Influence of rebar geometry on the steel-concrete interface of reinforced concrete

•Bleeding gap is found below rib of vertical rebar.•Interfacial porosity can be affected by rib and diameter of rebar.•Locations of rust stains are associated with locations with respect to rib.•Correlations between distribution of chloride ions and rebar geometry.•Recommended methods to reduce cutting damage on the steel-concrete interface. This paper investigates the effects of rebar geometry, namely the rib and diameter of rebar, on the steel–concrete interface (SCI) and corrosion initiation of reinforcing steel. Cutting-induced damage on the SCI is also studied using various W/C ratios, cutting wheels and rebar diameters. Interfacial porosity and the distribution of chloride ions at different locations with respect to the rib of vertical rebar and the phase distribution of the SCI of horizontal rebar with various diameters is quantified. The results show that a macroscopic gap can be found below the rib of vertical rebar. Corrosion initiation of vertical rebar is associated with interfacial porosity at different locations with respect to the rib of vertical rebars. Local water content near the SCI of horizontal rebar is increased when using a larger rebar diameter. Cutting-induced damage can be reduced by decreasing the water to cement ratio and rebar diameter.