Jotun ƒ Corrosion ƒ Service life and cost comparison ƒ Coating plant quality ƒ Job site practice Projects ƒ Conclusions

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EPOXY COATING FOR STEEL REBAR
Improving concrete structure durability and
reducing long term maintenance costs

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WHAT YOU WILL
LEARN
What causes corrosion of steel rebars
embedded in concrete and how to
effectively prevent corrosion comparing
different corrosion protection methods.
Why corrosion protection of steel
reinforcement is especially important for
concrete structures in GCC countries.
What is the initial cost increase to a
concrete structure and total life cycle
cost of a concrete structure with fusion
bonded epoxy coating for corrosion
protection comparing to other corrosion
protection methods.
Table of contents
Jotun
Corrosion
Service life and cost comparison
Coating plant quality
Job site practice
Questions
Projects
Conclusions

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A global paint solutions company,
established in Norway in 1926.

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90
countries
USD 1.9bn
in sales
39
factories
850 advisors
NACE / Frosio qualified
9000
employees

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13 4 3 6 8
Middle East India and Africa
regions includes 57
countries with 17 factories
and sales offices in 10 other
countries

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Regional
Laboratories
200 people working
in R&D
R&D investment
US34 million per year
Central Lab
Sandefjord, Norway
Regional Labs
Dubai, UAE
K.L, Malaysia
Pusan, South Korea

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For a more colourful world, we are
taking steps to be a little greener

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ENVIRONMENTAL CONDITIONS
SNOW
COAST
COAST
COAST
MOUNTAIN
Dubai 24° N

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ENVIRONMENTAL CONDITIONS
Dubai 24° N
COAST
COAST
COAST
SABKHA

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ENVIRONMENTAL CONDITIONS
Salt content

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ENVIRONMENTAL CONDITIONS
Mediterranean Atlantic Arabian Gulf Mean
21,380 17,480 33,660 19,800
Salt content (TDS mg/l)
Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals

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ENVIRONMENTAL CONDITIONS
Chloride and sulfate in air humidity
Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals
Salt (ppm/m3) UAE Long Beach
Chloride 63.2 0.13
Sulfate 33.8 0.32

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ENVIRONMENTAL CONDITIONS
Sabkha brine vs. Seawater
Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals
Ions (g/l) Sabkha brine Sea water
Cl- 157.2 36.9
SO4-- 5.45 5.12
pH [n/a] 6.9 8.3
Conductivity [µmhos/cm] 208,000 46,200

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• High pH = passive oxide layer
• Carbonation leads to lower pH
• Corrosion starts
• Corrosion propagation leads to cracking
• Cracking further accelerates corrosion

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• Physical and electrochemical
corrosion barrier
• Isolates the bar by reducing flow of
corrosion current by 98%

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Staining

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Cracking

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Spalling

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Without epoxy coating With epoxy coating

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FACTS & FIGURES
• Corrosion cost in UAE is estimated to be
US$ 12.5 billion (Dr. Nagi/AUD)
• More than 65.000 bridges use epoxy
coated rebars in the US
• Coated rebar has saved the federal
highways over US$ 50 billion in the US
(Paul Virimany, Corcon 2007)

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Kyösti Tuutti´s Service Life Model – Loss of cross‐section

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Kyösti Tuutti´s Service Life Model – Loss of cross‐section

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• 2011, research report titled “Evaluation of Multiple Corrosion
Protection Systems for Reinforced Concrete Bridge Decks”
• Test performed on damaged bars
• 75 years service life
LIFE CYCLE COST ANALYSIS – STUDY BY MATHEW O’REILLY

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Initial Cost

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Life cycle cost

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QUALITY CHANGES SINCE 1980
• Increased coating thickness
• Required roughness
• Clean substrate (backside contamination)
• No cracking allowed during bending
• Improved storage and handling
The 2014 product is greatly improved

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JOTUN APPROVED APPLICATOR
• Plant approvals acc. To ASTM 775 & CRSI
• Incorporated all changes to ensure
highest quality exceeding standards
• All major Rebar applicators in UAE &
neighboring countries are approved
Approved applicator = peace of mind

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SPECIFICATIONS
• ASTM A775/A775M - Coating Application and
Powder Qualification
• ASTM A934 - FBE Coating of Welded Mesh and
pre-fabricated Rebar
• ASTM D3963 - Standard Specification for
Fabrication and Field Requirements, Repair
Material Qualification
• Jotun Approved Applicator
How to specify epoxy coated Rebar

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FIELD HANDLING
• Damaged bars have lower performance than
undamaged bars
• BUT damaged bars still perform better than
uncoated bars
Appropriate handling

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FIELD HANDLING
• Spreader bars
• Nylon or padded slings
• Do not use chains or cables
• Cover with suitable material and minimize
condensation
Unloading, storage & job-site handling

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FIELD HANDLING
• Do not store directly on the ground
Storage

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FIELD HANDLING
• Only bend with the permission of the engineer
• Use appropiate bending diameters
• Bend at ambient temperature
Jobsite bending

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FIELD HANDLING
• Lift and set bars in place (don’t drag)
• Minimize traffic on bar placed bars
• Inspect bars and repair damaged coating with 2-
part patch material from approved coating
supplier
Bar placement

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FIELD HANDLING
• Use coated supports
• Tie using coated or plastic tie wire
Bar placement

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FIELD HANDLING
• Use power shears or chop saw
• No flame cutting
• Repair cut ends with two-part epoxy patching
material
Job-site cutting

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FIELD HANDLING
• Use plastic headed vibrators
Vibration

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QUESTIONS
1986 Florida keys bridges
Was this distress going to be typical
for the remaining 300 bridges?

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QUESTIONS
1986 Florida bridges
Poor quality concrete and coatings leading
to poor life
• Poor Concrete
• Poor Cover
• Chloride contamination
• Aggressive environment
• Poorly manufactured and stored
reinforcement

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QUESTIONS
2011 Florida bridges performance prediction
Most bridges in Florida with epoxy-coated
bars are predicted to last 100 years with
minimal corrosion damage

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QUESTIONS
Bond strength
Is the bond strength to concrete less with epoxy-coated
Rebar?
3 contributors to bond:
• Chemical adhesion
• Friction
• Bearing (Primary Factor)

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QUESTIONS
Bond strength
Is the bond strength to concrete less with epoxy-coated
Rebar?

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QUESTIONS
Bond strength
Is the bond strength to concrete less with epoxy-coated
Rebar?
Eventually lower bond strength can be easily overcome with:
• Longer development length
• Increased Rib area of Rebar

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PROJECTS

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CONCLUSIONS
• FBE‐coatings significantly reduce corrosion
rates compared to uncoated reinforcement
and some other technologies of corrosion
prevention
• FBE ‐ coatings provide lowest life cycle cost
among alternative technologies, with
minimal increase to initial project costs
• FBE – coatings increase the service life of a
structure to 75‐100 years in combination
with other good practices

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CONTACT JOTUN
ADDRESS:
P.O 51033
Sidra Office Tower 11th
floor
Al Soufouh, Dubai
UAE
PHONE:
+971-56 225 8008
EMAIL:
rene.mayer@jotun.com

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