The purpose of this research was to develop a new index for concrete bridge deck management in Utah. Data were collected in the summer of 2005 from 15 concrete bridge decks in the vicinity of Salt Lake City. The decks ranged from 2 to 21 years in age and were all constructed using epoxy-coated rebar. Visual inspection, sounding, Schmidt hammer testing, half-cell potential testing, and chloride concentration testing were performed on six 6-ft by 6-ft test areas randomly distributed within the single lane closed to traffic on each deck, and testing protocols followed American Society for Testing and Materials standards to the extent possible. Collected data were analyzed using statistics, and age, cover, and half-cell potential were ultimately selected for inclusion in a new Utah Bridge Deck Index (UBDI); these variables effectively reflect chloride-induced corrosion mechanisms active on Utah bridge decks, are highly correlated to delamination distresses, and are relatively easy to measure compared to chloride concentration. At the request of Utah Department of Transportation (UDOT) personnel, the UBDI equation was structured around a deduct system using a 100-point scale similar to the sufficiency rating system, in which a perfect bridge deck receives a score of 100. Coefficients were selected based largely on the judgment of the researchers and the UDOT personnel involved in the research, and threshold values for maintenance, rehabilitation, and replacement (MR&R) options were specified to be the same as those associated with the standard sufficiency ratings. The UBDI and corresponding MR&R recommendation were then provided for each of the bridge decks tested in this research; nine of the decks are recommended for preventive treatment, and six are recommended for rehabilitation. In addition, the possibility of treatment applications was considered, leading to required adjustments in the UBDI calculation; the treatment options that were considered include an epoxy seal, an HPC overlay, and an asphalt membrane overlay. Four case scenarios were developed to demonstrate the response of the revised UBDI equation to these treatments. Finally, as aids for UDOT personnel implementing this research, charts were created to facilitate rapid determination of the required number of half-cell potential and concrete cover measurements for different levels of reliability and tolerance. The UBDI developed in this research is recommended for implementation by UDOT personnel as a tool for optimizing the timing of MR&R treatments on concrete bridge decks similar to those evaluated in this project. In measuring cover and half-cell potential values, UDOT personnel should utilize the sampling guidelines presented in this report to ensure adequate characterization of each deck. Furthermore, to facilitate the inclusion of treatment effects in the UBDI, UDOT personnel should establish a policy of recording the types and dates of all MR&R treatments applied to bridge decks. As performance data are collected for specific treatments over time, the treatment lives proposed in this research for epoxy seals, HPC overlays, and asphalt membrane overlays should be revised as needed, and information for other treatments may be added. In addition, to maximize the predictive capabilities of the UBDI, more accurate relationships between half-cell potential values and deck age should be developed for estimating future deck condition.

Half-cell potential testing has been recommended as a non-destructive method for assessing the corrosion potential of reinforcing steel in concrete bridge decks. The technique is particularly useful because it can be utilized to evaluate the probability of corrosion before damage is evident at the surface of a bridge deck. The specific objective of this research was to quantify the effects of age, chloride concentration, concrete cover thickness, spatial position, temperature, and presence or condition of epoxy coating on half-cell potential measurements of concrete bridge decks typical of those in Utah. The laboratory testing associated with this research followed a full-factorial experimental design. Nine rectangular concrete slab specimens were prepared, each containing three black reinforcing steel bars at three different concrete cover depths and four epoxy-coated bars each having different coating conditions. Three replicate slabs were created at each of three different chloride concentrations. Three repeated measurements were made at each of three locations along each of the seven bars in all nine of the slabs at three ages, with testing performed at three temperatures per age. In addition, compressive strengths of the concrete cylinders were measured at 7 and 28 days. Statistical analyses of the half-cell potentials were performed using analysis of variation and Tukey's method for multiple comparisons. Although American Society for Testing and Materials C 876 only specifies the measuring of half-cell potentials of uncoated reinforcing steel, credible half-cell potentials were also obtained for epoxy-coated rebar in this research. The results of the testing indicated that all of the factors except for cover thickness and spatial position have important impacts on half-cell potentials over the ranges of levels investigated in this research. Half-cell potential measurements became consistently less negative with increasing age and consistently more negative with increasing chloride concentrations and increasing temperature. With regard to the factor of treatment, the uncoated rebar had the most negative half-cell potential, followed by epoxy-coated rebar with rib scrapes, pliers strikes, end cuts, and full epoxy coatings, in that order. While these data indicate that a coating, even damaged, reduces the probability of corrosion when compared to uncoated rebar, the data also suggest that both the amount and distribution of the coating damage over the affected rebar influence corrosion. Given these research findings, bridge engineers and managers should have confidence in using half-cell potential testing for assessing the corrosion probability of reinforcing steel in concrete bridge decks. In decks with properties similar to those investigated in this research, variations in age, chloride concentration, temperature, and presence or condition of epoxy coating cause variation in half-cell potential readings consistent with the effects of these factors on corrosion. Therefore, the half-cell potential technique is recommended for assessing the probability of corrosion of reinforcing steel on bridge decks. Although the use of epoxy-coated reinforcement, even when damaged, reduces the probability of corrosion, care should still be taken to minimize any damage to the coating during shipping and field handling. Owners and contractors alike should establish appropriate inspection protocols and repair methods for epoxy-coated reinforcing steel used on bridge decks to ensure maximum service life.