Saudi Aramco

OPERNS.

SAUDI ARAMCO OIL COMPANY
SECTION 03210 EPOXY COATED CONCRETE REINFORCEMENT
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

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SUBSECTION INDEX PART 1 - GENERAL

DESCRIPTION

1.01 1.02 1.03 1.04

Description of Work Quality Assurance Submittals Delivery, Handling and Storage

PART 2 - PRODUCTS
DATE JOB/EWO

2.01 2.02 2.03

Materials Epoxy Coating Fabrication

REV. NO.

PART 3 - EXECUTION 3.01 3.02 Installation Repair of Coated Bars

DISCIPLINE ENGINEER

__ ________ _ DATE: ________

PROJECT ENGINEER
____________ DATE

PART 1 - GENERAL 1.01 Description of Work A. The work of this Section includes furnishing, fabrication and placement of reinforcement with protective epoxy coatings for cast-in-place concrete and precast concrete, including bars, ties and supports. The coatings shall be applied by the electrostatic spray method. Related Work: 1. 2.
Date:

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

B.

Section 03100 - Concrete Formwork Section 03300 - Cast-in-Place Concrete

1.02

Quality Assurance A. Codes and Standards: Comply with the provisions of the following codes specifications and standards, except as otherwise shown or specified.
Section 03210

CONSTRUCTION SPECIFICATIONS

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OPERNS.

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1. ACI 301, Specifications for Structural Concrete for Buildings. ACI 315, Manual of Standard Practice for Detailing Reinforced Concrete Structures. ACI 318, Building Code Requirements for Structural Concrete. ASTM A615, Specification for Deformed and Plain BilletSteel Bars for Concrete Reinforcement. CRSI, Manual of Standard Practice. SASO 2, Steel Bars for the Reinforcement of Concrete. ASTM A775, Specification for Epoxy-Coated Reinforcing Steel Bars. ASTM A 884M, Specification for Epoxy-Coated Steel Wire and Welded Wire Fabric for Reinforcement. SSPC-SP10, Steel Structures Painting Council Surface Preparation Specification No. 10. 09-SAMSS-106, Epoxy Coating of Steel Reinforcing Bars.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

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2.

3.
DESCRIPTION

4.

5. 6.

DATE JOB/EWO

7.

8.

REV. NO.

9.
DISCIPLINE ENGINEER

__ ________ _ DATE: ________

10. 1.03 Submittals A.

PROJECT ENGINEER
____________ DATE

Manufacturer's Data: 1. Submit copies of manufacturer's specifications and installation instructions for all proprietary materials and reinforcement accessories for approval.

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

B.

Mill Certificates: 1. Contractor shall furnish Saudi Aramco copies of the manufacturer's records of chemical and physical properties of all heats of billet steel bars and copies of affidavit for materials stating that the material furnished meets the requirements for the steel reinforcement specified. Manufacturer's records shall include certificates of mill analysis, tensile strength tests, and bend tests.

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

Date:

C.

Shop Drawings: 1. Submit shop drawings for fabrication bending, and placement of concrete reinforcement. Comply with ACI 315 "Manual of Standard Practice for Detailing Reinforced
DWG. TYPE PLANT NO. INDEX DRAWING NO.

Section 03210
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Concrete Structures." Show bar schedules, stirrup spacing, diagrams of bent, bars, arrangements and assemblies, as required for the fabrication and placement of epoxy coated concrete reinforcement. 1.04 Delivery, Handling and Storage A. Deliver epoxy coated reinforcement to the project site bundled, tagged and marked. Use metal tags indicating bar size, lengths, and other information corresponding to markings shown on placement diagrams. Store epoxy coated concrete reinforcement materials at the site in protected racks above ground in an approved manner so as to avoid damage to the coating. Direct metal to coating contact shall be avoided wherever possible. Equipment for handling epoxy coated bars shall have padded contact areas. Bundles shall be lifted with strongback or have multiple supports to prevent bar-to-bar abrasion from sags in the bundle. Bars or bundles shall not be dragged or dropped. Any coating damaged due to handling, shipment and placing shall be repaired as described in Section 3.02 B.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

DESCRIPTION

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B.

DATE JOB/EWO

C.

REV. NO.

DISCIPLINE ENGINEER

__ ________ _ DATE: ________

PART 2 - PRODUCTS 2.01 Materials A. All reinforcing bars shall be deformed and shall comply with the r equirements of ASTM A615 and as follows: 1. B. C. Provide Grade 60 bars, except as otherwise indicated.

PROJECT ENGINEER
____________ DATE

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

Steel Wires shall conform to ASTM A82. Column Spirals: Plain, Cold-drawn, wire, ASTM A82, or hot-rolled rods for spirals, ASTM A615. Supports for Reinforcement: Bolsters, chairs, spacers and other devices for spacing, supporting and fastening reinforcement in place shall be coated with a dielectric material such as nylon, epoxy or plastic. 1. Use wire bar type supports complying with CRSI recommendations, unless otherwise indicated. Do not use wood, brick, and other unacceptable materials.
Section 03210

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

D.

Date:

CONSTRUCTION SPECIFICATIONS

DWG. TYPE PLANT NO. INDEX

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OPERNS.

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2. The supports shall be used in such a manner that they will not be exposed or contribute to the discoloration or deterioration of the concrete. For abrasive-blasted or bush-hammered concrete, provide special stainless bar supports (CRSI, Class E). Over waterproofing membranes, use precast concrete chairs to prevent penetration of the membrane.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

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3.

4.
DESCRIPTION

2.02

Epoxy Coating A. MATERIAL: 1. The epoxy coating material shall be an organic, powdered epoxy resin that is applied by electrostatic methods. Epoxy coating materials shall be approved by Saudi Aramco. Patching Material: Patching or repair materials shall be supplied by the epoxy coating manufacturer. The patching materials shall be compatible with the epoxy coating, inert in concrete, and shall be suitable for use in making field repairs.

DATE JOB/EWO

2.

REV. NO.

DISCIPLINE ENGINEER

__ ________ _ DATE: ________

B.

Coating Application 1. Surface Preparation: a. The surface of bars to be coated shall be blast cleaned to near-white metal in accordance with SSPC-SP 10. After blasting, the cleaned surface of the bar shall be defined by SSPC-Vis 1, Pictorial Standards ASa 2-1/2, BSa 2-1/2, or CSa 2-1/2, as applicable. The powdered 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.

PROJECT ENGINEER
____________ DATE

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

b.

Date:

2.

Coating Application: The powdered epoxy resin coating shall be electrostatically applied in accordance with ASTM A775 Standard. The epoxy coating may be applied before or after fabrication of the reinforcing bars. Coating Thickness: The epoxy coating shall be applied as a smooth, uniform coat. After curing, the coating thickness
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Section 03210
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OPERNS.

SAUDI ARAMCO OIL COMPANY
shall be 180 microns plus or minus 50 microns. Coating thickness shall be controlled by taking measurement on a representative number of bars from each production lot. Coating thickness measurements shall be conducted by the method outlined in ASTM G12. 4. Continuity of Coating: a. The coating shall be checked visually after cure for continuity. It shall be free from holes, voids, contamination, cracks and damaged areas. The coating shall not have more than three holidays (pinholes not visible to naked eye) in any 300 mm length of the coated bar. A holiday detector shall be used in accordance with the manufacturer's instructions, to check the coating for holidays.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

DESCRIPTION

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b.

DATE JOB/EWO

5.

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. Flexibility of Coating: a. The flexibility of 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 150 mm diameter mandrel. The bend shall be done at a uniform rate and any take up to one minute to complete. The test specimens shall be at a thermal equilibrium between 20 and 30 degrees C at the time of testing. No cracking of the coating shall be visible to the naked eye on the outside radius of the bend bar.

REV. NO.

DISCIPLINE ENGINEER

6.

__ ________ _ DATE: ________

PROJECT ENGINEER
____________ DATE

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

b.

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

C.

Testing and Sampling: 1. Lot Size: For test purposes, a production lot is the smallest number of reinforcing bars of the same type, heat and size as determined by the following requirements: a. A lot shall not exceed a single order, or delivered load, whichever is smaller. A lot shall consist of the number of bars as defined by the coating applicator except that it shall not
DWG. TYPE PLANT NO. INDEX DRAWING NO.

Date:

b.

Section 03210
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OPERNS.

SAUDI ARAMCO OIL COMPANY
exceed the number of reinforcing bars coated within a single working shift. 2. Quality Control: The coating applicator shall be responsible for quality control. This will include inspection for compliance with the requirements of coating thickness, continuity of coating, coating cure and the testing required under Flexibility of Coating. Plant Inspection: a. Saudi Aramco reserves the right to have its authorized representative observe the preparation, coating and testing of the reinforcing bars. The representative shall free access to the plant and any work done when access has been denied shall be automatically rejected.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

DESCRIPTION

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3.

DATE JOB/EWO

2.03

Fabrication A. General: Fabricate reinforcing bars to conform to required shapes and dimensions, with fabrication tolerances complying with CRSI "Manual of Standard Practice." In case of fabricating errors, do not re-bend or straighten reinforcement in a manner that will injure or weaken the material. Unacceptable Materials: Reinforcement with any of the following defects will not be permitted in the work: 1. Bar lengths, depths, and bends exceeding specified fabrication tolerances. Bend or kinks to indicated on drawings or final shop drawings. Bars with reduced cross-section due to excessive rusting or other cause. Epoxy coating not meeting the requirements of Section 2.02.

REV. NO.

DISCIPLINE ENGINEER

__ ________ _ DATE: ________

PROJECT ENGINEER
____________ DATE

B.

CERTIFIED _ __________
DATE: ________

2.

CONSTRUCTION AGENCY
________________ DATE:

3.

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

4. PART 3 - EXECUTION
Date:

3.01

Installation A. Comply with the Concrete Reinforcing Steel Institute (CRSI) recommended practice for placing reinforcing bars, for details and methods of reinforcement placement and supports, and as herein specified for reinforced concrete construction.
Section 03210

CONSTRUCTION SPECIFICATIONS

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OPERNS.

SAUDI ARAMCO OIL COMPANY
B. Clean reinforcement to remove dirt and other materials which reduce or destroy bond with concrete. Place reinforcement to obtain the minimum concrete cover as specified. Arrange, space, and securely tie bars supports and reinforcement together with 1.52 mm diameter coated wire to hold reinforcement accurately in position during concrete placement operations. Set wire ties so that twisted ends are directed away from exposed concrete surfaces. Provide sufficient numbers of supports and of strength to carry reinforcement. Do not place reinforcing bars more than 50 mm beyond the last leg of any continuous bar support. Do not use supports as basses for runways for concrete conveying equipment and similar construction loads. Splices: All splices in reinforcement shall be as shown on the drawings or as directed by Saudi Aramco representative. Minimum lap for bar splices shall be as noted on the plans. Bar splices shall be made by lapping ends, placing bars in contact, and securely wiring together. Epoxy coated reinforcing steel shall not be welded.
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.

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DATE JOB/EWO

E.

DISCIPLINE ENGINEER

3.02

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 alternatively, 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. 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 alternatively, stripped of epoxy coating, recleaned and recoated in accordance with the requirements of the specification.

__ ________ _ DATE: ________

PROJECT ENGINEER
____________ DATE

CERTIFIED _ __________
DATE: ________

CONSTRUCTION AGENCY
________________ DATE:

OPERATIONS
______________ DATE:_________ REVISION CERTIFICATION EDSD VERIFICATION THIS INDICATES THAT REV. NO.________ OF THIS DRAWING IS COVERED, FOR ALL APPROVAL/CERTIFICATION REQUIREMENTS,, CONTROL NUMBER BY DRAWING COMPLETION CERTIFICATE (DCC) NO.: __________________________ By:

Date:

C.

Material Safety Data Sheets shall be provided to Industrial Hygiene for review and comment before bringing any new epoxy coating resins into the area. END OF SECTION
Section 03210

CONSTRUCTION SPECIFICATIONS

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