Field Handling of Epoxy-Coated Rebar

Just like any material used on a jobsite, appropriate handling of ECR is required. These steps are aimed at reducing damage to the bars that would reduce the effectiveness of the coating to perform and provide long-term protection. Fabrication and handling of ECR is covered in ASTM D3963 Standard Specification for Fabrication and Jobsite Handling of Epoxy-Coated Steel Reinforcing Bars. Jobsite handling is also covered in the Appendix of ASTM A775 Standard Specification for Epoxy-Coated Steel Reinforcing Bars.

Bars that are handled correctly require less field repair than those that are not. ASTM D3963 requires all visible coating damage to be repaired. If the bar has more than 2% of its area damaged in any given 1 foot section of coated reinforcement the bar may be rejected. Care should also be taken during patching as if the total bar surface area covered by patching material exceeds 5% in any given 1 foot section of coated reinforcement the bar may be rejected. Both of these limits do not include sheared or cut ends.

Basic guidance steps for correct field handling of Epoxy-Coated Steel Reinforcing Bar (rebar) prior to or during concrete placement: 


Epoxy-Coated Steel Reinforcing Bars (rebar) should be lifted using a spreader bar or strongback with multiple pick-up points to minimize sag.

Nylon or padded slings should also be used.

DO NOT use bare chains or cables.

Unload as close as possible to the point of concrete placement to minimize rehandling.


Store bundles of Epoxy-Coated Steel Reinforcing Bar (rebar) on suitable material, such as timber cribbing.

If the Epoxy-Coated Steel Reinforcing Bars (rebar) are to be exposed outdoors for more than 30 days, cover with a suitable opaque material that minimizes condensation.

Store coated and uncoated bars separately.


Field Cutting

Use power shears or chop saw to cut Epoxy-Coated Steel Reinforcing Bars (rebar).

DO NOT flame cut Epoxy-Coated Steel Reinforcing Bars (rebar). 

Bar Supports

Use bar supports coated with non-conductive material or plastic bar supports.


Lift and set Epoxy-Coated Steel Reinforcing Bars (rebar) into place, DO NOT drag them.

Minimize traffic over Epoxy-Coated Steel Reinforcing Bars (rebar).

Tie Wire

Use a coated tie wire for securing Epoxy-Coated Steel Reinforcing Bars (rebar).


All damage (cut ends, cracks and abrasions) should be patched using a two-part epoxy repair material, approved by the coating manufacturer.

Follow manufacturer’s directions.

Concrete Placement

Avoid traffic and concrete hoses on placed Epoxy-Coated Steel Reinforcing Bars (rebar) (consider runway if necessary).

Concrete Vibration

Use plastic headed vibrator to consolidate concrete.