Study on Mechanical and Fatigue Behavior of Concrete Beams Prestressed with High Strength Aluminum Alloy Bars

The corrosion of prestressed tendons in concrete structures remains a major durability concern, especially for post-tensioned members exposed to aggressive environments. High-strength aluminum alloy (AA) bars exhibit favorable characteristics such as corrosion resistance, low density, and high ductility and may therefore provide an alternative or supplementary prestressing material in durability-oriented structural design. In this study, a bonded post-tensioned T-shaped concrete beam with hybrid prestressing combining prestressed steel (PS) strands and 7075 AA bars was investigated. A refined finite element model was developed by considering the bond-slip relationship between the AA tendons and grout inside corrugated tubes. The flexural behavior of the beam was analyzed through a combination of finite element simulation and sectional theoretical analysis. In addition, a fatigue-life assessment framework was established based on vehicle fatigue loads and material fatigue constitutive models, and the fatigue performance of the proposed hybrid beams was compared with that of conventional prestressed concrete beams. The theoretical predictions agreed reasonably well with the numerical results. Results indicated that partial replacement of PS strands with corrosion-resistant AA bars could alter the governing fatigue failure mode and improve the fatigue durability of prestressed beams under corrosive conditions. These findings highlight the potential of hybrid AA–PS prestressing as a durability-oriented strategy for concrete beams in corrosive environments.