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10217 Optimum Concrete Mix Design
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The use of trial mixes needs to be considered for the following additional problems: Admixture compatibility Rapid slump loss Plastic shrinkage cracking Variation in air content
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10218 Protecting Reinforcement from Corrosion
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Corrosion of reinforcing steel is a major concern for an aging infrastructure Repairing and replacing damaged concrete caused by rusting reinforcing steel requires time, money, and an imposition on the traveling public 1 Epoxy coated reinforcement: Epoxy coated reinforcement is the most frequently used type of corrosion protected reinforcement
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CONCRETE REPAIR METHODS
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Extra care is required during placement of epoxy-coated reinforcement Repair is required of epoxy coating that is damaged before or during placement Galvanized reinforcement: Galvanized reinforcement can be used in most applications where epoxy is suitable An advantage of galvanized reinforcement over epoxy is shorter development length Galvanized bars shall not be used in prestressed beams The current standard is to use a calcium nitrite corrosion inhibitor in prestressed elements, which negates the need for other corrosion protection measures Uncoated bars and galvanized bars shall not be mixed in the same structural element Uncoated (plain) reinforcement: In general, uncoated (plain) steel is the most economical choice when the concrete members provide adequate cover, and the reinforcement is not exposed to chlorides or other severe environments Stainless steel clad reinforcement: Bends, development length, and lap splice requirements are similar to plain bars The primary difference between stainless steel clad and solid stainless steel is that stainless steel clad has a plain core that must be protected after cutting, leading to increased time and effort in the eld Solid stainless steel and stainless steel clad reinforcement are appropriate for the following: When added durability reduces cost, either long-term or during construction This can occur: When environmental conditions are particularly severe When the cost of repairs is unusually high due to heavy traf c or construction conditions When design of concrete sections as uncracked under service load is not feasible When cover is less than standard In extreme environments such as in a cap beam beneath an expansion joint A substructure located in or near a body of salt water
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10219 Approximate Reinforcement Cost Comparison
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The following table shows comparative cost ratios: Bar Protection Type Solid stainless steel Stainless steel clad Galvanized Epoxy coated Plain In-Place Cost Ratio 20 16 11 11 10 Minimum Expected Service Life 100 80 60 50 40
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1 A review of the average bid prices (in place costs) indicates that the cost to fabricate, ship, and place plain reinforcing bars is $15/kg over the material cost 2 The cost to fabricate, ship, and place epoxy coated bars is an additional $050/kg ($2/kg over the material cost) due to the extra care required during placement and repair to the epoxy coating after placement 3 Cost to fabricate, ship, and place all types of bars is similar
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REPAIR AND RETROFIT METHODS
Expected Service Life
For the different types of reinforcing bars in conventional concrete (with standard cover) exposed to a corrosive environment, the expected service life is reduced by nearly half These values are approximate and are based on information obtained from industry sources, university research studies, and professional journals The standards for reinforcing bars are given in ASTM A615 and A996 These documents include the minimum dimensions for bending the various diameters and grades of bars The standard bends for galvanized reinforcing bars are given in ASTM A767 All substructure components immersed in seawater are considered to be exposed to chlorides on all faces
10221 Estimated Density of Steel per Unit Volume of Concrete
In lieu of performing an exact calculation from bar bending schedules, approximate values for steel content are given below: Abutments, retaining walls and solid piers 45 to 50 kg/m3of concrete volume Piers (except solid piers) 55 to 60 kg/m3of concrete volume
10222 Construction Inspection Requirements for Reinforcement
1 Check minimum cover, lap length, and location and embedment requirements as shown on the contract plans 2 Verify bar types: Plain, epoxy-coated, galvanized, solid stainless, or stainless clad 3 Bent bars shall conform to the details shown on the contract plans
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