What is the correct practice regarding field welding on epoxy-coated bars?

• A. Weld over damaged coating to ensure joint integrity
• B. Avoid field welding on damaged areas
• C. Welding is always preferred regardless of coating condition
• D. Field welding is never allowed under any circumstances

Answer: (B)

Epoxy-coated bars are protected against corrosion by the coating, but welding generates heat that can burn off or lift that coating in the weld area and the surrounding heat-affected zone. If the coating is damaged, welding there would remove the protective layer and create a new corrosion path, compromising both durability and the intended protection of the reinforcement. Therefore, the proper practice is to avoid field welding on any damaged epoxy coating areas. When a splice or connection is needed, use joining methods that preserve the coating’s integrity—such as mechanical splices or epoxy-coated couplers—and repair or replace damaged bars according to coating manufacturer guidance. Welding on intact coating areas is generally not preferred in field conditions because it still risks damaging the coating, but the emphasis here is on avoiding welding where the coating is already compromised.