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I disagree with the "much higher." Many iron workers I talk to actually prefer epoxy bars as they don't get as hot as black bars. In north america, costs for installation may be $0.05/lb more than black bars.

ENR publishes prices of uncoated and coated bars. The 20-city average costs published in September 2011 for the USA were $0.45 and $0.66 for black and coated bars, respectively. I would expect the A934 coating to cost in the range of $0.70 above the steel price, but there are so few coaters...

Single component or spray materials are not recommended. Two part epoxies are the best method for damage and end repair. They should be available from the bar supplier.

There are two general types of epoxy-coated reinforcing, but the most common meets ASTM A775. Approximately 600,000 ton of this is produced each year in the USA and about 400,000 ton is produced in the middle east. Please visit www.epoxyinterestgroup.org for more information.