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Incorporating pre-existing crack in service life prediction of reinforced concrete structures subjected to corrosion is crucial for accurate assessment, realistic modelling and effective decision-making in terms of maintenance and repair strategies.

An accelerated corrosion test was conducted by using impressed current method on cylindrical specimens with varying cover thickness and crack width. Mechanical properties of the specimens were evaluated by tensile tests.

The results show that, the pre-cracked samples exhibited shorter concrete cover cracking times, particularly with wider cracks when compared to the uncracked samples. Moreover, the load-bearing capacity of the reinforcement bars decreased owing to the pre-cracks, causing structural deflection and a shortened yield plateau. However, the ductility index remained consistent across all sample types, implying that the concrete had good overall ductility. Comparing the results of the non-corroded rebar and corroded rebar samples, the maximum reduction in the yield load was 25.22%, whereas the maximum reduction in the ultimate load was 26.23%. The simple mathematical model proposed in this study provides a reliable method for predicting the chloride ion diffusion coefficient in cracked concrete of existing reinforced concrete structures.

A simple mathematical model was proposed for evaluation of the equivalent chloride ion diffusion coefficient considering crack width, average crack spacing and crack extending lengths for cracked reinforced concrete structures, which is used to incorporate existing crack in service life prediction models.

Reliable estimations of the extent of corrosion and time required to reach specific safety limits are crucial for assessing the reliability of aging reinforced concrete (RC) bridges. Engineers and decision-makers can use these figures to plan suitable inspection and maintenance operations.

Analytical, empirical and numerical approaches for estimating the service life of corroded RC structures were presented and compared. The concrete cover cracking times, which were predicted by the previously proposed analytical models, were compared with the experimentally obtained cracking times to identify the model/s for RC bridges. The shortcomings and limitations of the existing models are discussed.

The empirical models typically depend on the rate of corrosion, diameter of steel reinforcement and concrete cover depth and based on basic mathematical formula. In contrast, the analytical and numerical models contain the strength and stiffness properties of concrete as well as type of corrosion products and incorporate more complex mechanical factors. Four existing analytical models were analyzed and their performance was evaluated against existing experimental data in literature. All the considered analytical models were assumed thick-walled cylinder models. The maximum difference between observed cracking time from different test data and calculated cracking time using the developed models is 36.5%. The cracking times extend with increase in concrete cover and decrease with corrosion current density. The development of service life prediction models that considers factors such as heterogeneity of concrete, non-uniform corrosion along rebar, rust production rate and a more accurate representation of the corrosion accommodating region are some of the areas for further research.

Outcome of this paper partially bridge the gap between theory and practice, as it is the basis to estimate the serviceability of corrosion-affected RC structures and to propose maintenance and repair strategies for the structures. For structural design and evaluation, the crack-width criterion is the greatest practical importance, and structural engineers, operators and asset managers should pay close attention to it. Additionally, repair costs for corrosion-induced serviceability failures, particularly concrete cracking and spalling, are significantly higher than those for strength failures. Therefore, to optimize the maintenance cost of RC structures, it is essential to precisely forecast the serviceability of corrosion-affected concrete structures. The lifespan of RC structures may be extended by timely repairs. This helps stake holders to manage the resources.

In order to improve modeling of corrosion-induced cracking, important areas for future research were identified. Heterogeneity properties of concrete, concept of porous zone (accommodation effect of pores should be quantified), actual corrosion morphology (non-uniform corrosion along the length of rebar), interaction between sustain load and corrosions were not considered in existing models. Therefore, this work suggested for further researches should consider them as input and develop models which have best prediction capacity.

This work has positive impact on society and will not affect the quality of life. Predicting service life of structures is necessary for maintenance and repair strategy plans. Optimizing maintenance strategy is used to extend asset life, reduce asset failures, minimize repair cost, and improve health and safety for society.

The degree of accuracy and applicability of the existing service life prediction models used for RC were assessed by comparing the predicted cracking times with the experimentally obtained times reported in the literature. The shortcomings of the models were identified and areas where further research is required are recommended.

Several experimental and numerical studies were performed in the past to estimate buckling capacity of corroded tubular members. However, the effect of initial imperfections has not been properly considered in most of these earlier proposed formulas. Therefore, the main objective of this paper is to propose an accurate analytical formula to determine the buckling capacity of patched corroded tubular members.

Tubular members with initial geometrical imperfections can be regarded as beam-columns because of the combination of axial load and bending moment. The proposed formula is derived for a rectangular corrosion patch. The proposed formula is verified with results from finite element analysis of corroded tubular members and experimental results. The formula is also applied to an existing offshore jacket structure to highlight its significance and applicability. It is found that the buckling capacity of jacket members in splash zone reduces significantly with ageing. This reduction is around 29 and 14% for the selected brace and leg member respectively, during the design life. Finally, it is concluded that corrosion reduces the buckling capacity significantly and the proposed formula can be easily applied by practicing engineers to give an accurate and slightly conservative estimate the remaining buckling capacity.

The main finding is the new formula which accurately and conservatively estimate the buckling capacity of corroded tubular members. The proposed formula considers the secondary effect of both initial geometrical imperfections and shifting of centroid because of corrosion.

The proposed new formula is unique and original in that it considers both secondary effects from geometrical imperfections, reduction of cross-section from corrosion wastage and shifting of centroid because of corrosion. Finally, it is concluded that corrosion reduces the buckling capacity significantly and the proposed formula can be easily applied by practicing engineers to conservatively estimate the remaining buckling capacity and verify if further, more advanced estimations are needed.

Brinell, Vickers and low-force Vickers hardness measurements are herein adopted to investigate and quantify the fatigue damage evolution in specimens made of S355J2+AR ferritic pearlitic steel. Though nano and microhardness measurements have been well adopted, they require a strict preparation routine, whereas macroscopic hardness measurements are not as stringent.

The feasibility of adopting macroscopic hardness measurements as a means of measuring fatigue damage is investigated through a combination of experimental tests and finite element analyses with both Brinell and Vickers hardness indenter.

It is found that the Brinell hardness measurements method seems more feasible, regarding finding a continuous and significant change during the fatigue life, in comparison to both Vickers and low-force Vickers. Thereafter, the question regarding the feasibility of the hardness measurements as a method of assessing accumulated fatigue damage in situ is discussed.

Much work has previously been performed towards correlation of the micro and nano hardness indentations, which generally has stringent preparation requirements before testing. Herein, the adoption of macroscopic hardness measurements as a means of assessing accumulated fatigue damage is considered both experimentally and theoretically.