Main Purpose of Rebar

Rebar is used in concrete to provide strength and stability of the structure and avoid cracks in Structures.

Epoxy-coated Rebar

Epoxy-coated reinforcement steel bars are used for corrosion protection. It is highly effective corrosion protection system for Reinforcement.

Epoxy treated rebars has been used in numerous other industries, including the general construction of buildings, piers, marine, industrial foundations, highway barriers, Bridges, coastal sea walls, and Salt Exposer Area where concrete is used.

Application of Epoxy Rebar

Epoxy Coated Steel Reinforcing Bars (rebar) may be used in any concrete subjected to corrosive conditions. Marine Structures: Corrosion of reinforcement has always have been a problem in Coastal Area (Marine) structures. Epoxy-coated steel reinforcing bars have demonstrated over the past 35 to 40 years that they can help reduce the damage which is caused by corrosion. 

 Manufacturing Process Epoxy Coating 

 The four basic manufacturing steps are required. 

1. SURFACE PREPRATION: Clean reinforcements surface such as oil, grease, rust etc. in short Blaster and clean and rough surface finished. During this process, salt contamination is also removed. 

2. HEATING OF BAR: Bars are heated to approximately 230°C typically using electrical induction heaters.

3. COATING OF BARS: The heated bar is passed through the epoxy coated booth where epoxy powder is sprayed by epoxy Spray Gun due to heated rebar the epoxy Powder melt and flow in whole profile. (200 –300 µm thick) epoxy coated layer is applied on rebars.

4. COOLING OF BARS: Epoxy coated TMT bar are given thermal treatment by keeping them at 225°C for during recommended by epoxy powder manufacturers resulting in fully cured coating. The coated bar are passed through a cooling tunnel after curing Where water is sprayed on the bar to cool them.

Field Handling

Just like any material used on a Construction site, these steps are aimed at reducing damage to the bars.

Storage: bundles of bars store in proper way such as timber cribbing. If the bars are to be exposed outdoors cover with a suitable opaque material to against damage. Uncoated and coated bars should be stored separately.

  • Placement: Lift and set bars into decided place, do not drag.
  • Tie Wire: Use coated Binding wire Field cutting: Do not cut bars by flames machines.
  • Patching: All damage in Epoxy coated Rebars (cut ends, cracks) should be patched using Epoxy repair material, approved by the coating manufacturer. Follow manufacturer’s directions.
  • Vibration: Use plastic headed vibrator

Advantages of Epoxy treated rebar

Disadvantages of Epoxy treated rebar

  •  Poor bonding with Concrete.
  •  Approx. 10% to 12% increase in cost of rebars.
  • In the Damage region, Bar break suddenly from that location.

CONCLUSION:- Epoxy coated rebar is provided in any concrete subjected in Coastal area (salt exposer area) to resist from corrosion and increase the service life of a structure. Which is used in Marine Structure, water treatment plant, Bridges, Piers and industrial foundation etc.

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Epoxy Coated Rebar