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In reinforced concrete structures cover is normally provided to protect steel reinforcement from corrosion and to provide fire resistance Extensive corrosion affects not only the structure’s service life but also the residents’ safety. However, the use of cover more than required is undesirable in the following ways:

There is no maximum limit on cover as far as i know When rebars corrode, the resulting volume spreading out leads to concrete spalling and thus the cracking of the plaster It's been a while since i looked into it, but the service level checks may inherently account for this when checking for cracking.

Causes corrosion, weakens the structure, reduces fire resistance, and leads to cracks

Reduces the effective depth of the section, affects structural capacity, and causes problems in bonding. Why clear cover can make or break your structure From a steel corrosion standpoint, too much cover is usually not a bad thing unless it gets really excessive to the point where you need to provide additional shrinkage and temperature reinforcing. Clear cover is crucial for the durability and safety of reinforced concrete structures

It protects against corrosion, boosts fire resistance, ensures strong bonding, and enhances overall durability. Adequate clear cover is essential for ensuring the durability and longevity of reinforced concrete elements, as it prevents direct exposure of the steel to corrosive agents and provides sufficient space for concrete to bond effectively with the reinforcement. Insufficient cover can result in corrosion of the reinforcement, which can weaken the structure and cause cracking and spalling of the concrete The cover also affects the strength of the concrete structure.

Clear cover refers to the distance between the outer surface of the concrete and the nearest exposed reinforcement bar

It is the measurement from the concrete surface to the outermost surface of the reinforcement, excluding any additional protective layers or coatings.

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