中文简体
EnglishRebar Fusion Bonded Epoxy (FBE) Powder Coating
Industrial-grade protective coating solutions: environmentally friendly, durable, and cost-effective.
Intro to Rebar Fusion Bonded Epoxy (FBE) Powder Coating
Rebar Fusion Bonded Epoxy (FBE) Powder Coating is a thermoset epoxy used exclusively as a corrosion-resistant coating for steel reinforcement bars (rebar) used in concrete structures. Applied to pre-heated steel, the powder melts, flows, and rapidly cures into a monolithic, continuous film. The primary purpose of FBE is to prevent the corrosion of the rebar caused by chloride ions (salt) and carbonation that penetrate the concrete. This protection is vital for infrastructure like bridges, marine structures, and parking garages, significantly extending the service life of the concrete asset.
Application Process and Barrier Protection
The FBE coating process is highly specialized: 1) The rebar is abrasive blasted (near-white) to achieve maximum cleanliness and a specified anchor profile. 2) The bar is induction heated to a specific temperature (e.g., 220∘C to 250∘C). 3) The powder is electrostatically sprayed onto the hot bar, where it instantly melts and adheres. The heat drives the fusion and rapid cross-linking. The resulting FBE film acts as a critical barrier against the ingress of corrosive agents, especially chlorides, which cause the steel to rust and the concrete to crack (spalling). FBE coatings are tested to exacting standards (e.g., ASTM A775) for holiday detection (pinholes), adhesion (bending tests), and thickness uniformity, ensuring the protective film is intact and robust over the ribbed surface of the rebar.
Specifications
| Property | ASTM A775 / AASHTO M 284 Standard |
| Chemical Base | High-Build Fusion Bonded Epoxy (Thermoset) |
| Minimum Film Thickness | 175 to 300 microns (Typically 7 to 12 mils) |
| Adhesion (Bend Test) | Must withstand mandated bend radii without cracking |
| Holiday Detection | Mandatory testing (Max allowed defects per foot) |
| Resistance to Chlorides | Excellent (Tested to long-term polarization) |
| Application Method | Fluidized Bed or Electrostatic Spray onto Hot Substrate |
| Substrate Requirement | Abrasive Blast Cleaned (Near-White) |
| Primary Function | Corrosion Prevention in Concrete |
Application Fields
- Bridges and Overpasses: Structural support in areas exposed to road salts.
- Parking Garages: Highly susceptible to corrosion from salt carried by vehicles.
- Marine Structures: Piers, jetties, and coastal foundations in high-chloride zones.
- Water Treatment and Chemical Plants: Structures exposed to corrosive liquids or vapors.
- Major Infrastructure: Highways, tunnels, and foundational concrete in severe environments.
Key Characteristics
- Superior Chloride Barrier: Forms an impermeable film that prevents salt from reaching the steel.
- Galvanic Protection Support: Works in tandem with the concrete's natural alkaline environment to stop rust.
- High Adhesion: Maintained bond strength even when the rebar is stressed during concrete pouring and curing.
- Tested Integrity: Each bar is inspected for holidays (pinholes) to ensure a continuous protective film.
- Structural Longevity: Significantly extends the useful life of concrete infrastructure in aggressive environments.
Comparison: FBE Rebar vs. Untreated Rebar
| Feature | FBE Coated Rebar | Untreated (Black) Rebar |
| Corrosion Protection | Excellent (Chloride Barrier) | Minimal (Relies on concrete alkalinity) |
| Service Life in Salt Environment | Extended (Decades) | Limited (Prone to early spalling/failure) |
| Initial Cost | Higher (Coating + Inspection cost) | Lower |
| Life-Cycle Cost | Lower (Fewer repairs, longer life) | Higher (Costly repairs/replacement) |
| Adhesion to Concrete | Very Good (Surface profile assists) | Good |
Why choose us
Customization: We have a strong R&D team,and we can develop and produce products according to different requirement of customers.
Cost: We have our own raw material production center.So we can offer the most favourable price and good-quality products directly.
Quality: We have our own testing lab and the most advanced and complete inspection equipment, which can ensure the quality of our products.
Capacity: Our annual production capacity is over 30000 tons, we can meet the needs of different customers with diverse purchase quantity.
Service: We focus on developing high-quality products for top-end markets. Our products are in line with international standards, and are mainly exported to Europe, America, Southeast Asia, South America and other destinations around the world.
Shipment: We are only 200 kilometers away from the Shanghai Port and 230 kilometers to Ningbo port, it is very convenient and efficient to ship goods to any other countries.
Customization
Quality
Capacity
Service
Shipment
Frequently Asked Questions (FAQs)
- Q: What is a "holiday" in FBE coating, and why is testing mandatory?
- A: A holiday is a pinhole or discontinuity in the coating film. Testing is mandatory because even small breaks in the barrier can allow chlorides to penetrate and initiate localized corrosion, compromising the entire bar.
- Q: Does the FBE coating reduce the strength or bond of the rebar to the concrete?
- A: No. FBE coatings, when applied correctly to the specified profile, have been proven to maintain the necessary bond strength and structural integrity required for concrete reinforcement.
- Q: Are all FBE powders the same?
- A: No. FBE formulations vary slightly in terms of gel time, cure temperature, and flexibility, but they must all meet the rigorous performance requirements of standards like ASTM A775 to be used on rebar.
Selection Guide: Rebar Fusion Bonded Epoxy (FBE)
Rebar FBE Powder Coating is the absolute necessity when:
- The concrete structure is exposed to high levels of chlorides (road salts, saltwater, de-icing chemicals).
- The extended service life of the infrastructure (50+ years) is a non-negotiable requirement.
- The project must comply with state, federal, or marine authority specifications for corrosion protection (e.g., AASHTO M 284).
- The process requires a thick, continuous, highly adhesive barrier that withstands installation stresses.
- The finished product must pass mandatory quality control inspections for film integrity (holiday testing).
