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Seel N Conc Protection IR
Seel N Conc Protection IR
CHAPTER - 8
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Product
HCR Rebars
Grade A and Grade M
TISCON- CRS
TISCON- 50 CRS
TISCON- 50 TMT
TEMP CORE REBARS
High Strength Corrosion Resistant A-1
Rebar
These bars have dual micro structures i.e. the surface layer is tempered
martensite while the inner shell is ductile ferrite-pearlite. To increase
corrosion resistance of these bars certain elements like nickel, chromium,
copper and phosphorus are also added. These bars form a protective layers
8.2.2.1
This method was developed by CECRI, Karaikudi. This is their
older system. It consists of application of cement based inhibited and sealed
reinforcement bars. The entire process of coating is based on following
system :
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De-rusting : Removal of rust, dirt and oil from steel surface
ii Phosphating: Phosphatisation of steel surface(by Phosphating
Jelly) offers temporary protection during time lag between
derusting and application of first coat of inhibited cement slurry.
iii Cement slurry:
Two coats of cement slurry made by OPC
cement and Inhibitor solution to protect steel surface from the
attack of Sulphate and Chloride ions and to keep the steel surface
in high pH environment.
iv Sealing: Two coats of Sealing solution to increase the adhesion
between steel and cement coating and to seal the surface and
make it impermeable for gaseous and water molecules.
8.2.2.2
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Merits
Demerits:
8.2.3.1 This is a new method developed by CECRI. This system has been
developed to overcome demerits of inhibited cement slurry coating system.
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Merits :
Demerits :
This system is newly developed system and the long term results
are not known.
8.2.3.5
Performance : This system is now being used on three fly over
bridges in Mumbai at Goregaon, Andheri and Mankhurd. As the system is a
newly developed system, hence field performance is not known. However
laboratory performance of the system, as reported by CECRI, is very good.
The system has passed bondability test, chemical resistance test, salt spray
test, impressed voltage test and abrasion resistance test as per test
procedure described in ASTM A77/775M-94. From structural point of view,
the coated bars have shown greater bond strength as compared to uncoated
bars.. This coating is superior to old CECRI coating and can be used
effectively in marine structures in future.
8.2.3.6 The cost of the coating is about 3200-8000/MT.
8.2.4.1
The Fusion Bonded Epoxy Coating is a process where epoxy
powder is applied by electrostatic spray on hot steel at pre-set temperature
level. The powder, when in contact with the hot bar, melts, flows, gels, cures
cools and produces a well-adhered continuous corrosion resistant protective
coating. This thermosetting is an irreversible process and provides the best
protection to rebar against corrosion. It prevents attack of chloride ion on the
metallic surface and occurrence of electro-chemical reaction initiating
corrosion of steel. The epoxy coated rebars were first tried in Pennsylvania
State in 1973 and commercially produced in the USA
since 1976.
Subsequently this system is introduced in Western Europe and Japan. In
India M/s PSL Holdings Ltd, 386, Veer Savarkar Marg, Prabhadevi, Mumbai400 025, are producing Fusion Bonded Epoxy Coated Rebar (FBECR) at their
plant at Wapi ( Daman ) near Mumbai .
8.2.4.2 The process involves following steps to be performed in a plant
controlled by automatic quality control system.
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8.2.4.3 Inspection and testing : Fusion Bonded Epoxy Coated Rebars are
tested at the coating plant to the codal requirements as specified in IS:136201993. On line and off line holiday checks, thickness checks are carried out.
The adhesion of the coated bars are also tested frequently by bending of the
bar. Beside this, various other tests are performed in laboratory like chemical
resistance, short spray, resistance in continuance boiling water, abrasion
resistance and impact resistance etc. These are conducted on every batch
of production.
8.2.4.4
Handling transportation and working : FBECR bars are required
to be handled with extreme care so that coating is not damaged during
transportation. handling/concreting. Thus, Fusion Bonded Epoxy Coated Bars
require padded contacts during transportation, stacking, handling and till the
concreting is done. The cut ends, welded spots and handling damages are
required to be repaired with special liquid epoxy compatible with the coating
material as per specification of the coating agency.
Merits :
Demerits :
8.2.4.6
8.2.4.6.1
In US Pennsylvania Department of Transportation had
undertaken a project to evaluate and compare the effectiveness and cost of
various bridge deck protective systems. Evaluation was done by conducting
field survey. The protective systems evaluated in this study included epoxy
coated reinforcing steel, galvanized reinforcing steel, water proofing
membranes, latex modified concrete of salt contaminated decks and low
slump dense concrete. This field evaluation was carried out after 9 years of
construction. Field survey revealed that :i
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Merits:
Demerits:
8.2.5.4
If galvanized bars are mixed with ungalvanized bars for use in the
same structure, accelerated depletion of the galvanizing occurs.
Electrochemical treatment to galvanized bar is fraught with danger
as it can result in severe pitting due to formation of galvanic cells.
It is not suitable for protection against chloride attack.
Performance :
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Demerits:
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Non-aggressive
environment
(Mild and Moderate)
All structures
8.3 Coatings for concrete : The protective surface coating, as the name
implies, protects the concrete surface from aggressive chemical attack.
Surface coating of the concrete reduces the ingress of oxygen, water gases
and chemicals present in the industrial and other aggressive environment. So
surface coating for concrete is an effective method of protecting life of
reinforcement steel. The coating on concrete should be breathing type.
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8.3.3 Epoxy coating: They are well proven for concrete surfaces. When
formulated with liquid epoxy resin, liquid curing agents and highly penetrating
solvents, they give good performance. They are classified as under:
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In Aggressive
environment):
environment
(Severe,
Very
severe
and
Extreme
Sub-structures of bridges
(In affected parts only)
- Coaltar epoxy
No coating is necessary.
Good dense cover-concrete with good cement content with low w/c
and extra depth of cover is enough,
Use blended cement to make the concrete impermeable
Use clean reinforcing bars.