Corrosion damage reduces the load-carrying capacity of bridges which poses a threat to passenger safety. The objective of this research was to reduce the resources involved in conventional bridge inspections which are an important tool in the condition assessment of bridges and to help in determining if live load testing is necessary. This research proposes a framework to link semi-automated damage detection on prestressed concrete bridge girders with the estimation of their residual flexural capacity. The framework was implemented on four full-scale corrosion damaged girders from decommissioned bridges in Virginia. 3D point clouds of the girders reconstructed from images using Structure from Motion (SfM) approach were textured with images containing cracks detected at pixel level using a U-Net (Fully Convolutional Network). Spalls were detected by identifying the locations where normals associated with the points in the 3D point cloud deviated from being perpendicular to the reference directions chosen, by an amount greater than a threshold angle. 3D textured mesh models, overlaid with the detected cracks and spalls were used as 3D damage maps to determine reduced cross-sectional areas of prestressing strands to account for the corrosion damage as per the recommendations of Naito, Jones, and Hodgson (2011). Scaling them to real-world dimensions enabled the measurement of any required dimension, eliminating the need for physical contact.

The flexural capacities of a box beam and an I-beam estimated using strain compatibility analysis were validated with the actual capacities at failure sections determined from four destructive tests conducted by Al Rufaydah (2020). Along with the reduction in the cross-sectional areas of strands, limiting the ultimate strain that heavily corroded strands can develop was explored as a possible way to improve the results of the analysis. Strain compatibility analysis was used to estimate the ultimate rupture strain, in the heavily corroded bottommost layer prestressing strands exposed before the box beam was tested. More research is required to associate each level of strand corrosion with an average ultimate strain at which the corroded strands rupture. This framework was found to give satisfactory estimates of the residual strength. Reduction in resources involved in current visual inspection practices and eliminating the need for physical access, make this approach worthwhile to be explored further to improve the output of each step in the proposed framework.