Fatigue-related corrosion is a complex phenomenon that induces damage accumulation and electrochemical deterioration throughout the service life of the structure. This article presents a previously proposed and modified strain-life Smith–Watson–Topper corrosion model for details on fillet-welded connection of highway sign support structures. To evaluate the degree of corrosion activity, hot-dip galvanized, weathering, and low-carbon steel are investigated with respect to chemical compositions, material properties, and the corresponding corrosion resistance indices. The existing fatigue testing data were analyzed and used to evaluate fatigue resistance under various corrosion environments. A modified Smith–Watson–Topper corrosion model is further utilized to determine acceptable constant amplitude fatigue thresholds for the American Association of State Highway and Transportation Officials fatigue limits under each corrosion category. It was found that low constant amplitude fatigue threshold values were observed for ASTM A588, A595, and A572 steels in locations with corrosion categories exposed to severe corrosive environments. Under these conditions, hot-dip galvanization or other surface treatments of the steel components of the sign supports are recommended to achieve higher constant amplitude fatigue threshold values.
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