Detecting Rebar Corrosion with Half-Cell Potential Testing

Concrete may appear durable from the outside, but within its depths, steel reinforcement bars (rebars) may be silently corroding. This hidden deterioration can compromise the long-term safety and performance of structures like columns, slabs, and beams. That’s where the Half-Cell Potential Test comes in — a non-destructive, cost-effective method to detect corrosion activity in steel embedded in concrete.

TCR Engineering conducts Half-Cell Potential Testing on steel dowels embedded in columns at the customer’s site. Our qualified team will visit the location, bringing along the necessary equipment and expertise to conduct this vital evaluation. The Half-Cell Potential Test (also called the Half-Cell Potentiometer Test) is a standard electrochemical technique used to assess the likelihood of corrosion in steel reinforcement without damaging the structure.

Using a copper-copper sulfate reference electrode, measurements of electrical potential differences are taken on the surface of the concrete. These values indicate whether the embedded steel is actively corroding, and if so, how severely.

Why is this Test Important?

1. Early Corrosion Detection The test identifies areas where corrosion has likely started—even if there are no visible signs. Early detection enables timely intervention.

2. Non-Destructive & Reliable Since the test doesn’t harm the structure, it’s safe for operational buildings and sensitive infrastructure.

3. Structural Health Monitoring It allows asset owners, engineers, and consultants to monitor and track deterioration trends over time.

4. Optimized Maintenance Planning The results guide the repair strategy. Resources can be focused on the most vulnerable zones, improving cost-efficiency.

5. Safety and Longevity Timely action based on test results can prevent structural failures, ensuring both safety and extended lifespan of the asset.

Test Procedure at the Site

For this project, TCR Engineering will deploy trained technicians to the customer’s site to conduct the test during a dedicated shift. Here's how the process typically works:

• Surface Preparation: Selected concrete areas are cleaned to ensure good electrical contact.

• Bar Exposure (Customer Scope): The steel reinforcement at specific test points must be exposed to allow electrical connection to the electrode. This preparation is to be arranged by the customer.

• Half-Cell Measurement: TCR’s technician uses specialized equipment to record electrical potentials at designated grid points on the concrete surface.

• Data Interpretation: The recorded potentials are analyzed to identify zones with a high probability of active corrosion.

• Post-Test Restoration (Customer Scope): Once testing is complete, the exposed concrete must be refilled by the customer.

Why Choose TCR Engineering?

• On-Site Testing Expertise: Our team is equipped to travel to your location, ensuring seamless execution with minimal disruption.

• Highly Trained Technicians: All tests are performed by qualified professionals with years of experience in structural condition assessment.

• Advanced Equipment & Standards: We use calibrated, industry-compliant instruments and follow standard test methods to ensure accuracy and repeatability.

• Actionable Insights: Our reports don’t just show readings—they guide decision-makers with engineering interpretations and repair recommendations.

Scheduling and Coordination

To ensure efficient mobilization of our team and equipment, we request a 3-day advance notice for scheduling. Coordination with your site team for access, bar exposure, and concrete refilling will help keep the testing smooth and timely.

Conclusion

The Half-Cell Potential Test is a critical diagnostic tool that enables structural engineers and asset owners to take proactive steps before corrosion turns into costly damage. TCR Engineering brings this advanced testing capability right to your site, combining deep technical knowledge with efficient execution.

If you're managing aging infrastructure or need assurance about the condition of embedded steel reinforcements, get in touch with TCR Engineering for reliable on-site testing services.