FAQs About GatorBar FRP Rebar

Fiber Reinforced Polymer (FRP) rebar is a composite concrete reinforcement bar constructed of fiber (glass, basalt or carbon fiber) providing strength, and a binding matrix that protects and transfers load between the fibers.  The binding matrix typically comprises of resin, epoxy and vinyl ester. Polyester is specifically banned as a matrix by the American Concrete Institute.

FRP rebar is a modern, non-corrosive alternate for steel rebar used to reinforce concrete.  GatorBar is currently constructed using fiberglass fibers and a proprietary resin.  FRP rebar specifically made from glass fiber is referred to as Glass Fiber Reinforced Poly (GFRP).    

GatorBar was originally manufactured using basalt fibers.  Basalt is basically rock fiber.  The best sources for basalt currently originates from China, Russia and possibly Turkey. When GatorBar made the decision to transition to fiberglass fibers, we did so because we would be able to:

1. Increase GatorBar’s performance,
2. Source fiber material from within the United States, and
3. Decrease the price of GatorBar to our customers.  

It was the best of all worlds for us, and more importantly, our users.  
 

GatorBar fiberglass rebar is sized in 1/8 inch increments exactly like steel rebar. For example, #3 equates to a diameter of 3/8”, whereas #4 equates to 4/8” (or ½” as it’s more commonly called).

GatorBar reinforcing rebar is currently offered in three sizes: #3, #4 and #5.  With these sizes, GatorBar currently focuses on reinforcing concrete used in parking lots, slab on grade concrete, footings, foundations, driveways, sidewalks, curb and gutter and marine applications. 

Steel reinforcing bar is often sold in a variety of grades depending upon required application.  The two more commonly referenced grades are Grade 60 and Grade 40.  What the number refers to is the yield tensile strength with the number being in thousands of pounds per square inch.  For example, a Grade 60 steel rebar would have a rating of 60,000 pounds per square inch.  

In comparison, GatorBar #3 and GatorBar #4 have guaranteed tensile strengths of 155,000 pounds per square inch or Grade 155.  GatorBar #5 will have a guaranteed tensile strength of 129,000 pounds per square inch.  GatorBar’s advanced tensile strength is achieved through the increased material properties afforded by fiberglass in comparison to most of the steel used in rebar.

GatorBar’s shear strength is comparable to Grade 40 steel rebar at the same bar size.  We recommend decreasing the bar spacing for use in pinning together adjacent concrete slabs.  Even though GatorBar may have a lower shear strength than Grade 60 steel rebar, GatorBar’s lack of corrosion at water exposed joints provides greater joint longevity in comparison to water exposed steel rebar that begins rusting and spalling almost immediately.

Yes and no.  GatorBar can be flexed into large radius bends and then tied into place; however, it cannot be permanently bent into a small radius bend in the field.  All small radius bends need to be manufactured and cured at our factory.  GatorBar produces a standard set of bends and shapes, the most inventoried of which are 90° bends with 24” (#3 and #4) and 30” (#5) legs.  

If additional shapes are required, please contact GatorBar at 906.934.2661 or your sourcing retailer.  In many lower quantity cases, GatorBar can ship bends within 24 hours.  Alternatively, many contractors simply bend steel on-site as needed and tie into each end with GatorBar straight bars.

GatorBar can be cut in the same manner as steel rebar with one exception.  The American Concrete Institute (ACI) recommends avoiding the use of a shear so as to prevent ends from fraying and possible intrusion of water, plus, cutting fiberglass rebar will wear out shears very quickly.  However, GatorBar has almost zero water absorption anyway so many take that recommendation with a grain of salt.  

Many concrete installers use diamond cut-off blades or abrasive steel cutting blades and can cut through an entire bundle of GatorBar in the time it would have taken to cut through just one or two bars of steel rebar.  Proper safety equipment should be worn when cutting.  Further, an additional benefit of cutting GatorBar, especially in areas prone to grass fires, is that it does not spark.  

GatorBar should be chaired or dobied just as steel rebar for placement.    We caution installers that pull (vs. chair) bar as GatorBar is considerably lighter than steel and could be pulled out of the concrete.  Like chairing, GatorBar is tied the same as steel rebar.  In the case of non-metallic or decorative projects, plastic ties or clips can be used instead of regular rebar tie wire.   

GatorBar does not contain hazardous materials.  However, the dust created when cut can be an irritant.  When cutting we recommend that you wear long sleeves shirts, protective glasses and masks.  

GatorBar should be stored off the ground on skids or pallets.  When stored outside in direct sunlight, the American Concrete Institute (ACI) requires that composite rebar be covered if stored for four (4) or more months.  While UV rays may discolor composite rebar over time, GatorBar does not degrade.  To minimize discoloration, all GatorBar skids ship wrapped in UV protective plastic and the surface film of the bars themselves have UV inhibitor.  

The United States is divided into seismic zones A – F.  GatorBar rebar can be used in any application within zones A & B but is restricted to only slab on grade applications by national building code from zones C – F in lateral load resisting applications.  This is an area of much research by the FRP rebar industry and further updates will be coming soon.  

Absolutely.  GatorBar is often used in footings, foundations and walls up to 10’ in non-seismic areas.  For use in higher walls and or non-flatwork in seismic areas, please contact us at 906.934.2661 and a member of our team will work with you on a case-by-case basis.  

GatorBar is structurally approved and is not limited to only these applications.  
 

Actually, it is true in many situations.  GatorBar has standard recommendations based on concrete thickness and in applications where the design focus is tensile strength.  Additionally, projects requiring temperature and shrinkage control, this often results in construction with a size down replacement compared to steel rebar.  These applications include: parking lots, slab on grade construction, sidewalks, curb and gutter, patios, footings and foundations.  

For walls, #3 GatorBar is permitted for the horizontal members, while vertical members less than 10’ should be size for size.  For stem wall vertical members over 10’, please contact us at 906.934.2661 for appropriate usage.   

Installation is simple, if you can install steel rebar, you can install GatorBar.  Simply follow the same installation methods as you would with steel and or as the project plans and specifications indicate.  Everything will just be easier.  

GatorBar is sold in all 50 states through a network of concrete and building supply distributors and select wholesalers for lumber yard availability.  Please feel free to visit the  dealer locator page on our web site or contact us at 906.934.2661 and we would be happy to direct you to the closest source.  

GatorBar takes pride in being the most economically International Code Council (ICC) structurally approved FRP reinforcing manufacturer on the market.   Currently, GatorBar is cost comparable, or better, than steel rebar bar size to bar size.  When a size down substitution is utilized, for instance using GatorBar #3 vs. steel #4, product cost savings are considerable.  Having said that, we encourage all users using GatorBar to consider a total project cost perspective where initial purchase savings, added labor savings (typically 30% – 45%) and additional soft savings from transportation advantages, increased crew performance and less long term maintenance, all combine to create incredible cost advantages with GatorBar use.  

Not all FRP rebar is created equal.  Given that many flatwork applications are unspecified, some fiberglass rebar manufacturers offer non-certified FRP rebar using alternative components, in some cases resins that are industry prohibited, at lower cost.  

Further confusion can be introduced by the predominately used certification house, ICC, by having different testing standards and certifications for both structural and flatwork FRP.  An ICC structurally approved bar will have an AC454 certification while an ICC flatwork approved bar will have an AC521 certifications.  

In fact, however, most “flatwork” bars have no certification.  Confusion can arise when entities or individuals claim an ICC AC521 certified bar is suitable for structural use when it is not.  
GatorBar has attempted to make this easy for all involved by manufacturing an FRP rebar that is cost competitive against steel that meets ICC structural rebar requirements.  Strangely enough, steel rebar does not have similar third-party certification processes.  

Many fail to realize two things about traditional concrete:

1. Concrete will crack regardless of what reinforcement material is used, and
2. Steel rebar begins attacking the concrete from the minute it’s installed due to corrosion from water and chemicals within the concrete.  

As concrete cracks, and the more water is introduced to the concrete, the more steel rebar corrosion occurs. As steel corrodes, it expands and breaks the concrete it is supposed to protect.  

GatorBar however, does not absorb water, does not corrode/rust and is therefore not destructive to the concrete.  As a result, the concrete will be longer lived and have lower maintenance costs in the long run.  similar third-party certification processes.