EPOXY-COATED STEEL REINFORCEMENT

GENERAL

This IM covers epoxy-coated steel reinforcement.  The requirements for epoxy coated steel reinforcement can be found in standard specification 4151.  Approved epoxy coaters, reinforcing steel manufacturers, suppliers, fabricators and epoxy powder can be found in the Materials Approved Products Listing Enterprise (MAPLE).

APPROVAL PROCESS

· Refer to IM 451.03B Appendix A for the coater approval requirements.

· Refer to IM 451.03B Appendix B for the epoxy powder approval requirements.

· Refer to IM 451.03B Appendix C for the dowel bar basket assemblies/load transfer dowels approval requirements.

· Refer to IM 451.03B Appendix D for the epoxy coated steel reinforcement fabricator/supplier approval requirements.

CERTIFICATION PROCEDURES

• The steel mill, epoxy coater and/or supplier shall furnish an identification list, invoice or bill of lading for each shipment to each project.  It shall show the project number, size, length, grade, heat number, source and weight of pieces in the shipment.  In addition, the name and location of the epoxy coating plant and supplier/fabricator if different from the coating plant must be shown.
• The signed mill test reports/certification shall include the physical, chemical and mechanical properties, ASTM designation, grade and type for each heat. 
• A copy of the epoxy powder certificates and epoxy coating test certificates shall be provided. 

o The epoxy-coating certifications shall provide the coating lot number and powder lot numbers for the heat numbers included in the shipment and the quality control test results for coating thickness, coating continuity, profile measurements and coating flexibility for all coating lots represented in the shipment. 

o The epoxy powder certifications shall be for the powder lot numbers for all coating lots represented in the shipment.

• The signed mill test reports/certification shall also include a statement indicating the steel meets the requirements of IM 107, Group 1, Buy America.
• Each epoxy coated bundle shall have a tag showing the heat number, mill, coater’s name and the date the coating was applied.

· Certification of compliance shall include a statement indicating materials in shipment are certified to be in compliance with:

Applicable Iowa DOT IMs, Standard Plans, and Specifications

Applicable AASHTO and/or ASTM requirements

All Buy America Group 2 requirements as described in IM 107.

The statement shall be signed by a designated, responsible company representative.

A copy of these documents is required for each shipment to a project and shall be provided to the Project Engineer and the District Materials Office responsible for project administration or warehouse stock monitoring.

ACCEPTANCE

Acceptance of epoxy-coated steel reinforcement will be based on complying verification test samples and as follows:

a. Black reinforcing steel originates from an approved manufacturer of steel reinforcement. Approved manufacturers of reinforcing steel are listed in IM 451 Appendix D.

b. Epoxy coating has been applied by an approved epoxy coater as listed in Appendix A of this IM.

c. Steel reinforcement is supplied through approved suppliers/fabricators listed in Appendix B of IM 451.

d. Approved epoxy powders and patching compounds are listed in Appendix B of this IM.

VERIFICATION SAMPLING & TESTING

The location of the sample within a reinforcement bar shall be at least 3 ft. from the ends of the bar.

For each project, Personnel from the District Materials Office shall secure a random field verification sample 6 ft. of any size reinforcement bar in the project. For pavements, one random dowel bar and one tie bar sample per project per year shall be secured.

Two additional samples of the same size shall be secured if the first sample indicates non-compliance. Non-compliance may be considered a cause for rejection. If a bar size in a shipment is rejected, a similar sampling procedure shall be applied to the remaining bar sizes in the shipment.