Epoxy coated rebar
Epoxy coated rebar
corrosion-resistent epoxy coating
Epoxy-Coating protects the steel using several mechanisms. If undamaged, the coating prohibits the passage of chloride ions, thus protecting the steel from corrosion damage. If minor holes or damage are present in the coating and sufficient chloride ions are available in the concrete, then localized corrosion may occur. For the corrosion reaction to proceed, a cathode is required. If all bars are coated, then only very small cathodes are present, substantially reducing the corrosion rate. Tests conducted for the FHWA demonstrated that if both top and bottom mats were coated, the corrosion rates of Epoxy-Coated Steel Reinforcing Bars were 40 to 50 times less than that of similar uncoated bars.
Epoxy-Coated rebar may be used in any concrete subjected to corrosive conditions. These may include exposure to deicing salts or marine waters.
. Bridges (decks, piers, etc.)
. Marine structures (seaports, airports, tunnels, etc.)
. Pavements (highway, airport runway, etc.)
. Parking structures
. Buildings (seaside, power plants, etc.)
. Repair
Standard
ASTM A775/A775M, ASTM A934/A934M
Rebar diameter
8mm ~ 40mm (1/3" ~ 1 1/2")
Powder brand
Jotun, Valspar
- Mill direct sale
- One-stop solution
- Rich supply reference
Manufacturing process
Surface preparation
Rebars are blast-cleaned to a near white metal finish using abrasive grit.
Heating
Bars are heated to approximately 230°C, typically using electrical induction heaters.
Powder application
The heated steel is passed through a powder-spray booth where the dry epoxy powder is emitted from a number of spray guns.
Cure
Water cooling.
The sustainable choice for concrete structures
Black
Epoxy coated
Galvanized
Stainless
ITEM
ASTM A615
ASTM A775/A934
ASTM A767
ASTM A955
%recycled
>75
>97
>97
>99
Durability
Low
High
Moderate
Very High
Cost
Low
Low
Moderate
High
Available alloys and dimensions
Grades
ASTM A615
BS 4449
Canadian
HRB 400
GR 60
B500
400R/400W
HRB 500
GR 75
500R/500W
GB/T 1499.2 |
BS 4449 |
ASTM A615 |
Canadian Sizes |
6 |
6 |
|
|
8 |
8 |
|
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|
#3 |
|
10 | 10 |
|
|
|
|
|
10M |
12 | 12 |
|
|
|
|
#4 |
|
14 |
|
|
|
|
|
#5 |
|
16 | 16 |
|
15M |
18 | #6 |
|
|
|
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|
20M |
20 | 20 |
|
|
22 |
|
#7 |
|
25 | 25 |
|
25M |
|
|
#8 |
|
28 |
|
#9 |
|
|
|
|
30M |
32 | 32 |
#10 |
|
36 |
#11 |
35M | |
40 | 40 |
|
|
50 | 50 |
|
|
Frequently Asked Questions
*Epoxy-Coated Steel Reinforcing Bar protects even in cracked concrete.
*Life-cycle analysis shows that Epoxy-Coated Steel Reinforcing Bar provides the lowest cost.
*Unlike corrosion protection systems used within the concrete mixture, Epoxy-Coated Steel Reinforcing Bar is readily identified at the job site.
*Continuous reinforced concrete pavement
*Parking garages
*Piers and docks
*Water towers
*Columns and parapets
*Dowels
*Repair
*Maintain concrete cover.
*Epoxy-Coated Steel Reinforcing Bar has outperformed galvanizing in almost every laboratory corrosion test of Epoxy-Coated Steel Reinforcing Bar.
*Galvanized coating quality depends on the steel quality, while Epoxy-Coated Steel Reinforcing Bar does not.
*Galvanizing may result in brittle bars that break during bending.
*Epoxy-Coated Steel Reinforcing Bar does not have these embrittlement issues.
In environments subjected to marine or deicing salts, corrosion initiates when sufficient chloride ions reach the reinforcing steel. The time for these salts to reach the bars is dependent on the concrete permeability and the amount of cracking in the concrete as well as the exposure conditions.
The permeability of concrete depends on the water-cement ratio as well as the presence of pozzolans including fly ash and silica fume or various concrete additives that impart water resistance. When uncoated reinforcing is placed in cracked concrete, corrosion initiates almost immediately the concrete is placed in contact with the salt solution; thus, the presence of cracks will significantly reduce the repair -free life of a structure. Epoxy-coated bars have been found to perform well in cracked concrete compared with the use of concrete modifications alone.
To optimize the design life of structures that use epoxy-coated bars it is recommended that high quality concrete is used with appropriate cover over the reinforcing and that cracks in the concrete are repaired.
During a typical concrete repair, it is common only to remove the damaged concrete, where the steel corrosion has resulted in expansion that sufficiently damages the concrete. Unless precautions are taken as part of the repair process, corrosion damage in immediately surrounding areas may rapidly occur. This “ring anode” effect occurs as the area after the repair becomes the new anode, and the repaired area may become a strong cathode. At the cathode, electrons react with water and oxygen.
Due to the dielectric (non-conducting) coating on epoxy-coated bars, it is difficult for these bars to become cathodes. Thus, replacing exposed bars in the repair area with epoxy-coated bars substantially reduces the cathode and thus dramatically reduces the ring anode effect, leading to significantly enhanced repair life. Where bars are too short to be replaced or where areas of exposed uncoated reinforcing bars are present, it is recommended that they be coated with a repair material specifically designed to reduce the cathodic effect.
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