ASTM D3963/D3963M-01(2007)
(Specification)Standard Specification for Fabrication and Jobsite Handling of Epoxy-Coated Steel Reinforcing Bars
Standard Specification for Fabrication and Jobsite Handling of Epoxy-Coated Steel Reinforcing Bars
ABSTRACT
This specification covers the fabrication and jobsite requirements for deformed and plain steel reinforcing bars with protective epoxy coating. The fabrication of steel reinforcing bars after coating shall meet the requirements prescribed. The storage, handling and placement at the jobsite of epoxy-coated steel reinforcing bars shall meet the requirements prescribed. The repair method of damage incurred during fabrication and incurred during shipment and handling at the job sites shall meet the requirements prescribed.
SCOPE
1.1 This specification covers the fabrication and jobsite requirements for deformed and plain steel reinforcing bars with protective epoxy coating applied in accordance with Specification A 775/A 775M.
1.2 This specification is applicable for orders in either SI units (as Specification D 3963M) or inch-pound units (as Specification D 3963).
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. Within the text, the inch-pound units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system must be used independently of the other. Combining values from the two systems may result in nonconformance with the specification.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
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Designation:D3963/D3963M −01(Reapproved2007)
Standard Specification for
Fabrication and Jobsite Handling of Epoxy-Coated Steel
Reinforcing Bars
This standard is issued under the fixed designation D3963/D3963M; the number immediately following the designation indicates the
year of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last
reapproval. A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope E691Practice for Conducting an Interlaboratory Study to
Determine the Precision of a Test Method
1.1 This specification covers the fabrication and jobsite
G20Test Method for Chemical Resistance of Pipeline Coat-
requirementsfordeformedandplainsteelreinforcingbarswith
ings
protective epoxy coating applied in accordance with Specifi-
2.2 Federal Highway Administration Report
cation A775/A775M.
FHWA-RD-74-18Nonmetallic Coatings for Concrete Rein-
1.2 This specification is applicable for orders in either SI
forcing Bars
units (as Specification D3963M) or inch-pound units (as
Specification D3963).
3. Coating Repair Materials
1.3 The values stated in either SI units or inch-pound units
3.1 Thepatchingorrepairmaterialshallbecompatiblewith
are to be regarded separately as standard. Within the text, the
the coating, inert in concrete, and feasible for repairs at the
inch-pound units are shown in brackets. The values stated in
applicator, fabricator, or in the field. This material shall be
each system are not exact equivalents; therefore, each system
approved in accordance with Annex A1 prior to use.
must be used independently of the other. Combining values
3.2 The manufacturer shall specify the method of metal
from the two systems may result in nonconformance with the
surfacepreparation,andthepatchingapplicationproceduresto
specification.
be used in the field.
1.4 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
4. Handling and Identification
responsibility of the user of this standard to establish appro-
4.1 Coated bars shall be transported and handled with care.
priate safety and health practices and determine the applica-
Allsystemsforhandlingcoatedbarsshallhavepaddedcontact
bility of regulatory limitations prior to use.
areas.All bundling bands shall be padded, or suitable banding
2. Referenced Documents
shall be used to prevent damage to the coating.All bundles of
coated bars shall be lifted with a strong back, spreader bar,
2.1 ASTM Standards:
multiple supports, or a platform bridge to prevent bar-to-bar
A775/A775MSpecification for Epoxy-Coated Steel Rein-
abrasionfromsagsinthebundles.Thebarsorbundlesshallnot
forcing Bars
be dropped or dragged.
B117Practice for Operating Salt Spray (Fog) Apparatus
D374Test Methods for Thickness of Solid Electrical Insu-
4.2 The identification (including heat number, mill test
lation
results, date and type of coating system used, etc.) of all
D2967Test Method for Corner Coverage of Powder Coat-
reinforcingbarsshallbemaintainedthroughoutthecoatingand
ings
fabrication processes to the point of shipment.
E177Practice for Use of the Terms Precision and Bias in
ASTM Test Methods 5. Fabrication of Steel Reinforcing Bars After Coating
5.1 The steel reinforcing bars to be fabricated after applica-
tion of the coating shall meet the requirements of this specifi-
This specification is under the jurisdiction ofASTM Committee D04 on Road
and Paving Materials and is the direct responsibility of Subcommittee D04.32 on
cation.
Bridges and Structures.
5.2 Handling and storage of coated bars at the fabricator’s
Current edition approved Dec. 1, 2007. Published January 2008. Originally
approved in 1981. Last previous edition approved in 2001 as D3963/D3963M–01.
facility shall meet the requirements of Section 4 and 6.3.
DOI: 10.1520/D3963_D3963M-01R07.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on Available from National Technical Information Service (NTIS), 5285 Port
the ASTM website. Royal Rd., Springfield, VA 22161, http://www.ntis.gov.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D3963/D3963M−01(2007)
5.3 Drive rolls on shear beds, and back-up barrels on 7.1.2 Visible cracks, including hairline cracks without bond
bendersshallbeprotectedwithasuitablecoveringtominimize loss (the coating cannot be easily removed with a peeling
damage during the fabrication process. action by the fingers of the inspector), and damage to the
coating within each fabricated area of the reinforcing bar shall
6. Storage, Handling and Placement at the Jobsite
be repaired. All disbonded areas of coating shall be removed,
cleaned and repaired. The cleaning shall remove loose or
6.1 Thefinished,installedcoatedsteelreinforcingbarstobe
deleteriousmaterial,orboth.Incaseswhererustispresent,the
used in the construction shall meet the requirements of this
rustshallberemovedbyathoroughcleaningpriortotherepair.
specification.
This cleaning shall be done by blast cleaning, filing, power
6.2 All systems for handling the coated bars at the jobsite
brushing or other method recommended by the patching
shall have padded contact areas. Coated bars or bundles shall
material manufacturer and approved by the purchaser in a
not be dropped or dragged.
manner that minimizes damage to the sound coating.
6.3 Coatedsteelreinforcingbarsshallbeoff-loadedasclose 7.1.3 When coated bars are sheared, saw-cut or cut by other
as possible to their points of placement or under the crane so
means during the fabrication process, the cut ends shall be
that the bars can be hoisted to the area of placement to patched.
minimize rehandling. 7.1.4 Therepairsshallbeperformedassoonaspossibleand
before visible oxidation appears on the steel surface and prior
6.4 Coated bars or bundles shall be stored above the ground
to shipment to the jobsite.
on wooden or padded supports with timbers placed between
7.1.5 The fabricator shall be responsible for repair to the
bundles when stacking is necessary. Space the supports suffi-
coating due to damage during fabrication and handling at the
ciently to prevent sags in the bundles.
fabricator’s facility.
6.5 Coated and uncoated steel reinforcing bars shall be
7.2 Repair of Damage Incurred During Shipment and Han-
stored separately.
dling at the Jobsite:
6.6 Long-term storage shall be minimized and material
7.2.1 Coating damage, visible to a person with normal or
delivery scheduled to suit construction progress.
corrected vision, incurred during shipment, storage or place-
6.7 Coated bars shall be tied with tie wire coated with ment of epoxy-coated bars at the jobsite shall be repaired with
epoxy,plastic,nylonorothernon-conductivematerialthatwill patching material meeting the requirements of 3.1.
not damage or cut the coating. 7.2.2 The contractor shall be responsible for repair to the
coating due to damage during shipment, storage, or placement
6.8 Barsupportsandspacersshallbecoatedwithormadeof
at the jobsite.
a non-conductive material compatible with concrete.
7.2.3 The patching shall be performed in accordance with
6.9 Placed coated bars shall be covered with opaque poly-
the written recommendations of the patching material manu-
ethylene or other suitable protective material if cumulative
facturer. The patching material shall be dry to the touch prior
environmental exposure of the coated bars, including previous
to concrete placement.
uncovered storage time, of greater than two months prior to
7.3 The total damaged surface area (prior to repair with
concrete embedment is expected. Provisions shall be made for
patching material), shall not exceed 2% in any given 0.3 m [1
adequateventilationtominimizecondensationunderthecover.
ft] section of coated reinforcement. The total bar surface area
NOTE1—Extendedstorageofthebarsatthejobsiteshouldbeavoided.
coveredbypatchingmaterialshallnotexceed5%inanygiven
It is recommended that coated bars be covered immediately upon arrival
0.3 m [1 ft] section of coated reinforcement. This limit on
at the job site.
damaged and repaired area shall not include sheared or cut
6.10 After placing, walking on coated steel reinforcing bars
ends.
shall be minimized. The placement of mobile equipment shall
8. Rejection
be planned to avoid damage to the coated bars.
8.1 Coated bars that do not meet the requirements of this
NOTE2—Researchhasshownthatsteel-headedvibratorscausedamage
specification shall be rejected.
to epoxy-coated steel reinforcing bars when used to consolidate concrete.
When consolidating concrete reinforced with epoxy-coated bars, it is
9. Field Sampling
recommended that vibrators with heads made of rubber or other resilient
material approved for concrete consolidation be used.
9.1 Thepurchaserortheirrepresentativeshallhavetheright
to select samples of the coated reinforcement to be used in the
7. Repairs
project at the jobsite for testing on site or at the purchaser’s
7.1 Repair of Damage Incurred During Fabrication:
facility.
7.1.1 All coating damage due to fabrication or handling at
10. Keywords
thefabricator’sfacilityshallberepairedwithpatchingmaterial
meeting the requirements of 3.1. The patching shall be per- 10.1 coating requirements; concrete reinforcement; corro-
formedinaccordancewiththewrittenrecommendationsofthe sion resistance; epoxy coating; fabrication repair; field repair;
patching material manufacturer. steel bars
D3963/D3963M−01(2007)
ANNEX
(Mandatory Information)
A1. QUALIFICATION OF PATCHING MATERIAL USED TO REPAIR ORGANIC COATINGS FOR STEEL REINFORCING
BARS
A1.1 Scope
A1.1.1 This specification covers qualification requirements
for patching materials used to repair barrier organic coatings
such as epoxy powder coatings used for protecting steel
reinforcing bars from corrosion.
A1.2 Coating Patching Material
A1.2.1 A minimum of 0.5 L [1 pt] of patching material,
compatible with the coating and inert in concrete, shall be
submitted to the testing agency. The material shall be feasible
forrepairstothecoatedreinforcingbarsdamagedbyhandling.
The product name and a description of the patching material
shall be given in the test report. A complete list of powder
coatingmaterials(productnamesandmanufacturers)forwhich
the patching material has been approved for use with shall be
FIG. A1.1Chloride Permeability Test Equipment Configuration
provided and included in the test report.
Permeability Cell Components
A1.3 Test Specimens
A = Compartment containing distilled water.
A1.3.1 Thefollowingtestspecimensshallbesubmittedasa
B = Epoxy film sandwiched between two glass plates, each
minimum for test:
having centered one-inch diameter holes.
A1.3.1.1 Four free films of coating patching material with a
C = Component containing 3M NaCl.
thickness within 625 µm [61 mil] of the patching material
manufacturer’s minimum recommended patching material
coating application thickness.
A1.3.1.2 Six75by150mm[3by6in.]by3mm[ ⁄8in.]flat
The cell shall consist of two glass compartments separated by
panels that have been blast cleaned and coated on both sides
a coating film sandwiched between two glass plates, each
with 175 to 300 µm [7 to 12 mils] of epoxy powder coating in
having a centered 25-mm [1-in.] hole. One compartment shall
accordance with the powder coating manufacturer’s written
contain 175 mL [5.3 oz.] of 3M NaCl and the other 115 mL
instructions. The hanger marks on the panels shall be sealed
[3.5oz]ofdistilledwater.Theactivityofchlorideionspassing
with silicone or other suitable sealant.
through the film shall be measured using a specific ion meter
equipped with a chloride electrode and a double junction
A1.3.2 A description of the sample preparation process for
electrode. Activity measurements shall be converted into con-
the free films and flat panel samples (for example, the number
centrationvaluesofmoleperL[M]withaconversiondiagram,
of coats of patch material applied to the intentional coating
constructed by plotting measured chloride ion activities versus
defect to achieve the minimum required coating thickness),
known chloride ion concentrations. The accumulative concen-
used in this prequalification evaluation shall be provided in the
tration of chloride ions permeating through the film shall be
test report. The patching material manufacturer shall specify
less than1×10 M.
the minimum recommended patching material coating appli-
cation thickness to be used. In addition, the patching material
A1.4.2 Salt Spray Resistance—The resistance of the patch-
manufacturer shall specify the method of metal surface prepa- ing material to a hot, wet corrosive environment shall be
ration and the patching application procedures. These proce-
evaluated in accordance with Practice B117. Three coated 75
dures and minimum thickness shall be followed by the testing by 150 mm [3 by 6 in.] by 3 mm [ ⁄8 in.] flat panels, with
agencytopreparethecoatedmetalspecimensfortestandshall
intentionaldefectsrepairedwiththepatchingmaterial,shallbe
be listed in the test report.
exposed to 35 6 2°C [95 6 3.6°F] salt spray comprised of 5
% NaCl by mass dissolved in distilled water for 400 6 10 h.
A1.4 Patching Material Requirements
Each intentional defect shall be an area of 12 by 25 mm [ ⁄2 by
A1.4.1 Chloride Permeability—The chloride permeability 1 in.] removed from the center of one side of the coated panel
characteristics of the patching material shall be measured on using a grinding wheel or other suitable method. Dust and
two test films and a control film at 24 6 2°C [75 6 3.6°F] for loosematerialshallberemovedfromtheintentionaldefectsite
45 days. The permeability cells shall be of the type shown in with a clean cloth after the coating’s removal. The patching
Fig.A1.1. Films selected for testing shall be carefully handled material shall be prepared for application in accordance with
and examined for any defects prior to installation in the cell. the written instructions of the patching material manufacturer.
D3963/D3963M−01(2007)
The patching material shall be applied with a new paint brush suitable solvent to remove all oil, grease and foreign matter.
totheintentionaldefecttoformapatchedareaof25by37mm The test pieces shall then be air-dried.
[1 by 1.5 in.] fully covering the intentional defect. The coated A1.4.4.2 A25-mm[1-in.]micrometercaliper,inaccordance
panel shall be lying flat on a table during the patching material with Method C of Test Methods D374, or other suitable
applic
...
This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation:D3963/D3963M–00a Designation: D 3963/D 3963M – 01 (Reapproved 2007)
Standard Specification for
Fabrication and Jobsite Handling of Epoxy-Coated Steel
Reinforcing Bars
This standard is issued under the fixed designation D 3963/D 3963M; the number immediately following the designation indicates the
year of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last
reapproval. A superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This specification covers the fabrication and jobsite requirements for deformed and plain steel reinforcing bars with
protective epoxy coating applied in accordance with Specification A 775/A 775M.
1.2 This specification is applicable for orders in either SI units (as Specification D 3963M) or inch-pound units (as Specification
D 3963).
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. Within the text, the
inch-pound units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system must
be used independently of the other. Combining values from the two systems may result in nonconformance with the specification.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory
limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:
A 775/A 775M Specification for Epoxy-Coated Reinforcing Steel Reinforcing Bars
B 117 Practice for Operating Salt Spray (Fog) Apparatus
D 374 Test Methods for Thickness of Solid Electrical Insulation
D 2967 Test Method for Corner Coverage of Powder Coatings
E 177 Practice for Use of the Terms Precision and Bias in ASTM Test Methods
E 691 Practice for Conducting an Interlaboratory Study to Determine the Precision of a Test Method
G 20 Test Method for Chemical Resistance of Pipeline Coatings
2.2 Federal Highway Administration Report
FHWA-RD-74-18 Nonmetallic Coatings for Concrete Reinforcing Bars
3. Coating Repair Materials
3.1 The patching or repair material shall be compatible with the coating, inert in concrete, and feasible for repairs at the
applicator, fabricator, or in the field. This material shall be approved in accordance with Annex A1 prior to use.
3.2 The manufacturer shall specify the method of metal surface preparation, and the patching application procedures to be used
in the field.
4. Handling and Identification
4.1 Coatedbarsshallbetransportedandhandledwithcare.Allsystemsforhandlingcoatedbarsshallhavepaddedcontactareas.
All bundling bands shall be padded, or suitable banding shall be used to prevent damage to the coating.All bundles of coated bars
shall be lifted with a strong back, spreader bar, multiple supports, or a platform bridge to prevent bar-to-bar abrasion from sags
in the bundles. The bars or bundles shall not be dropped or dragged.
This specification is under the jurisdiction of ASTM Committee D04 on Road and Paving Materials and is the direct responsibility of Subcommittee D04.36 on Bridge
Deck Protective Systems.
Current edition approved July 10, 2000. Published September 2000. Originally published as D3963–81. Last previous edition D3963/D3963M–00.
This specification is under the jurisdiction ofASTM Committee D04 on Road and Paving Materials and is the direct responsibility of Subcommittee D04.32 on Bridges
and Structures.
Current edition approved Dec. 1, 2007. Published January 2008. Originally approved in 1981. Last previous edition approved in 2001 as D 3963/D 3963M – 01.
For referencedASTM standards, visit theASTM website, www.astm.org, or contactASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
, Vol 01.04.volume information, refer to the standard’s Document Summary page on the ASTM website.
Annual Book of ASTM Standards, Vol 03.02.
Available from National Technical Information Service (NTIS), 5285 Port Royal Rd., Springfield, VA 22161, http://www.ntis.gov.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
D 3963/D 3963M – 01 (2007)
4.2 The identification (including heat number, mill test results, date and type of coating system used, etc.) of all reinforcing bars
shall be maintained throughout the coating and fabrication processes to the point of shipment.
5. Fabrication of Steel Reinforcing Bars After Coating
5.1 The steel reinforcing bars to be fabricated after application of the coating shall meet the requirements of this specification.
5.2 Handling and storage of coated bars at the fabricator’s facility shall meet the requirements of Section 4 and 6.3.
5.3 Drive rolls on shear beds, and back-up barrels on benders shall be protected with a suitable covering to minimize damage
during the fabrication process.
6. Storage, Handling and Placement at the Jobsite
6.1 The finished, installed coated steel reinforcing bars to be used in the construction shall meet the requirements of this
specification.
6.2 All systems for handling the coated bars at the jobsite shall have padded contact areas. Coated bars or bundles shall not be
dropped or dragged.
6.3 Coated steel reinforcing bars shall be off-loaded as close as possible to their points of placement or under the crane so that
the bars can be hoisted to the area of placement to minimize rehandling.
6.4 Coatedbarsorbundlesshallbestoredabovethegroundonwoodenorpaddedsupportswithtimbersplacedbetweenbundles
when stacking is necessary. Space the supports sufficiently to prevent sags in the bundles.
6.5 Coated and uncoated steel reinforcing bars shall be stored separately.
6.6 Long-term storage shall be minimized and material delivery scheduled to suit construction progress.
6.7 Coated bars shall be tied with tie wire coated with epoxy, plastic, nylon or other non-conductive material that will not
damage or cut the coating.
6.8 Bar supports and spacers shall be coated with or made of a non-conductive material compatible with concrete.
6.9 Placed coated bars shall be covered with opaque polyethylene or other suitable protective material if cumulative
environmentalexposureofthecoatedbars,includingpreviousuncoveredstoragetime,ofgreaterthantwomonthspriortoconcrete
embedment is expected. Provisions shall be made for adequate ventilation to minimize condensation under the cover.
NOTE 1—Extended storage of the bars at the job site should be avoided. It is recommended that coated bars be covered immediately upon arrival at
the job site.
6.10 After placing, walking on coated steel reinforcing bars shall be minimized. The placement of mobile equipment shall be
planned to avoid damage to the coated bars.
NOTE 2—Researchhasshownthatsteel-headedvibratorscausedamagetoepoxy-coatedsteelreinforcingbarswhenusedtoconsolidateconcrete.When
consolidating concrete reinforced with epoxy-coated bars, it is recommended that vibrators with heads made of rubber or other resilient material approved
for concrete consolidation be used.
7. Repairs
7.1 Repair of Damage Incurred During Fabrication:
7.1.1 All coating damage due to fabrication or handling at the fabricator’s facility shall be repaired with patching material
meeting the requirements of 3.1.The patching shall be performed in accordance with the written recommendations of the patching
material manufacturer.
7.1.2 Visible cracks, including hairline cracks without bond loss (the coating cannot be easily removed with a peeling action
by the fingers of the inspector), and damage to the coating within each fabricated area of the reinforcing bar shall be repaired.All
disbonded areas of coating shall be removed, cleaned and repaired. The cleaning shall remove loose or deleterious material, or
both. In cases where rust is present, the rust shall be removed by a thorough cleaning prior to the repair. This cleaning shall be
done by blast cleaning, filing, power brushing or other method recommended by the patching material manufacturer and approved
by the purchaser in a manner that minimizes damage to the sound coating.
7.1.3 When coated bars are sheared, saw-cut or cut by other means during the fabrication process, the cut ends shall be patched.
7.1.4 The repairs shall be performed as soon as possible and before visible oxidation appears on the steel surface and prior to
shipment to the jobsite.
7.1.5 The fabricator shall be responsible for repair to the coating due to damage during fabrication and handling at the
fabricator’s facility.
7.2 Repair of Damage Incurred During Shipment and Handling at the Jobsite:
7.2.1 Coating damage, visible to a person with normal or corrected vision, incurred during shipment, storage or placement of
epoxy-coated bars at the jobsite shall be repaired with patching material meeting the requirements of 3.1.
7.2.2 The contractor shall be responsible for repair to the coating due to damage during shipment, storage, or placement at the
jobsite.
7.2.3 The patching shall be performed in accordance with the written recommendations of the patching material manufacturer.
The patching material shall be dry to the touch prior to concrete placement.
7.3 Thetotaldamagedsurfacearea(priortorepairwithpatchingmaterial),shallnotexceed2 %inanygiven0.3m[1ft]section
of coated reinforcement. The total bar surface area covered by patching material shall not exceed 5 % in any given 0.3 m [1 ft]
D 3963/D 3963M – 01 (2007)
section of coated reinforcement. This limit on damaged and repaired area shall not include sheared or cut ends.
8. Rejection
8.1 Coated bars that do not meet the requirements of this specification shall be rejected.
9. Field Sampling
9.1 The purchaser or their representative shall have the right to select samples of the coated reinforcement to be used in the
project at the jobsite for testing on site or at the purchaser’s facility.
10. Keywords
10.1 coating requirements; concrete reinforcement; corrosion resistance; epoxy coating; fabrication repair; field repair; steel
bars
ANNEX
(Mandatory Information)
A1. QUALIFICATION OF PATCHING MATERIAL USED TO REPAIR ORGANIC COATINGS FOR STEEL REINFORCING
BARS
A1.1 Scope
A1.1.1 This specification covers qualification requirements for patching materials used to repair barrier organic coatings such
as epoxy powder coatings used for protecting steel reinforcing bars from corrosion.
A1.2 Coating Patching Material
A1.2.1 A minimum of 0.5 L [1 pt] of patching material, compatible with the coating and inert in concrete, shall be submitted
to the testing agency. The material shall be feasible for repairs to the coated reinforcing bars damaged by handling. The patching
material shall be a two-component liquid that hardens to a solid on curing. The product name and a description of the patching
material shall be given in the test report.Acomplete list of powder coating materials (product names and manufacturers) for which
the patching material has been approved for use with shall be provided and included in the test report.
A1.3 Test Specimens
A1.3.1 The following test specimens shall be submitted as a minimum for test:
A1.3.1.1 Four free films of coating patching material with a maximum thickness of 175within 625 µm [7 mils]. [61 mil] of
the patching material manufacturer’s minimum recommended patching material coating application thickness.
A1.3.1.2 Six 75 by 150 mm [3 by 6 in.] by 3 mm [1/8[ ⁄8 in.] flat panels that have been blast cleaned and coated on both sides
with 175 to 300 µm [7 to 12 mils] of epoxy powder coating in accordance with the powder coating manufacturer’s written
instructions. The hanger marks on the panels shall be sealed with silicone or other suitable sealant.
A1.3.2 A description of the sample preparation process for the free films and flat panel samples (for example, the number of
coats of patch material applied to the intentional coating defect to achieve the minimum required coating thickness), used in this
prequalification evaluation shall be provided in the test report. The patching material manufacturer shall specify the minimum
recommended patching material coating application thickness to be used. In addition, the patching material manufacturer shall
specifythemethodofmetalsurfacepreparationandthepatchingapplicationprocedures.Theseproceduresandminimumthickness
shall be followed by the testing agency to prepare the coated metal specimens for test and shall be listed in the test report.
A1.4 Patching Material Requirements
A1.4.1 Chloride Permeability—The chloride permeability characteristics of the patching material having the minimum
thickness proposed for use shall be measured on two test films and a control film at 24 6 2°C [75 6 3.6°F] for 45 days. The
permeability cells shall be of the type shown in Fig. 1. Films selected for testing shall be carefully handled and examined for any
defects prior to installation in the cell. The cell shall consist of two glass compartments separated by a coating film sandwiched
betweentwoglassplates, each having a centered 25-mm[1-in.]hole.Onecompartmentshallcontain175mL[5.3oz.]of3MNaCl
and the other 115 mL [3.5 oz] of distilled water. The activity of chloride ions passing through the film shall be measured using
a specific ion meter equipped with a chloride electrode and a double junction electrode.Activity measurements shall be converted
into concentration values of mole per L [M] with a conversion diagram, constructed by plotting measured chloride ion activities
versus known chloride ion concentrations. The accumulative concentration of chloride ions permeating through the film shall be
less than 1 3 10 M.
A1.4.2 Salt Spray Resistance—The resistance of the patching material to a hot, wet corrosive environment shall be evaluated
in accordance with Test Method Practice B 117. Three coated 75 by 150 mm [3 by 6 in.] by 3 mm [1/8[ ⁄8 in.] flat panels, with
intentional defects repaired with the patching material, shall be exposed to 35 6 2°C [95 6 3.6°F] salt spray comprised of 5 %
D 3963/D 3963M – 01 (2007)
FIG. 1 Chloride Permeability Test Equipment Configuration
Permeability Cell Components
A = Compartment containing distilled water.
B = Epoxy film sandwiched between two glass plates, each
having centered one-inch diameter holes.
C =
...
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