Two specifications are available for epoxy-coated reinforcing steel, ASTM A775 and ASTM A934. Reinforcing steel bars meeting ASTM A775/A775M Standard Specification for Epoxy-Coated Steel Reinforcing Bars are coated in a straight condition and then bent, whereas ASTM A934/A934M Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars covers bars that are bent prior to coating.

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In the early s it was believed that bending of the coated bars would reduce the corrosion performance of coated bars.  At that time, ASTM A775 required bars to pass a flexibility test that only bent the bars 120 degrees. Coatings would often crack or debond from the steel surface when bent to 180 degrees, reducing their corrosion performance. More recent ASTM A775 specifications require that the bars pass a 180 degree flexibility test. This improved specification has been met through improved surface preparation of the steel prior to coating and use of more flexible coatings. 

According to the specifications, Coatings meeting A775 and A934 are required to pass an abrasion test meeting ASTM D. In this test, they are required to exhibit less than 100 mg of weight loss during cycles. Both standards also require coatings to be tested for impact according to ASTM G14 using a 4-lb tup.  ASTM A775 requires coatings to pass an impact requirement of 80 in-lbf without shattering, cracking or bond loss, whereas ASTM A934 requires an impact of only 40 in-lbf. Thus, the general belief that coatings meeting ASTM A934 are tougher is not supported by the relevant ASTM specifications.

Side-by-side corrosion tests were conducted by McDonald et al. as part of a 5-year FHWA research program[1]. These studies found no significant difference in the performance of either the flexible or non-flexible coatings.

For all coated bars, it is important that coated product be inspected after fabrication and prior to placement into the concrete to ensure that any damage is repaired. Further details on fabrication of epoxy-coated bars are presented in Appendix X1 of ASTM A775 and ASTM D.

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