Development of a remaining useful life (RUL) model for reinforced concrete beams subjected to high-cycle fatigue

Purpose Failure of a critical reinforced concrete beam due to fatigue can have severe safety and production consequences, and preventative repair/replacement of such a beam is expensive. It would therefore be beneficial if repair/replacement can be done based on an accurately and conservatively predicted remaining useful life (RUL). The purpose of this paper is to develop such a model. Design/methodology/approach Condition-based maintenance is a maintenance approach that uses empirical/analytical models and a measurable condition to predict remaining useful life. The P-F curve (condition-life) is a useful tool that can aid in making these decisions. A model to create a P-F curve is developed using rebar fatigue test results (in the form of an S-N curve) and the Palmgren-Miner law of damage accumulation. A Monte Carlo simulation with statistical distributions is employed to provide confidence levels of RUL outputs. Findings An example of how the model can successfully be used in practice is shown in this paper, and a sensitivity study is performed leading to conclusions being drawn with regard to damage tolerant design considerations. Originality/value If a critical reinforced concrete beam fails due to fatigue can have serious consequences. This paper develops a model to help base repair/replacement decisions based on accurately and conservatively predicted RUL. Financial and safety benefits would be gained if this model would be used in practice.