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Several experimental and numerical studies were performed in the past to estimate buckling capacity of corroded tubular members. However, the effect of initial imperfections has not been properly considered in most of these earlier proposed formulas. Therefore, the main objective of this paper is to propose an accurate analytical formula to determine the buckling capacity of patched corroded tubular members.

Tubular members with initial geometrical imperfections can be regarded as beam-columns because of the combination of axial load and bending moment. The proposed formula is derived for a rectangular corrosion patch. The proposed formula is verified with results from finite element analysis of corroded tubular members and experimental results. The formula is also applied to an existing offshore jacket structure to highlight its significance and applicability. It is found that the buckling capacity of jacket members in splash zone reduces significantly with ageing. This reduction is around 29 and 14% for the selected brace and leg member respectively, during the design life. Finally, it is concluded that corrosion reduces the buckling capacity significantly and the proposed formula can be easily applied by practicing engineers to give an accurate and slightly conservative estimate the remaining buckling capacity.

The main finding is the new formula which accurately and conservatively estimate the buckling capacity of corroded tubular members. The proposed formula considers the secondary effect of both initial geometrical imperfections and shifting of centroid because of corrosion.

The proposed new formula is unique and original in that it considers both secondary effects from geometrical imperfections, reduction of cross-section from corrosion wastage and shifting of centroid because of corrosion. Finally, it is concluded that corrosion reduces the buckling capacity significantly and the proposed formula can be easily applied by practicing engineers to conservatively estimate the remaining buckling capacity and verify if further, more advanced estimations are needed.