The role of overstrength in welded joints for rebar substitution in damaged RC columns

Rehabilitating corroded or seismically damaged reinforced concrete (RC) bridge columns often involves replacing the longitudinal steel rebar. Welded joints offer a practical and efficient in-situ solution for connecting new rebar segments to existing undamaged rebar, even with irregularities in the steel reinforcement. However, traditional approaches to rebar joint welding have paid little attention to the overstrength of the welding seam, which can result in a brittle response. Properly designing such joints should aim for a ductile rebar failure. However, in-situ rehabilitation solutions often require reducing the seam length to save time and material costs and, not secondarily, avoiding the plastic hinge formation in the rehabilitated column. Therefore, providing the seam with adequate overstrength is crucial to achieving a ductile failure of the welded joint. This study presents an experimental investigation into the most effective methods for connecting existing and new rebar segments through welding, addressing on-site welding challenges such as limited operational space and weld orientation. Over 100 tensile tests have been conducted at Fuzhou University’s laboratory in China to understand the response of nine welded joints. Among indirect butt joints, the study identifies two performance groups based on the ductile failure rate as the welding seams reduce. The symmetry of the joint and the presence of additional direct butt welding also in asymmetric joints can significantly improve the joint performance, determining a ductile failure with minimal welding lengths. In a second step, following a probabilistic approach, the study assesses the overstrength of indirect butt joints as a function of seam length for the two identified performance groups. Empirical failure probabilities of the rebar and the seam are estimated to fit probability density functions representative of the tensile strength of the rebar and the seam. Based on a target reliability class, the overstrength factors are estimated.