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