Deck Replacement - Use of Extra Coating Thickness Epoxy-Coated Bars

The results of this study were implemented in the form of design recommendations for bond of epoxy-coated bars with thicker coatings up to 18 mils. The scope of the work included evaluation of AASHTO LRFD (2004) and ACI 318 design recommendations for the development and splice length of extra epoxy-coating thickness reinforcing bars in normal-weight concrete bridge decks and a proposed monitoring plan for a generic concrete bridge deck in Indiana where epoxy-coated bars with thicker coatings might be employed. The use of the current provisions for development and splice length of epoxy-coated bars in tension in both the AASHTO LRFD (2004) and ACL 318-05 is supported by the test findings of the experimental program consisting of 20 beam splice tests of No. 5 and No. 9 bars with the coating thickness up to 21 mils in normal-weight concrete. However, since the ACI 318-05 specifications consider the critical parameters of cover and transverse reinforcement and the AASHTO LRFD (2004) do not, the authors encourage the Indiana Department of Transportation to use the ACI 318 provisions in the design of development and splice length of bars with coating thickness up to 18 mils. INDOT 700 Committee is implementing the results of this study through a change in the specifications for epoxy-coated bar thickness. A monitoring plan for a future concrete bridge deck to be built in Indiana using coated bars with thickness of coating up to 18 mils is also included as part of this report.