Corrosion in exposed rebar is occurred due to the presence of moisture

water penetration; the water enters through the crevices of the concrete and comes into
contact with the metal, which, over time, leads to rusting of the reinforced steel and
corrosion from the inside out of both the rebar and the concrete.
Spalling is best corrected by using a high-pressure sprayer to remove any and all
surface rust that may be present. Next, a specialty protective coating containing anti-
corrosive agents is applied to the exposed metal to prevent further damage. After this
material has set, fresh mortar can be applied to fill the gap and in effect cover the
exposed rebar.

Clean steel reinforcement with mechanical wire-brushing or by sand blasting.

• In case the reinforcing bars are corroded and have lost more than 25% of their diameter, they have
to be cut and removed.

Step 3:
• In such event, removed steel bars should be replaced with new steel bars of the same diameter
either by respecting the overlap length or by welding 100 mm length to the existing steel
Step 4:
• Remove dust by air blowing and wash with clean water to achieve a Surface Saturated Dry (SSD)
substrate.
Protection of steel reinforcement against corrosion:
After all necessary preparation, steel reinforcement should be protected against corrosion with
a highly alkaline product Conrep.370 PF or a zinc rich product that delays the aggressive
elements attack on steel, like Conrep.501 ZRP

https://www.sodamco-weber.com/technical-repair-mortars/help-and-advice/cases-solutions/repair-
of-damage-with-exposed-steel-reinforcement.html

(BERTOLINI & PEDOFIRI) The anodic process can be stopped by restoring passivity on the steel
surface, by coating the rebars, or by application of cathodic protection.

Applying a coating to the reinforcement that acts as a physical barrier between the steel and the
repair mortar. For this purpose only organic coatings, preferably epoxy based, should be used. he
surface of the steel to be coated must be very carefully cleaned from corrosion products, bringing
the metal to blast-cleaning grade SA 21/2.
The reinforcement exposed during repair has to be cleaned so that protective treatment can be
applied. Even if no protective treatment is to be applied cleaning has to be carried out so that the
steel surface is in intimate contact with the new concrete or mortar. The only effective methods of
cleaning reinforcement are by grit blasting and water jetting. Other methods, such as wire
brushing, even by mechanical means, do not clean to the necessary standard. Grit blasting and
water jetting are also the only methods that can reach the backs of bars and the difficult locations
where bars cross.
Once the reinforcement has been cleaned it should be examined to check whether sufficient
cross-sectional area remains. As a rule of thumb, any bar that has lost more than 20% of its area
should be replaced but the amount of steel required for structural reasons should be checked. If
additional bars are provided they need to have an adequate lap to existing bars or be adequately
anchored into sound concrete
http://www.concrete.org.uk/fingertips-nuggets.asp?cmd=display&id=492

) Coating of reinforcement: New and existing bars that have been cleaned
may be coated with epoxy, polymer cement slurry, or a zinc-rich coating for
protection against corrosion. The coating must have a thickness less than 0.3
mm to minimize loss of bond development at the deformations.

loose rust is removed from the steel by wire mechanical brushing or grit blasting and the concrete
cover replaced with fresh sand and cement mortar. Additional protection from further corrosion can
be carried out by use of corrosion inhibitors in the mortar or by painting the steel before the mortar
is applied.