Sherwin-Williams launches Sher-Bar TEC coating for rebar

Sherwin-Williams Protective & Marine introduces Sher-Bar TEC, a revolutionary new coating technology for the concrete industry. Designed for a range of construction applications and environments, Textured Epoxy Coatings (TEC) redefine the standard for rebar coatings, delivering increased bond strength, damage tolerance and corrosion resistance for horizontal and vertical concrete projects. These properties extend asset life and reduce the environmental impact associated with construction and maintenance.

"Sher-Bar TEC is a breakthrough in concrete and construction innovation," said Jeffrey Rogozinski, global director, Protective and Marine Performance Coatings, Sherwin-Williams. "Textured epoxy coatings have the potential to significantly extend the life of critical infrastructure assets – providing a cost-effective solution that adds unprecedented value. With this novel TEC technology, Sherwin-Williams Protection & Marine is ushering in a new era of infrastructure protection and sustainability. "

As a secondary coating, Sher-Bar TEC provides additional protection against the industry’s leading anti-corrosion solution: epoxy-coated rebar (ECR), often referred to as “green rebar.” ECR has a smoother surface than uncoated steel, thus reducing the bond strength to the concrete, requiring more steel to be used in the project. This additional steel added cost and weight and caused the on-site steel mesh to become clogged when the concrete was poured. These shortcomings limit the use of ECR worldwide, leaving structures susceptible to corrosion and decay.

Sher-Bar TEC has textured elements that offer significant improvements over ECR and uncoated steel bars (called “black bars”). Testing by independent laboratories and research universities documents and demonstrates Sher-Bar TEC's superior performance in bond strength, durability and corrosion resistance. This research led to the development of the new ASTM A1124/A1124M-23 Standard Specification for Textured Epoxy Coated Rebar, emphasizing the importance of TEC in the construction industry.

According to a Wisconsin Department of Transportation study, Sher-Bar TEC can reduce rebar overlap by 10 to 60 percent compared to black rebar and ECR. This reduction helps reduce project weight, raw material costs and logistics expenses, while also potentially allowing the use of higher grades of concrete.

Testing at the University of Illinois showed that cracks in concrete with Sher-Bar TEC-coated rebar were about half as wide as those with ECR rebar, suggesting that road salt and water that can penetrate the concrete and meet the rebar will reduce corrosion. Other tests show that concrete with Sher-Bar TEC-coated rebar has lower stress levels because the textured rebar is more involved in the structure.

"Extensive testing has shown that Sher-Bar TEC is a unique and value-added solution compared to existing rebar coatings and black rods," Anthony Del Percio, North American Sales Manager for Rebar, Valve and Traffic Markings for Sherwin-Williams Protective & Marine. "Its performance marks a major leap forward in concrete reinforcement."

Application of Sher-Bar TEC is also practical and efficient under highly controlled shop conditions. Powdered Sher-Bar TEC is applied immediately after applying powdered sintered epoxy to the rebar to form the ECR. Both layers cure simultaneously and create a seamless, monolithic coating that enhances barrier properties and durability, providing superior corrosion resistance and damage tolerance. Furthermore, the resulting texture restores the required bonding interaction between steel and concrete, which is lost with smooth ECR surfaces.

Sher-Bar TEC also provides beneficial sustainability impacts. Made from up to 30% upcycled materials repurposed from landfill, Sher-Bar TEC supports environmentally friendly practices and promotes the potential use of alternative cement technologies, thereby reducing the substantial carbon emissions associated with concrete production.