or repair material, compatible with the coating and inert in concrete, shall be made available by the epoxy coating manufacturer. This material shall be suitable for repairs made by the installation contractor of areas of the coating damaged during fabrication and/or handling in the field. 559.04 Application Requirements (a) Coating Applicator. The coating applicators facilities shall be subject to approval by the Government. Applications for approval of facilities shall be made to the Government by the coating applicator. (b) Surface Preparation. (1) The surface of bars to be coated shall be blast cleaned in accordance with the Steel Structures Painting Council-Surface Preparation Specification No. 10 (SSPC-SP10), Near White Blast Cleaning. After blasting, the cleaned surface of the bar shall be defined by SSPCVis 1, Pictorial Standards ASa 2 1⁄2, or CSa 2 1⁄2, as applicable. (2) The powered epoxy resin coating shall be applied to the cleaned surface as soon as possible after cleaning and before visible oxidation occurs. In no case shall more than 8 hours elapse between cleaning and coating. (c) Coating Application. The powdered epoxy resin coating shall be electrostatically applied in accordance with the recommendations of the coating manufacturer. The epoxy coating may be applied before or after fabrication of the reinforcing bars. (d) Coating Thickness. The epoxy coating shall be applied as a smooth uniform coat. After curing, the coating thickness shall be 7±2 mils. Coating thickness shall be controlled by taking measurements on a representative number of bars from each production lot. Coating thickness measurements shall be conducted by the method outlined in ASTM G12. (e) Continuity of Coating (1) The coating shall be checked visually after cure for continuity. It shall be free from holes, voids, contamination, cracks and damaged areas. (2) The coating shall not have more than two holidays (pinholes not visible to the naked eye) in any linear foot of the coated bar. A holiday detector shall be used, in accordance with the manufacturer's instructions, to check the coating for holidays. (f) Coating Cure. The coating applicator shall check each production lot to determine that the entire production lot of coated bars is in a fully-cured condition. (g) Flexibility of Coating. (1) The flexibility of the coating shall be evaluated on a representative number of bars selected from each production lot. The coated bar shall be bent 120 degrees (after rebound) around a 6-inch diameter mandrel. The bend shall be done at a uniform rate and may take up to one minute to complete. The test specimens shall be at thermal equilibrium between 20 and 30 degrees C (68-85 F) at the time of testing. (2) No cracking of the coating shall be visible to the naked eye on the outside radius of the bent bar. 559.05 Testing and Sampling. (a) Lot Size. For test purposes a production lot is the smallest number of reinforcing of the same type, heat and size as determined by the following requirements: (1) A lot shall not exceed a single order, or delivered load, whichever is smaller. (2) A lot shall consist of the number of bars as defined by the coating applicator except that it shall not exceed the number of reinforcing bars coated within a single work shift. (b) Quality Control. The coating applicator shall be responsible for performing quality control and tests. This will include inspection for compliance with the requirements of Coating Thickness, Continuity of Coating and Coating Cure and the testing required under Flexibility of Coating. (c) Plant Inspection (1) The Government reserves the right to have its authorized representative observe the preparation, coating and testing of the reinforcement bars. The representative shall have free access to the plant, and any work done when access has been denied shall be automatically rejected. (2) If the representative elects, lengths of coated bars may be taken from the production run, on a random basis, for test, evaluation and check purposes by the Government. (d) The Contractor shall furnish a Certificate of Compliance from the coating applicator with each shipment of coated bars. The Certificate of Compliance shall (1) verify that the coated bars and coating material have been tested in accordance with the requirements of these specifications, (2) state the actual test results for each requirement, and (3) state that the test results comply with the requirements. 559.06 Shop Repair of Coated Bars. (a) Epoxy coated reinforcement bars which do not meet the requirements for Coating Thickness, Continuity of Coating, Coating Cure or Flexibility of Coating shall not be repaired. Reinforcement bars with these defects shall be replaced or alternately, stripped of epoxy coating, recleaned and recoated in accordance with the requirements of this specification. (b) Coating breaks due to fabrication and handling shall be repaired with patching material if the defective area is greater than the cross-sectional area of the reinforcement bar. Defects which are smaller than the cross-sectional area need not be repaired. The repair of coating breaks shall be limited to bars on which the total of the defective coating areas does not exceed 5 percent of the surface area of the reinforcement bar. Bars with greater than 5 percent damage shall be replaced or alternately, stripped of epoxy coating, recleaned and recoated in accordance with the requirements of this specification. Construction Requirements 559.07 Handling. All systems for coated bars shall have padded contact areas for the bars, wherever possible. All bundling bands shall be padded and all bundles shall be lifted with a strong back, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle. The bars or bundles shall not be dropped or dragged. Chairs, tie wires, and other devices used to support, position, or fasten the reinforcement shall be made of or coated with, a dielectric material. The specific hardware that the Contractor proposes to use shall be approved by the Engineer. 559.08 Field Repair-Epoxy Coated Bar Reinforcement. The Contractor shall be required to field repair damaged areas of the bar coating, and to replace bars exhibiting severely damaged coatings. The material used for field repair shall be that supplied by the coating applicator. Field repair shall be required wherever the area of coating damaged exceeds the crosssectional area of the reinforcing bar. Field repair shall not be allowed on bars which have severely damaged coatings. A severely damaged coating is defined as a coating which has a total damaged area greater than five (5) percent of the surface area of the reinforcing bar. The Engineer shall be the sole determiner of the severity of damaged areas for purposes of repair or replacement. A reinforcing bar having a coating determined by the Engineer to be severely damaged shall not be incorporated in the work and it shall be removed from the work site. All such bars shall be replaced in kind by the Contractor at no additional cost to the Government. Other construction requirements shall be in accordance with Section 554 and the contract plans. Method of Measurement 559.09 The accepted epoxy coated steel reinforcing bars will be measured in accordance with Section 554. No addition to or deduction from the theoretical weight per foot of the uncoated bars will be made because of additional requirements for blast cleaning and epoxy coating of the bars. Basis of Payment 559.10 The accepted epoxy coated steel reinforcing bars will be paid for in accordance with Section 554 and all additional expenses that may be incurred by the Contractor or his suppliers as a result of the requirements in these specifications will be considered incidental to and included in the contract unit price per pound for "Epoxy Coated Steel Reinforcement". Payment will be made under: Pay item Epoxy Coated Steel Reinforcement Pay unit Pound Section 600 INCIDENTAL CONSTRUCTION Section 601.-MOBILIZATION Description 601.01 Mobilization. Mobilization shall consist of preparatory work and operations, including, but not limited to, those necessary to the movement of personnel, equipment, supplies and incidentals to the project site; and for all other work and operations which must be performed or costs incurred prior to beginning work on the various items on the project site. Basis of Payment 601.02 Partial Payments will be made as the work progresses in accordance with the following schedule: (1) When 5 percent of the original contract amount is earned from other bid items, 50 percent of the amount bid for mobilization, or 5 percent of the original contract amount, whichever is lesser, will be paid. (2) When 10 percent of the original contract amount is earned from other bid items, 100 percent of the amount bid for mobilization, or 10 percent of the original contract amount, whichever is lesser, will be paid. (3) Upon completion of all work on the Project, payment of any amount bid for Mobilization in excess of 10% of the original contract amount, will be paid. (4) The total sum of all payments shall not exceed the original contract amount bid for mobilization, regardless of the fact that the Contractor may have, for any reason, shut down his work on the project or moved equipment away from the project and then back again. Payment will be made under: Pay item 601(1) Mobilization... Pay unit Section 602.-MINOR CONCRETE STRUCTURES Description 602.01 Scope. This work shall consist of reinforced concrete headwalls, inlet basins, and other minor concrete structures constructed in conformity with the lines, grades, and dimensions shown on the plans or as ordered in writing by the engineer, and in accordance with this and other specification sections involved. Materials 602.02 Materials. Materials shall meet the requirements specified in the following subsections. |