Corrosion significantly compromises the durability of reinforced concrete structures, leading to progressive strength loss and eventual structural failure. This study aims to develop an eco-friendly, organic carbon-based coating for mild steel using carbon derived from sugarcane bagasse and eggshell, with the objective of enhancing corrosion resistance. The findings suggest that a synergistic combination of amorphous and crystalline carbon phases improves the protective properties of the coating. Various coating formulations were prepared, including 100 % sugarcane bagasse (SG100 %), 100 % eggshell (ES100 %), and composite blends of 25 % eggshell + 75 % sugarcane bagasse (ES25 %+SG75 %), 50 % eggshell + 50 % sugarcane bagasse (ES50 %+SG50 %), and 75 % eggshell + 25 % sugarcane bagasse (ES75 %+SG25 %). Coated mild steel strips were immersed in 3.5 % NaCl contaminated simulated concrete pore solution (SCPS) to mimic a saline environment, and in 0.5 M HCl to represent an acidic medium. Corrosion behavior was evaluated through potentiodynamic polarization studies, supported by physicochemical characterization, mechanical testing, and COMSOL simulation. Among the tested formulations, the ES50 %+SG50 % composite exhibited superior corrosion resistance, with corrosion rates of 0.04 mm/year in SCPS and 1.06 mm/year in HCl. Furthermore, no visible morphological or structural degradation was observed after 2000 test cycles, confirming the coating's stability and effectiveness as a corrosion-resistant barrier for reinforced concrete applications.


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