Reinforcing MEADOW BURKE TECHNICAL MANUAL
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Reinforcing Technical Manual www.MeadowBurke.com Table of Contents Reinforcing Bar Supports (Metal & Platic) Metal Bar Supports......................................................................................................... 5-8 Slab Bolster.................................................................................................................................6 Slab Bolster - Upper....................................................................................................................6 Beam Bolster...............................................................................................................................6 Beam Bolster - Upper..................................................................................................................6 Continuous High Chair.................................................................................................................7 Reinforcing Bar Supports Continuous High Chair - Upper....................................................................................................7 Continuous High Chair - Metal Deck............................................................................................7 High Chair - Metal Deck..............................................................................................................7 High Chair...................................................................................................................................7 Bar Chair.................................................................................................................................... 8 Joist Chair...................................................................................................................................8 Joist Chair - Upper..................................................................................................................... 8 Continuous Support - Zig Zag......................................................................................................8 Wire Girder - Double....................................................................................................................8 Plastic Bar Supports.................................................................................................... 9-10 Rebar Splicing Products Tuff Plus SB - Slab Bolster..........................................................................................................9 Tuff Plus SBR - Slab Bolster with Runner....................................................................................9 Tuff Chair....................................................................................................................................9 Intersectional Chair......................................................................................................................9 Mesh Chair with Base..................................................................................................................9 PC-2 Snap-On Mesh Chair.........................................................................................................10 PC-3 Snap-On Mesh Chair with Base........................................................................................10 PC-4 Snap-On Paving Chair with Base......................................................................................10 PC-5 Snap-On Bar Chair............................................................................................................10 PW-11 Plaswheel......................................................................................................................10 PW-14 Unispacer.......................................................................................................................10 BC-2, BC-4 Bar Cap..................................................................................................................10 Rebar Splicing Products Threaded Splice System...........................................................................................11-18 BT Couplers Type 1 & Type 2HS Rebar Splicing System........................................................... 12 Three-part Mechanical Connect System................................................................................... 13 Setting Bar Assemblies............................................................................................................. 14 Splice Bars............................................................................................................................... 15 Tension Splice Lap Length Data............................................................................................... 16 BT Couplers Installation............................................................................................................ 17 ZAP Screwlock & Double ZAP Screwlock.................................................................................. 18 3
Metal Reinforcing Bar Supports www.MeadowBurke.com Meadow Burke metal reinforcing bar supports can be manufactured in compliance with American Concrete Institute (ACI) ACI-SP-66, ACI-315 and ACI-315R. Quality rebar metal supports are available in the following CRSI Classification for finishes: Class 1A – Epoxy coated. Class 2 (A or B) – Manufactured with Stainless steel legs. Class 3 – Plain wire, no protection. Also available: Epoxy coated meeting AASHTO specifications. Epoxy coated with plastic dipped feet. Complete plastic coating (100% encapsulate) up to 3” heights. (not available for the Slab Bolster) Notes: Stainless steel utilized by Meadow Burke in the manufacture of rebar supports conforms to ASTM A-493 and AISI Type 430 and may display some magnetic qualities which shall not be cause for rejection. Heights available in 1/4” increments. METAL REINFORCING BAR SUPPORTS (SB) SLAB BOLSTER SLAB BOLSTER DATA Available Leg Spacing Type Length Height (c/c) SB 3/4” to 3” 5” 5’-0” To Order, Specify: quantity, type, height and finish classification. (SBR) SLAB BOLSTER – UPPER SLAB BOLSTER - UPPER DATA Available Leg Spacing Type Length Height (c/c) SBR 3/4” to 3” 5” 5’-0” To Order, Specify: quantity, type, height and finish classification. (BB) BEAM BOLSTER BEAM BOLSTER DATA Available Leg Spacing Type Length Height (c/c) BB 1” to 5” 2-1/2” 5’-0” To Order, Specify: quantity, type, height and finish classification. (BBU) BEAM BOLSTER – UPPER BEAM BOLSTER - UPPRT DATA Available Leg Spacing Type Length Height (c/c) BBU 1” to 5” 2-1/2” 5’-0” To Order, Specify: quantity, type,height and finish classification. 6
Metal Reinforcing Bar Supports www.MeadowBurke.com (CHC) CONTINUOUS HIGH CHAIR CONTINUOUS HIGH CHAIR DATA Available Leg Spacing Type Length Height (c/c) CHC 2” to 20” 7-1/2” 5’-0” To Order, Specify: quantity, type, height and finish classification. (CHCU) CONTINUOUS HIGH CHAIR – UPPER CONTINUOUS HIGH CHAIR - UPPER DATA Available Leg Spacing Type Length Height (c/c) CHCU 2” to 20” 7-1/2” 5’-0” Reinforcing Bar Supports To Order, Specify: quantity, type,height and finish classification. (CHCM) CONTINUOUS HIGH CHAIR – METAL DECK CONTINUOUS HIGH CHAIR - METAL DECK DATA Available Leg Spacing Type Length Height (c/c) Type A 1” to 5” 7-1/2” 5’-0” Type B Type B 1” to 5” Varies 5’-0” Type A To Order, Specify: quantity, name, type A or B, leg spread, height. (HCMD) HIGH CHAIR – METAL DECK HIGH CHAIR - METAL DECK DATA B Type A HHCMD Available Height Height Increments A Type A or B 2” to 15” 1/4” To Order, Specify: quantity, name, type, A, B and C C dimension. B To insure accuracy of order please include metal A Type B deck profile. C (HC) HIGH CHAIR HIGH CHAIR DATA Available Height Type Height Increments HC 2” to 40” 1/4” To Order, Specify: quantity, type, height and finish classification. (Available with metal or plastic sand plate) 7
Metal Reinforcing Bar Supports www.MeadowBurke.com (BC) BAR CHAIR (JC) JOIST CHAIR BAR CHAIR DATA JOIST CHAIR DATA Available Height Available Height Type Type Height Increments Height Increments BC 3/4” to 2” 1/4” JC 3/4” to 2” 1/4” To Order, Specify: quantity, type, To Order, Specify: quantity, type, height and finish classification. height and finish classification. (UJC) JOIST CHAIR – UPPER JOIST CHAIR - UPPER DATA Height Available Type SPAN Height UJC -1” to +3-1/2” 14” To Order, Specify: quantity, type, Span height and finish classification. (CS) CONTINUOUS SUPPORT (ZIG-ZAG) CS Continuous Support (Zig-Zag) is a steel support for horizontal wire mesh, structural fabric or reinforcing bars and an excellent spacer for vertical steel in concrete walls. The support is very stable, it will not slide or tip and has excellent load carrying capacity. It is easy to install and can be bent around voids and/or partitions. CONTINUOUS SUPPORT (ZIG-ZAG) DATA Available Height Type Length Height Increments CS 2” to 12” 1/4” 8’-0” To Order, Specify: quantity, type, height and finish classification. WIRE GIRDER – DOUBLE The Wire Girder – Double is designed to quickly and accurately position wire mesh in large slab- on-grade applications. The girder is available in heights from 3” to 9” in 1” increments and in lengths up to 40’. Optional snap-on sand plates are available for use on sandy soils to prevent the girder from turning during concrete placement. When using on a firm casting bed, the snap- on plates are not a necessity but will give better support on slabs exceeding 6” in thickness. The optional snap-on plates are field installed by simply squeezing the bottom runners of the girder inward until they slip inside the plate tabs. Release of the runners will let them slide under the tabs and be held firmly in place by the tabs. To Order Specify: quantity, type, height & length. To Order Optional Snap-On Plate, Specify: quantity and type. 8
Plastic Reinforcing Bar Supports www.MeadowBurke.com TUFF PLUS SB – SLAB BOLSTER The Tuff Plus SB is a composite slab bolster that is used to provide accurate cover for lower mats of steel reinforcement in concrete elements. Suitable for a wide range of uses, the Tuff Plus SBslab bolster can be used in Tilt-Up Concrete Construction, Precast Concrete Construction, Post Tensioned Concrete and other Cast in place applications. The Tuff Plus SB, all plastic slab bolster, may also be used as side form spacers in vertical formwork. The Tuff Plus SB slab bolster is fabricated from fiber filled gray composite material designed to blend with the concrete surface, if exposed. Top bar corrugations are placed on 1” centers to visually aid rebar placement. The Tuff Plus SB plastic slab bolster is manufactured in true 60” lengths, eliminating assembly and expedites field placement. TUFF PLUS SBR – SLAB BOLSTER with RUNNER Reinforcing Bar Supports The Tuff Plus SBR Slab Bolster with Runner, is typically used to provide accurate and efficient placement of upper mats of steel reinforcement in concrete elements. The Tuff Plus SBR is a composite slab bolster upper that can be used in Bridge, Tilt-up, Precast, Post Tension and other segments of concrete construction. The Tuff Plus SBR Slab Bolster Upper, is fabricated from fiber filled composite material. Top bar corrugations are located at 1” centers to aid in rebar placement. The Tuff Plus SBR with Runner is a direct replacement for metal slab bolster upper. X-TUFF SLAB BOLSTER X Tuff Slab Bolster is a new rebar support manufactured in the U.S. using high-performance PC/ABS plastic for best-in-class strength and durability. MB TUFF CHAIR MB Tuff Chair is engineered for strength, durability, recoverability and consistent ruggedness, and are available in a range of heights from 3/4” to 10”. (IC) INTERSECTIONAL CHAIR The IC Intersectional Chair or is designed for use at the intersection of two crossing lengths of post tensioning cable rebar to correctly position and firmly hold the two bars in place. The large support base gives added benefit when used on vapor barriers or soft fill. The chair fits 1/2” PT cable or up to #5 rebar, and is available in most heights from 1-1/2” to 7” in 1/2” increments. (MBCB) MESH BAR CHAIR WITH BASE The Mesh Bar Chair with Base (MBCB) is a light duty, composite chair with sand plate for use on soft surfaces and/or slab on grade to correctly position and hold the wire mesh securely in place. Each size chair is designed to service two mesh positioning heights. It is available in heights from 5/8” to 6”. It can be used to support up to a #5 rebar. To order any of these products, specify: quantity, type and height. 9
Plastic Reinforcing Bar Supports www.MeadowBurke.com PC-2 SNAP-ON MESH CHAIR PC-2 PC-3 PC-3 SNAP-ON MESH CHAIR WITH BASE The PC-2 and PC-3 Snap-On Mesh Chairs are economical heavy duty, four sided chairs that quickly snap onto 4 ga. to 10 ga. mesh to correctly position it in the slab. The Snap-On Mesh Chair is available in most heights from 3/4” to 3” and the PC-2 is available in heights from 3/4” to 3”. The PC-3 is available in heights fro 1-1/2” to 3”. Both Chairs will accommodate wire mesh 4 ga. to 10 ga. To Order, Specify: quantity, type and height. PC-4 SNAP-ON PAVING CHAIR WITH BASE PC-4 PC-5 PC-5 SNAP-ON BAR CHAIR The PC-4 Snap-On Paving Chair and PC-5 Snap-On Bar Chair are substantial plastic bar supports available to support reinforcing steel in various applications. The Snap-On Paving Chair for #3 to #4 rebar or #4 to #6 rebar (PC-4) is available in heights from 3/4” to 7” and the Snap-On Bar Chair for #3 to #7 rebar (PC-5) is available in heights from 3/4” to 3”. To Order, Specify: quantity, type and height. PW-11 PLASWHEEL The PW-11 Plaswheel is designed to quickly snap onto and space vertical or horizontal steel at side walls and columns. They are available to accommodate #2 through #8 rebar and provide 5/8” through 4”concrete cover. To Order, Specify: quantity, type, bar size and cover. PW-14 UNISPACER The PW-14 Unispacer is an economical spacer available in one size to provide a 1” concrete cover. It slides onto any rebar up to #14 size and permits rotation and/or movement of the rebar without risk of the spacer coming off. To Order, Specify: quantity and type. BC-2, BC-4 BAR CAP The BC-2 and BC-4 Bar Cap is available in two sizes for the purpose of protection from scrapes, cuts and torn clothing caused by protruding rebar. It is not intended for use as an impalement protector. The small size BC-2 accepts rebar sizes #3 through #8 and the larger size BC-4 accepts rebar from #9 through #14. To Order, Specify: quantity, type and rebar size. 10
Rebar Splicing Products www.MeadowBurke.com Mech Saver – Type I & II Rebar Splicing System Mechanically connect rebar sections in segmental pours Rebar Splicing Products 11
Rebar Splicing Products www.MeadowBurke.com BT Couplers Type 1 & Type 2HS Rebar Splicing System BT Couplers are a versatile and robust mechanical rebar splicing system. BT Couplers are a Type 1 & Type 2HS Rebar Splicing System used to mechanically connect rebar sections in segmental pours as an alternative to traditional dowel bars. The three-part system consists of a Splice Bar, Coupler and Setting Bar that meets the mechanical splice strength requirements of ACI-318-19 when used to splice grade 60 rebar. FEATURES • Improved performance: Exceeds ACI-318-19 Type 1 & Type 2HS splice requirements and maintains reinforcing steel continuity independent of concrete cover. • Saves time and money: Reduces costly form repairs by eliminating drilling of forms and simplifies form striping. • Available in standardized lengths (sizes #4 – #11) and configured to order. BT COUPLERS SPLICING PERFORMANCE Nominal Grade 60 Type 1 Type 2HS Bar Size Area Rebar Yield 125% Yield 90 KSI Tensile (inch2) Strength (lbs) Strength (lbs) Strength (lbs)* #4 0.20 12,000 15,000 18,000 #5 0.31 18,600 23,250 27,900 #6 0.44 26,400 33,000 39,600 #7 0.60 36,000 45,000 54,000 #8 0.79 47,400 59,250 71,100 #9 1.00 60,000 75,000 90,000 #10 1.27 76,200 95,250 114,300 #11 1.56 93,600 117,000 140,400 *ASTM A615 and A706 compliant 12
Rebar Splicing Products www.MeadowBurke.com The Three-part Mechanical Connect System STANDARD LENGTH SETTING BARS Type I Type II Rebar Grade 60 “A” Length Item Number Item Number Size Finish: Plain (inch) MBR2610424F #4 RC-61-T2 Setting Bar 24” A MBR2610448F #4 RC-61-T2 Setting Bar 48” Contact MBR2610530F #5 RC-61-T2 Setting Bar 30” L Meadow Burke MBR2610548F #5 RC-61-T2 Setting Bar 48” MBR2610636F #6 RC-61-T2 Setting Bar 36” MBR2610648F #6 RC-61-T2 Setting Bar 48” The setting bar is attached against the interior side of the formwork. Additional lengths are available for Type I & II upon request STANDARD LENGTH SPLICE BARS Type I Type II Rebar Grade 60 “C” Length Item Number Item Number Size Finish: Plain (inch) ength MBR2610424M #4 RC-61-T2 Setting Bar 24” Overall L C MBR2610448M #4 RC-61-T2 Setting Bar 48” Contact MBR2610530M #5 RC-61-T2 Setting Bar 30” Meadow Burke MBR2610548M #5 RC-61-T2 Setting Bar 48” MBR2610636M #6 RC-61-T2 Setting Bar 36” The splice bar is screwed in the setting bar after the form is MBR2610648M #6 RC-61-T2 Setting Bar 48” stripped, continuing the rebar. Additional lengths are available for Type I & II upon request TYPE I COUPLER DETAIL Rebar Splicing Products Standard Flange Rebar Couple “L” Length Diameter Weight Coupler PN# Coupler PN# Size Thread Size (inch) (inch) (lbs.) (plain finish) (plain finish) MB860501 MB860502 #4 1/2-13 UNC 1.875 0.875 0.24 L MB860651 MB860652 #5 5/8-11 UNC 2.125 1.000 0.34 MB860801 MB860802 #6 3/4-10 UNC 2.250 1.125 0.41 MB860951 MB860952 #7 7/8-9 UNC 2.625 1.250 0.57 MB861101 MB861102 #8 1-8 UNC 3.250 1.500 1.08 MB861251 MB861252 #9 1-1/8-7 UNC 3.750 1.625 1.39 MB861401 MB861402 #10 1-1/4-7 UNC 4.250 2.000 2.61 The coupler is a steel sleeve that the splice bars MB861551 MB861552 #11 1-3/8-6 UNC 4.750 2.000 2.66 thread into, providing rebar continuity. TYPE II COUPLER DETAIL Standard Flange Rebar Couple “L” Length Diameter Weight Coupler PN# Coupler PN# Size Thread Size (inch) (inch) (lbs.) (plain finish) (plain finish) MB860551 MB860552 #4 5/8-11 UNC 1.250 1.000 0.17 MB860681 MB860682 #5 3/4-10 UNC 1.625 1.125 0.25 MB860851 MB860852 #6 7/8-9 UNC 2.250 1.250 0.40 MB860981 MB860982 #7 1-8 UNC 2.500 1.500 0.70 MB861151 MB861152 #8 1-1/8-8 UN 2.750 1.625 0.88 MB861281 MB861282 #9 1-1/4-8 UN 3.000 2.000 1.70 MB861451 MB861452 #10 1-7/16-8 UN 3.250 2.125 1.84 MB861581 MB861582 #11 1-9/16-8 UN 3.625 2.250 2.19 BT Couplers are sold as an engineered component system, proof tested and third party certified. Under no circumstances will Meadow Burke permit the mixing other manufactures splicing parts with genuine MB components. 13
Rebar Splicing Products www.MeadowBurke.com SETTING BAR ASSEMBLIES Meadow Burke BT Setting Bars are assemblies comprised of threaded rebar coupler and a length of Grade 60 deformed reinforcing steel threaded on one end. Setting Bars are available in all rebar sizes #4 through #11 and in any required length. The Setting Bar (RC-61/RC-61T2) model is furnished straight for standard lap splice applications and the Setting Bar (RC-63/RC-63T2) is furnished with a 90° bend. All setting bars are manufactured to furnished job specifications. A L RC-61/RC-61T2 A L RC-63/RC-63T2 B To Order, Specify: For Setting Bar (RC-61/RC-61T2) – quantity, type, rebar size and overall length. (“A” + “L”) For Setting Bar (RC-63/RC-63T2) – quantity, type, rebar size, “A” and “B” dimensions. 14
Rebar Splicing Products www.MeadowBurke.com SPLICE BARS Overall Length C RC-61/RC-61T2 Overall Length C RC-62/RC-62T2 Meadow Burke BT Splice Bars are manufactured from Grade 60 deformed rebar material and are available in all of the corresponding sizes to the Threaded Rebar Coupler. After the Setting Bar has been placed and the concrete has set the Splice Bar is threaded into the Setting Bar to complete the splice. Splice Bars are available in the following configurations: RC-61/RC-61T2 straight, RC-63/RC-63T2 90° bend, RC-62/RC-62T2 threaded at both ends and with a RC-64/RC-64T2 return bend. For Hook Bar development lengths actual dimensions C, B, D and R are functions of f’c (concrete strength), PSI and minimums based on ACI-318-05 section 12.5 both code and commentary. Overall Length Rebar Splicing Products C RC-63/RC-63T2 Overall Length C B RC-64/RC-64T2 B To Order, Specify: For Splice Bars (RC-61/RC-61T2 ) and (RC-62/RC-62T2) – quantity, type, rebar size and “C” dimension. For Splice Bar (RC-63/RC-63T2) – quantity, type, rebar size, “C” and “B” dimensions. For Splice Bar (RC-64/RC-64T2) – quantity, type, rebar size, “C”, “B” and “D” dimensions. D 15
Rebar Splicing Products www.MeadowBurke.com TENSION SPLICE LAP LENGTH DATA Lap Splice Length RC-64/RC-64T2 Setting Bar RC-61/RC-61T2 LAP SPLICE LENGTH OF DEFORMED BARS IN TENSION No. 6 and No. 7 and CASE f’c (psi) Smaller Bars Larger Bars 3,000 44 db 55 db Clear spacing of bars or wires being developed or spliced not less than db clear cover not less 4,000 38 db 48 db than db and stirrups or ties throughout Id not 5,000 34 db 43 db less than the code minimum or clear spacing of bars or wires being developed or spliced not 6,000 31 db 39 db less than 2db and clear cover not less than db 8,000 27 db 34 db (ACI 318-05 section 12.2.2) 10,000 24 db 30 db 3,000 66 db 83 db 4,000 57 db 72 db 5,000 51 db 64 db Other Cases (ACI 318-05 section 12.2.2) 6,000 47 db 59 db 8,000 41 db 51 db 10,000 36 db 45 db Table is based on the following criteria: 1. Grade 60 reinforcing steel bars. 2. Normal weight concrete factor o=1.0. 3. Uncoated reinforcement factor, o=1.0. 4. Reinforcement location factor, o=1.0. 16
Rebar Splicing Products www.MeadowBurke.com STEP 1 Ensure you are installing the bar size as per plan. Be sure that the STEP 2 Lay the BT Coupler Setting Bar dowel parallel with rebar to be spliced. protective thread plug is installed in the end of the coupler. Position coupler plate flush against formwork and tie the female BT Coupler to the rebar mat. Be sure the bars are properly supported. Note: Roofing nails can be used to assure the coupler plate stays flush against formwork. The plate on the coupler is not intended to support the weight of the bar, workmen or equipment. Rebar Splicing Products STEP 3 After concrete is placed and forms are stripped, the protective thread STEP 4 Remove the bar end protector from the male bar. Visually inspect the plug and face plate of the coupler are visible. The protective thread plug can be thread to make sure it is undamaged and free of rust or debris. If the threads easily removed using a screwdriver or pliers. need to be cleaned use a wire brush. NOTE: In situations where proper positioning of setting or splice bar is not possible after hand tightening assembly, it is acceptable to unscrew one side up to 1 turn to correctly index hooks or bent bar in rebar cage. STEP 5 Thread a Splice Bar into Setting Bar until Splice Bar threads bottom out against Coupler Thread Stop, tighten hand tight (10 ft lbs.) 17
Rebar Splicing Products www.MeadowBurke.com ZAP SCREWLOCK® DOUBLE ZAP SCREWLOCK® The ZAP Screwlock® is a high strength mechanical rebar connection device available for splicing #4 through #11 rebar. No rebar end preparation is required. Simply insert the ends of the two bars into the connector body. A positive center stop ensures proper installation. A B S Tightening the lock-bolts generates a positive mechanical interlock as the rebar deformations are pressed into the ductile steel wedge-shaped body of the connector. Visual inspection is easily accomplished; just verify that the heads of the lock-bolts have sheared off during the tightening sequence. The ZAP SCREWLOCK exceeds 125% of the specified yield strength of the rebar and is approved by or meets the following: ACI-318, ICBO and AASHTO. ZAP SCREWLOCK DATA Nominal Coupler Ave. Dim. Dimension Number of Torque (Ave.) Hex Head Bar Size Coupler Lgth. “L” (in.) “A” (in.) “B” (in.) Screws / Bar (ft.-lbs.) Ø Wt. (lbs) #4 1.9 7” 1-1/16” 11/16” 3 50 1/2” #5 3.7 9” 1-1/8” 3/4” 4 50 1/2” #6 5.2 11” 1-3/16” 15/16” 5 50 1/2” #7 7.6 13” 1-1/4” 1-1/16” 5 100 5/8” L #8 10.3 15-1/4” 1-5/16” 1-1/16” 6 100 5/8” #9 16.9 16-3/4” 1-5/8” 1-1/4” 6 200 3/4” #10 21.7 19-1/8” 1-11/16” 1-7/16” 7 200 3/4” #11 24.7 21-1/2” 1-13/16” 1-1/2” 8 200 3/4” DOUBLE ZAP SCREWLOCK DATA Nominal Coupler Ave. Dim. Dimension Dimension Number of Torque (Ave.) Hex Head Bar Size Coupler Wt. (lbs) Lgth. “L” (in.) “A” (in.) “B” (in.) “S” (in.) Screws / Bar (ft.-lbs.) Ø L #4 1.3 2-1/8” 1-1/16” 1/2” 15/16” 2 50 1/2” #5 2.3 3” 1-1/8” 5/8” 15/16” 3 50 1/2” #6 3.2 3-7/8” 1-3/16” 3/4” 15/16” 4 50 1/2” 18
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