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We are putting together some guidance for our field staff on
acceptable damage to concrete worker protection barriers.  One of the
questions that has come up it – How much damage to the connecting hoop bars is
acceptable?  Is there any guidance in AASHTO for this?

Section loss is undesirable. I would say that minor surface corrosion is acceptable as long as there is not much section loss. Further, we may not want to see any vertical deformation of the loops or lateral distortion. PCBs are not to be lifted by the loop bars. Finally, one may not want any gouges or nicks that may result in a stress concentration when loaded in tension. Those are my preliminary thoughts.