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Frequently Asked Questions (FAQ) About Hot-Dip Galvanized Reinforcing Bars
Frequently Asked Questions (FAQ) About Hot-Dip Galvanized Reinforcing Bars
ETN-M-10-16
Frequently Asked Questions
(FAQ) About Hot-Dip Galvanized
Technical Note Reinforcing Bars
Introduction [#10 through #36, #43, #57, and #64]. Met-
ric sizes are 10M, 15M, 20M, 25M, 30M,
CRSI routinely receives inquiries concern- 35M, 45M, and 55M.
ing various aspects of reinforcing bars, and
reinforced concrete design and construc- Galvanized reinforcing steel bars are gen-
tion. This Technical Note presents a col- erally available in standard lengths up to 40
lection of typical questions that are asked feet. Lengths longer than 40 feet may be
regarding hot-dip galvanized steel reinforc- available through special arrangement, de-
ing bars. Most of these questions come pendent on local galvanizing capacity. De-
from licensed design professionals (LDPs), signers and engineers should not specify
namely engineers, architects, field person- galvanized bars longer than 40 feet without
nel (inspectors, code enforcement officers, verifying whether the desired length can be
contractors), and state DOTs. suitably galvanized.
In general during hot-dip galvanizing, the maximum As a general guide, if there is any concern about the
temperature reached in the zinc bath is about 840°F effect of galvanizing on the properties of the steel con-
[450°C]. This temperature is not sufficiently high to cerned, a simple retest of the steel after galvanizing may
cause any noticeable heat treatment effect in reinforc- be appropriate.
ing steel. Reinforcement that has been cold-worked
might soften very slightly during hot-dipping but this has Why are chromates used to treat galvanized
not been identified as being of any concern. There are reinforcement and is this treatment necessary?
sometimes concerns about the effects of cold working When freshly galvanized steel comes in contact with
and potential development of strain age embrittlement wet cement, a reaction occurs at the zinc surface, which
when fabricated bars are subsequently galvanized. If passivates the coating by the precipitation of a protec-
tighter bend radii than those in ASTM A767/A767M are tive layer of calcium hydroxyzincate. A by-product of this
necessary, the standard calls for stress relieving of the reaction is the liberation of hydrogen, which may reduce
material prior to galvanizing. the bond capacity of the reinforcement with the sur-
rounding concrete. To prevent the hydrogen evolution
High strength steels with yield strengths approaching
from occurring, chromates are used to passivate the
145 ksi [1000 MPa] are regularly galvanized without any
reinforcing steel surface prior to embedment into wet
significant effect on their properties. One concern with
concrete. ASTM A767/A767M requires galvanized rein-
these types of steels is embrittlement, which may occur
forcement to be chromate passivated immediately after
when they are exposed to heat and hydrogen, an effect
galvanizing.
known as hydrogen embrittlement.
2 Frequently Asked Questions (FAQ) about Hot-Dip Galvanized Reinforcing Bars [ETN M-10-16]
The most common method of chromate treatment is Engineering Design Issues
to quench passivate the freshly galvanized steel in wa-
ter containing a low concentration of sodium dichromate In designing reinforced concrete are there differ-
(usually less than 0.5%). This treatment produces a pro- ent requirements when galvanized bar is to be
tective film on the surface that provides initial protection used; or more specifically, are there any spe-
to the zinc and gives it time to develop its own protective cial design guidelines for galvanized reinforc-
oxide film. ing bars in ACI 318 or AASHTO Bridge Design
It is to be noted that such treatment is only temporary Specifications?
as the chromate film, which is slightly soluble in water, There are no special requirements for the design of
can be washed off the surface. If the exposure condi- galvanized reinforced concrete beyond those that apply
tions are aggressive, e.g., coastal, the chromate film to conventional reinforced concrete. In particular, splice
may be lost in a few weeks. and lap lengths are the same as for black steel bar, as are
bond and load transfer considerations. The best practice
How long have galvanized steels been used in
when utilizing galvanized reinforcement is to use appro-
concrete? priately designed and placed concrete as would normally
The first use of zinc-coated steel in concrete dates to be used in general reinforced concrete construction.
about 1908, and the first regular use in the USA as a rein-
forcing material was in the 1930s. An early example was in What are the yield strengths of galvanized rein-
the construction of concrete water tanks where galvanized forcing bars?
wire was used to prestress the tank wall. Bars meeting ASTM A615/A615M are available in yield
strength grades of 40, 60, 75, 80 and 100 ksi [280, 420,
How does hot-dip galvanizing protect reinforcing
520, 550 and 690 MPa]. Bars meeting ASTM A706/
steel? A706M are available in yield strength grades of 60 and
Hot-dip galvanizing provides both barrier and sacrificial 80 ksi [420 and 550 MPa]. Bars meeting ASTM 996/
protection to steel. A996M are not as readily available as the other two steel
Because it is first a barrier, a galvanized coating on rein- types, but these are available in yield strength grades of
forcement isolates the steel from the cement matrix. Also, 40, 50, and 60 [280, 350 and 420 MPa].
as zinc cathodically protects iron, corrosion of the underly-
ing steel will only commence once the coating has been Can galvanized reinforcing bars be mixed with
consumed. Because the corrosion rate of zinc in concrete is other reinforcing steel bars?
usually lower than black bar, this extra time delays corrosion When galvanized reinforcing bars are used in concrete,
of the steel. Since zinc coatings are metallurgically bonded they should not be directly in contact with uncoated
to the base steel, under-film corrosion does not occur. steel reinforcing bars, copper or other dissimilar met-
als. If required, polyethylene spacers or similar dielectric
Availability and Cost tapes can be used to provide insulation between galva-
What is the availability of galvanized steel rein- nized bars and other dissimilar metals.
forcing bars?
Can the concrete cover to galvanized bars be
Galvanizing of reinforcing bars is available throughout
reduced?
North America.
The AASHTO LRFD Bridge Design Specifications per-
What are the lead times necessary to order and mit a reduction in concrete cover when galvanized rein-
get the bars fabricated? forcing steel is used, while the ACI 318 Building Code
Purchasers are encouraged to inquire with a local fabrica- Requirements for Structural Concrete does not permit a
tor about lead times for specific grades, sizes, and quanti- reduction in concrete cover when galvanized reinforcing
ties early in the project schedule. steel is used.
What is the cost of galvanized steel reinforcing Is development length changed when using
bars compared with normal “black” bars or other galvanized reinforcing steel?
corrosion-resistant bars on the market?
No. The development length used in design is the same
As a trade organization, CRSI does not comment on costs, as that for uncoated bars.
and costs will vary by location and with the price of uncoat-
ed reinforcing steel. Manufacturers or suppliers should be Concrete tightly adheres to galvanized reinforcement
contacted for current pricing information. that may provide adhesion better than that achieved with
uncoated steel due to the formation of a surface layer of
calcium hydroxyzincate.
4 Frequently Asked Questions (FAQ) about Hot-Dip Galvanized Reinforcing Bars [ETN M-10-16]
calls for welds to be made on steel that is free of zinc ad- What is “white rust” and does it harm galva-
jacent to the weld to prevent strength reduction through nized reinforcement?
zinc inclusion in the weld itself. The zinc coating should be
removed at least one inch from either side of the intended Zinc is a relatively active metal, and like aluminium,
weld zone and on all sides of the bar by grinding or equiva- relies on the formation of an oxide film (which later con-
lent means. Once the weld is completed, the zinc coating verts to a carbonate film) on its surface for its long-term
in the area of the weld should be repaired using proce- durability. Once this film is formed, the rate of corrosion
dures described in ASTM A780/A780M. Fumes from of zinc coatings is very slow, typically less than 2 mi-
welding galvanized reinforcing bars may contain zinc, iron crons per year in atmospheric environments. When steel
and other potentially noxious substances, and proper ven- is freshly galvanized, there is no significant oxide film on
tilation that minimizes worker exposure to fumes is es- its surface and in conditions where water is present and
sential. The specific precautions are found in ANSI/AWS oxygen is deficient, such as between contacting surfac-
Z49.1 Safety in Welding, Cutting and Allied Processes. es where water can penetrate, water reacts with zinc,
Tack welding is not permitted. resulting in the formation of a heavy surface layer of zinc
hydroxide and zinc oxide, known as white rust.
After completion of the welding on galvanized bars, the Though not particularly damaging, and with very little
damaged areas should be repaired using patch materials effect on the corrosion resistance of the coating, it does
meeting ASTM A767/A767M. detract from the appearance. There is no evidence to
suggest that small quantities of white rust on the sur-
What is the appropriate method of repairing or face of galvanized reinforcement have any effect on the
touching up galvanized reinforcing bars? adhesion of concrete to the bar or the long-term corro-
In-place galvanized steel reinforcing bars should be in- sion resistance provided by the coating.
spected for coating damage prior to placing concrete.
Where damage exists, it should be repaired with a zinc-
References
rich formulation complying with Specification A780/ American Association of State Highway and Trans-
A780M. portation Officials - AASHTO (2014), AASHTO LRFD
Areas of uncoated steel should be coated prior to con- Bridge Design Specifications, U.S. Customary Units, 7th
crete placement. When the extent of coating damage Edition, American Association of State Highway Officials,
exceeds 1% of the surface area of the coated steel rein- Washington, D.C., 2160 pp.
forcing bar in any one-foot [0.3-metre] length, the coated American Concrete Institute - ACI Committee 315
bar should be rejected. When the extent of the damage (1999), Details and Detailing of Concrete Reinforcing,
does not exceed 1% of the surface area in any one- American Concrete Institute, Farmington Hills, Michigan,
foot [0.3-metre] length, all damaged coating discern- 44 pp.
ible to a person with normal or corrected vision should
American Concrete Institute - ACI Committee 318
be repaired with a zinc-rich formulation complying with
(2014), Building Code Requirements for Structural Con-
Specification A780/A780M.
crete (ACI 318-14) and Commentary (ACI 318R-14),
Repair material should be applied in strict accordance American Concrete Institute, Farmington Hills, Michigan,
with the written instructions furnished by the repair ma- 520 pp.
terial manufacturer. Prior to application of the repair ma-
ASTM International – ASTM A123 (2015), Standard
terial, rust should be removed from the damaged areas
Specification for Zinc (Hot-Dip Galvanized) Coatings on
by suitable means. The repair material should be allowed
Iron and Steel Products, ASTM A123/A123M-15, ASTM
to cure before placing concrete over the coated steel
International, West Conshohocken, PA, 8 pp.
reinforcing bars.
ASTM International – ASTM A615 (2015), Standard
What is the effect of uncoated areas on the Specification for Deformed and Plain Carbon-Steel Bars
bars’ performance for Concrete Reinforcement, ASTM A615/A615M – 15,
If the coating has been locally dissolved, or mechanical- ASTM International, West Conshohocken, PA, 8 pp.
ly damaged such that the underlying steel is exposed, the ASTM International – ASTM A706 (2015), Standard
remaining zinc on the adjacent surface becomes anodic Specification for Deformed and Plain Low-Alloy Steel
and provides sacrificial cathodic protection to the exposed Bars for Concrete Reinforcement, ASTM A706/A706M –
steel and corrosion is further delayed. The extent of cover- 15, ASTM International, West Conshohocken, PA, 7 pp.
age afforded by this reaction depends on many factors but
ASTM International – ASTM A767 (2015), Standard
primarily the conductivity of the nearby environment, i.e.
Specification for Zinc-Coated (Galvanized) Steel Bars for
the concrete pore solution. Experimental data has shown
Concrete Reinforcement, ASTM A767/A767M-15, ASTM
that in sand-cement mortars with a water to cement ratio
International, West Conshohocken, PA, 5 pp.
of about 0.4, exposed steel to a distance of about 0.3 in.
[8 mm] is protected by the presence of the zinc.
Contributors: The principal author on this publication is Gary W. Dallin with review by members of
the CRSI Durability Committee.
Keywords: corrosion, couplers galvanized steel, handling reinforcing bars, storage, zinc-coated.
Reference: Concrete Reinforcing Steel Institute - CRSI (2016), “Frequently Asked Questions (FAQ) 933 North Plum Grove Rd.
About Hot-Dip Galvanized Reinforcing Bars”, CRSI Technical Note ETN-M-10-16, Schaumburg, IL, 6 pp. Schaumburg, IL 60173-4758
Historical: None. New Technical Note. p. 847-517-1200 • f. 847-517-1206
www.crsi.org
Note: This publication is intended for the use of professionals competent to evaluate the significance and limitations of Regional Offices Nationwide
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A Service of the Concrete Reinforcing Steel Institute
Institute reports the foregoing material as a matter of information and, therefore, disclaims any and all responsibility for ap-
plication of the stated principles or for the accuracy of the sources other than material developed by the Institute. ©2016 This publication, or any part thereof, may not be
reproduced without the expressed written consent of CRSI.