To evaluate the corrosion performance of epoxy-coated reinforcing bars in concrete in
marine environments, a condition survey of a Georgia concrete bridge substructure
constructed in 1984 and reinforced with epoxy-coated steel bars was conducted. The field
survey of this structure included visual physical condition inspection, concrete cover
measurement, half-cell potential measurement, concrete coring, and epoxy-coated bar
sampling. Concrete cores taken from the structure were sectioned for chloride analysis, and
sampled bar segments were inspected for coating adhesion, coating thickness, extent of
damage and corrosion. No concrete distress induced by corrosion of epoxy-coated bars was
observed. Low coating adhesion was observed on all sampled bars as well as various levels of
coating damage. The average coating thickness was 155 µm (6.1 mils), and 18% of the
measurements were smaller than 125 µm (5 mils). The coating apparently did not meet the
thickness requirements of either ASTM A775-81 Standard Specification for Epoxy-Coated
Steel Reinforcing Bars (valid at the time of the bridge construction) or the current version of
this specification, ASTM A775-06.