MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 1 of 14

Contract xxx/xx Document 04/10136 Issue 24/10/12

SPECIFICATION 822
STEEL REINFORCEMENT
Copyright MAIN ROADS Western Australia


MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 2 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12


SPECIFICATION 822
STEEL REINFORCEMENT
REVISION REGISTER
Date Clause
Number
Description of Revision Authorised
By
24 Oct 12 822.06 Inclusion of ACRS
Certification
A/SDSE
11 J une 10 Whole
document
Complete review no
change
A/SDSE
1 Aug 06 Whole
document
Complete revision of Issue
1.3 to new format
MCP














MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 3 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

CONTENTS

Clause Page No

GENERAL ........................................................................................................................ 4
822.01 SCOPE ......................................................................................................... 4
822.02 REFERENCES ............................................................................................. 4
822.03 CLEAR COVER REQUIREMENT ................................................................ 4
822.04 822.05 NOT USED...................................................................................... 4
PRODUCTS AND MATERIALS ...................................................................................... 4
822.06 STANDARDS ................................................................................................ 4
822.07 BENDING AND CUTTING ............................................................................ 5
822.08 STORAGE .................................................................................................... 6
822.09 CLEANING ................................................................................................... 6
822.10 MECHANICAL SPLICES .............................................................................. 6
822.11 822.25 NOT USED...................................................................................... 6
OPERATIONS .................................................................................................................. 6
822.26 FIXING .......................................................................................................... 6
822.27 WELDING ..................................................................................................... 7
822.28 LAP SPLICES ............................................................................................... 7
822.29 TOLERANCES FOR FIXING ........................................................................ 7
822.30 822.70 NOT USED.................................................................................... 11
AS BUILT AND HANDOVER REQUIREMENTS ........................................................... 11
822.71 822.90 NOT USED.................................................................................... 11
CONTRACT SPECIFIC REQUIREMENTS .................................................................... 11
822.91 822.99 NOT USED.................................................................................... 11



MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 4 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

SPECIFICATION 822
STEEL REINFORCEMENT

GENERAL

822.01 SCOPE

1. The work under this specification consists of the scheduling,
supply, delivery and fixing of steel reinforcement to be cast into
concrete.

822.02 REFERENCES

1. Australian Standards, MAIN ROADS Western Australia
Standards and MAIN ROADS Western Australia Test Methods are
referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA
123). For convenience, the full titles are given below:

Australian/New Zealand Standards

AS/NZS 1554.3 Structural Steel Welding Welding of Reinforcing
Steel

AS/NZS 4671 Steel Reinforcing Materials
822.03 CLEAR COVER REQUIREMENT

1. The minimum cover measured from the surface of the
concrete to the face of any reinforcing steel shall be as shown on the
Drawings.

822.04 822.05 NOT USED

PRODUCTS AND MATERIALS

822.06 STANDARDS

1. Reinforcement used in the Works shall comply with the
Australian Standards listed in Table 822.1.
2. Manufacturers and processors of steel reinforcing materials
must hold a valid certificate of approval issued by the
Australian Certification Authority for Reinforcing Steels Ltd
(ACRS).



MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 5 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

TABLE 822.1 REINFORCEMENT USED IN WORKS
Reinforcement Specification
Grade 500N Hot Rolled Deformed Steel
Reinforcing Bars for Concrete
AS/NZS 4671
Reinforcing Wire AS/NZS 4671
Reinforcing Fabric/Welded Mesh Grade 500L AS/NZS 4671


822.07 BENDING AND CUTTING

1. The Contractor shall prepare reinforcement bending
schedules from the Drawings.
Schedule
2. Reinforcement shall be accurately cut and bent to the
dimensions and shapes shown on the Drawings. All bars shall be bent
in accordance with Table 822.2 unless otherwise detailed on the
Drawings. Pin diameters for bends shall be in accordance with Table
822.3 and hook and cog allowances in accordance with Table 822.4.

3. Reinforcement partially embedded in concrete shall not be
field bent unless it is allowed for on the Drawings. Where field bending
is required it shall be carried out by the application of a constant force
using a pin diameter as specified in Table 822.3.

4. Heating of reinforcement shall not be permitted except where
indicated on the Drawings and shall then only be carried out in
accordance with the following requirements:

a) The steel shall be heated uniformly for at least 100 mm
each side of the portion to be bent.

b) For grade 500 steel the heating shall be controlled such
that the temperature does not exceed 450C and shall
be measured with temperature indicating crayons. Steel
heated beyond 450C shall be rejected.

c) Grade 250N steel may be heated to a dull cherry red.
d) Heated bars shall not be cooled rapidly by quenching or
any other means.

e) All heating shall be carried out in the presence of the
Superintendent.

5. Prior to heating any reinforcement the Contractor shall
supply to the Superintendent full details of the proposed heating
procedure.
HOLD
POINT

MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 6 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12


822.08 STORAGE

1. Reinforcing steel shall be stored above ground level and
shall be protected from damage and deterioration.

822.09 CLEANING

1. Reinforcement placed in the Works shall be clean and free
from all loose rust and mill-scale and all dirt and grease and all other
foreign substances. After being placed in position all reinforcement shall
be maintained in a clean condition until it is embedded in the concrete.

822.10 MECHANICAL SPLICES

1. Mechanical splices shall be used only where shown on the
Drawings. Alternative mechanical splices to the ones shown on the
Drawings may be used provided that they are capable of developing at
least 125% of the specified yield strength of the bar and meet the
dimensional and clearance requirements shown on the Drawings.

822.11 822.25 NOT USED

OPERATIONS

822.26 FIXING

1. Reinforcing steel shall be accurately placed in the positions
shown on the Drawings in accordance with the tolerances given in Table
822.5.

2. The reinforcement shall be secured in position so that it shall
not be displaced during the placement of concrete and the Contractor
shall ensure that there is no disturbance of the reinforcement in concrete
that has already been placed.

3. Reinforcing bars intended to be in contact at points where
they cross shall be bound together with 1.6mm annealed soft iron tie
wire. Stirrups shall be wired securely to the bars they are intended to
restrain so as to form an effective reinforcement cage.

4. All reinforcing steel supported off formwork where the
resulting concrete surface will be exposed, shall be supported on special
purpose bar spacers approved by the Superintendent.

5. Reinforcement not supported off formwork or where the
resulting concrete surface will be concealed may alternatively be
supported on concrete blocks or plastic chairs approved by the
Superintendent.


MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 7 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

822.27 WELDING

1. Welding or tack welding of reinforcement shall not be
permitted except where indicated on the Drawings and shall then comply
with the following requirements:

a) Welding shall be in accordance with AS/NZS 1554.3.
b) Welding of grade 500 steel will not be permitted within
75mm of a bend.

c) Welds shall not be broken out.
2. Prior to welding any reinforcement, the Contractor shall
supply to the Superintendent documentation showing that welders
to be employed on the Works are suitably qualified and that the
qualification of welding procedures has been verified by testing in
accordance with the requirements of AS/NZS 1554.3
HOLD
POINT
822.28 LAP SPLICES

1. Reinforcement shall only be spliced at locations shown on
the Drawings.

2. The minimum length of lap shall be as indicated on the
Drawings.

3. Welded steel wire fabric shall be lapped as detailed on the
Drawings and where not detailed shall overlap by at least one complete
mesh on all sides such that the end cross wire of one sheet overlaps
with the second end wire of the adjacent sheet. Loose bars shall not be
used in conjunction with fabric reinforcement except where shown on the
Drawings. Loose small pieces of fabric shall only be used where they
are essential for fitting into small confined parts of the Works.

822.29 TOLERANCES FOR FIXING

1. The tolerances for fixing of reinforcement are given in Table
822.5.


MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 8 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

1 2 3 4
Nominal length Nominal size Tolerance
Condition or Dimension or Diameter of (mm)
L (mm) Bar (mm)
On each overall dimension, or on the overall dimension
of each straight portion, or on that offset dimension,
controlled by concrete cover at both ends for bars
other than fitments. Up to 600 Up to 20 +0 -20
Up to 600 Over 20 +0 -30
Over 600 Up to 20 +0 -40
Over 600 Over 20 +0 -50
Up to 600 Up to 20 -0 +20
Up to 600 Over 20 -0 +30
Over 600 Up to 20 -0 +40
Over 600 Over 20 -0 +50
On that overall dimension controlled by cover at
both ends, for fitments (ties, stirrups, helices,
hoops, and the like) only.
Up to 600 Up to 12 +0 -10
Up to 600 16 to 20 +0 -15
Over 600 Up to 20 +0 -20
Any Length Over 20 +0 -30
Up to 600 Up to 12 - 0 +10
Up to 600 16 to 20 -0 +15
Over 600 Up to 20 -0 +20
Any Length Over 20 -0 +30
On the overall dimension, or on the overall dimension
of each straight portion, or on that offset dimension,
controlled by concrete cover at one end only or at
neither end.
Any length Any size -0 +50
including
allowances
for laps.
On the overall offset dimension of a cranked column bar Any offset Up to 20 -0 +10
On the deviation from square measured in relation to Any bar 24 and over

the end 300mm of the sawn or machined end of a length.

a straight bar intended for use as an end bearing


TABLE 822.2 FABRICATION









MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 9 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12


Case Material Diameter
a) Reinforcement, other than that specified
in items (b), (c) or (d) below.
All deformed bars
Fabric
5 d
b
3 d
b

b) Fitments Wire and fabric
Grade 230R bars
All deformed bars
3 d
b
3 d
b
4 d
b

c) Reinforcement in which the bend is
intended to be subsequently
straightened or re-bent
Size 16 mm or less
Size 20 mm or 24
mm
Size 28 mm or
greater
4 d
b
5 d
b
6 d
b

d) Reinforcement which is epoxy-coated or
galvanised, either before or after
bending
Size 16 mm or less
Size 20 mm or
greater
5 d
b
8 d
b

NOTE: d
b
is the diameter of the bar being bent.

TABLE 822.3 PIN DIAMETERS FOR BENDS

Bar Diam (mm) 6 10 12 16 20 24 28 32 36
Length Allowance (mm)
(assumed pin diameter, 5
d
b
)
120 140 160 180 220 260 300 340 380

TABLE 822.4 HOOK AND COG ALLOWANCES FOR BENT BARS AND FITMENTS



MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 10 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

1 2 3
Case Condition Tolerance(mm)
1 Where concrete cover to the 1a. At the end of
reinforcement is the controlling reinforcement.
factor. Tolerances on Dimensions 'C'
-0 +30
1b.
At the outside edge of
Tolerances on Dimension 'T'
reinforcement or fitment. -0 +20 when compression face
-0 +10 when tension face
Tolerances on Dimension 'B'
-0 +10 when tension face
-0 +20 when compression face
2 Where cover is not 2a. At the end of reinforcement. Tolerance on Dimension 'L'.
controlling. 50
(see Case 1)
2b. At the outside edge of Tolerances on Dimension 'E'
reinforcement including 10
fitments.
3 Lateral spacing of 3a. Beam or column type member.
reinforcement.
Tolerance on Dimension 'S'
+0.1S or 15mm
whichever is greater.
3b. Slab or wall type member.
4 Bars in corners, crossing bars Bars to be placed in configuration
starter bars, etc. shown on the Drawings.
Tolerances on location of an
individual bar 15mm unless
otherwise limited by cover
requirements of case 1 above.
The tolerances given above are the maximum permissable, but it should be noted that
in some circumstances, where reinforcement is fabricated to maximum tolerance,
they may not be fully available.
NOTE: This table should be read in conjuction with Table 822.2


TABLE 822.5 TOLERANCES ON FIXING REINFORCEMENT







MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 11 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12



822.30 822.70 NOT USED

AS BUILT AND HANDOVER REQUIREMENTS

822.71 822.90 NOT USED

CONTRACT SPECIFIC REQUIREMENTS

822.91 822.99 NOT USED




MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 12 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12


SPECIFICATION 822 GUIDANCE NOTES
DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE
All edits to downloaded TDP documents shall be tracked (most word processing
software allows this to be done automatically). Deletions shall be struck through e.g.
example. Insertions shall be in italics e.g. example. If all information relating to a clause
is deleted then the clause number should be retained and the words "NOT USED"
should be inserted.

The proposed documents with tracked changes shall be submitted to the Project
Manager for review, prior to printing the final batch of documents. When this final
printing is carried out, the tracked changes option is to be turned off.
The Custodian of this specification is the Structures Design and Standards Engineer.

NO GUIDANCE NOTES OR CONTRACT SPECIFIC REQUIREMENTS AVAILABLE AT
THIS TIME.

MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 13 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE

The following clauses are to be placed under the CONTRACT SPECIFIC
REQUIREMENTS as required.









MAIN ROADS Western Australia Specification 822 Steel Reinforcement Page 14 of 14
Contract xxx/xx Document 04/10136 Issue 24/10/12

SPECIFICATION AMENDMENT CHECKLIST

Specification Name: No: 822 Revision No: _______Title: STEEL
REINFORCEMENT

Project Manager: Name: _______________Signature: ____________Date:______

Checked By: Name: _______________Signature: _______________Date:______

Contract No: ___________Contract Description: _______________________________

ITEM DESCRIPTION SIGN
OFF
Note: All changes/amendments must be shown in Tracked Change mode until
approved.
1. Project Manager has reviewed Specification and identified
Additions and Amendments.

2. CONTRACT SPECIFIC REQUIREMENTS addressed?
Contract specific materials/products/clauses added? (Refer
Specification Guidance Notes for guidance).

3. Any unlisted Materials/Products proposed and approved by the
Project Manager? if Yes provide details at 15.

4. Standard Clauses amended? MUST SEEK approval from
MCP.

5. Clause deletions shown as NOT USED.
6. Appropriate INSPECTION & TESTING parameters included in
Spec 201 (Test Methods, Minimum Testing Frequencies
verified).

7. ANNEXURES completed (Refer Specification Guidance Notes).
8. HANDOVER and AS BUILT requirements addressed.
9. Main Roads QS has approved changes to SMM.
10. Project Manager certifies completed Specification reflects intent
of the design.

11. Completed Specification independent verification arranged by
Project Manager

12. Project Managers review completed.
13. SPECIFICATION GUIDANCE NOTES deleted.
14. TABLE OF CONTENTS updated.
15 Supporting information prepared and submitted to Project
Manager.

Further action necessary:


Signed: (Project Manager) Date: _______________