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Nondestructive Evaluation of Steel Bridges: Methods and Applications

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Nondestructive Evaluation of Steel Bridges: Methods and Applications Transportation Kentucky Transportation Center Research Report University of Kentucky Year 2016 Nondestructive Evaluation of Steel Bridges: Methods and Applications Theodore Hopwood II∗ Christopher Goffy Jared Fairchildz Sudhir Palle∗∗ ∗University of Kentucky, [email protected] yUniversity of Kentucky, chris.goff@uky.edu zUniversity of Kentucky, [email protected] ∗∗University of Kentucky, [email protected] This paper is posted at UKnowledge. https://uknowledge.uky.edu/ktc researchreports/1587 Nondestructive Evaluation of Steel Bridges: Methods and Applications Kentucky Transportation Center Research Report — KTC-16-26/SPR14-485-1F DOI: https://doi.org/10.13023/KTC.RR.2016.26 The Kentucky Transportation Center is committed to a policy of providing equal opportunities for all persons in recruitment, appointment, promotion, payment, training, and other employment and education practices without regard for economic or social status and will not discriminate on the basis of race, color, ethnic origin, national origin, creed, religion, political belief, sex, sexual orientation, marital status, or age. Kentucky Transportation Center College of Engineering, University of Kentucky Lexington, Kentucky in cooperation with Kentucky Transportation Cabinet Commonwealth of Kentucky © 2017 University of Kentucky, Kentucky Transportation Center Information may not be used, reproduced, or republished without KTC’s written consent. KENTUCKY Kentucky Transportation Center • University of Kentucky Transporation Center Kentucky 176 Raymond Building • Lexington KY 40506 • 859.257.6898 • www.ktc.uky.edu Research Report KTC-16-26/SPR14-485-1F Nondestructive Evaluation of Steel Bridges: Methods and Applications Theodore Hopwood II, P.E. Program Manager, Research Christopher Goff Transportation Technician II Jared Fairchild Transportation Technician II and Sudhir Palle, P.E. Senior Research Engineer Kentucky Transportation Center College of Engineering University of Kentucky Lexington, Kentucky In cooperation with Kentucky Transportation Cabinet Commonwealth of Kentucky The contents of this report reflect the views of the authors, who are responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the University of Kentucky, the Kentucky Transportation Center, the Kentucky Transportation Cabinet, the United States Department of Transportation, or the Federal Highway Administration. This report does not constitute a standard, specification, or regulation. The inclusion of manufacturer names or trade names is for identification purposes and should not be considered an endorsement. December 2016 1. Report No. 2.Government Accession No. 3. Recipient’s Catalog No. KTC-16-26/SPR14-485-1F 4. Title and Subtitle 5. Report Date Nondestructive Evaluation of Steel Bridges: Methods and Applications December 2016 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Theodore Hopwood II, Christopher Goff, Jared Fairchild and Sudhir KTC-16-26/SPR14-485-1F Palle 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Kentucky Transportation Center College of Engineering University of Kentucky 11. Contractor Grant No. Lexington, KY 40506-0043 SPR 14-485 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Kentucky Transportation Cabinet State Office Building Frankfort, KY40622 14. Sponsoring Agency Code 15. Supplementary Notes Prepared in cooperation with the Kentucky Transportation Cabinet, Federal Highway Administration, and U.S. Department of Transportation. 16. Abstract Nondestructive evaluation (NDE) methods can be used to assess in-service steel bridges for problematic conditions caused by factors such as design, manufacturing, fabrication, and the service effects of traffic and corrosion. This report discusses typical NDE test methods used on bridges, including penetrant testing, magnetic particle testing, eddy current testing, ultrasonic testing (including phased array testing), radiography, and acoustic emission testing. NDE operations such as flaw location, characterization, and sizing are covered as well. Results of a national survey of departments of transportation’s (DOTs) use of NDE are presented. A simple procedure for using NDE to address DOT bridge concerns is proposed along with a risk-based inspection approach to scheduling/scoping bridge inspections. 17. Key Words 18. Distribution Statement acoustic emission testing, bridge inspection, crack detection, defects, eddy Unlimited with the approval of current testing, flaws, magnetic particle testing, nondestructive evaluation, the Kentucky Transportation phased array ultrasonic testing, radiography, steel bridges, ultrasonic testing, Cabinet welds 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 114 Table of Contents Executive Summary .......................................................................................................................................1 1. Introduction ................................................................................................................................................1 1.1 Background ..........................................................................................................................................2 1.2 Bridge Design Flaws ...........................................................................................................................2 1.3 Bridge Steels ........................................................................................................................................3 1.4 Common Types of Bridge Steel Damage ............................................................................................4 1.4.1 Corrosion ......................................................................................................................................6 1.4.2 Cracking .......................................................................................................................................6 1.4.3 Wear .............................................................................................................................................9 1.4.5 Surface Blemishes ......................................................................................................................11 1.5 The Roles of Inspectors and NDE Specialists in Performing Bridge Inspections ............................11 2. Nondestructive Evaluation Methods for Steel Bridges ............................................................................14 2.1 Flaws ..................................................................................................................................................14 2.2 Nondestructive Evaluation Methods .................................................................................................15 2.2.1 External/Surface NDE Methods .................................................................................................16 2.3 Internal/Subsurface NDE Methods ....................................................................................................23 2.3.1 Radiographic Testing .................................................................................................................23 2.3.2 Ultrasonic Testing ......................................................................................................................27 2.3.3 Acoustic Emission Testing .........................................................................................................37 2.4 Miscellaneous NDE Methods ............................................................................................................43 2.5 Ancillary Test Tools and Supplies ....................................................................................................44 2.6 Surface Preparation, Worker Safety and Compliance with Environmental Regulations ..................44 3. Use of NDE for Bridge Inspections .........................................................................................................46 3.1 Range of NDE Applications ..............................................................................................................46 3.1.1 Evaluations of Potential Flaw Indications ..................................................................................46 3.1.2 Searching for Potential Flaws ....................................................................................................46 3.1.3 Flaw Detection ...........................................................................................................................47 3.1.4 Flaw Sizing .................................................................................................................................47 3.1.5 Flaw Characterization ................................................................................................................48 4. National Bridge NDE Survey ..................................................................................................................53 5. Decision Making Related to NDE ...........................................................................................................55 5.1 Options for Structural Inspections .....................................................................................................55 5.2 A Process to Address Specific Concerns ...........................................................................................56
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