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SRES College of Engineering, Kopargaon, Maharashtra - 423 603

NON DESTRUCTIVE TESTING (NDT) ADVANTAGES AND LIMITATIONS

Author N.R. fatil
Assistant Professor Bharati Vidyapeeth University College of Engineering, Dhankawadi, Pune-43. nrpatil_20@rediffmail.com
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Author J.R. Patil

Professor D. Y. Patil College of Engineering Akurdi, Pune-44 jalinder ..patil@yahoo.co.in

ABSTRACT: Non destructive testing is a form of testing to be carried out on various construction members and materials without causing any permanent damage to' them. As NDT is used in concrete, it can also be used very effectively for other building members and materials. , Thispaper covers case study of NDT on concrete as well as other elements of building. Concrete has been used in construction industry for its compressive strength and for protection of reinforcement of steel. NDT is used to test concrete by two methods namely, surface testing technique and through testing technique. In surface testing Schmidt Hammer, pull out tester etc. are carried out and compressive strength is determined by using imperial formula In through testing technique ultrasonic pulse velocity, impact echo, X-ray etc. are the techniques used INTRODUCTION: Non- Destructive Testing is a form of testing to be carried out on various construction materials . and members without causing any permanent damage to them members. Though,' N.D.T. is predominantly used on concrete, the same can be very effectively used for other building. materials/members also. This paper covers case studies of NDT on concrete as well as other building elements. Concrete has been used in construction industry for its compressive strength and for-protection to reinforcing steel. NDT application to concrete can be broadly divided into 2 methods i.e. surface testing and through testing. A) Surface Testing Technique: Schmidt Hammer, pull off tester, Windsor probe test etc. fall in this category. These tests are practically used to determine the compressive strength of concrete. It is interesting to note that no NDT can measure the compressive strength of in situ concrete directly but all the tests measure some other property of concrete like surfacehardness, toughness, penetration resistance etc. and the compressive strength is deduced based on empirical formulae. B) Through Testing Techniques: . Ultrasonic Pulse Velocity, impact echo, X Ray, RADAR, etc. are the techniques which fall in this category. All these techniques have a common theory of passing some form of waves, either high frequency sound or electromagnetic or mechanical or light etc., through the body of concrete to assess the interiors of the same. Some of these techniques have been successfully '.' ~ in laboratories to preduct the compressive strength of concrete but due to extreme variables , It ISPractically nearing impossible task to do the same on site. .' ,".In Indian construction industry NDT finds its application on several fronts. Prediction of .;compressive strength by using any of the techniques has maximum demand. Compressive
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strength of in situ concrete of age less than one year can be predicted by using Schmidt H to an accuracy 15%. After this age the concrete starts getting carbonated thereby beco . hard on surface. Since, the technique of rebound hammer is based on surface hardness, inaccuracy in measuring the compressive strength of older concrete goes up. It is recomme by international codes and manufacturers of Rebound Hammer that the carbonated concrete s be ground off using grinders to the depth of uncarbonated concrete before 'using this techni This procedure has several practical limitations and cannot be meticulously followed on . Hence, Schmidt Hammer becomes practically not suitable for older concretes. Another popular technique to find out compressive strength is Ultrasonic Pulse Velocity T Ultrasonic Velocity in concrete depends on 3 properties of the-sameviz. Dynamic Modulus elasticity, density, Poisson's ratio. These properties in turn depend on the stress in the con member, the water content, the methods of production of the concrete member etc. Due to, fact that all the codes recommend that substantial No. of cubes shall be tested with Ultras~ and cube" crushing strength on a site before using USPV technique to predict compre strength of structural concrete for the site.

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Case study-Application ofNDT for testing ofRCC building.

RCC building constructed in 1970 in Mumbai containing 13 floors and 25 flats was tested for its safety by using rebound hammer test, ultrasonic pulse velocity test and carbonation test. Also visual and delam survey was carried out and the observations and instrumentation test results presented in this paper VISUAL SURVEY: The structure was investigated flat by flat for ease in observation. Each column, beam and s within the section was observed for a range of defects such as cracks, spalls, rust stains, c . seepage (water) etc. These defects were noted on the observation sheets which formed the b of the date collected. Each section observation was plotted on an individual observation sh Various symbols used in definition of observed defects were as per attached legend sheet. DELAM SURVEY: Every column, beam was subjected to tapping by three different types of hammers. MJ effective was the medium hammer which gave the delams from 15 mm to 25 mm depth. hollow sound was recorded as Hollow and that part was evaluated for remedial measure. results of each structural members viz., columns & beams were again recorded onto observati' sheet and the cumulative area of defect was simultaneously recorded. \, INSTRUMENTATION: Three different tests were carried out on a representative spread of columns and beams. tests thatwere carried out identified the damage potential due to four different defects.

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The tests carried out comprised of:

CARBONATION TESTS to identify the depth of carbonation. REBOUND HAMMER TESTS to give a picture of the surface strength of the section. ULTRASONIC PUSLE VELOCITY TESTS to define the integrity and d of defect in the RC section. CARBONATION TEST: Chemical reaction of the concrete surface to a Phenolphthalein based' staining agent recorded at varying depth at the same location. The first depth were the stain turned pink ,record the depth of carbonation. These tests were carried out jn close proximity to the s ' strength profile test locations to note the densification effect of carbonation on surface strength. :

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SURFACE STRENGTH PROFILE: REBOUND HAMMER METHOD The hammer is principally a surface hardness tester. The principle is that when a spring-loaded shaft strikes a surface, its rebound is a function of the surface. The force on the shaft and its rebound developed are measured by the hammer. The Operations are very simple. They consist of releasing the plunger from locked position by pressing gently against the hard surface and check for zero setting of rebound number indicator on the graduated scale. The hammer is then strongly pressed against the prepared spot of the surface under investigation which leases the spring-loaded weight which strikes the plunger and causes the impact The position of the indicator on the scale is read as "rebound number" and recorded in test data log. This recorded data log is then corrected for position of the hammer position of the reinforcement, moisture contents in the elements and carbonation depth. This together with other data would help design of other actions . INTEGRITY TESTING: ULTRASONIC PULSE VELOCITY MEmOD: .It is known that speed of a sound wave varies with the density of its propagation medium. The' J"l}ncreteis a medium through which ultrasonic pulse is made to propagate. The pulse is sent ough transmitting transducer acoustically coupled with the surface and is received by a similar uansducer placed in position. The time elapsed from transmittance to receipt of pulse is measured in microseconds and displayed. The pulse velocity is calculated by expressions: Pulse travel path Pulse Velocity
=

Pulse travel time Is converted to rnIsec or KmIsec The Pulse velocity in concrete ranges from 3 krnI see to 4.8 krnI see The ULTRASONIC PUSLE VELOCITY in concrete is a function of density and compactness of concrete, which within limits bears a relationship with strengths and elastic properties of concrete. Beyond these limits, the relationship is very weak. OBSERVED DEECTS AND DISTRESS SYMPTOMS: RCCFRAME: The observations are based on visual and delam survey conducted by team of engineers and technicians as per standard methodology. The frame element shows presence of distress in the ". form of cracks and delams, seepages. The cracks are mostly longitudinal and at some places .hese cracks are observed to be transverse. Most of the longitudinal cracks are along the rebars, mdicating high corrosion activity. The cracks extend from ground floor in some of the . Comer columns show cracks 10mm wide within permissible limits. The crack width is varying from 1mm to 10 mm. Cracks wider than 20mm indicate severity of distress. The crack depth as recorded varied from superficial to about 20mm deep. Few cracks on the exterior face are deep and extend up to the rebar depth. The crack depth of about 30mm indicates that the crack extends up to the rebar location. The cover depth on an average is 40mm. The depth of crack beingwithin the cover concrete, it can be concluded that the core concrete is not affected in most of the columns. Beams also show a similar distress level but compared to columns they are having less distress. Slab cover shown crazing & seepage marks & efflorescence in most of the '. flats. Delamination is observed in stilt areas. Most of the columns & beams in this area are .shOwingcracks. Instrumentation results correlate with the observed distress pattern. UPV resultsprove that the integrity of the columns tested is poor but in some of the locations they are .beyondpermissible limits. Surface strength tests show uniform deterioration ijl strength. Beams ~\ Sanjivani Vision - 08
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SRES College of Engineering, Kopargaon, Maharashtra - 423 603

in stilt area show porosity & honeycombing, this being a construction defect affecting the en' section, for which grouting will have to done. The UPV readings being taken on plaster s & plaster of paris, the effect of plaster carbonation and hardening is accounted and it t concluded that the member shows uniformdeterioration, Carbonation test is carried out &iv the carbonation depth as being 10 to 30mm in locations indicating the part cover is be' carbonated. Carbonation is normally extensive along the face of the columnslbeams and 10 on other sides. Assuming concrete has been manually made and casting has been in stages discounting for carbonation induced increase in surface strength. The grade of concrete exists today is about to MIS to M20. However as most of the core being unaffected carbonation and corrosion affected distress, the frame is safe, if cover is repaired. The staira!j landing beams and soffit show distress in the form of cracks & hollowness & delamination.

FAC;ADE:
The facade of the building shows weathering effect. The facade shows beam wall delaminatl and column wall delamination to some extent This is a potential area for seepage propagati The plaster on all faces shows crazing, cracking. Cracks arising due to thermal variation are noticed around most of the openings. All theses defects lead to common defect mainly seep Seepage near to any RC member leads to further propagation of defects like carbonation corrosion. The terrace Parapet wall is also seepage prone. Plumbing and sanitation lines are maintained well. Hence they need to be repaired. Most of the lines are covered with vegetati growth around it which will lead to the seepage problems in future. Vegetation growth tends penetrate the roots in to the RC section and wall section. These roots create cracks in the secti and should be removed immediately. In general no vegetation or plants should be allowed grow on .the building elements. Defects in soffit of balcony slab and lintel are in the form delaminating cracks, hollowness. Stair case waist slab shows hollowness and crazing. Re . to such areas are essential. WATER PROOFING: Terrace water proofing is reported to be in good condition as same has been done recent!) There are no leakages reported. Most of the external walls show seepage in the building. parapet wall show crazing on most of the locations. It has been reported that in many flats is seepage from flat above. This seepage is from toilet and sunken area and this being an inte matter needs to be appraisal to every member of society to rectify this defect before rahabilization work is completed. In case it is decided to rectify such defects from society then the bill of quantity shall undergo changes accordingly. GENERAL: General cleanliness is maintained and can positively be enhanced overhead water tanks she leakage marks. Surface crazing and seepage marks will require repairs and replasteri Plumbing lines are not maintained. During replastering it will be essential for a total retrofit all lines as during working damage can occur to the same. TABLE NO .. 1 LEGEND SHEET DESCRIPTIONS MINOR CRACK OPEN CRACK WIDE CRACK CRACK ALONG MAIN REINFORCEMENT
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DIAGONAL CRACK BEARlNGSHOULDER(HAUNCm/CRACK DELAMINATED SECTION SPALLING CRACK PERPENDICULAR TO THE MAIN REINFORCEMENT JUNCTION S~P ARA TION COLUMN WALL DELAMINATION BEAM WALL DELAMINATION SAG IN FOUNDATION, COLUMN, BEAM, SLAB. CRAZING BUILDING SETTLMENT TILT STEEL CORRODED SEEPAGE MARKS OIL SEPAGE MARKS SEEP AGE EVIDENT POROUS HOLLOWNESS SECTIONS CARBONAGTED SECTION NON CARBONATED SECTION BOTTOM FACE SIDE FACE GRID REFERENCE NO PRECIPITATION HONEY COMBING RUSTING ENCASEMENT STEEL EXPOSED NOT A VAILABLEINOT ACCESSIBLE PAINT PEELING LOOSE PLASTER PLASTER OF PARIS FALSE CEILING LINTEL CRACK BEAM SLAB DELAMINATION BEAM NO. 1/2 2/3 OBSERVATIONS RP,CRA,RC RP,CRA,RC RP,CRA,RC RP,CRA,RC - TAPING H H H -H REMARKS

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and instrumentation test results of arcand floor external side .

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INSTRUMENTATION: LOCATION REBOUND HAMMER TEST st 00 1 2 3ro AVG 22 30 28 26 15 48 38 32 39 1 24 20 20 21 2 36 40 40 38 5 28 26 24 22 30 24 20 20 21 23 CARBONATION TEST: LOCATION Cl C2

ULTRA PULSE VELOCITY TEST READ VEL DIST 2.63 260 99 1.26 260 200

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2) Observations and instrumentation test TAPPING OBSERVATIONS COL NO H CWO 15 CWO H 13 CWO H 19 H CWO 20 H CWO 21 POP,OK H 2 H CWO 8 H OK 16 H 10 F.C. POP H POP 3 CWO, POP H II F.C. H 17
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results of flat no101 BEAM OBSERVATIONS NO. LC,RC 15/13 POP 13/20 POP 19120 POP 15/19 13A116 POP,RP OK 20/21 POP 1/2 POP,MC 2/9 POP 9/10 POP, RP 3/10 RP 2/3 L.C, SPM 2A13A

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INSTRUMENTATION: LOCATION REBOUND HAMMER TEST 1 st 2na 3ra AVG 14 16 18 16 22 20 22 22 ULTRA PULSE VELOCITY TEST READ VEL DIST 200 72 2.78 200 79 2.53 REMARK

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3) Observations and instrumentation t est results of flat no 402 COL NO 3 4 5 10 11 7 17 18 , 14 22 SLAB V VI VII -r>.

OBSERVATIONS CWD OK OK CWD CWD CWD OK OK OK OK OBSERVATIONS CRA SPM CRA

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BEAM NO. 10/11 3/10 4/11 3/4 17122 4/5 5/7 14/18 18/24 23/24 14/17

OBSERVATIONS RP RP,BWD OK OK RP RC OK Me OK RC,CRA MC

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INSTRUMENTATIONLOCATION REBOUND HAMMER TEST nd st 2 3ra AVG 1 . 14 10/11 14 14 14 3/4 26 28 28 28

ULTRA PULSE VELOCITY TEST DIST READ VEL 2.38 300 126 1.72 174 300

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SRES College of Engineering, Kopargaon, Maharashtra

- 423 603

CARBONATION LOCATION C5
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1. The defects in the RC members are due to a combined effect of carbonation, corrosion

effect of continuous drying and wetting in the vicinity of thin RC Sections. The results of vi and tapping prompt us to following observations. The Combined results ofUPV surface stre and carbonation all confirm that the distress is restrictive in the surface cover of the RC mem Surface rehabilitation of external surfaces is essential. RC section in stilt is exposed ext Tht carbonation and corrosion. At 2. The propagation of defects will proceed faster once the entire cover has deteriorated. C co width and depth of.crack in most ofthe column is within acceptable safety limits Instrumentati v > '1J also confirms the prognosis that the cover of most the RC sections shows distress but it is wi ' ; acceptable limits. Surface strength shows a major reduction. Carbonation has reached p , wet cover depth on some of the RC members. Corrosion potentials are 90% to 95% percent at so sh external locations where tests have been conducted Core concrete is in good condition but bee cover will require repairs. Th 3. The external plaster has failed due to delamination; crazing and cracks hence total retrofit' of1 essential: sin. 4. Water Proofing will not require retrofitting as it is reported to be in good condition. too 5. Overhead Water tanks will require repairs including grouting and replastering. the. replumbing of sanitary lines will be required. sh 6. A well-defmed and specified rehabilitation plan is essential and this programme sho rep: be carried out under expert's guidance. Some items of repairs should be taken up immediately one or two column/beam locations in the stilt area. Thelest of the repairs can proceed in phased manner .. Due to the expected monsoon season. It will be of advantageous to take up repairs right now and start with the internal repairs during monsoon. Also the effect ofmo can be noted by the Supervisory staff at site during monsoon. The external repairs can suitably modified to take that into account. The phased plan can extend to over l O.to 12 mon However 'above points are based on observation and are fairly accurate. Foundation assessm has not been carried out. pro' exp 7. The cost of rehabilitation will be about Rs. 42 lakh to Rs. 45 lakh. The costs are based on ge market prices as of 1st August 2001. The split up and essential list can be worked out based incr the budgetary constraints. It is our opined that repairs are essential & should be carried immediately. The committee is suggested to plan their repair fund mobilization based on ' scie realistic figure. This budget does not consist of any provision for extra structural support the for the sunshades that will be essential. It also does not cover any defect not identified due to' inaccessibility during inspection. However the budget is realistic and should not vary beyo~ percent of the stated figure. .. 8. All observations and test results are based on factual records. No suppression, extrapolations have been adopted. Foundation status survey has not been carried out due to.. availability of details. The observation and facts presented here relate to the findings as of. date of investigation. The process of deterioration is continuous and the level of distress will

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