Development of Flexural Strength Rating Procedures for Adjacent Prestressed Concrete Box Girder Bridges

An investigation was conducted on noncomposite prestressed precast concrete adjacent-box-beam bridges that suffered catastrophic failures resulting from the corrosion of the prestressing steel. These failures highlight the need to improve the methods used to detect corrosion damage and, subsequently, to load rate the damaged members. Currently, the inspection of concrete box girder sections relies on visual methods that correlate longitudinal and transverse cracking, spalling, and exposed strands with the rated level of performance of the member. To improve the current inspection techniques, visual assessment methods were examined through the destructive evaluation and material characterization of seven box-beam segments. The research results indicate that the fabrication techniques used for box-beam construction in the 1950–1960 time period allowed for large variations in construction tolerance. Half-cell methods were shown not to provide an accurate or reliable method of identifying the corrosion of prestressing strands. Longitudinal cracking was shown to be an accurate and reliable indicator of the underlying corrosion of prestressing strands. The probability of corrosion on strands adjacent to longitudinal cracks was determined and quantified. On the basis of the results, a new recommendation for determining the residual flexural strength of corroded prestressed beams is provided.