Epoxy coated rebar - "To coat or not to coat?"

This particular subject appears to be a little bit of a controversial one. There are many opinions regarding the the longevity and corrosion protection of epoxy coated rebar (ECR), but the purpose of this article is to simply discuss some findings and allow for people to just talk and have dialogue about it. Over the years (whether in the repair or new construction), I've seen quite a bit of ECR installed (within core and shell jobs as well as infrastructure repair work) in the hopes that it will prevent salts, moisture & carbon to hit the surfaces of the rebar and start the corrosion process. And in most cases, that appears to be the case. Here are a couple abstract links from ACI (American Concrete Institute) showing their long term findings and prove that:

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* 35-Year Field Performance of Epoxy-Coated Reinforcing Bars (concrete.org) Snapshot - "The corrosion state of bar samples removed in cores was examined as well as bond between the epoxy coating and steel and coating thickness. Chloride profiles from concrete cores were also obtained. Overall, the epoxy-coated reinforcing bars were in excellent condition, with very little active corrosion after up to 35 years of service."

* Assessment of Epoxy Coating on Bridge Deck Reinforcement (concrete.org) Snapshot - "Although the percentage of specimens exhibiting corrosion and cracking of the concrete cover was significantly lower for specimens containing epoxy-coated reinforcement, the results indicated that there was significant variability in the corrosion protection provided by the epoxy coating. Factors influencing the time to cracking of specimens containing epoxy-coated bars are discussed."

There is some research being done by a few DOT departments in the US and Canada that continue to challenge and explore the protection characteristics that ECR will provide over long periods of time. Here's an interesting investigation article:

* Field investigation of the corrosion protection performance of bridge decks and piles constructed with epoxy-coated reinforcing steel in Virginia. (bts.gov) Snapshot - "Abstract Virginia Department of Transportation E. Broad Street Richmond, VA The corrosion protection performance of epoxy-coated reinforcing steel (ECR) was assessed in three bridge decks and the piles in three marine structures in Virginia in . The decks were 17 years old, two of the marine structures were 8 years old, and the other marine structure was 7 years old at the time of the investigation. The deck investigations included visually surveying surface cracks in the right traffic lane and drilling 12 cores randomly located in the lowest 12th percentile cover depth. The pile investigations included removing 1 core at an elevation between high and low tides from each of 30 piles. The evaluation of the concrete in each core included visually inspecting and measuring moisture content, absorption, percent saturation, carbonation depth, and effective chloride diffusion constant. The evaluation of the ECR from each core included visually inspecting and measuring physical damage, coating thickness, adhesion loss and corrosion at damaged sites, and undercoating corrosion at adhesion test sites. The chloride content of the concrete and the carbonation of the ECR trace were also determined for each core. In the majority of bars examined, the epoxy coating has debonded or is debonding from the reinforcing bar. This occurs without the presence of chloride, and its rate is related to concrete moisture conditions, temperature, coating defects, and other bar and coating properties. Based on the results of this field study, epoxy coatings can be expected to debond from reinforcing steel in Virginia's marine environments in about 6 years and from bridge decks in about 15 years. The authors recommend that additional bridge decks be evaluated to confirm these results"

I believe that there are a few variables at play here.....such as the thickness and quality of the epoxy applied to the surface of the bar and the imperfections (holidays) on the surface of the rebar caused during fabrication, delivery, storage, handling, installation, age, etc.

What type of rebar you use is ultimately up to your Engineer and how they feel about their design criteria and anticipated performance. I personally have always been a fan of black or galvanized rebar due to cost, availability, bond to concrete, etc. And I feel that there are so many technologies out there that can enhance the performance of your reinforcement starting with good quality concrete, proper coverage, coating systems, etc. It's not to say that epoxy coated rebar is a bad option but there are options. Epoxy coated rebar is a viable option and I think overall, it will provide you with significant protection from corrosion based on much history and testing. But knowing that the quality of the protection is based on the condition/quality of the epoxy coating on the bar itself is very important.

Another option to consider can be FRP bars (carbon fiber). FRP bars are expensive and their structural characteristics differ from a standard ductile iron bar. The major benefit is the elimination of corrosion all together by removing the iron component. But again, the unique performance characteristics of FRP bar and price are things to consider. Here's a good video by Tyler Ley (TylerLey.com - About Me) regarding this very topic :

I find this topic to be very interesting and no one seems to have the silver bullet answer to it but talk to your Professional Engineers, specialty contractors and ask tons of questions. Educate yourself and make the best possible decision for your building. Most of the time, the need, cost, design criteria, environment and availability will dictate what you use.

This habit alone will allow you to add many years to the life of your building & structure. Share and educate. Restore and protect.

#concrete #construction #maintenance #nycrealestate #dcrealestate #forensics #corrosioncontrol #parkinglotmaintenance #westernspecialtycontractors #preventivemaintenance #infrastructure #buildingenvelope #buildingmanager #epoxycoatedrebar #reinforcement #rebar #debonding #westernspecialtycontractors #research #design #building #aci #metals #corrosion #rust #imperfections #reinforcement #parkinggarage #industrialconstruction #knowledge #awareness #carbonfiber #FRP

Wire decking is a critical element of any pallet racking system. The cross-hatch wire mesh provides the support needed to store loads reliably while allowing light and air transfer, a benefit for various storage applications. But not all wire decking is created equal.

Not only can build quality vary from manufacturer to manufacturer, but there are different coatings that each come with unique advantages and, of course, disadvantages. What are these different types of coatings? How can you choose the right one for your facility&#;s needs? Those are the questions we&#;ll be exploring today.

Different Wire Deck Coatings: The Basics

Pallet rack wire decking might appear at first glance as a basic accessory of a pallet racking system. But, under the surface, there are a variety of considerations that can have an impact on not only the efficacy of the decking choice but also its longevity.

The most common coating options you&#;ll find on the market today include:

• Galvanized (also known as zinc-coated)
• Epoxy-based powder coated
• Painted

Each option here will offer different benefits in terms of strength, resistance to environmental factors, and cost. Before you start shopping around for the right decking choice for your facility, it&#;s important to understand what each coating type offers. Not only will it help you uncover how each type of decking will play into your daily operations, but having a grasp of overall costs will help you better plan a budget for your pallet racking system. Let&#;s dive a little deeper into this topic.

Painted Wire Decking

First on our list is painted wire decking. Relative to other options, painted decking is one of the more basic and cost-effective decking choices. This type of decking receives a coating of industrial paint, and it&#;s often the case that they can be customized to meet the aesthetic needs of your warehouse.

While cost-effective, you get what you pay for. Painted wire decks are prone to chips, scratching, and peeling over time. This is especially true for high-traffic facilities with fast-rotating stock, which can speed up the wear and tear on painted decks.

Powder-Coated Wire Decking

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Powder-coated decks go through a dry finishing process called electrostatic dry deposition. Basically, a dry mixture of polymer resins, often epoxy, is applied through a spray gun using an electrostatic charge that binds the mixture to the wire.

The powder coating process is longer lasting and more durable relative to regular painting. Moreover, the paint doesn&#;t hinder the deck&#;s flexibility, allowing it to withstand vibration without cracking. However, this process is more time-consuming and expensive, which drives up the cost.

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East Coast Storage Equipment has a massive inventory of both used and new decking choices to find the right type for your facility.CONTACT US

Galvanized Wire Decking

Last on our list is galvanized, also known as zinc-coated wire decking. Instead of paint or powder-coating, these decks leverage a dipping process in hot molten zinc. During this galvanization process, the zinc binds to the steel wire.

This helps prevent corrosion and wear, much more so than other coating options. As a result, this type of deck coating is much more durable but also the most expensive. 

Coating Performance

So, how do these coatings stack up against each other? Luckily, research from decking manufacturer J&L Wire tells a pretty compelling story. They put these popular wire deck coatings up to the test in several key experiments. They are:

• Bend testing
• Abrasion testing
• Salt-spray test

In the bend test, painted and powder-coated wire failed after bending around a mandrel equal to the diameter of the test sample. Galvanized wire, on the other hand, passed without any visible cracks. It was found that the chemical bond that binds both the painted and powder-coated wire was insufficient to handle the bending stress. The galvanized coating, which binds through a metallic bond, did not.

During the abrasion test, a pallet loaded with around 1,500 pounds was pulled across the decking for a total of 50 times. In the end, there was visible wear on both the painted and powder-coated decking, but not the galvanized. 

The salt spray test also presented similar results. Here, the worn samples from the abrasion test underwent a laboratory salt spray analysis. Both the painted and powder-coated deck saw visible red rust after 24 hours of exposure. The galvanized deck, however, only presented signs of white rust and minimal red rust spots.

Choosing the Right Coating for Your Needs

So, what does all this research mean? Well, for the most part, galvanized wire decking, as well as galvanized pallet racks, are the preferred choice for most storage applications. It&#;s far more durable and long-lasting. It&#;s an excellent choice for a variety of applications: 

• Outdoor storage environments
• Indoor storage environments
• Cold storage environments
• Sanitary environments where regular cleanings are needed
• Environments where regular maintenance is difficult

But, this strength and durability come at a cost. If the price of galvanized options is stressing your budget, the next best choice would be powder-coated decking. 

While best for indoor use, it can also work well in outdoor environments. The high level of durability helps powder-coated decking maintain color and gloss while being more environmentally friendly and sustainable relative to paint-coated decks.

If the price of galvanized options is stressing your budget, the next best choice would be powder-coated decking. 

If both powder-coated and galvanized options are off the table, regular paint-coated decks will still offer some level of strength and durability, although not as much as those other options. Paint-coated decks will show wear and tear much quicker. They&#;ll also need regular maintenance and touch-ups on the paint coating to help prevent rust.

Explore Your Wire Decking Options with East Coast Storage Equipment

If you&#;re searching for the perfect wire decking for your facility, you have a few options. Between paint, powder-coating, and galvanized steel, galvanized wire decks offer the most in terms of durability and longevity. But they&#;re also the most expensive. 

Ultimately, you&#;ll need to weigh your budget against your needs to find the right decking choice for your business. If you&#;re searching for a reputable supplier to meet all your equipment needs, look no further than East Coast Storage Equipment. We carry a wide selection of both used and new wire decking. Get in touch today to learn more about your options or if you need help finding the right decking for your facility.

For more information, please visit Epoxy Coated Wire Mesh.