Non Destructive Concrete Testing - Aaryan Engineers, Mumbai www.aaryanengineers.com 1.UPV TEST IS Codes applicable: As per IS 13311.

(Part 1): 1992 Applications of the test: The test is performed on structural elements. Homogeneity of Concrete. Presence of Cracks, Voids & Other Imperfections. Changes in Concrete Structure with time. Velocity co-related to strength. Equipment Used: Electric Pulse Generator. Transducer: One Pair. Amplifier. Electronic Timing Device. Test basis: Ultrasonic pulses travel faster in denser material. Each material has typical ultrasonic pulse velocities. E.g. steel, Concrete etc. using benchmarks over a period of time and conducting extensive laboratory and in-situ tests, we have co-related ultrasonic pulse velocity and estimated strength. Methodology: Assess access, Single sided, double sided etc on the structural element Clean the concrete surface thoroughly (on plaster or without plaster). Apply grease on the concrete surface where test is to be conducted. Press probes on the surface of the structural element to remove air gaps. Note down the distance between the 2 probes. Read time taken for the ultrasonic pulse from the instrument. Calculate Velocity = distance / time Repeat the test on multiple areas of the element if necessary. Test at different members of the structure.

Influencing factors for readings: Readings taken on plaster or directly taken. New/old construction in elements. New + old material (e.g. jacketed columns where new and old concrete coexist). Single sided or double sided access. (indirect or direct) Grade of Concrete. Understanding results: The estimated strength may vary from actual strength upto about +/- 15%. or so. In order to confirm the findings of the tests, core tests may be conducted on a select sample of elements, if necessary. The interpretation of strength of concrete from the UPV is based on our experience, judgment & to the best of our knowledge. The IS code 13311 (Part 1) 1992 (Indian Standard Code of Practice) gives velocity. Criterion for concrete quality grading, part of which is reproduced below: Sr. No Pulse velocity be cross probing (direct method) Concrete Quality Grading 1. Above 4.5 km/s Excellent 2. 3.5 km/s to 4.5 km/s Good 3. 3.0 km/s to 3.5 km/s Medium 4. Below 3.0 km/s Doubtful However the code does not give any interpretation of UPV in terms of strength. Hence the IS code gradings should be taken only as guidelines. However our experience shows that for M20 grade concrete a velocity of 3.5 km/s may be good but for high strength concretes like M40 or M60, the velocities for both may be above 4.5 km/s, however M40 cannot be used in place of M60, hence the IS code gradings should be taken only as guidelines. For new construction, for concrete grades higher than M30, the customer must provide reference cubes, crushing results and mix design in order to correctly arrive at the estimated strength. 2.REBOUND HAMMER This test measures the surface hardness of concrete. For new structures, the hardness reading is used to co-relate the strength of concrete. The hammer has to be used normal to the test surface, vertically (up or down) or horizontally depending on the structural element. IS Codes applicable: IS 13311, (Part 2): 1992. References: IS 516: 1959 Test for strength of concrete IS 8900: 1978 Criteria for rejection of outlying observations. Applications of the test: Assessing the Compressive Strength of Concrete Assessing the Uniformity of Concrete. Applicable for new concrete. Applicable for old concrete only with special techniques. Equipment Used: Rebound Hammer

Test basis: Harder the surface of the material tested, greater is the rebound. In new concrete, as it gains strength, hardness increases and as a result, the readings increase. The hammer can be used in 3 orientation, Vertical up or down (typically used for slab), horizontal (for columns). Depending on the orientation used and age of concrete, the results are interpreted for strength. Methodology: Identify test Locations. Clean the concrete surface thoroughly (remove plaster, if present ). Press hammer and release. Note down the reading. Take an average of multiple readings. Repeat the test on multiple areas of the element if necessary. Test at different members of the structure. Influencing factors for readings: Readings taken on directly concrete. New/old construction in elements. New + old material (e.g. jacketed columns where new and old concrete coexist). Carbonation of surface. Condition of the surface. Moisture content. Curing and age of concrete. Cement and aggregates ( detailed mix design) used. Understanding results: The Rebound Hammer test measures surface hardness only (upto about 50 mm depth). In order to assess continuity inside the element, UPV test is recommended. The estimated strength may very from actual strength about +/- 10%. In order to confirm the findings of tests, core tests may be conducted on a select sample of element. 3. HALF CELL POTENTIAL Half call potential test determines the probability of corrosion activity taking place at the point in the Reinforcement. A higher probability means more chances of corrosion. This test measures the probability and not the extent of corrosion. Codes Applicable: ASTM - C -876, 1991. Applications of the test: Assessment of probability of corrosion being present. Equipment Used: HCP Kit. Carbonation Measurement Kit. Test basis: Half Cell Potential The potential in millivolts decrease with the increase in probability of corrosion in the steel reinforcement. Carbonation:

Concrete, being basically a porous material, undergoes carbonation process with ageing. As the protective cover of the concrete carbonates completely, the corrosion reaches the steel reinforcement, rapidly accelerating the process of corrosion in steel.

Methodology: Half Cell Potential Identify test locations. Drill hole with a electric drill machine to reach the steel reinforcement rod. Establish electric contact to the reinformcement. Measure voltage in millivolts. on the surface of concrete at multiple locations of the member. Test at different members of the structure. Methodology: Carbonation Identify test locations. Drill hole with a electric drill machine to reach the steel reinforcement rod. Inject indicator chemical & insert steel rod. Indicator chemical determines at what depth the color changes. Influencing factors for readings : Extent of corrosion. Understanding results: The HCP test gives probability of corrosion and not the actual corrosion. For better understanding, ASTM have classified this into 3 categories as 10%, 50% and 90% probability. Carbonation test gives the depth in mm to which the carbonation has taken place in the concrete cover. 4. REINFORCEMENT MAPPING This method is used to assess reinforcement bar diameter and spacing of main bars and stirrups. For new structures it can be used to determine the exact usage of steel. In old buildings this is used to gather information on the reinforcement, not available or otherwise. This information is then used to prepare the structural drawings as constructed. 5. CORE TESTING 75mm, 100mm or 150mm diameter cores are taken on site using state of the art core cutting machines. Cover meter is used to locate the reinforcement steel before core cutting. This prevents structural damage to the RCC

member by avoiding the reinforcement. These cores are dressed in our lab and tested using standard compression testing methods to determine compressive strength and arrive at equivalent cube strength of concrete. IS Codes applicable: IS : 456 / IS : 516 / IS : 1199 Applications: Assessment of strength. Study of aggregates used in the mix design. Assessing probable causes of failures/problems. Equipment Used: Core cutter. Core compression testing machine. Test basis: A core sample is the actual representation of the material used in the structural element. When processed and subjected to load, it fails at a particular load, giving a fair idea of its compressive strength. Methodology: Step1: Reinforcement Mapping. By using a special instrument, based on eddy currents, the reinforcements are mapped in the structural member. Step 2: Core cutting. Cores are taken using special diamond cutters of 75 mm, 100 mm or 150 mm diameter. Locations are selected to avoid steel so as to minimize the damage to the structure.

Step 3: Dressing. The edges of the core are smoothend using grinding and cutting wheels and epoxy mortar is applied on both sides for capping. This ensures that the ends are approximately at 90% to the axis and are within 0.05 mm plane ness.

Step 4: Immersion in water

The core samples are immersed in water for 48 hours. The cores are weighed before and after immersion. Step 5: Compression testing. The cores are then subjected to compression forces on compression testing machine. The breaking point is observed. Step 6: Reporting. Based on the lab report, sizes of the core etc. an equivalent cube strength is calculated for the concrete applying necessary correction factors. The density, core strength and equivalent cube strength are reported. Influencing factors: Core diameter and length (h / d ratio) Proper capping and hydration of the cores as per IS code. Old/new/Mixed (jacketed) concrete. Understanding results: The result is normalized for comparison with compressive test results of a standard cube. This is done so that the cube results can be compared with the core results. Standard correction factors as per IS code are used for this purpose. This value may not be the same as the core strength. We report results as per IS code. IS code does not take into account the core cutting effect. When accounted for, the results can be higher than those reported. Discussion on this can be taken up with consultants as a separate assignment. Visual observations of the aggregate, failure pattern and probable causes of failure and suitalble remedies can be discussed separately and are not a part of the scope of conducting the test and reporting results. 6. PILE INTEGRITY TEST Pile integrity test is used to assess the continuity of piles. With this test, necking or bulging and uniformity of quality of concrete is checked.Piles that are doubtful for integrity are taken up for Dynamic load testing along with some piles which are ok. Typical defects identified by this test are shown below. Code: Method of Testing : There are Indian Standards for the pile integrity test & the most commonly used worldwide is Pile Integrity Test as per ASTM D 5882 00, Standard Test Method for Low Strain Integrity Testing of Piles. Relevant clause from the said ASTM standard is reproduced below: Clause no. 5.2.3 : Placement of Transducers The motion sensor should be placed at or near the pile head using a suitable, or temporary, bonding material (that is wax, vaseline etc.) so that it is assured that it correctly measures the axial pile motion. The motion sensor is placed generally near the center of pile. Additional locations should be considered for piles with diameters

greater than 500 mm. The low strain impact should be applied to the pile head within a distance of 300 mm from the motion sensor. Objective: To check the pile for continuity for the continuity of the shaft of the pile

Background: In the sonic test, the top of the pile is hit with a plastic hammer and the reflected waves are recorded by a suitable computerized equipment. From the resulting signal, or reflectogram, one can determine both length and continuity of the pile. Although a powerful tool, the sonic method also has limitations, such as: the test produces no information regarding the pile capacity, and gives only limited information about the concrete quality. The sonic system, can only discover material impedance changes. It cannot tell anything whether these impedance changes are due to poor concrete or due to reduced cross section. Even then this test is a fast & economical tool for determining discontinuities in the pile shaft. If pile records are available, then the results can be fine tuned for greater & more reliable information. Limitations of the test: The accuracy of the length determination depends on the assumed wave velocity. This factor, which depends on the grade and age of the concrete, varies from pile to pile and may cause an error of the order of 10 percent. Site preparation Guide: For the test to be effective, the top of the pile should consist of clean concrete and free of debris, laitance and bentonite. Testing a pile with a head which was not properly prepared may yield misleading results. Table 2: Sample Report Sheet (Pile Integrity Test)

7. PILE DYNAMIC TEST Pile dynamic test is used to assess the load bearing capacity of the pile. This test uses a hammer of a couple of tons to drop on the pile. Displacements are measured using a high tech instrument. This data is processed to arrive at the pile dynamic load bearing capacity as per IS-2911(part-1 section-1). This test is easy to conduct and requires very few site arrangements. Code: Background: Modified Hileys formula is given in IS 2911, part 1, section 1. To obtain a reliable capacity prediction from dynamic pile testing, some very basic guidelines must be followed. Advantages: As a supplement to or replacement for static tests, dynamic testing takes far less time to perform and thus reduces the costs. Methodology The methodology of test is based on a large weight giving a dynamic impact to the elastic body. It equates the energy of hammer blow to work done in overcoming the resistance of the founding strata to the penetration of the ordinary cast-in-situ piles as well as grouted micro piles. Allowance is made for losses of energy due to the elastic compression of the pile, subsoil as well as losses caused by the impact of the pile. The modified Hileys

formula given in the code I.S. 2911 part 1 section 1 is used in estimating the ultimate driving resistance in tonnes. From that with a factor of safety as outlined in the code the safe load on pile can be worked out. The instantaneous displacements including rebounds of the pile are precisely recorded in an automatic data acquisition system. This is done for several cycles & then using formulae as in I.S. 2911, the safe load capacity of the pile is calculated. An optical instrument is used for position sensitive measurement by non-contact continuous measurement with the instrument placed away from the vibrations due to impact load. The system is based on combined light emitting diode transmitters & a position sensitive detector. The transmitter & receiver are installed so that the light beam forms a reference line from the transmitter, receiver to the prism group reflector. The reflected light can be received & recorded 100 times per second. Using the energy transmitted to the pile & accounting for temporary compression of the pile, ground & dolly occurring during the impact loading the ultimate driving resistance is calculated. Modified Hileys Formula R = Whn / (s + c / 2) Where R = Ultimate driving resistance in tonnes W = Mass of Ram in tonnes h = Height of free fall in cm considered at 80% for winch operated drop n = Efficiency of the blow representing ratio of energy after impact to striking energy of ram s = Average final set per blow in cm c = Average sum of temporary elastic compression Applying the factor of safety, the safe load for the pile is then calculated. Some of the significant advantages of this method are: 1. Non-contact 2. Transparent 3. Accurate 4. Easy to Understand 5. Logical 6. Quick 7. No need to cut projecting reinforcement from pile head 8. No need to cast concrete on pile head 9. Greater capacity utilization in design Standard Setup Diagram 1.Non-contact 2. Transparent 3. Accurate 4. Easy to Understand 5. Logical 6. Quick 7. No need to cut projecting reinforcement from pile head 8. No need to cast concrete on pile head 9. Greater capacity utilization in design

Dynamic Testing Procedure Notes: 1.To the cured pile, to avoid splitting of head due to impact, a steel cap with timber cushioning between steel & pile head is provided. 2. The instrument and laptop computers is set up at a distance away from the vibrations due to impact. 3. The test considers average/best of 4 blows. It is a known fact that during the first blow, the settlement is larger. The results are co-related with other parameters before arriving at a final conclusion.

Dynamic Pile Test Methodology:

Information required before testing from the customer site: 1.Pile records (total length, socketing length etc.), soil profile in the area, pile drawings, plans etc. 2.Mix design (if used) details of grade of concrete. Facilities required at the client site to conduct the test: 1.Clear approachable test locations with unobstructed view of one meter length of cleaned pile top. 2.Steel Plate & Wooden Cushion. 3.Loading facilities like piling winch along with chisel of known weight with operators installed at the location.

Sample Dynamic testing Report: