Durability and ultimate performance of concrete beams with epoxy-coated reinforcing bars

A series of experimental tests on reinforced concrete specimens with normal uncoated and epoxy-coated reinforcing bars (ECRBs) was carried out. A comprehensive report of the specimens, from material level to overall performance, is presented in this paper. At the material level, evaluation of the epoxy coating thickness showed that the production quality was not good. Some mechanical properties of bars with a thinner coating were better than those of their uncoated counterparts, while an increase in coating thickness offset the better mechanical properties and decreased the bond strength. Regarding durability, a comparison of the corrosion behaviour of the reinforcing bars and chloride penetration of the concrete cover in unloaded, statically-loaded and fatigue-loaded test specimens showed that higher fatigue loads and longer fatigue loading cycles decreased the corrosion resistance of the bars and increased the chloride penetration. The ultimate loads of the specimens were reduced and comparatively lower values were obtained for beams with bars with thicker coatings. The results of this work highlight the interrelationships among materials performance, durability and ultimate performance to achieve sustainable design for concrete elements with ECRBs in chloride-containing environments.