Circular steel tube members with the absence of anticorrosive protection or coating failure are prone to uniform corrosion, which threatens the reliability and safety of members in the atmospheric environment. To fully study the mechanical behavior of uniformly corroded circular steel tubes, compression test and theoretical analysis were conducted, and two methods considering section reduction and material degradation, respectively, were adopted for the calculation of ultimate load carrying capacities of specimens. The results indicate that uniform corrosion did not change the failure modes of specimens, and all of them belonged to global buckling failure. The load carrying capacities and stiffness of specimens decreased with the increase of corrosion ratio, and the degree of reduction was greater than that of material degradation, showing a linear relationship with the corrosion rate. Under the same corrosion ratio, the specimens with larger eccentricity represented more obvious load carrying capacity and stiffness degradation. The load carrying capacities predicted by both methods were in good agreement with the test results and had a certain safety margin. The conservative degree of calculation results from three specifications followed a descending order of ANSI/AISC 360-16, GB 50017-2017, and EN 1993-1-1. Under the same corrosion ratio, the load carrying capacity variation of specimens between one-sided corrosion and two-sided corrosion was less than 3%.

In order to achieve a comprehensive and accurate evaluation of the safety of compression members made of circular steel tubes, image processing technology is commonly utilized to extract the morphology of the steel tubes before and after rust removal. The obtained results have validated the feasibility and applicability of employing digital cameras and image processing technology to analyze the images of the steel tubes before and after rust removal and to extract useful structural mechanics features. The feature values of the apparent morphology before rust removal grow with the increase of the corrosion depth, while after rust removal, the feature values first increase and then decrease with the growth of the corrosion depth. Based on this fact, a simplified equation is proposed to quantify the relationship between the feature values of the apparent morphology before and after rust removal and the corrosion depth. In continuing, a simple, fairly accurate, and comprehensive safety evaluation methodology for corroded circular steel tubes under compression is established. Finally, an example is illustrated to check the applicability and effectiveness of the proposed approach.

Coastal and offshore steel infrastructures such as transmission towers and wind turbine towers are prone to coating degradation after long-term exposure to salt fog, high humidity, and ultraviolet radiation. The subsequent uniform corrosion significantly reduces the cross-sectional load-carrying capacity and threatens structural safety. This paper presents a numerical parametric analysis on the compression behavior of circular steel tube (CST) members subjected to uniform corrosion induced by coating failure, based on 18 accelerated corrosion tests. The effectiveness of the wall thickness reduction method for simulating uniform corrosion after coating degradation is verified, and the influence of key parameters on load-carrying capacity degradation is systematically investigated. A simplified formula for elastic local buckling of corroded CSTs is derived, and a direct strength method (DSM) calculation framework considering both global buckling and local–global interactive buckling is established. The results show that the uniform corrosion ratio is the dominant factor affecting load-carrying capacity degradation, while sectional dimension, slenderness ratio, and eccentricity have negligible influence. The proposed DSM method achieves a prediction error within 5% compared with test and numerical results. It is primarily applicable to uniformly corroded steel tubes represented by equivalent wall thickness loss, and its applicability to scenarios with localized corrosion, pitting corrosion, weld-zone corrosion, or non-uniform wall thickness reduction requires further validation. This method provides a rapid and accurate tool for residual load-carrying capacity assessment and life cycle management of coastal steel infrastructures after coating failure.