Table 1:
Comparison of Standard Epoxy Coating Application Specifications

Steel

Bars shall be free of contaminants

Bars shall be free of contaminants.

Note- bars with sharp edges/ rollovers should not be coated

Bars shall be free of contaminants.

Note- bars with sharp edges/ rollovers should not be coated

Certifications

Upon request, furnish written certification to purchaser that identifies batch, manufacture date & meets requirements of spec

Furnish written certification to purchaser that identifies batch, manufacture date & meets requirements of Annex A1

Furnish written certification to purchaser that identifies batch, manufacture date & meets requirements of Annex A1

Powder Storage

none

Stored in temperature controlled environment

Stored in temperature controlled environment

Surface Preparation

Near white per SSPC-SP10 and SSPC-Vis 1

Near white per SSPC-SP10

Near white per SSPC-SP10

Average Blast Profile

One third of coating thickness

1.5 to 4.0 mils

1.5 to 4.0 mils

Use of Profilometer

Not specified

Recommended

Recommended

Contamination

Not specified

Air Knives required.

Clean salt-contaminated bars by acid washing or other suitable method

Air Knives required.

Salt-contaminated bars should be cleaned by acid washing or other suitable method

Pretreatment

Not addressed

Permitted

Permitted

Cleaning/
Coating Interval

No more than 8 hr.

No more than 3 hr.

No more than 3 hr.

Temperature

Shall be controlled as recommended by the manufacturer to assure a workmanlike finish

Measured prior to coating with crayons or infrared at least once every 30 min.

Measured prior to coating with crayons or infrared at least once every 30 min.

 Use of both infrared and crayons is recommended

Application

Electrostatic spray

Electrostatic spray or other suitable

Electrostatic spray or other suitable

Thickness

90% measurements-7 to 12 mils;

single measurement < 5 mils cause for rejection

Measurement = average of 3 readings; minimum of 5 measurements per side

Use correction factor for gage calibration

90% measurements-7 to 12 mils;

single measurement < 5 mils cause for rejection

Measurement = average of 3 readings; minimum of 5 measurements per side

Test a minimum of 2 bars of each size every 4 production hours

90% measurements-7 to 12 mils;

single measurement < 5 mils cause for rejection

Measurement = average of 3 readings; minimum of 5 measurements per side

Test a minimum of 2 bars of straight section and 2 bars of bent section of each size every production hour

Coating Continuity

No more than average of 2 per ft.

No more than average of 1 per ft.

No more than average of 1 per ft.

Coating Flexibility
(Bend Test)

Temperature: 68 to 85 degrees F

Bend: For No. 3 -- 6: 120 degrees @6-in pin; For Nos. 8--11: 120E @8d; For Nos. 14&18: 120 degrees @17-in. & 23-in pins respectively

Time: For all bar sizes, time to complete test =90 seconds

Frequency: may be specified by purchaser

Test Temperature: 68 to 86 degrees F

Bend: For No. 3 -- 11: 180 degrees @8d; For Nos. 14 &18: 90 degrees @. 10d;

Time: For No. 3 -- 6: 15 seconds; For Nos. 7--18: =45 seconds

Frequency: Test a minimum of 1 bar every 4 production hours

Test Temperature: 68 to 86 degrees F

Pin Diameter: For No. 3 -- 11: 8d; For Nos. 14 & 18: 10d;

Degree of Bend: For Nos. 3-5= 9 deg.; for Nos. 6-18 = 6 deg.

Time: 5 seconds

Frequency: Test a minimum of 1 bar every 4 production hours

Coating Adhesion

Cathodic Disbondment test not specified; bend test used (see above)

Cathodic Disbondment test on one bar every 8 hrs.

Cathodic Disbondment test on two bars every 8 hrs.; one straight bar section, one bent section

Retest

If coating flexibility test fail-take 2 retests, both of which must pass

If coating thickness or flexibility test fail-take 2 retests, both of which must pass

If coating thickness or flexibility test fail-take 2 retests, both of which must pass

Damage

Maximum area of patched damage shall not exceed 5% of surface area

Maximum amount of repaired damaged shall not exceed 1% of surface area in a given foot of bar

Maximum amount of repaired damaged shall not exceed 1% of surface area in a given foot of bar

Total area covered by patch material shall not exceed 2%

Repair

Repair all visible damage; Minimum thickness = 7 mils

Repair all visible damage; Minimum thickness = 7 mils

Repair all visible damage; Minimum thickness = 10 mils

Storage

Store off the ground on protective cribbing

Cover if stored outdoors for more than 2 months

Store off the ground on protective cribbing

Cover if stored outdoors for more than 2 months

Store off the ground on protective cribbing