Deterioration Envelopes for Predicting Concrete Bridge Deck Deterioration due to Chloride Exposure

Bridge decks are exposed to chloride ingress from de-icing salts, freeze-thaw cycling, and repeated wetting and drying, which gradually degrades the concrete over time. Many existing models treat concrete conditions as static and do not capture time-varying chloride exposure. This study develops deterioration envelopes for concrete bridge decks that predict loss of compressive strength and internal integrity by combining accelerated laboratory testing with in-situ bridge core data extracted from Delaware bridges. The model is supported by three data sources: accelerated laboratory tests, cores from in-service bridges provided by the Delaware Department of Transportation (DelDOT), and climate and asset datasets from the National Oceanic and Atmospheric Administration (NOAA) and the Federal Highway Administration's (FHWA) InfoBridge™ database. Laboratory specimens (n = 300) were reproduced based on Delaware mix designs from the 1970s and 1980s and were tested in accordance with ASTM and ACI protocols. Environmental conditioning applied wet-dry and freeze-thaw cycles at chloride contents of 0, 3, and 15 percent to replicate field exposure within a shortened test period. Measured properties included compressive strength, modulus of elasticity, resonance frequency, and chloride penetration. Results show a gradual, near-linear reduction in compressive strength and resonance frequency with increasing chloride content over 160 cycles, which corresponds to about 2 to 5 years of service exposure. Resonance frequency was the most sensitive indicator of internal damage across the tested chloride contents. By combining test results, core data, and bridge inspection history into a single durability index, the deterioration envelopes forecast long-term degradation under different chloride exposures, providing a basis for prediction that extends beyond visual inspection.