Standard Specification for Corrosion-Resistant Coated Dowel Bars AASHTO Designation: M 254-77 (2000) We 4. -~* SCOPE ~ 44 This specification covers the materials, manufacture, and installation of coated dowel bars to be used where corrosion resistant performance is essential and may be used in lieu of stainless or other approved noncorrosive metals. The dowel shall consist of a steel core covered by an organic coating 1.2. The coated dowels shall be one of the two following types: Type A—The coating material develops sufficiently low bond strength with concrete that a bond breaker is not required. Type B—The coating material develops bond strength with concrete such that a bond breaker is required, The type of bond breaker used shall be as recommended by the coating manufacturer. 1.3. The values stated in SI units are to be regarded as the standard. 2) "REFERENCED DOCUMENTS — 24 AASHTO Standards: = M25SM/M 255, Steel Bars, Carbon, Hot-Wrought, Special Quality, Mechanical Properties = 1253, Coated Dowel Bars * 22 ASTM Standards: = A633, Normalized High-Strength Low-Alloy Structural Steel Plates = G12, Nondestructive Measurements of Film Thickness of Pipeline Coatings of Stee! 23, Other References: = FHWA-RD-74-18, “Nonmetallic Coating for Concrete Reinforcing Bars,” 1974 3. GENERAL REQUIREMENTS atte The coated dowels shall resist corrosion and degradation caused by roadway deicing materials and normal highway debris. 3.2 The coating shall develop low-bond strengths with portland cement concrete without a bond breaker, if Type A, or with the proper bond breaker if Type B. 33 The coating shall resist wear due to abrasion resulting from pavement expansion and contraction. 34 The coating used over the steel core shall be continuous on the lateral surface of the dowel TS-4g M 254-1 AASHTO3.5, 3.6. 37. 3.8. Test procedures as stated herein and in T 253 shall apply to both Type A and Type B dowels. In the event there is any change in material composition or geometries of the joint support system, any or all parts of the dowels and assembly are subject to retesting. The frequency of qualification testing will be determined by the purchasing agency. The processing facilities of the manufacturer and the fabricator shall be open to inspection by the agent of the purchaser at all times during the manufacturing and fabricating of the material A minimum of 24 dowel bars shall be made available for testing. Of these, 2 maximum of six bars may be in a basket assembly. 44 42. 5.1. 5.2. 5.3. 54. MATERIALS The core material shall be of steel meeting the requirements of ASTM A 633/A 633M or M 255M/M 255 as specified by the purchasing agency. The coating material shall be of organic composition with the exception of the pigment which may ‘oF may not be present and which may have an inorganic composition. Note 1—The Type B coating material may be one of ie types recommended in Report No. FHWA-RD-74-18 or other types approved by the purchasing agency. DIMENSIONS ‘The core metal shall be 31.8-mm (1"ve-in.) diameter or as specified by the purchasing, agency. The nonabraded thickness of the Type A coating shall be 0.64 £ 0.13 mm (25 £$ mils). The nonabraded thickness of the Type B coating shall be 0.18 + 0.05 mm (7 2 mils), Coating thickness shal! be determined according °o ASTM G 12 or by sttipping the coating irom the bar. The dowels shall be supplied to lengths and in support assemblies or baskets as specified by the purchasing agency. 61 6.2. PHYSICAL REQUIREMENTS ‘The free ends of the dowels shall be saw cut and free of burrs and projections. Dowel coatings shall be free from contamination, perforations, cracks, and holidays (pinholes not Nisually discemible). Check for holidays shall be performed by the electric resistance process A 67.5-volt holiday detector shall be used, as recommended by the manufacturer of the test equipment, for the determination of holidays. Any damage which results from welding or mechanical fixation to achieve a fixed-end condition Shall not extend more than 25.4 mm (I in.) in from the weld or point of fixation Welding to achieve a fixed-end condition shall be sufficiently strong to maintain dowel alignment lunder the forces imposed by concrete placement and construction practices M 254-2 AASHTO.