Epoxy-coated rebar (ECR) was used by the Florida Department of Transportation (FDOT) up to the early 1990's, but severe corrosion was observed after only a few years of service in several major FDOT ECR bridges built with highly permeable concrete. Corrosion projections based on concrete permeability indicated that corrosion damage was likely to be present by now for other FDOT bridges built with highly permeable concrete. Early corrosion initiation was not projected for other ECR bridges built with low permeable concrete, but there was concern that thin structural cracks and associated chloride ingress may have locally promoted deterioration. In an investigation in progress, field observations and laboratory examination of extracted ECR samples did show active corrosion in two Florida ECR bridges built with highly permeable concrete, confirming projections. Little to no corrosion was observed on ECR from another bridge with low permeability concrete, and no correlation between the presence or position of thin cracks and corrosion deterioration was observed. Further tests are in progress.
