4/5/2021 Comparison of Epoxy coated rebar vs CPCC rebar vs CRS rebar

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Comparison of Epoxy coated rebar vs CPCC rebar vs CRS rebar

Posted in Civil Engineering Information, Steelworks | Email This Post |

By
Sourav Dutta
Manager-Civil
Ion Exchange India Limited

Now-a-days for controlling rust/corrosion of rebar some extra treatment is being carried out on rebar, making it more resistant to rusting/corrosion
under unfavorable circumstances. Some of these treated rebars normally used are: (1) Fusion bonded epoxy coated rebar, (2) Cement-polymer
composite coated rebar,(3) Corrosion resistant steel (CRS) rebar. The following comparison is being made aiming to give a clear cut idea on
advantages/disadvantages of each type, which might help and give an idea to construction industry for decision making of selection of any particular
type.

Sl. Fusion bonded epoxy Cement-polymer composite Corrosion resistant steel

Parameter
No. coated rebar coated (CPCC) rebar (CRS) rebar
For protection of For protection of
reinforcing bars against For protection of reinforcing bars reinforcing bars against
Corrosion corrosion, epoxy coating is against corrosion, coating of corrosion, chemical
Resistance done on these bars by rapid setting primer followed by composition of rebar is
1 Technology electrostatic spraying of a coat of cement polymer sealing made such as to develop
fusion bonded epoxy product is done. inherent corrosion
powder. resising property.
No BIS code available.
Developed by CECRI,
No BIS code available for
Karaikudi. They have the
CRS yet. Complying to
detailed specification of
2 BIS code BIS13620-1993 BIS1786-2008 500D.
chemicals and quality control
with them.
Manufacturing Difficult, as it needs to pass Difficult, as it involves various Easier to control, as it is
3 process some critical procedures as steps like surface preparation, dependant on mother
control per BIS. coating application on rebar. billet composition.
A coating of 0.1-0.3mm on
external surface of rebar
and liable to damage.
Performance of the system
4 Damage depends upon least defect It can be brush applied or Inherent property of rebar
possiblity in the coating. sprayed and hence defects in the itself. No chance of

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4/5/2021 Comparison of Epoxy coated rebar vs CPCC rebar vs CRS rebar
coating can be patch repaired. damage/change in
property.

About 20% less strength Has good bond strength and

Bond strength than conventional hence bond between coated rod No effect on bond
5
of rebar reinforcing bars, due to the and concrete unaffected, as per strength.
coating. CECRI.

Special procedure is there

for handling such rebar,
otherwise the coating may
get damaged. Even Care to be taken while handling
No restriction in handling
6 Handing dropping or dragging such such rebar, otherwise the coating
procedure.
rebar is prohibited. may get damaged.

Chance of damage in Chance of damage in coating

Fabrication coating during fabrication. during fabrication. Exposed edge
(Cutting) Exposed edge of rebar will of rebar will be affected by Normal practice like
7 be affected by corrosion. corrosion.
conventional rebar.

Chance of disbonding in coating

Chance of disbonding in Normal practice like
8 Bending during bending. Bending of rebar
coating during bending. conventional rebar.
to be completed prior to coating.
Not advisable as coating get Not advisable as coating get No special care is
9 Welding
damaged during welding. damaged during welding. required.
Threading and coupler
Threaded portion of rebar Threaded portion of rebar
Usage of usage is not an issue due
10 without coating for fixing without coating for fixing
couplers to inherent property of
couplers leads to corrosion. couplers leads to corrosion.
rebar.

No measurement of extent
of protection to rebar due to
the coating, as per BIS.
Extent of Smallest damage in coating This system is newly developed About 25% lower rate of
11 can initiate corrosion under by CECRI and the long term corrosion compared to
protection
severe environment. results are not known. conventional rebar.

Cost higher compared to

conventional rebar typically
by Rs 6000-13000/MT, due
to the coating. Moreover,
due to less bond strength, Cost higher compared to
more development length conventional rebar typically by Cost higher compared to
12 Cost saving required, leading to more Rs 5000-8000/MT, due to the conventional rebar by Rs
cost. 2500-3000/MT.
coating.

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We at engineeringcivil.com are thankful to Er. Sourav Dutta for submitting this paper to us. We hope this paper will be helpful for the whole
construction industry in general.

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