Condition Survey of Older West Virginia Bridge Decks Constructed with Epoxy-Coated Reinforcing Bars

Chloride-induced corrosion of steel reinforcing bars is a major cause of deterioration in concrete bridge decks in northern climates. Corrosion-resistant epoxy-coated reinforcing (ECR) bars were introduced in the 1970s. In 1993, the West Virginia Department of Transportation (DOT) performed surveys of bridge decks treated with ECR and uncoated bars built in the mid-1970s. While deterioration was observed on uncoated bar decks, deterioration of decks built with ECR was found to be limited. The current investigation consisted of a questionnaire and review of the condition reports of the decks examined by the West Virginia DOT in 1993, followed by field condition surveys of six decks built with ECR to determine how the ECR was performing. The six bridge decks inspected were in good to excellent condition, with the exception of two spans of Bridge 2930, which were reinforced with uncoated black bars. The decks with ECR exhibited less than 0.15% corrosion-induced deterioration. Any deterioration observed on ECR decks was concentrated at cracks or construction joints. All actively corroding ECR bars had an average coating thickness less than 7 mil (0.007 in.), the current minimum specified thickness. Decks reinforced with uncoated black bars included in the 1993 study had an initial service life of 18 to 21 years, and an overlay was applied to all of these decks to address corrosion-related damage. The decks constructed with ECR are now 33 to 35 years old, and none have required rehabilitation to address corrosion-related deterioration.