A Report on Research Sponsored by FEDERAL HIGHWAY ADMINISTRATION

ii Multiple corrosion protection systems for reinforcing steel in concrete and the laboratory and field test methods used to compare these systems are evaluated. The systems include conventional steel, epoxy-coated reinforcement (ECR), ECR with a primer containing microencapsulated calcium nitrite, multiple coated reinforcement with a zinc layer underlying DuPont 8-2739 epoxy, ECR with a chromate pretreatment to improve adhesion between the epoxy and the steel, two types of ECR with high adhesion coatings produced by DuPont and Valspar, 2205 pickled stainless steel, concrete with water-cement ratios of 0.45 and 0.35, and three corrosion inhibitors (DCI-S, Rheocrete 222+, and Hycrete). The rapid macrocell test, three bench-scale tests (Southern Exposure, cracked beam, and ASTM G 109 tests), and a field test are used to evaluate the corrosion protection systems. The linear polarization resistance test is used to determine microcell corrosion activity. An economic analysis is performed to find the most cost-effective corrosion protection system. Corrosio