Enhanced Corrosion Testing and Analysis for Steel Rebars in Reinforced Concrete Bridge Decks Based on Effective Pre‐Cracking

ABSTRACT The degradation of concrete structures is a significant issue in the United States, with the corrosion of steel reinforcement being a primary contributor. Cracks in concrete intensify the corrosion process by allowing easier access for chloride ions from deicing salts, adversely affecting the lifespan of structures. This study examines the corrosion rates of four primary types of steel reinforcement bars (rebars) through laboratory‐based accelerated corrosion tests. To closely simulate the conditions encountered by bridges, the rebars were embedded in pre‐cracked concrete specimens and exposed to diluted and concentrated chloride solutions. The experimental setup included two types of concrete (Class A and high‐performance concrete [HPC]), two levels of chloride concentration (3% and 15%), and four distinct cracking patterns. These patterns varied by crack width (0.011 and 0.035 inches) and depth (0.5 inches and 1 inch). Over a 3‐year data collection period, a two‐stage degradation model was employed to accurately depict and analyze the corrosion behavior of the rebars under various conditions. Additionally, the study translated the testing duration for pre‐cracked samples into a corresponding timeframe for assessing uncracked bridge rebars. The findings from this research underscore the utility of employing pre‐cracked concrete specimens for accelerated corrosion testing, offering valuable insights into the corrosion dynamics of steel reinforcement within concrete structures.