SECTION 5 REINFORCEMENT

SECTION 5 - REINFORCEMENT

5.1 - GALVANIZED REINFORCEMENT

Galvanized Reinforcement shall be used in all locations. Galvanizing provides corrosion resistance

by adding a sacrificial coating of zinc to the reinforcement. The zinc is consumed by the movement

of electrons and, therefore, does not expand to the same magnitude that bare metal expands as it

corrodes. Therefore, concrete cracking and spalling due to reinforcement corrosion is delayed until

the zinc coating has been fully consumed. The advantages of using galvanized reinforcement as

compared to epoxy-coated reinforcement include:

A. Better bond strength between the concrete and reinforcement.

B. Shorter lap lengths.

C. The galvanized coating is more durable during handling and installation requiring less touch-

up and repair of the galvanized coating.

D. The galvanized coating is chemically bonded to the bar, whereas an epoxy coating relies

upon adhesion.

E. The coating coverage requirements are more stringent.

F. Comparable unit cost.

G. Comparable service life.

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The following guidelines shall apply for galvanized reinforcement:

A. The lap lengths and imbedment lengths for galvanized reinforcement are the same as for

uncoated reinforcement.

B. The maximum out-to-out dimension of any galvanized rebar should not exceed 12.0 m after

bending.

C. Galvanized reinforcement may be used in conjunction with existing uncoated or epoxy-

coated reinforcement when necessary.

5.2 - REINFORCEMENT GRADE

All new and replacement bar reinforcement shall be ASTM A 615M-03a, GRADE 420. (Billet steel

only). Bars shall be galvanized and fabricated in accordance with ASTM A 767M-00b, and meet the

requirements of NYSDOT Material Specification 709-11.

5.3 - SPACING

The spacing between parallel bars shall not be more than 450 mm or 1.5 times the wall or slab

thickness.

For cast-in-place concrete, the clear distance between parallel bars in a layer shall not be less than

1.5 times the nominal bar diameter, 1.5 times the maximum size of the coarse aggregate, or 40 mm,

whichever is greater.

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For precast concrete (manufactured under plant control conditions), the clear distance between

parallel bars in a layer shall not be less than 1 bar diameter, 1.33 times the maximum size of the

coarse aggregate, or 25 mm, whichever is greater.

When reinforcement is placed in beams and girders in two or more layers, the bars in the upper

layers shall be placed directly above those in the bottom layer wherever possible.

In concrete slabs, the reinforcing bars in separate mats shall be offset so that they are not directly

over each other.

The clear distance between bars shall also apply to the clear distance between a splice and an

adjacent splice or bar.

For structural elements designed by the load factor design method, the flexural reinforcement shall

be distributed in accordance with AASHTO Section 8.16.8.4.

5.4 - COVER

The concrete cover required between reinforcing steel and the outside face of a structural unit is

dependent on the type of structure and outside environment. The following list indicates the

minimum required cover for most circumstances.

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Traditionally Reinforced Deck Slabs on Beams or Stringers:

Top of slab with separate wearing surface................................................................. 50 mm

Top of slab with integral wearing surface ................................................................. 65 mm

Bottom of slab............................................................................................................ 35 mm

Isotropically Reinforced Deck Slabs on Beams or Stringers:

Top of slab with separate wearing surface................................................................. 65 mm

Top of slab with integral wearing surface ................................................................. 65 mm

Bottom of slab............................................................................................................ 35 mm

Beams..................................................................................................................................... 50 mm

Walls and piers above footings (including those adjacent to water) ..................................... 75 mm

Footings (including unformed bottom)................................................................................ 75 mm*

Face of culverts in contact with earth .................................................................................... 50 mm

Bottom of bottom slab of culvert ........................................................................................... 75 mm

Bottom of top slab of culverts and low rise rigid frames....................................................... 40 mm

Arches, intrados and extrados................................................................................................ 50 mm

Precast and cast-in-place piles ............................................................................................... 50 mm

Precast piles exposed to sea water ......................................................................................... 75 mm

All concrete surfaces exposed to sea water ......................................................................... 100 mm

Top of sidewalk slabs ............................................................................................................ 75 mm

Pedestal (Top) ........................................................................................................................ 75 mm

Pedestal (Sides)...................................................................................................................... 75 mm

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*- When footings are placed on piles, the cover is normally measured from the top of

the pile. However, if spacing allows, the designer may place the bottom mat of

reinforcement the cover distance above the bottom of footing.

5.5 - MAXIMUM BAR LENGTHS

Specified bar lengths are limited due to fabrication and coating constraints and design

considerations. This allows for the most economical price by increasing the number of competing

bidders. Most reinforcing bar plants in the United States produce bars in a standard length of 18.3

meters. However, most galvanizing tanks are limited to 12.0 meters long. Therefore, the maximum

length of a straight galvanized bar should not exceed 12.0 m. Where bars can be shop bent prior to

galvanizing, the 12.0 m length limitation applies to the out to out dimension of the bent bar. Where

shop bending is not allowed (typically only on projects in NY Division), all bar bending is done in

the field after galvanization. In this case, the length limitation would apply to the overall length of

the bar.

5.6 - SPLICING REINFORCEMENT

5.6.1 - GENERAL

During the design process, consideration must be given to splicing reinforcing bars. This is

necessary due to limited bar lengths (12.0 m max.) and construction practices (stage construction).

Splice lengths and locations shall be shown on the contract plans. The Thruway Authority generally

accepts three types of splices: Lap Splices, Mechanical Splices and Welded Splices. See Detail 5.6.

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Of the three, lap splices are the most economical, and so, should be used whenever possible. Lap

splices shall be wired together the full length of the splice. Allowable mechanical splices are limited

to the "screw" type. These are used at construction joints where space is limited. When splicing a

galvanized bar to an existing epoxy-coated bar, the epoxy-coated bar splice length shall be used.

Mechanical splices are typically used at bulkheads of construction joints on staged construction

projects. Space between the stages is usually limited. A bar that needs to be continuous between

stages will end in Stage 1 with a female flanged connection welded to the end of the reinforcing bar

and attached to the bulkhead. During Stage 2, a short bar of adequate lap length and a threaded end

is screwed into the Stage 1 female connector. The appropriate Stage 2 bar is then lapped to the short

bar. See Detail 5.6.1. Welded splicing of reinforcement shall be limited to spiral reinforcement in

pier columns & CIP piles, and replacement reinforcement in concrete repair areas where the

appropriate lap length of the existing bar cannot be exposed. See the Thruway Standard Detail

Sheets for Class D and Deck Concrete Repair Details. Reinforcement shall not be tack welded. All

welding of reinforcing bars shall be in accordance with the New York State Steel Construction

Manual.

5.6.2 - SPLICING REINFORCEMENT IN DECKS

Splices of reinforcement in decks should be in compression zones wherever possible.

Splices of transverse bars in the bottom mat should be directly over the beams or stringers.

Transverse bars in the bottom mat should be spliced between the beams or stringers.

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When stage construction is required, splicing of the transverse bars shall be within a closure pour

between adjacent beams. A closure pour should never be directly over a beam. Where room is

limited between stages, mechanical bar splices should be used as described in Subsection 5.6.1.

On simple span bridges, the placement of splices on longitudinal bars is not critical due to the deck

being in longitudinal compression for its full length. Splices in both top and bottom mats should be

placed to maximize bar lengths (12.0 m maximum) and staggered where possible.

On continuous and rigid frame bridges, portions of the deck will be in tension due to superimposed

dead loads and live loading. These areas must be identified during design and indicated on the

contract plans. Splicing of longitudinal bars should be excluded from these areas. The longitudinal

reinforcement in tension zones should have its ends anchored into adjacent compression zones

whenever possible. In the case of a continuous structure where the tension zone over the pier is at or

greater than 12.0 meters, the bars should be spliced away from the pier, closer to the dead load point

of contraflexure. At no time should the longitudinal reinforcement be spliced directly over the pier.

5.6.3 - SPLICING REINFORCEMENT IN WALL STEMS

Splices of vertical bars shall be made in accordance with the seismic criteria found in AASHTO

Section 3.21.

Splices between main vertical wall reinforcement and the reinforcement emerging from the footing

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shall be made in the wall stem. The steel emerging from the footing shall extend up into the wall

stem the full development length of the bar. The wall stem steel shall be lapped to the steel from the

footing. The lap length required for these splices shall be that required for the smaller bar. In some

cases, it may be practical to eliminate splices by extending the bars emerging from the footing to the

top of wall stem.

Horizontal reinforcing steel in wingwalls, retaining walls and conventional abutment stems are for

temperature only. However, the splices of these bars shall be of the tension type, recognizing that

soil loads will be translated along the length of the structure. Horizontal reinforcing in abutment

stems of integral abutment bridges and rigid frame bridges is tension steel designed for the soil

loading between piles and the confinement of the core concrete and vertical reinforcing steel during

seismic activity. See AASHTO Division 1A Sections 6.6 &7.6. All splices shall be the tension type

and staggered where possible.

5.6.4 - SPLICING REINFORCEMENT IN PIER STEMS AND COLUMNS

Splices of vertical bars shall be made in accordance with the seismic criteria found in AASHTO

Section 3.21. When a plinth is provided at the base of a column or stem, the design vertical

reinforcement for the column or stem shall extend through the plinth and into the footing its full

development length. Lap splices in the design vertical reinforcement shall be provided (if necessary)

within the center half of the column's height. Splices should be staggered wherever possible. In some

cases, it may be practical to eliminate splices by extending the bars emerging from the footing to the

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top of the stem or column. Vertical design reinforcement shall extend into the cap beam of column

piers for the full imbedment length, bent or hooked as required.

Horizontal reinforcing in pier stems is tension steel designed for the confinement of the core

concrete and vertical reinforcing steel during seismic activity. See AASHTO Division 1A Sections

6.6 &7.6. All splices shall be the tension type and staggered where possible.

5.7 - MARKING OF BARS

Bars shall be marked consecutively, beginning with the number one (1), through each structural unit.

A structural unit, such as an abutment, includes all concrete subdivisions (abutment footing,

abutment stem, wingwall footing, wingwall stem, etc.) which together comprise the entire unit. In

the bar list, structural units are to be identified by a general heading, e.g., South Abutment.

Appropriate subheadings shall also precede the listing of bars in each subdivision, e.g., Southeast

Wingwall stem. When a subdivision is still further divided into more than one pour, the listing of

bars in each pour shall also be preceded by appropriate identification, e.g., Abutment Stem, Pour 1.

A typical bar marking might be 29AG20. This bar mark represents a #29 size galvanized bar in the

abutment that is the 20th different type to be placed in the abutment. The letter G following the

structural unit letter (A) in the bar mark indicates that the bar is galvanized.

When a bar is imbedded in two or more subdivisions (such as a dowel), the subheading under which

the bar is listed shall be the subdivision in which the bar is initially imbedded.

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The same bar mark may be reused throughout the same structure unit provided the bar is identical

each time it is used.

In applying the sequential bar number where two or more structure units are involved, such as two or

more similar abutments, piers, spans etc., it is desirable that the same bar number be applied to bars

in similar locations in the structure unit. The fact that two bars lying in different structure units may

have the same bar number but have different lengths, or they may have the same length but have

different sizes or different shapes, or any combination of these factors will not be confusing to the

fabricator due to our practice of providing a separate bar list, properly titled, for each structure unit.

For varying length bars, give minimum, maximum and average lengths of bars. Give number of sets

of bars even if the number of sets is one. All the bars within a set will have the same bar mark. If the

length varies by less than 100 mm between the minimum and maximum length of the set, rather than

vary the bar length, use the length of the shortest bar. Deviations from the above system of marking

bars must have the approval of the Director, Structures Design (DSD).

5.8 - BAR BENDING DIAGRAMS & STANDARD HOOKS

In order to conform to practices used in the reinforcing bar industry, the Authority has adopted the

bar bending diagrams and standard hook dimensions found in the Manual of Standard Practice (first

printing) of the Concrete Reinforcing Steel Institute (C.R.S.I). These diagrams, as well as several

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additional diagrams commonly required in our structures, are shown on the following pages. The

drawing of bar bending diagrams should be inserted into the contract plans. These diagrams shall be

used in all in-house and Consultant designs prepared for the Authority. All dimensions on these

diagrams are measured from out-to-out of bar bends. Any additional bar configurations required for

a project shall be added manually to the contract plans. As noted in the C.R.S.I. Manual, the stirrup

(Type "S") and tie bars (Type "T") have tighter fabrication tolerances than other bars. Since this will

increase costs, the Designer should choose these bar types with care. Lengths for each leg of the bars

should be rounded to the nearest 10 mm. The direction of rounding shall be such that minimum

cover and minimum lap lengths are maintained. The average length of a set of bars shall also be

rounded to the nearest 10 mm.

5.9 - DRILLING AND GROUTING REINFORCING BARS

There are two items for drilling and grouting reinforcing bars, Item 586.01M and 16586.20XXYYM.

Item 16586.20XXYYM has testing requirements for pullout strength, and should be used for any

primary tensile reinforcement (e.g., vertical reinforcement for the rear face of abutment stems, etc.).

Item 586.01M should be used for secondary, shear or compression reinforcement (e.g., vertical

reinforcement in the front face of abutment stems, pedestal reinforcement, horizontal reinforcement

between stages in an abutment stem, etc.).

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STANDARD HOOKS

BAR 180 HOOKS 90 HOOKS

SIZE
D A or G J A or G

#10 60 130 80 150

#13 80 150 100 200

#16 100 180 130 250

#19 120 200 150 300

#22 180 280 220 380

#25 210 330 250 430

#29 240 380 300 480

#32 275 430 340 560

#36 305 480 380 610

#43 465 690 550 790

#57 610 910 720 1040

Note: All dimensions are rounded to nearest "10" millimeters.

SEISMIC STIRRUPS AND TIE HOOKS

BAR 90 HOOK 135 HOOK

D
SIZE
A or G A or G H

#10 60 100 130 90

#13 80 130 160 110

#16 100 160 200 140

#19 120 300 280 160

#22 180 380 320 200

#25 210 430 370 230

Note: All dimensions are rounded to nearest "10" millimeters.

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5.10 - MINIMUM REINFORCEMENT REQUIREMENTS

The minimum reinforcement requirements for various structural elements are presented in the

following subsections.

5.10.1 - FOOTINGS - ABUTMENTS AND PIERS

The minimum top reinforcement for individual pier footings shall not be less than 50% of the design

bottom reinforcement, but not less than #19 bars at 300 mm centers (both directions). The minimum

top reinforcement for continuous pier footings shall be # 19 bars at 300 mm centers (both

directions).

The minimum transverse and longitudinal reinforcement required for bottom reinforcement in

continuous pier footings and for top and bottom reinforcement in abutment and wingwall footings

shall be #16 bars at 450 mm centers (both directions). In all cases, these bars shall be either hooked

at both ends, or a hooked bar shall be lapped to both ends of these bars. In abutment spread footings,

additional transverse reinforcement may be required by design (generally in the bottom of toe and

top of heel). See Subsection 5.12 for suggested placement details. In spread footings of piers having

columns, additional transverse and longitudinal reinforcement may be required by design. In pile-

supported footings of abutments and piers, additional transverse and longitudinal reinforcement may

be required by design.

All reinforcing steel extending into stems or columns shall be bent or hooked in the footing. Vertical

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stirrups (Type N18), #13s at a maximum 1.2 m (both directions) grid, shall be provided to connect

the top and bottom mats of pier, abutment and wingwall footings. The footing stirrups shall have

135 hooks on both ends.

5.10.2 - WALLS, STEMS AND SOLID PIERS

The vertical reinforcement for the tensile face of walls, stems and solid piers shall be that required

by design, but in no case less than #16 bars at 300 mm centers. Vertical reinforcement for the

compression face of walls and stems shall be a minimum of #16's at 300 mm centers. Horizontal

stirrups, #13's at 300 mm centers (both directions), shall be provided to connect the front and rear

mats of reinforcement in walls, stems, solid piers, and plinths. The wall stirrups shall have a 135

hook on one end and a 90 hook at the other end. Stirrups shall be placed alternately so that a 135

hook is next to a 90 hook.

The minimum horizontal reinforcement for walls, stems and solid piers shall be #16 bars at 450 mm

centers. This minimum amount of reinforcing is included to help prevent shrinkage cracking of the

concrete. More reinforcement may be required by design. Cases of this condition include but are not

limited to horizontal wall flexure and pier stem vertical steel containment requirements.

The tops of pier and abutment stem bridge seats shall have #25 bars at 150 mm centers

longitudinally full length with hooked ends. The front and back of the bridge seats shall be tied

together with "U"-shaped #25 bars at 300 mm centers.

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5.10.3 - COLUMNS

When a plinth is provided at the base of a column, the design vertical reinforcement for the column

shall extend through the plinth and into the footing.

Vertical reinforcement shall consist of at least four (4) #16 bars or larger, placed at the corners of

rectangular sections or equally spaced for circular sections.

Vertical design reinforcement shall extend into the cap beam for the full imbedment length (bend or

hook as required). Continuous #16 ties shall surround the vertical reinforcement in rectangular

columns. For circular columns, the ties shall be a minimum #10 spiral.

The spacing of ties shall not exceed the least dimension of the column or 300 mm. Additional ties

shall be provide at 150 mm centers at the top and bottom of the column over a length equal to the

greater of:

A. The maximum dimension of the column.

B. 17% of the column height.

C. 450 mm.

The ties shall continue for a distance equal to 50% the maximum column dimension but not less than

375 mm from the face of the column connection into the adjoining cap beam or footing.

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5.10.4 - STIRRUPS AND TIES

All stirrups and ties shall be provided with 135 hooks unless otherwise noted. The minimum cover

requirements of Subsection 5.4 apply to the outermost rebar. Stirrups and ties shall be placed to

encompass all other reinforcement. For minimum spacing requirements see Subsection 5.2.

5.11 - REINFORCEMENT DEVELOPMENT LENGTHS AND LAP LENGTHS

The basic development length and lap lengths provided in tables A through F are based on the data

provided in Subsections 8.25 through 8.32 of AASHTO.

The assumed rebar yield strength (fy) is 420 MPa, and the assumed compressive strength of the

concrete (fc) is 21 MPa. The classes of tension lap splices are defined in Table 5.11.

TENSION LAP SPLICE CLASS

Percent of As Spliced Within

Required Lap Length
As Provided/As Required 50% 75% 100%
2 Class A Class A Class B
<2 Class B Class C Class C
TABLE 5.11

As an example, if the area of steel required by the design moments is AsR = 100mm2/lm and the area

provided is AsP = 150mm2, AsP/AsR = 1.50. If 50% of the bars are spliced in the same line then a

Class B splice would be required.

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Top reinforcement is defined as any horizontal reinforcement with more than 300 mm of fresh

concrete cast below it. When the area of steel provided is greater than that required to develop the

ultimate moment capacity of the section, the basic development length and splice lengths indicated

in the tables may be reduced by the ratio: AsR/ AsP.

The development length and lap lengths for reinforcement encompassed by spirals, assumes the

spiral reinforcement has at least a 100 mm pitch.

The modification factor for cover and spacing is 1.0 if either the cover (in line with the spacing) is

less than 75 mm, or the spacing is less than 150 mm. If the cover is at least 75 mm and the spacing is

at least 150 mm, the modification factor is 0.8.

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5.12 - SUGGESTED REINFORCEMENT PLACEMENT DETAILS

Refer to details in Section 3 Deck Systems, and Section 4 Substructures, for examples of various

placement schemes.

5.12.1 - DESIGN REINFORCEMENT - SPREAD FOOTINGS

5.12.1.1 - TOE STEEL

Tensile reinforcement is required in the bottom of the toe. The length of the bar from the front face

of the wall to the front end of the bar (dimension "B1") must be equal to or greater than the

minimum development length for tensile reinforcement other than top bars as shown in the tables

(see Detail 5.12.1). The remaining length of bar, "B2", should extend to the footing heel as shown.

All bottom tensile reinforcement shall be hooked 180 at both ends.

5.12.1.2 - HEEL STEEL

Tensile reinforcement is required in the top of the heel. The length of the bar from the rear face of

the wall to the rear end of the bar (dimension "T1") must be equal to or greater than the minimum

development length for tensile reinforcement ("top bars"). The remaining length of the bar, "T2",

should extend to the footing toe as shown. All top tensile reinforcement shall be hooked 180 at both

ends.

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5.12.2 - DOWEL PLACEMENT FOOTING INTO STEM

Hook all footing dowels 90 or 180. Place dowels so that a minimum of three inches of clear cover

is provided (see Detail 5.12.2). Typically, the hook end is placed on top of the bottom matt of footing

reinforcing. The required lap lengths for compression and tension laps are shown in the tables. When

all the wall tensile reinforcement is lapped to the footing dowels at the base of the wall, the lap

length must satisfy the requirements of a class "C" splice. Splice locations in pier stems shall be as

required in AASHTO Division 1A Subsection 7.6.2(F).

5.12.3 - POSSIBLE DOWEL COMBINATIONS

It may sometimes be desirable to bend some of the transverse bottom steel up into the wall and use it

as the dowel to the tensile reinforcement in the stem. One reason for doing this is if the footing is too

shallow to develop the strength of the standard doweled hook.

The designer should keep in mind that bottom transverse reinforcement should extend to the back of

the footing at a maximum spacing of 300 mm. See Details 5.12.3.a and 5.12.3.b. The designer should

also remember that the lap length at the base of the stem is controlled by the size of the vertical stem

steel, not the size of the dowel.

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5.12.4 - COMPRESSION BARS

Use lap lengths for compression bars for the following situations:

1. Longitudinal (distribution/temperature) reinforcement in footings.

2. Longitudinal (distribution/temperature) reinforcement in structural slabs

(compression zones, not in tension zones over piers).

3. Longitudinal reinforcement in the top of bridge seats and the top of solid piers.

4. Lapping U-shaped stirrups in sidewalks, backwalls, wingwalls and retaining walls.

See Detail 5.12.4.

For situations that include compressive and tensile zones, such as pier caps on multi-column piers

and decks on multi-span continuous bridges, the designer shall identify all stress reversal zones.

Tensile reinforcement shall be anchored beyond this zone into the compression zone using lap

lengths for tensile reinforcement. Compressive (distribution/temperature) reinforcement shall be

anchored to the tensile reinforcement. The lap length will be that required for the tensile

reinforcement.

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