The corrosion protection performance of epoxy-coated reinforcing steel (ECR) was evaluated in 18 concrete bridge decks in Virginia in 1997. The decks were 2 to 20 years old at the time of the investigation. The concrete bridge deck inspections included crack survey and cover depth determination in the right traffic lane. Maximum of 12 cores with the top reinforcement randomly located in the lowest 12th percentile cover depth and 3 cores with the truss bars were drilled from each bridge deck. The concrete core evaluation included visual examination and determination of carbonation depth, moisture content, absorption, percent saturation and chloride content at 13 mm depth. Rapid chloride permeability test was also performed for the surface and base concrete on samples obtained from cores containing truss bars. The ECR inspection consisted of visual examination and damage evaluation, coating thickness and adhesion determination. The condition of the steel underneath the epoxy coating was also evaluated. Adhesion loss of the epoxy coating to the steel surface was detected for 4 years old bridge decks. The epoxy coating had debonded from the reinforcing bar before the chloride arrival. Visible signs of a possibility of a corrosion process underneath the coating suggest that ECR will not provide any or little additional service life for concrete bridge decks in comparison to black steel. Other systems, which will provide longer protection with a higher degree of reliability against chloride induced corrosion of steel in concrete, should be considered. / Ph. D.

It is known that subsidence cracking may cause premature deterioration of concrete slab structures in salt laden environments. Chlorides from either deicing salts or marine environments may cause chloride-induced corrosion of the reinforcing steel resulting in spalling of the cover concrete. Concrete specimens with 16 mm (# 5) diameter bars were cast with various cover depths, bar spacing and two concrete mixture types to determine the influence that epoxy coated reinforcement, cement type and bar spacing may have on the probability of subsidence cracking in bridge deck slabs. It was determined that there is not a significant difference in the probability of cracking of concrete between concrete cast with epoxy coated reinforcing steel and bare reinforcing steel. Concrete subsidence cracking was found to be dependent upon the clear cover depth and cement type. / Master of Science

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Three epoxy-coated reinforcing steel (ECR) types removed from job sites, one shipped directly from the coater's plant, three commercial corrosion inhibitors, and one ECR plus a corrosion inhibitor were evaluated as reinforcing steel corrosion protection systems against chloride induced corrosion. The three corrosion inhibitors were calcium nitrite, an aqueous mixture of esters and amines, and a mixture of alcohol and amine. The ECR was tested in two groups, 0% and 1% coating damage. Corrosion protection performance was evaluated by the amount of visually observed blister surface area, for the ECR, and corroded surface area, for the tested corrosion inhibitors. Results of the ECR testing demonstrated that coating debondment and corrosion of ECR is directly related to the amount of damage present in the coating, as well as coating thickness. For the bare steel tested with and without corrosion inhibitors, the results showed that corrosion increases with increasing chloride concentrations. Corrosion inhibition characteristics were demonstrated only by the calcium nitrite corrosion inhibitor. A corrosion protection evaluation test was developed for concrete corrosion inhibitor admixtures. The test solution is a simulated concrete pore water. Corrosion is accelerated by evaluating the temperature to field conditions of 40 C. The test consists of a 7 day pretreatment period followed by a 90 day test period. The corrosive sodium chloride is added to the solution containing the bare or epoxy-coated reinforcing steel specimens after the 7 day pretreatment period. In addition, the solution is periodically saturated with oxygen. / Master of Science

This study is an evaluation of epoxy coated reinforcing steel (ECR) and its ability to effectively provide corrosion protection in reinforced concrete highway bridge decks. An analysis was conducted on 10 bridge decks built in the state of Virginia between the years 1981 and 1995. A total of 141 cores containing either ECR or bare steel were evaluated. A chloride solution was applied to the surface on a weekly cycle (for a total duration of 3.06 years) and a nondestructive electrochemical testing was performed on each core on a monthly cycle. Cores were also inspected for surface cracks, the thermal properties of the epoxy coating, and the concrete conditions at bar depth. The concrete was tested for saturation percentages, diffusion coefficients, and chloride contents, while the epoxy was tested for its glass transition temperature, moisture content, and amount of surface cracking. The results indicate that the best predictor for estimating the times to corrosion initiation and cracking is the amount of chlorides present in the concrete encasing the ECR. The presence of chloride ions will have a determining effect on corrosion regardless of the epoxy coating condition. As a result, it is likely that ECR is not the solution to corrosion prevention and it is recommended that closer attention be given to improving concrete conditions that reduce the diffusion of chloride ions. The conclusion that ECR is an unreliable corrosion prevention method is in agreement with the results of previous studies. / Master of Science

Corrosion of reinforcing steel in concrete is a significant problem around the world. In the United States, there are approximately 600,000 bridges. From those bridges 24% are considered structurally deficient or functionally obsolete based on the latest, December 2010, statistic from the Federal Highway Administration (FHWA). Mainly, this is due to chloride attack present in deicing salts which causes the reinforcing steel to corrode. Different solutions have been developed and used in practice to delay and prevent corrosion initiation. The purpose of this research is to investigate the influence of corrosion on the failure mechanism that occurred on an Interstate 81 bridge deck. After 17 years in service, a 3ft x3ft closure pour section punched through. It was part of the left wheel path of the south bound right lane of the bridge deck. The bridge deck was replaced in 1992 as part of a bridge rehabilitation project, epoxy coated reinforcement were used as the reinforcing steel. Four slabs from the bridge deck, containing the closure, were removed and transported to the Virginia Tech Structures and Materials Research Laboratory for further evaluation. Also, three lab cast slabs were fabricated as part of the assessment program. Corrosion evaluation and concrete shrinkage characterization were conducted in this research. The corrosion evaluation study included visual observation, clear concrete cover depth, concrete resistivity using single point resistivity, half-cell potential, and linear polarization using the 3LP device. Shrinkage characteristics were conducted on the lab cast slabs only, which consisted of monitoring shrinkage behavior of the specimens for 180 days and comparison of the data with five different shrinkage models. Based on the research results, guidance for assessment of other bridge decks with similar conditions will be constructed to avoid similar types of failures in the future. / Master of Science

Chloride-induced deterioration of concrete bridge decks can be described in terms of three phases: 1) initiation of rebar corrosion, 2) rust formation and development of deck damage, and 3) accelerated deck damage towards structural failure. The first objective of this research was to investigate relationships among chloride concentration at the top mat of reinforcing steel, deck age, cover depth, and occurrence of delamination for concrete bridge decks with selected surface treatments and rebar types. Relating these factors can help establish greater understanding about the duration of each phase of the deterioration process. A second objective of this research was to investigate the relationship between chloride concentrations that develop between the bars and those that develop directly above the bars in the top mat of reinforcing steel to better understand the effects of the presence of reinforcing steel on diffusion of chloride ions through the concrete matrix.Data collected from 48 concrete bridge decks in Utah were used to address both of the objectives stated for this research. Surface treatment types included bare concrete, thin-bonded polymer overlays, and asphalt overlays, and rebar types included uncoated and epoxy-coated rebar. Regarding the first objective, baseline relationships between chloride concentration, deck age, and cover depth were developed for all three deck types. The results show that, as deck age increases, chloride concentration also increases and that chloride concentrations are much higher for shallower concrete depths than for deeper concrete depths. Based on these relationships, the duration of the first phase of the deterioration process was estimated using the critical chloride threshold of 2.0 lb Cl-/yd3 of concrete. For decks with asphalt or polymer overlays, development of clear relationships between chloride concentration, deck age, and cover depth required consideration of treatment time. The data show that chloride concentrations for decks that had an overlay applied 10 or more years after construction are higher than those for decks that had an asphalt overlay applied immediately after construction. Relevant to determining the duration of the second phase of the deterioration process, the relationship between delamination occurrence and chloride concentration for bare concrete bridge decks was developed. In general, the results show that the occurrence of delamination increases with increasing chloride concentration. Estimated durations of the second phase of the deterioration process were then determined using a chloride concentration threshold of 4.0 lb Cl-/yd3 of concrete for each of the same combinations of surface treatment and cover depth used for determining durations of the first phase of the deterioration process. Regarding the performance of epoxy-coated bar, the data clearly demonstrate the benefit of epoxy coatings on reinforcing steel for the purpose of significantly delaying the onset of chloride-induced delamination in concrete bridge decks. The relationship between the ratio of chloride concentrations directly above and between steel reinforcing bars and deck age was then developed. The results show that, as deck age increases, the average ratio of chloride concentrations directly above and between the bars asymptotically decreases from above 1.5 toward 1.0, which is reached at a deck age of approximately 30 years. Given that increasing deck age generally corresponds to increasing chloride concentration, which would in turn eventually lead to similar chloride concentrations directly above and between bars as the concrete pore water within the cover depth approached chloride saturation, this observed relationship is consistent with theory.

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.