Comparison of Epoxy coated rebar vs CPCC rebar vs

CRS rebar
www.engineeringcivil.com/comparison-of-epoxy-coated-rebar-vs-cpcc-rebar-vs-crs-rebar.html

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. Parameter Fusion bonded epoxy Cement-polymer Corrosion resistant

No. coated rebar composite coated steel (CRS) rebar
(CPCC) rebar

Corrosion For protection of reinforcing For protection of For protection of

1 Resistance bars against corrosion,
Technology epoxy coating is done on
these bars by electrostatic
spraying of fusion bonded
epoxy powder.
reinforcing bars reinforcing bars
against corrosion, against corrosion,
coating of rapid chemical composition
setting primer of rebar is made such
followed by a coat of as to develop
cement polymer inherent corrosion
sealing product is resising property.
done.

No BIS code No BIS code

2 BIS code BIS13620-1993 available. Developed available for CRS yet.
by CECRI, Karaikudi. Complying to
They have the BIS1786-2008 500D.
detailed specification
of chemicals and
quality control with
them.

3 Manufacturing Difficult, as it needs to pass Difficult, as it involves Easier to control, as it

process some critical procedures as various steps like is dependant on
control per BIS. surface preparation, mother billet
coating application composition.
on rebar.

A coating of 0.1-0.3mm on
4 Damage external surface of rebar and It can be brush Inherent property of
possiblity liable to damage. applied or sprayed rebar itself. No
Performance of the system and hence defects in chance of
depends upon least defect in the coating can be damage/change in
the coating. patch repaired. property.

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 5 Bond strength About 20% less strength
of rebar than conventional reinforcing
bars, due to the coating.
Special procedure is there
6 Handing for handling such rebar,
otherwise the coating may
get damaged. Even dropping
or dragging such rebar is
prohibited.
Fabrication Chance of damage in
7 (Cutting) coating during fabrication.
Exposed edge of rebar will
be affected by corrosion.
8 Bending Chance of disbonding in
coating during bending.
9 Welding Not advisable as coating get
damaged during welding.
10 Usage of Threaded portion of rebar
couplers without coating for fixing
couplers leads to corrosion.
No measurement of extent of
11 Extent of protection to rebar due to the
protection coating, as per BIS. Smallest
damage in coating can
initiate corrosion under
severe environment.
Cost higher compared to
conventional rebar typically
by Rs 6000-13000/MT, due
12 Cost saving to the coating. Moreover,
due to less bond strength,
more development length
required, leading to more
cost.
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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.
Has good bond No effect on bond
strength and hence strength.
bond between
coated rod and
concrete unaffected,
as per CECRI.
Care to be taken No restriction in
while handling such handling procedure.
rebar, otherwise the
coating may get
damaged.
Chance of damage in
coating during Normal practice like
fabrication. Exposed conventional rebar.
edge of rebar will be
affected by corrosion.
Chance of Normal practice like
disbonding in coating conventional rebar.
during bending.
Bending of rebar to
be completed prior to
coating.
Not advisable as No special care is
coating get damaged required.
during welding.
Threaded portion of Threading and
rebar without coating coupler usage is not
for fixing couplers an issue due to
leads to corrosion. inherent property of
rebar.
This system is newly About 25% lower rate
developed by CECRI of corrosion
and the long term compared to
results are not conventional rebar.
known.
Cost higher Cost higher
compared to compared to
conventional rebar conventional rebar by
typically by Rs 5000- Rs 2500-3000/MT.
8000/MT, due to the
coating.
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