Sherwin-Williams Protective & Marine launched Sher-Bar TEC, a transformative new coating technology for the concrete industry. Designed for an array of construction applications and environments, the textured epoxy coating (TEC) redefines standards for rebar coatings, offering increased bond strength, damage tolerance and corrosion resistance for both horizontal and vertical concrete projects. These properties enable improved asset longevity and reduced environmental impacts associated with construction and maintenance.

“Sher-Bar TEC is a breakthrough in concrete and construction innovation,” says Jeffrey Rogozinski, Global Director of Functional Coatings for Sherwin-Williams Protective & Marine. “The textured epoxy coating has the potential to significantly extend the lifespan of critical infrastructure assets – offering a cost-effective solution that adds unprecedented value. With this novel TEC technology, Sherwin-Williams Protective & Marine is ushering in a new era of infrastructure protection and sustainability.”

As a secondary coating, Sher-Bar TEC provides added protection for the industry’s leading corrosion protection solution: epoxy-coated rebar (ECR), which is commonly referred to as “green bar.” With a smoother surface than uncoated rebar, ECR results in reduced bond strength with concrete, necessitating the use of more rebar in projects. This additional rebar adds costs and weight, as well as on-site rebar grid congestion when pouring concrete. These drawbacks have limited the use of ECR worldwide, leaving structures susceptible to corrosion and decay.

Sher-Bar TEC, with its textured elements, offers significant improvements over both ECR and uncoated rebar, known as “black bar.” Tests by independent labs and research universities have documented and demonstrated Sher-Bar TEC’s superior performance in bond strength, durability and corrosion resistance. The research led to the development of the new ASTM A1124/A1124M-23 Standard Specification for Textured Epoxy-Coated Steel Reinforcing Bars, underlining 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%, compared to black bar and ECR. This reduction helps to lower project weights, raw material costs and logistical expenses while also potentially allowing for the use of higher grades of concrete.

Tests 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 bars – suggesting that less road salt and water will be able to infiltrate concrete and meet rebar where it could promote corrosion. Additional tests showed concrete with Sher-Bar TEC-coated rebar had lower levels of stress because the textured rebar was more engaged in the structure.

“Extensive testing has shown that Sher-Bar TEC is a unique and value-adding solution compared to existing rebar coatings and black bar,” says Anthony Del Percio, North American Sales Manager for Rebar, Valve and Traffic Markings for Sherwin-Williams Protective & Marine. “Its performance marks a significant leap forward in the realm of concrete reinforcement.”

Application of Sher-Bar TEC is also practical and efficient in highly controlled shop conditions. After coating the rebar with powdered fusion-bonded epoxy to create ECR, the powdered Sher-Bar TEC is immediately applied. The two layers cure simultaneously and form a seamless, monolithic coating that enhances barrier and durability properties to deliver superior corrosion resistance and damage tolerance. Additionally, the resulting texture restores the desired bonding interaction between the steel and concrete that is lost with smooth ECR surfaces.

Sher-Bar TEC also provides favorable sustainability impacts. Made with up to 30% upcycled materials redirected from landfills, Sher-Bar TEC supports environmentally friendly practices and promotes the potential use of alternative cementitious technologies that could reduce the significant carbon emissions associated with concrete production.