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Comparison Between CPCC, FBEC & CRSD

Priyanka Gupta

Before doing the comparison study lets know what these terms mean.
CPCC Cement-Polymer Composite Coated Rebars
FBEC Fusion Bonded Epoxy Coated Rebars
CRSD Corrosion Resistant Steel Deformed Rebars

1.0 Corrosion Control of Reinforcement bars (Rebars)

40% of failure of structures is on account of corrosion of embedded steel reinforcement
in concrete. Therefore corrosion control of steel reinforcement is a subject of paramount
importance.First and foremost for corrosion control is the good quality of concrete
through good construction practices.

2.0 Cement-Polymer Composite Coated Rebars (CPCC)

System at a glance

Products involved in CPCC normally are:

De-rusting Solution
Alkaline Powder
Phosphating Jelly
Inhibitor Solution
Sealing Solution

S Parameter Requirement

1. Pre-treatment Sand blasting to the near white metal


2. Primer Coat To be given within 4 hours of sand blasting.

3. Sealer Coat Within 30 minutes of primer coat, this should be given. Thickness 150
microns plus minus 25 microns.

4. Air curing Six hours before use in the work.

5. Continuity of No defects such as cracking, bulging, peeling, no rust mark. Inspect

coating visually.

6. Adhesion of Coated bars are bent at 120 o around a mandrel. NO peeling or cracking
coating test should be observed on outer radius.

7. Stacking Stack bars on buffer material.

8. Cutting , Coat bars can be cut and bent. Cut ends and weld positions should be
bending, welding treated with same formulation.

This system has been developed mainly as a factory / shop process.
The approach behind development of this system is that the base metal of rebars,
contains ? electrons which get readily released in corrosive environment leading to
oxidation of iron and thereby formation of Ferrous Oxide (II) (rust) as principal deterrent.

In order to prevent this oxidation a surface coating capable of interacting/nullifying the

released electrons is provided.

Further pre-stressing and reinforcing steel, in concrete during service life, are exposed
to an alkaline environment and this necessitates introductions of a top coat which should
be compatible to primer and alkaline environment.

3.0 Fusion Bonded Epoxy Coated Rebars (FBEC)

System at a glance

No. Parameter Requirement

1. Pre- 1. Bars are first cleaned from surface contamination
treatment such as oil, grease etc. by chemical process before shot blasting.
(Surface 2. The reinforcement bars are cleaned by shot blasting or
reparation) grit blasting to white or near white stage.

3. The blast cleaned bars are then heated through

induction heaters at preset temperature level around 230C.

2. Coating Hot bars are then fed to the coating booth, where the
epoxy powder is sprayed electrostatically.

3. Curing and Coated bars are then cured and forced

Cooling cooled by water spraying to enable handling and testing.

4. Continuity of On line and off line holiday checks, thickness checks are carried out. The
coating adhesion of the coated bars is also tested frequently by bending of the bar.

5. Testing of Various other tests are performed in laboratory like chemical resistance, short
Performance spray, resistance in continuance boiling water, abrasion resistance and impact
of resistance etc. These are conducted on every batch of production.

6. Handling & Fusion Bonded Epoxy Coated Bars require padded contacts during
Stacking transportation, stacking, handling and till the concreting is done.

7. Cutting, The cut ends, welded spots and handling damages are required to be repaired
bending & with special liquid epoxy compatible with the coating material as per
welding specification of the coating agency.

Fusion bonded epoxy is basically 100% solid finely ground fused powder particles,
which when heated; melt to form a continuous adherent film.

There is no passivating primer film provided in case of FBEC rebars.

This coating introduces a medium of weakness in the path of an intimate bond between
rebar and alkaline concrete.

Extensive investigation carried out on 40 bridges in Florida Key in USA has revealed
that disbandment can occur easily in the FBEC rebars which lacked passivation layer of
Ferrous oxide (II) and is a precursor to corrosion.

Higher co-efficient of Thermal Expansion of fusion bonded epoxies impose large

thermal stresses in epoxy coating leading to its early failure.

Epoxy coats the rebar in the following manner:

Adheres as coating

4.0 Corrosion Resistant Steel
Deformed Rebars (CRSD)
Mechanism of resistance to
corrosion begins with the
formation of initial layer of
protective oxide or rust. (Hypo
oxides). Unlike common rust on
normal rebars, the CRSD rust is
passive, tenacious and self-

The protective oxide is fine

textured, tightly adherent and a
barrier to moisture, oxygen,
carbon dioxide, Sulphur dioxide
and chloride effectively
preventing further corrosion.

Scale on normal bars of steel is

coarse textured flaky oxide that
does not prevent moisture or
oxygen from reaching the
underlying bars and continuing
the corrosion.

As corrosion resistance is in the chemistry of the grade, if the passive oxide layer gets
removed somehow, a new passive layer is formed immediately.

CRSD Mechanical Properties

Properties IS:1786 Fe500D CRSD

Yield Stress, YS (min, N/mm 2 ) 500 500

% Elongation 16 16

Ultimate Tensile Strength, UTS (min, N/mm 2 ) 565 580

5.0 Comparison (CPCC FBEC CRSD)


Thickness 175 mm 300 mm 300 mm 675 mm No coating required

of Coating

Type of Extrinsic Extrinsic Intrinsic

to rebar

Pre- Pretreatment is required Pretreatment is required No pre-treatment
treatment before coating before coating required

Treatment to Before coating the surface Before coating the surface The surface of the
surface made little rough when made little rough when finished good is not
some damage is some damage is disturbed or damaged
introduced. introduced. at all.

Temperature The whole process is done 230C 400C No treatment required

treatment at room temperature.

Special Modified mandrel diameter Modified mandrel diameter Same as other TMT
Bending is specified by Indian is specified by Indian rebars of Fe 500D
requirement Standard Standard grade

Defects Holiday Effect Holliday Effect Nil


6.0 Reference
Durability of Concrete Structures, RDSO, India
Guidelines for the use of High performance Concrete in Bridges, RDSO, India
IS: 13620 Fusion Bonded Epoxy Coated Reinforcement Bars Specification
A775/A775M ? 07b (Reapproved 2014) Standard Specification for Epoxy-Coated
Steel Reinforcing Bars


We at are thankful to Er Priyanka Gupta for submitting this very

important paper to us.