Concrete cover

Concrete cover, in reinforced concrete, is the least distance between the surface of embedded reinforcement and
the outer surface of the concrete (ACI 130). The concrete cover depth can be measured with a cover meter.

Purpose of provision of concrete cover[edit]

The concrete cover must have a minimum thickness for three main reasons:

 to protect the steel reinforcement bars (rebars) from environmental effects to prevent their corrosion;

 to provide thermal insulation, which protects the reinforcement bars from fire, and;
 to give reinforcing bars sufficient embedding to enable them to be stressed without slipping. [1]
The premature failure of corroded steel reinforcements and the expansion of the iron corrosion products around the
rebars are amongst the main causes of the concrete degradation. The carbon steel of rebars is protected from
oxidation by atmospheric oxygen by the high pH of concrete interstitial water. Iron bar surface is passivated as long
as the pH value is higher than 10.5. Fresh cement water has a pH of about 13.5 while evolved cement water pH
~ 12.5 is controlled by the dissolution of calcium hydroxide (portlandite). Carbon dioxide present in the air slowly
diffuses through the concrete cover over the rebar and progressively reacts with the alkaline hydroxides
(KOH, NaOH) and with calcium hydroxide leading to the carbonatation of the hydrated cement paste. As a result,
the pH of the cement drops and when its value is below 10.5 – 9.5, steel surface is no longer passivated and starts
to corrode. A sufficient thickness of concrete cover is thus required in order to slow down the carbonatation process
towards the rebar. The minimum concrete cover will depend on the environmental conditions encountered and
must be thicker when the concrete is also exposed to moisture and chloride (proximity to the sea, use of de-icing
salt for bridges or roads, ...). A high quality concrete made with a low water-to-cement (w/c) ratio will have a
lower porosity and will be less permeable to water and to the ingress of corrosive species (dissolved oxygen,
chloride, ...). A thicker cover or a more compact concrete will also reduce the diffusion of CO 2 in the concrete,
protecting it better from carbonatation and maintaining a higher pH for a longer time period, increasing so the rebar
service life.

Structural Applications[edit]
Concrete covers are frequently used in the construction of commercial developments, homes, bridges,
municipalities, curb forming, and other locations or projects requiring long-lasting, durability. [2] Concrete and steel
reinforcement bars combine to create strong, resilient in the following ways:

 Upon contact with each other, the cement paste and steel rebar form a non-reactive surface film preventing
corrosion.
 Reinforcement bars or beams can be strategically set throughout the concrete to achieve the required
support system.
 The bond created by utilizing rebar and concrete can also be attributed to the ridged rebar surface. This
allows stresses to transfer from the concrete to the steel, and from the steel to concrete.
 Concrete and steel have similar thermal expansion coefficients. Upon freezing or heating, they contract and
expand in a similar manner, maintaining the structure needed
Minimum Concrete Cover for Reinforcement
Concrete cover for reinforcement is required to protect the rebar against corrosion and to provide
resistance against fire. The thickness of cover depends on environmental conditions and type of
structural member.

The minimum thickness of reinforcement cover is indicated in the drawings, or shall be obtained
from the relevant code of practice.

Below are the specifications for reinforcement cover for different structural members in different
conditions.

a) At each end of reinforcing bar, concrete cover not less that 25 mm or less than twice the diameter of
the bar should be provided.

b) For a longitudinal reinforcing bar in a column, concrete cover not less than 40 mm not less than the
diameter of such bar should be provided. In case of columns of minimum dimension of 20 cm or
under, whose reinforcing bars do no not exceed 12 mm, concrete cover of 25 mm to be used for
reinforcement.

c) For longitudinal reinforcing bars in a beam, not less than 30 mm or less than the diameter of the bar.

d) For tensile, compressive shear or other reinforcements in a slab or wall not less than 15 mm, not
less that the diameter of such bar.

e) For any other reinforcement not less than 15 mm, concrete cover not less than the diameter of such
bar.
f) For footings and other principal structural members in which the concrete is deposited directly
against the ground, cover to the bottom reinforcement shall be 75 mm. If concrete is poured on a layer
of lean concrete, the bottom cover maybe reduced to 50 mm.

g) For concrete surfaces exposed to the weather or the ground after removal of forms, such as
retaining walls, grade beams, footing sides and top etc. cover should not be less than 50 mm.

h) Increased cover thickness shall be provided as indicated on the drawings, for surfaces exposed to
the action of harmful chemicals (or exposed to earth contaminated by such chemicals), acid, alkali,
saline atmosphere, sulphur, smoke etc.

i) For liquid retaining structures, the minimum cover to all steel shall be 40mm or the diameter of the
main bar, whichever is greater. In the presence of sea water and oils and waters of a corrosive
character the covers, shall be increased by 10 mm.

j) Protection to reinforcement in case of concrete exposed to harmful surroundings may also be given
by providing a dense impermeable concrete with approved protective coatings. In such a case the extra
cover mentioned in (b) & (i) above may be reduced.

k) The correct cover shall be maintained by cement mortar cubes (blocks) or other approved means.
Reinforcements for footings, grade beams and slabs on a sub-grade shall be supported on precast
concrete blocks as approved by EIC. The use of pebbles or stones shall not be permitted.

l) The minimum clear distance between reinforcing bars shall be in accordance with IS:456 – 2000 or
as shown in drawing.