California Test 686

STATE OF CALIFORNIA—BUSINESS, TRANSPORTATION AND HOUSING AGENCY December 2002

DEPARTMENT OF TRANSPORTATION
DIVISION OF ENGINEERING SERVICES
Transportation Laboratory
5900 Folsom Boulevard
Sacramento, California 95819-4612

METHOD FOR EVALUATING BEND TEST RESULTS OF

FUSION-BONDED EPOXY COATINGS ON
ASTM DESIGNATION: A 934/A 934M STEEL REINFORCEMENT

CAUTION: Prior to handling test materials, performing equipment setups, and/or

conducting this method, testers are required to read "SAFETY AND HEALTH"
in Section F of this method. It is the responsibility of the user of this method
to consult and use departmental safety and health practices and determine
the applicability of regulatory limitations before any testing is performed.

A. OVERVIEW which is applied in the form of a

The procedures outlined in this
document provide a method to visually
evaluate the results of bend tests of
reinforcement coated with fusion-
bonded epoxy coatings applied to
prefabricated steel reinforcing bars in
accordance with ASTM Designation: A
934/A 934M. The purpose of the bend
test for these coatings is to provide a
qualitative measure of coating cure
and/or failure of coating due to
backside contamination through a
visual assessment. Other quantitative
methods of assessing coating cure and
backside contamination are available
and required per ASTM Standards;
however, successful passing of the bend
test is also required.
powder onto a clean, heated metallic
substrate that fuses to the metal to
form a continuous barrier coating.
2. Prefabricated bars – steel reinforcing
bars that are cut to specified lengths
and bent to the required shape prior
to coating with fusion-bonded epoxy
coatings.
3. Normal or corrected vision – 20/20
vision or better, as verified by a
vision acuity test.
4. Standard laboratory lighting – Level
of lighting considered typical for
inspection work; within the range
of 750 to 2000 Lux (1 Lux =
1 Lumen/m2).

Information contained in this test 5. 10X Magnifying lens – Lens capable

method supersedes information of producing a magnification of 10
contained in sub-Section 9.3.2 of times that seen with normal or
“Coating Flexibility” in ASTM corrected vision.
Designation: A 934/A 934M.
6. Break – a separation in a coating
B. TERMINOLOGY that extends from the exterior
surface of the coating to or near the
1. Fusion-bonded epoxy coating – a bar surface. Since the break may
product containing pigments, be extremely narrow, the underlying
thermosetting epoxy resins, cross- metal may not always be visible with
linking agents, and other additives, 20/20 vision or 10X magnification.

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to be circled with a permanent

7. Crack – a break in the epoxy coating marker of a contrasting color to that
experienced after bending through of the epoxy coating. Care should
which the underlying metal is be taken not to mark over the actual
visible. crack or discontinuity.

8. Coating discontinuity – a break in 7. If needed, confirm the presence of

the coating experienced after exposed underlying metal at cracks
bending through which the using a 10X-magnification device.
underlying metal cannot be seen by
the unaided eye or with a 10X- D. NOTES
magnification device.
1. The intent of this test method is to
9. Isolated coating crack or establish a relatively quick visual
discontinuity – an isolated break in test method for assessing the
the coating experienced after the coating cure and integrity of non-
bend test attributed to a burr on the bendable fusion-bonded epoxy
surface of the steel reinforcing bar. coatings. The procedure for
identifying cracks is intended to be
10. Stretching and discoloration – performed by a person with normal
Identifiable changes in color of the or corrected vision. A 10X
fusion-bonded epoxy coating that magnifying lens should only be used
may occur after bending. to confirm the presence of visible
Discoloration is an indication of underlying metal at a crack, and
stretching. Note that discoloration of should not be used to search for
epoxy coating under applied stress cracks.
does not indicate a separation of the
coating. 2. Holiday detection devices should not
be used to identify or confirm the
C. TEST PROCEDURE presence of coating cracks or
discontinuities.
1. Figure 1 provides a decision tree for
the test procedure. 3. Cracks and coating discontinuities
in improperly cured fusion-bonded
2. Coated reinforcement test bar epoxy-coatings will usually appear
samples should be dry and free of at multiple locations along the
contamination prior to testing. outside bend radius of the test bar.

3. Bend coated reinforcement test bar 4. Three or more cracks on the outside
sample in accordance with the bend radius of the test bar
requirements of sub-Section 9.3.1 of constitute nonconforming material.
ASTM A934/A934M.
5. Three or more coating
4. Evaluate the bend area under discontinuities on the outside
standard laboratory lighting using radius of the test bar constitute
normal or corrected vision as nonconforming material.
identified in this test method.
6. Breaks, cracks or coating
5. Note the presence of cracks and/or discontinuities within the coating at
coating discontinuities in the contact points of mandrel devices
coating on the outside radius of the used to produce the bend in a bar
test bar bend area using normal or for the bend test should be
corrected vision. disregarded.

6. Cracks and coating discontinuities 7. Stretching and/or discoloration of

as described in this test method are the epoxy coating within the outside

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radius of the test bar after bending

does not constitute nonconforming
material.

8. Figures 2 through 5 may be used to

assist in identifying and classifying
coating breaks.

E. REPORTING RESULTS

On an appropriate form (Figure 6 is an

example) record the number of coating
breaks and identify them as either
cracks or coating discontinuities on the
appropriate test form. Also note
whether or not stretching or
discoloration was seen on the bar
sample after testing.

On an appropriate form (Figure 7 is an

example) report results for the test bar
as complying or not complying with
specifications on the test report form.
Results for the test bar sample should
be documented with the coating
company’s name, material lot number,
appropriate ASTM coating specification,
inspector’s name, date sampled and
date tested.

F. SAFETY AND HEALTH

Prior to handling, testing or disposing of

any waste materials, testers are
required to read: Part A (Section 5.0),
Part B (Sections: 5.0, 6.0 and 10.0) and
Part C (Section 1.0) of Caltrans
Laboratory Safety Manual. Users of
this method do so at their own risk.

REFERENCE
California Standard Specifications
ASTM Designation: A 934/A 934M

End of Text
(California Test 686 contains 10 pages)

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Bend Test Sample

Bend test is No Yes

complete.
Break in coating?
Material meets
bend requirement.

No Yes Break is
Break is identified
Is underlying identified
as a coating
metal visible? as a crack
discontinuity

No Are there three Yes

or more coating
discontinuities?

BBend
en d ttest
es t com-
is Bend test is
cplete.
om p l eMaterial
t e. complete.
Mmeets
a t er i bend
a l m eet s Material does not
brequirements
en d r eq u i r em en t . meet bend
requirement.

No Yes
Are there three
or more cracks?

Bend test is Bend test is

complete. complete.
Material meets Material does not
bend requirement. meet bend
requirement.

Figure 1. Decision tree for evaluating bend test results.

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Figure 2 Breaks in the coating after bending that have been identified as coating
discontinuities. The discontinuities have a repeated pattern that extends over
the entire bend radius. The test bar has failed the bend requirements of this
test method.

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Figure 3 Test bar showing two of three breaks in the epoxy coating at the outer bend
radius of a test bar. The breaks appear to be cracks that expose the underlying
metal. Exposed underlying metal can be confirmed, if needed, by viewing with a
10X-magnification device.

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Figure 4 10X magnification of the test sample from the photograph shown in Figure 3.
The magnified view shows that the coating is separated from the bar surface and
the underlying metal is exposed. The two other breaks on the test bar sample
were also identified as cracks. Since the test bar incurred three cracks after
bending, it has failed the bend requirements of this test method.

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Figure 5 Test sample showing discoloration in coating after the bend test. This type of
discoloration is due to stretching of the coating during bending and is typical.
Discoloration of the coating after bending does not constitute a failure of the
bend test.

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Figure 6. Test Form for Recording Bend Test Results

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Figure 7. Sample Testing Report

TL-101 No.

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