Deterioration Envelopes for Predicting Concrete Bridge-Deck Deterioration Due to Chloride Exposure

Bridge decks are exposed to chloride ingress from deicing salts, freeze–thaw cycling, and repeated wetting and drying, which gradually degrades the concrete over time. Many existing models treat concrete conditions as static and do not capture time-varying chloride exposure. This study develops deterioration envelopes for concrete bridge decks to predict long-term loss of compressive strength and internal integrity by integrating accelerated laboratory wet–dry and freeze–thaw testing with in-service bridge-deck core measurements from Delaware bridges. The model is supported by three data sources: accelerated laboratory tests, cores from in-service bridges provided by the Delaware Department of Transportation (DelDOT), and climate and asset datasets from the National Oceanic and Atmospheric Administration (NOAA) and the Federal Highway Administration’s (FHWA) InfoBridge™ database. Laboratory specimens (n = 300) were reproduced based on Delaware mix designs from the 1970s and 1980s and were tested in accordance with ASTM and ACI protocols. Environmental conditioning applied wet–dry and freeze–thaw cycles at chloride contents of 0, 3, and 15 percent to replicate field exposure within a shortened test period. Measured properties included compressive strength, modulus of elasticity, resonance frequency, and chloride penetration. The results show a gradual, near-linear reduction in compressive strength and resonance frequency with increasing chloride content over 160 cycles, which corresponds to about 2 to 5 years of service exposure. Resonance frequency was the most sensitive indicator of internal damage across the tested chloride contents. By combining test results, core data, and bridge inspection history into a single durability index, the deterioration envelopes forecast long-term degradation under different chloride exposures, providing a basis for prediction that extends beyond visual inspection.