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ANNEXES
(Mandatory Information)
A1.1 Powder Coatings submitted to the testing agency. The fingerprint and generic
A1.1.1 This annex covers qualification requirements for description shall become an integral part of the qualification
barrier organic coatings for protecting steel reinforcing bars test report.
from corrosion. A1.2.2 A sample of patching material conforming to Annex
A1.1.2 The powder coating shall be of organic composition A2 shall be submitted to the testing agency. The product name
except for the pigment which may be inorganic if used. and a description of the patching material shall be given in the
test report.
A1.2 Test Materials
A1.2.1 A 0.5-kg [1-lb] sample of the powder coating with A1.2.3 Test Specimens:
its generic description and fingerprint (including the method A1.2.3.1 The following specimens shall be submitted as a
such as infrared spectroscopy or thermal analysis) shall be minimum for test:
A2. REQUIREMENTS FOR PATCHING MATERIAL USED TO REPAIR ORGANIC COATINGS FOR STEEL REINFORCING
BARS
A2.1 Scope Fig. A1.2. Films selected for testing shall be carefully handled
A2.1.1 This annex covers qualification requirements for and examined for any defects prior to installation in the cell.
patching materials that are used to repair barrier organic The cell shall consist of two glass compartments separated by
coatings such as epoxy coatings. a coating film sandwiched between two glass plates, each
having a centered 25-mm [1-in.] hole. One compartment shall
A2.2 Coating Patching Material contain 175 mL [5.3 oz] of 3M NaCl and the other 115 mL [3.5
oz] of distilled water. The activity of chloride ions passing
A2.2.1 The coating patching material shall be of organic
through the film shall be measured using a specific ion meter
composition except for the pigment and fillers which may be
equipped with a chloride electrode and a double junction
inorganic if used.
electrode. Activity measurements shall be converted into con-
A2.2.2 A minimum of 0.95 L [1 qt] of patching material, centration values of mole per L [M] with a conversion diagram,
compatible with the coating and inert in concrete, shall be constructed by plotting measured chloride ion activities versus
submitted to the testing agency. The material shall be feasible known chloride ion concentrations. The accumulative concen-
for repairing damaged epoxy coating. The product name and a tration of chloride ions permeating through the film shall be
description of the patching material shall be given in the test less than 1 × 10-4 M.
report. A complete list of powder coating materials (product A2.4.2 Salt Spray Resistance—The resistance of the patch-
names and manufacturers), for which the patching material has ing material to a hot, wet corrosive environment shall be
been approved for use, shall be provided and included in the evaluated in accordance with Practice B117. Three coated 75
qualification test report. by 150 mm [3 by 6 in.] by 3 mm [1⁄8 in.] flat panels, with
A2.3 Test Specimens intentional defects repaired with the patching material, shall be
exposed to 35 6 2° C [95 6 3.6° F] salt spray comprised of
A2.3.1 The following test specimens shall be submitted as a 5 % NaCI by mass dissolved in distilled water for 400 6 10 h.
minimum for test: Each intentional defect shall be an area of 12 by 25 mm [1⁄2 by
A2.3.1.1 Four free films of coating patching material with a 1 in.] removed from the center of one side of the coated panel
thickness within 625 µm [61 mil] of the patching material using a grinding wheel or other suitable method. Dust and
manufacturer’s minimum recommended patching material loose material shall be removed from the intentional defect site
coating application thickness. with a clean cloth after the coating’s removal. The patching
A2.3.1.2 Six 75 by 150 mm [3 by 6 in.] by 3 mm [1⁄8 in.] flat material shall be prepared for application in accordance with
panels that have been blast-cleaned and coated on both sides the written instructions of the patching material manufacturer.
with 175 to 300 µm [7 to 12 mils] of epoxy powder coating in The patching material shall be applied with a new paint brush
accordance with the powder coating manufacturer’s written to the intentional defect to form a patched area of 25 by 37 mm
instructions. The hanger marks on the panels shall be sealed [1 by 1.5 in.] fully covering the intentional defect. The coated
with silicone or other suitable sealant. panel shall be lying flat on a table during the patching material
A2.3.2 A description of the sample preparation process for application and shall remain in such a position until the coating
the free films and flat panel samples (for example, the number has cured according to the manufacturer’s instructions. The
of coats of patching material applied to the intentional coating patching operation and the patched panels shall be maintained
defect to achieve the minimum required coating thickness), at a temperature of 24 6 2°C [75 6 3.6°F]. The patched area
used in this prequalification evaluation shall be provided in the coating thickness shall be within 625 µm [61 mil] of the
test report. The patching material manufacturer shall specify patching material manufacturer’s minimum recommended
the minimum patching material coating application thickness patching material coating application thickness. The patched
to be used. In addition, the patching material manufacturer panels shall be allowed to cure for a minimum of three days
shall specify the method of metal surface preparation and the before placement in the salt spray apparatus. The patched area
procedures for application of the patching material. These coating thickness shall be measured and reported. Upon
procedures shall be followed by the testing agency to prepare examination after completion of the test, the patched areas on
the coated metal specimens for test and shall be listed in the each of the three coated panels shall not be observed to have
qualification test report. formed blisters nor have developed areas of rust from holes in
the patch itself or from the patching material interface with the
A2.4 Patching Material Requirements coated panel.
A2.4.1 Chloride Permeability—The chloride permeability A2.4.3 Chemical Resistance—The ability of the patching
characteristics of the patching material shall be measured on material to resist blistering and corrosion in a solution that
two test films and a control film at 24 6 2°C [75 6 3.6°F] for simulates concrete pore solution shall be evaluated in accor-
45 days. The permeability cells shall be of the type shown in dance with Test Method G20. Three coated 75 by 150 mm [3
APPENDIX
(Nonmandatory Information)
X1.1 This specification is a product standard. Requirements for any cast-in-place concrete construction project. Standard
for fusion-bonded epoxy coated steel reinforcing bars from the Specifications ACI 301 includes provisions for epoxy-coated
point of shipment to the job-site and subsequent practices at the steel reinforcing bars.
job-site are not delineated in this product standard.
X1.3 The project specifications should prescribe require-
X1.2 The American Concrete Institute has published ments for the coated steel reinforcing bars from the point of
“Specifications for Structural Concrete (ACI 301).” Standard shipment to the job-site and subsequent practices at the
Specifications ACI 301 is intended to be used in its entirety in job-site. In the absence of these requirements in the project
the project specifications. An architect-engineer may cite specifications, the following guidelines for job-site practices
Standard Specifications ACI 301 in the project specifications are recommended:
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