G A LVA N I ZI N SGI G H T S N

Spring 2001 Vo l . V I No. II

Galvanized Rebar Protects Concrete Structures

C
oncrete structures using rebar for structural support often face corrosion problems. Staining, cracking and spalling can be attributed to the corrosion of reinforcing steel in the concrete. This problem causes expensive repair and maintenance costs. Ungalvanized reinforcing steel embedded in concrete makes the concrete susceptible to staining, spalling or even complete failure of the structure. Reinforcing bar encased in concrete is exposed to moisture within the concrete mix or moisture that seeps in and begins the corrosion of rebar. The iron corrosion byproducts are more voluminous than the metal and build up around the reinforcing steel, distributing stress throughout the structure. The buildup of stress in concrete eventually causes the structure to crack, stain and ultimately spall. Under normal service conditions in a nonaggressive environment, the corrosion reaction proceeds very slowly, but only when concrete permeability is low and there are no cracks or voids in the concrete surface. This is rarely the case. Compared to ungalvanized steels expansive corrosion byproducts, galvanized reinforcing steel produces a white, powdery corrosion byproduct that migrates away from the reinforcing steel and into the concrete matrix and does not cause destructive pressure on the concrete. Galvanized reinforcing steel can be effectively and economically used in concrete in situations where black reinforcing steel will not have adequate durability. Galvanized steel reinforceConcrete structures use galment is especially vanized reinforcing steel bars to maintain stability. useful where the reinforcement is exposed to the weather before construction commences. Mechanically, the strength and ductility of reinforcing steel has Hot-dip galvanized rebar can been tested and be walked on and does not found to be unaf- need to be treated as delifected by the gal- cately as epoxy-coated rebar. vanizing process. Additionally, in some tests, galvanized steel rebar was found to have an even stronger bond strength with concrete than black steel reinforcing bars. Details regarding galvanizing reinforcing steel, and specifics of bending galvanized rebar, are found in ASTM A767, Standard Specification for Zinc-coated (Galvanized) Steel Bars for Concrete Reinforcement. The AGA has several publications that contain information about galvanized rebar: Galvanizing for Corrosion Protection: A Specifiers Guide to Reinforcing Steel; Rebar: A Processing and Inspection Guide for Quality Hot-Dip Galvanized Reinforcing Steel and Field Handling Guide: HotDip Galvanizing vs. Fusion Bonded Epoxy.

IN
THIS

ISSUE:
Plainville Farms: An Application Report
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Dr. Galv compares fusion-bonded epoxyb coated rebar and hotdip galvanized rebar
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New Publications and GalvanizeIt! Seminars I

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An Application Report on the Plainville Farms explains why hot-dip galvanizing was chosen. See page 2

The Specifier Newsletter of the American Galvanizers Association

PLAINVILLE FARMS
A GALVANIZED STEEL APPLICATION REPORT

AGRICULTURE

SUBJECT:
Plainville Farms in central upstate New York is a family-owned farm in business since 1835. The farm provides responsibly produced turkey and turkey products (no added filler, nitrites or phosphates) to regional grocery stores and its own Plainville Farms Restaurant.

LOCATION:
Plainville, upstate New York.

ENVIRONMENT:
Plainville Farms is situated in a relatively non-aggressive environment (average 3.2 inches of rainfall per month, summer months average 79F [26C], winter months 32F [0C]). However, the complex design of the farms grain chutes and the chutes supporting structures pose many maintenance difficulties. Galvanizing is the chosen method of corrosion protection because the minimum coating of 3.9 mils of zinc guarantees maintenance-free performance for more than 60 years, allowing Plainville Farms to focus upon its core business.

DATE OF GALVANIZING:
1994

DETAILS:
Plainville Farms chose hot-dip galvanizing for the feed chutes that transport grain for storage and for the feed grain chutes supporting steel. On a larger scale, the agricultural industry is one of the leading users of galvanized steel. Ease of installation, long service-life, material strength, fire-, rodent- and vermin-proofing, and simplicity of keeping structures hygienic are just some of the reasons hot-dip galvanizing is specified for this mainstay industry.
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American Galvanizers Association

6881 So. Holly Cir. #108 Englewood, CO 80112 (720) 554-0900 (720) 554-0909 aga@galvanizeit.org 2001 AGA

The Specifier Newsletter of the American Galvanizers Association

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D r. G a l v :
Galvanized Rebar is Easier to Handle Than Epoxy-coated

Dear Dr. Galv: What are the differences between hot-dip galvanized reinforcing steel and epoxy-coated d c reinforcing steel?
When galvanized rebar and epoxy-coated rebar are compared, one of the more notable advantages of the galvanized rebar is that it is very easy to handle and does not require any special care at the job site. Epoxy-coated rebar must be handled carefully to prevent damage to the coating. It must be inspected to ensure that no damage has been done to the coating and if so, must be repaired instantly. Fusion-bonded epoxy (FBE) coatings are applied as dry powder and heated to form a coating on steel. If the coating is damaged at cut ends or scratched during handling, corrosion can start and progress unimpeded along the steel under the FBE coating as if no protection exists. The full extent of the corrosion will not be visible since it proceeds under the FBE coating. Repair of corrosion beneath the FBE coated rebar is difficult and expensive, and can run as high as 10 percent of the entire structures original cost. In some structures, replacement or repair of rebar may be impossible. Also, the process of bonding the epoxy to the steel does not ensure that the base steel is clean. There is the potential that corrosion already exists or has started underneath the coating. A hot-dip galvanized coating, on the other hand, provides both barrier and cathodic protection to steel and cannot be chipped away since it forms a durable metallurgical bond with the steel. Zinc will also cathodically protect steel from corrosion by sacrificing itself at a scratch or slight recess in the coating. The alloy layers of the zinc coating on galGalvanized rebar can be stored safely on site without fear of vanized rebar are actual- rusting or damage to the galvanized coating. ly harder than the base steel, which further bond with concrete as strong as that resists damage due to handling. of black steel. FBE rebar actually has a lower bond strength to concrete than black steel. According to studies at the University of California at Berkeley, hot-dip galvanized steel forms a The AGA publication, Field Handling Guide: Hot-Dip Galvanizing vs. Fusion Bonded Epoxy, compares these two types of rebar. It is available in pdf format on the Web site: www.galvanizeit.org. To receive a single complimentary copy, please contact the AGA at 1-800-468-7732 or by e-mail at: marketing@galvanizeit.org.

The coating on hot-dip galvanized rebar will not be compromised during installation.
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The Specifier Newsletter of the American Galvanizers Association