When something NEW hits the FBE powder scene you can guarantee people will be talking! With that in mind, we asked our resident FBE powder expert, Rob Phillippi, what are the top 5 questions he’s asked the most. The results are in!

1. Textured rebar - really? What is that?

This is a dual layer epoxy coating system designed to provide a DOT bridge engineer with an option to specify rebar that will provide a 100 year bridge design.  The base layer is the same fusion bonded epoxy used on rebar since 1973 to provide the best corrosion resistance in the industry. The difference is the innovative, next generation textured top coat.  The top texture layer provides several benefits, including excellent concrete adhesion and additional field damage tolerance.

2. What is the main benefit of texture epoxy coating?

Adhesion!  We know, based on strict laboratory testing, the current green fusion bonded epoxy provides 85% adhesion to concrete when compared to uncoated carbon steel rebar.  Adding this new texture layer now provides a minimum of 96% adhesion under the same testing conditions.  That’s impressive! The epoxy coating industry is currently performing additional studies that so far show adhesion is closer to 100%.  This added adhesion provides a design engineer the option of a product with over 50 years of excellent corrosion protection AND will now provide similar adhesion to uncoated bar, instead of inferior corrosion resistant materials that provide similar adhesion to the carbon steel.

3. OK – but we’ve been ok with the existing FBE for years. Are there any other advantages to Textured Epoxy Coating?

The texture coating layer was formulated to provide additional field handling ease by providing a more damage resistant rebar.  This layer has been tested against a modified chip resistance test (ASTM D3170) and impact testing (ASTM G14) with excellent results.  The added layer of coating provides a sacrificial coating to protect the corrosion resistant epoxy below from the tough environment of a construction job site. More protection at every stage. It’s a win-win.

4. You mentioned testing. Is there an ASTM standard associated with texture epoxy coating?

ASTM 1124 was developed and approved in the fall of 2023 by the A01 Main Committee.  It was published and available for public viewing in early 2024.  This standard provides the CRSI Certified Epoxy Applicators the requirements and regulations to apply to this new generation technology.

5. Is this just IFS or is this an industry thing? Is Concrete Reinforcing Steel Institute involved with creating a coating standard?

The Epoxy Coating Committee is currently in the process of developing a coating standard that will allow CRSI Certified Epoxy Applicators to be audited for conforming to the ASTM 1124 standard.  This committee is working hard to have a standard approved by the CRSI Independent Manufacturing Certification Committee (IMCC) in early 2025, which will allow coating plants to begin applying texture coating to a verified standard.