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ASD 004 Nondestructive Evaluation for Structural Repair and Rehabilitation Jacob Bice, Ph.D., P.E. Issue date: September 21, 2009 Revised: July 10, 2010 MOORE LEARNING PROGRAM | Introduction to NDE Techniques| DMT 102 What is Structural

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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

Nondestructive Evaluation for Structural Repair and Rehabilitation

ASD 004 Jacob Bice, Ph.D., P.E.

Issue date: September 21, 2009 Revised: July 10, 2010

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What is Structural Diagnostics?

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Traditional Design Process

Construct

Design

Conceptualize Schematic Design Detailed Design Coordination

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The Diagnostic Process

Assess

Hypothesize Test / Analyze

Design Construct

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Firm Profile

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Introduction to NDE

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Agenda

  • Overview of NDE
  • Physical phenomena
  • NDE techniques
  • Case studies
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How Do We Characterize Structures?

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What is Nondestructive Evaluation?

Methods for assessing the condition of a structure without causing any structurally significant damage.

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Destructive vs. Nondestructive

Original Approach (bad) NDE Approach (better)

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When is Nondestructive Evaluation Used?

  • Quality control of new construction
  • Condition assessment of structures

– Rehab – Due diligence – Change of use

  • Quality control of repairs
  • Identify as-built construction
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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

What are Types of NDE for Concrete Structural Evaluation?

Visual

Electromagnetic

Electrical Stress Wave

Magnetic

Nuclear

??

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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

What are Common Types of NDE Methods?

  • Short pulse radar
  • Stress wave

– Impact-echo – Impulse response – Ultrasonic pulse velocity – Ultrasonic Echo

  • Electric & Magnetic

– Half-cell potential

  • Nuclear

– Radiography

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Short Pulse Radar (SPR)

  • Commonly known as GPR
  • Reflected electromagnetic waves
  • Applications

– As-built conditions – Rebar location – Voids beneath slabs – CMU grouting – Honeycombing

  • Limitations

– Wet soils – Cannot detect small discontinuities

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SPR Schematic

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SPR: Common Limitations

PT Slab 4x4 WWR

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Cover Meter Schematic

A.C. Source Current Indicator Coil

  • Presence of bar causes electrical flow
  • Generates a secondary current
  • Reinforcement inferred by monitoring current
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Stress Wave Methods

  • Induce a stress wave (impact)
  • Measure response
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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

Impact-Echo

  • Measure properties of reflected P-wave
  • Applications

– Concrete thickness – Crack depths – Delaminations – Unconsolidated concrete

  • Limitations

– Near surface discontinuities – Edge effects

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Impact-Echo Schematic

Calibrated Weight Receiver

Thickness Crack / Delamination Honeycombing

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Cambridge Street Approach Slab Cracking

  • Constructed in 2008
  • Cracking in 2009
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  • 12” thick reinforced

concrete slab

  • Two layers of

reinforcement

– #5 bars @ 12” OC – Top and bottom

  • Are there voids

beneath the slab causing settlement?

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Approach Slab GPR

PAVEMENT SLAB APPROACH SLAB MEDIAN INSIDE LANDE OUTSIDE LANE INSIDE LANDE OUTSIDE LANE

CONTROL JOINT

SCAN A SCAN B

Scan A Scan A Scan B Scan B

BOTTOM OF SLAB DEPTH: ~12” REINFORCEMENT LAYER DEPTH: ~6”; SPACING: ~6” CONTROL JOINT REINFORCEMENT LAYER

  • AVG. DEPTH: ~8”; SPACING: ~12”

REINFORCEMENT LAYER

  • AVG. DEPTH: ~8”; SPACING: ~12”
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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

Impact-Echo Surface Crack Depths

81.5 137
  • 0.12
  • 0.1
  • 0.08
  • 0.06
  • 0.04
  • 0.02
0.02 0.04 50 100 150 200 250 Vo Voltage, m mV Tim Time, m microseconds
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Validation!

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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

FDA Building 71

  • Under Construction – 2012
  • Two reinforced concrete structures
  • Connected by steel framed breezeway

–Supported on steel brackets

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FDA Building 71

  • Welding
  • Torch Cutting
  • Has the concrete behind the embed plate

experienced heat damage?

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FDA Building 71

  • Impact Echo testing

24”

TEST LOCATION

8”

SECTION VIEW OF TYPICAL TEST LOCATION

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TEST 1 TEST 1 TEST 2 TEST 2 TEST 3 TEST 3 TEST 4 TEST 4

TYPICAL TEST LOCATIONS

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FDA Building 71: Testing Results

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 10 20 30 40 50 60 70

Amplit litude Fr Freque uency, k kHz

Level 5, Test 1 (No embed PL) Level 5, Test 2 (Embed PL,Welded) Level 5, Test 3 (Embed PL, Torch Cut) Level 5, Test 4 (No embed PL

TYPICAL FREQUENCY DOMAIN RESPONSE Thickness Frequency = 3.4 kHz

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Impact of Testing

  • Cost to perform testing: $4,500/day + expenses
  • Total cost of testing: ~$17,000
  • Approximate cost of repairs:

–Chip out and replace concrete: $25,000 per beam

x 6 beams $150,000

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Case Study: Bobby Dodd Stadium

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Case Study: Bobby Dodd Stadium

  • $75 Million Expansion project
  • Design Build Project
  • Tight Schedule
  • High Profile
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Case Study: Bobby Dodd Stadium

  • Testing
  • SPR
  • Impact Echo
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Findings of Field and NDT Study

  • SPR of the columns

–Concrete cover varied between 2” – 6” –Tie spacing was large at the embedment plate

–Headed studs located outside rebar cage

  • Impact Echo determined cracks were

deep and hence needed to be repaired.

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Ultrasonic Pulse Velocity (UPV)

  • Wave speed through concrete
  • Applications

– Delaminations – Unconsolidated Concrete – Concrete material properties

  • Limitations

– Access to both sides (preferred) – Qualitative

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UPV Schematic

Normal Concrete Crack / Delamination Unconsolidated Concrete Data Acquisition

5 10 15 20 10 20 30 40 50 60 70 80 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410

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Parking Garage Fire

  • Reinforced concrete

pan-joist deck

  • Ford F-150 @ 2 AM
  • Visible spalls and

delaminations

  • Pink concrete
  • What is the extent of

area which requires repair?

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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

Parking Garage Fire

  • Options

–Visual –Cores –NDE (!!)

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MOORELEARNING PROGRAM | Introduction to NDE Techniques| DMT 102

Parking Garage Fire

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 26'-10"

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SAMMC Shear Wall

  • 36-inch thick shear

wall

  • Voids observed after

form removal

  • Visible cold joints
  • Are there other

locations with voids that are not visible?

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SAMMC Shear Wall

5 10 15 20 25 30 35 40 45 50 55 5 10

  • Black areas denote

locations with visible voids

  • Arrows indicate

recommended locations for coring

2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400

2000 5600

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Impulse Response

  • Low-strain impact
  • Mobility plot
  • Applications

– Stress transfer – Delaminations – Deep foundation integrity

  • Limitations

– Cannot determine depth of flaws – Qualitative – Verify with coring

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What is a Mobility Plot?

Force

Frequency Velocity

Mobility

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What Information is in a Mobility Plot?

50 Hz

Dynamic Stiffness Average Mobility Mobility Slope

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Impulse Response Schematic

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Mobility Slope Measured Impulse Measured Response Dynamic Mobility Calibrated Geophone Data Acquisition System

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7 1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Average Mobility Dynamic Stiffness

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Voids Index

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Mobility Slope Measured Impulse Measured Response Dynamic Mobility Hammer Data Acquisition System

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7 1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Average Mobility Dynamic Stiffness

1 2 3 4 5 6 7 8 9 10 S1 S2 S3 S4 S5 S6 S7

Voids Index

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Case Study: Precast Concrete Panel Connection Failure

Gravity Connections

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1020 Holcombe Marble Panel Assessment

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1020 Holcombe: Impulse-Response Results

Good Connections

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Voids beneath Slab on Grade

  • Downward movement

reported by owner

  • Evidence of possible

voids visible

  • What are the extents of

the void?

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MOORELEARNING PROGRAM | DMT 102 | JANUARY 2008

WALTER P MOORE PROJECT NO. D03.10030.00 BOTTOM OF SLAB TOP OF SLAB VOID BELOW SLAB (YELLOW) TOP OF SLAB VOID BELOW SLAB (YELLOW) TOP OF SLAB BOTTOM OF SLAB BOTTOM OF SLAB VOID BELOW SLAB (YELLOW) TOP OF SLAB BOTTOM OF SLAB VOID BELOW SLAB (YELLOW) PARTION WALL PARTION WALL ROOM 120 ROOM 121 ROOM 122 ROOM 123 ROOM 125 ROOM 128 ROOM 129 ROOM 130 ROOM 131 ROOM 132

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MOORELEARNING PROGRAM | DMT 102 | JANUARY 2008

WALTER P MOORE PROJECT NO. D03.10028.00

S2 APPROXIMATE VOID BASED ON GPR DATA NO ACCESS TO THIS ROOM

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WALTER P MOORE PROJECT NO. D03.10028.00

0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2 0.21 0.22

IMPULSE RESPONSE LOCATION

VOID BELOW SLAB (YELLOW) VOID BELOW SLAB (YELLOW)

Impulse Response + GPR

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Straight Beam Ultrasonic Testing (UT)

  • Wave speed through metallic substrates
  • Applications

– Section Thickness Verification – Detecting Delaminations – Detecting Section Loss – Detecting Interface depth

  • Limitations

– Requires calibration and knowledge of the substrate medium. – Requires contact with the medium being tested – Requires parallel surfaces which are generally smooth for quantitative measurements. – May require cleaning to removal thick coatings or surface corrosion.

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Parking Garage Bumper Wall Failure

  • Precast Concrete

Bumper Wall panel supported by steel beams fell off of the side of the parking structure.

  • Are there other

locations where there is a hidden problem?

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Parking Garage Bumper Wall Failure

  • Options

–Visual –NDE

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Rebound (Schmidt) Hammer

  • Elastic rebound of hammer impact
  • Applications

– Concrete compressive strength – Fast, qualitative assessment of overall quality

  • Limitations

– Near-surface properties only – Affected by many variables – Uniformity of concrete

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Building Envelope Testing

Equipment: Infrared Thermography; Anemometer; Moisture Meters; Spray Nozzle Infrared Thermometer; Hygrometer; Rilem Tubes; Elcometer Smoke Tracer; Manometer; Moisture Capacitance Meter Software: WUFI; THERM ; eQuest; WPM Hygrothermal Analysis Spreadsheet

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Infrared Techniques

  • Infrared thermal emissivity
  • Noncontact
  • Highly absorptive materials

– Concrete – Masonry

wabs wref

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  • Infrared thermal emissivity
  • Applications

– Water Intrusion – Air leakage – Bonding of FRP sheets – Location of termite infestation

  • Limitations

– Not effective with reflective materials

What is Thermography?

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Before Coating After Coating

Case Study: Moisture Infiltration

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  • Electrochemical reaction
  • Galvanic corrosion

– 2Fe  Fe2+ + 2e- – 2H2O + O2 +4e-  4OH-

  • Measure electrical potential

What is Half-Cell Potential?

2Fe  Fe2+ + 2e-

Voltage

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Half-Cell Potential & Corrosion Rate

  • Linear Polarization Technique
  • Measures corrosion activity
  • Applications

– Corrosion prediction

  • Limitations

– Cathodic protection – Requires connection to rebar – Depth of cover less than 4 inches – Saturated concrtete*

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Half-cell Potential Schematic

Voltage

1 2 3 4 5

Corrosion Potential (mV vs. Cu/CuSO4)

Corrosion Potentials

100-150 50-100 0-50

  • 50-0
  • 100--50
  • 150--100
  • 200--150
  • 250--200
  • 300--250
  • 350--300
  • 400--350

Corrosion Potential (mV vs Cu/CuSO4)

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LCRA: TC Ferguson Turbine Building

Exterior Foundation Framing Wall Interior Sub-Basement Framing Wall Basement Slab Fin Mat Foundation Sand Infill Sub-Basement (Tunnel) Sub-Basement (Tunnel)

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LCRA: SPR

SPR used to position sample locations

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LCRA: Sub-basement Level

Fin F56 – Ultrasonic Pulse Velocity (UPV)

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LCRA: Sub-basement Level

Fin F56 – Corrosion Testing

Corrosion Potential (mV vs. Cu/CuSO4)

100 - 150 50 - 100 0 - 50

  • 50 - 0
  • 100 - -50
  • 150 - -100
  • 200 - -150
  • 250 - -200
  • 300 - -250
  • 350 - -300
  • 400 - -350

Half- lf-cell Po ll Pote tentia ntial vs. l vs. Cu Cu/CuSO4

(1 (1)

Pro Probabil ability o ity of Cor Corrosio ion More positive than -200 mV Less than 10% Between -200 and -350 mV Uncertain More negative than -350 mV More than 90%

1 2 3 4 5

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Evaluation of Cathodic Protection System

  • 2 Hyperbolic Natural-Draft Cooling Towers

–Reinforced Concrete Shells –453 feet tall –320 feet diameter at base

  • Cathodic Protection (CP)

–Life Jackets on columns –Zinc mesh over lifts 1-12

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Tower Elevation

Lifts 1‐12 Columns

Stack

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Passive CP System

  • Zinc Mesh

–Electrically connected to reinforcement –Gunite shotcrete overlay –Is the CP system working? –Is the overlay sound?

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Nondestructive Evaluation

  • Half-Cell Potential
  • Corrosion Rate
  • Impulse Response
  • Bond Testing
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NDE Quadrant Summary

Impulse‐Response

Full panel half‐cell Galvapulse

Bond Test

Half‐cell potential (6 points per panel) Continuity measurements

Potential Readings Test

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Half Cell Potential

mV vs Cu/CuSO4

Corrosion Rate

m/year

1 2 3 4 5 6 7 8 1 2 3 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 1 2 3 4 5 6 7 8 1 2 3

  • 500
  • 425
  • 350
  • 312.5
  • 275
  • 200
  • 175
  • 150
  • 100
  • 50

Unit 1 Stack 55 Opening

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Impulse-response testing

  • Grids over 60’ of

stack

  • Low voids index

values

5 5 10 15 20 25 30 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4

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Supplemental testing

  • Pull-off testing

–Bond strength 25 psi – 150 psi

  • Chloride Testing

–High chlorides (~2,000 ppm)

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Conclusions

  • CP system is performing adequately

–Low values for active corrosion –Half-cell potentials indicate uncertainty

  • Overlay cracking but not debonding
  • Replacement not necessary

–Save $11,000,000

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JEA: Construction Quality Control

  • Confirm contractor is

correctly identifying delaminations

–Unit Pricing –Cost controls

Impulse Response Test Area

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JEA: Impulse-Response

1 70 60 80 30 50 40 10 20

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JEA: Impulse-Response

1 5 1 1 5 15 10 1 5 9 1 1 9

EX- 3

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Summary

  • Techniques to assess in-situ state

–Obscured conditions –Rapid characterization –Minimal impact

  • Differing techniques for differing problems
  • Very powerful when used in combination
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A final thought….

Better information

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A final thought….

Better information = Better Decisions Better Solutions

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MOORELEARNING PROGRAM | DMT 102 | JANUARY 2008

Thank You