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Proceedings of the 20th International Conference on Nuclear Engineering Collocated with the ASME 2012 Power Conference

ICONE20-POWER 2012
July 30 - August 3, 2012, Anaheim, California, USA

Paper No. ICONE20POWER2012-54088


EVALUATION OF CONCRETE STRUCTURES USING NONDESTRUCTIVE TECHNIQUES

Hemant S. Limaye Ashok M. Kakade, P.E.


Concrete Science, Inc. Concrete Science, Inc.
1534 B Street, Hayward, CA, USA 1534 B street, Hayward, CA, USA

ABSTRACT terms of the frequency spectrum. Another way of classifying


the methods would be based on the category under
To renew the expiring licenses of the nuclear power plants, the investigation such as concrete strength, embedded reinforcing
operators will need to evaluate major structural components for steel, concrete quality and deterioration, and integrity and
the age related deterioration. Assessment of the interior of the performance. The most common methods used in the industry
concrete structures can be made using the available include the following:
nondestructive testing (NDT) methods. This paper presents a
quick overview of the methods and describes how some of • Visual inspection, which is an essential precursor to
these methods were used for the two projects-one for the new any intended non-destructive test. An experienced
construction and one for the existing project going through the engineer may be able to establish the possible
modification/renovation. cause(s) of damage to a concrete structure and hence
identify which of the various NDT methods available
INTRODUCTION could be most useful for any further investigation of
the problem.
In the United States, currently there are 104 licensed nuclear • Rebound hammer test, used to evaluate the surface
power plants supplying approximately 20% of the electricity. hardness of concrete.
In the next ten years, approximately 30% of these power plants • Penetration resistance or Windsor probe test, used to
will need to renew their initial 40-year license period. To renew measure the surface hardness and hence the strength
the license for the next 20 years, major structural components of the surface and near surface layers of the concrete.
of the power plants will need to be evaluated for the age related • Rebar Survey to locate rebars (depth or size).
degradation. Concrete is used in the construction of nuclear • Half-cell electrical potential method, used to detect
facilities because of its structural strength and its ability to the corrosion potential of reinforcing steel in
shield radiation. Experience with the performance of concrete concrete.
structures used in the power plants has been very good. For the • Ultrasonic pulse velocity testing, mainly used to
concrete structures, age related degradation can occur due to measure the sound velocity of the concrete and
corrosion of reinforcing steel which in turn can lead to cracking hence the compressive strength of the concrete.
and spalling of concrete. There is no significant effect on • Impact echo testing used to detect voids,
concrete for low doses of radiation (<1010 neutron/cm2 or delamination and other anomalies in concrete.
<1010 Gy gamma) over periods of less than 50 years. There is • Impulse response testing in which “mobility” of the
no readily available data for longer-term exposure. Some types structural member under investigation is determined.
of concrete has been reported to exhibit reduction in The value of the mobility is used to determine the
compressive and tensile strength with the increase in volume condition on the comparative basis.
for higher doses of radiation (>1020 neutron/cm2 or >1010 • Ground penetrating radar or impulse radar testing,
rads of gamma). used to detect the position of reinforcing bars,
stressing wires or ducts.
Periodic observations of the structures can identify the exterior • Infrared thermography, used to detect voids,
degradation in the form of cracking, spalling, leakages, scaling delamination and other anomalies in concrete and
or discoloration. Nondestructive techniques are valuable tools also detect moisture intrusion in buildings.
to identify interior degradation, if any. • Radiographic (X-ray) testing, used to detect accurate
location of reinforcing steel, voids in the concrete
OVERVIEW OF THE NDT METHODS and the position of stressing wires and ducts.
Basic methods for NDT of concrete structures can be classified
in a variety of ways. Figure 1 shows the principal methods in
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The NDT methods have been discussed in the literature The testing was conducted at the grid points of a 0.3 x 0.3-
extensively and hence, their details are not provided in this m. grid as shown in Fig. 4. Scaffolding was erected around
paper. Concrete structures of the nuclear power plants impose the columns to gain access. If there was a surface flaw
special challenges since most of these structures are massive, present at the grid point, the sensors were moved to the
heavily reinforced and with difficult and often limited access. nearest unflawed location. Direct and semi-direct
Following case histories illustrate the use of some of the NDT transmission (Fig. 5) methods were selected to acquire the
methods. time of arrival (TOA) readings in micro-seconds. The
average TOA values for the four columns varied between
CASE HISTORIES 473 and 479 micro-seconds in the well consolidated area of
the columns. For a travel path of 1.98-m TOA values
Two case histories are presented in this paper -one for the new convert in to average velocities between 4163 and 4189-m
construction and one for the existing structure which was going per second. TOA values adjacent to the visible
through modification and rehabilitation. The new construction honeycombed areas were unstable indicating questionable
project consisted of evaluating four columns supporting the quality of the concrete.
steam turbine generator (STG) pedestal foundation. Existing
project consisted of evaluating cooling water intake structure Results Verification: To verify the results, a few areas of
consisting of approximately 101-m long tunnel. These case unconsolidated concrete were chipped deeper and wider
histories illustrate how different nondestructive and semi- and it showed sound quality concrete in the interior portion
destructive test methods are used to evaluate the structures. of the column. In addition, concrete condition behind the
steel channels was verified by drilling 13-mm diameter
Evaluation of STG Columns holes to a depth of 76-mm. Observations of the holes using
a fiber scope indicated sound concrete with absence of rock
Schematic of the STG pedestal is shown in Fig. 2 and pockets or voids.
photograph 1. The rectangular concrete columns were
approximately 9.75-m high measuring 1.98 x 2.44-m and 1.98 A repair procedure using a polymer modified, cementitious
x 2.74-m. The columns contained primary reinforcement of two mortar with silica fume was provided to the client.
rows of no. 11 bars and no. 4 hoop bars spaced at 0.3-m on- Properties of the mortar such as compressive strength,
center. Each column also contained two embedded steel modulus of elasticity, shrinkage and coefficient of thermal
channels (C12 x 25), 6.1-m long approximately 2.74-m from expansion were closely matched to that of column concrete.
the base. During the construction phase when the forms were
removed, honeycombed (unconsolidated) concrete was Evaluation of Cooling Water Intake (CWI) Tunnel
discovered in varying degrees from minor to severe including
the area adjacent to the steel channels. Because of such a The overall plan and elevation views of the CWI structures are
visible nature of the unconsolidated concrete, condition of the shown in Fig. 6. The structures consist of water intake, stop log
interior concrete was of suspect. Because of the size of the guides and trash racks, long tunnel (~ 101-m) and the screen
columns and congested steel reinforcement, pulse velocity well/pump structure. The tunnel structure is divided in to two
technique was selected for the nondestructive evaluation tunnels by a longitudinal divider wall. CWI structures were
process. abandoned in place for a number of years and the owners
wanted to evaluate these structures for continued use as part of
Observations: Detailed observations of the columns the new facilities.
showed that unconsolidated concrete was not concentrated
in one area but was scattered at various elevations. At some Observations: Overall physical condition of the structure
locations, in addition to the honeycombed concrete, there was observed for obvious signs of settlement, deflection
were significant voids behind the reinforcing steel and the and expansion/contraction related issues. Surface condition
embedded channels; Fig. 3. None of the columns exhibited of the concrete was observed for cracking, spalling, scaling,
other flaws such as cracking or spalling. exposed reinforcing, corrosion stains, efflorescence,
previous repair patches and abrasion/erosion related issues.
Pulse Velocity Testing: In this method, a pair of The walls of the tunnel were cleaned using the high
piezoelectric sensors is placed at opposite ends of the test pressure water. There was insignificant surface
member. In one of the sensors (transmitter), electronic deterioration caused by either abrasion or cavitation. Most
pulses are generated and the time it takes for the pulse to of the observed surface wear was caused by the removal of
propagate through the concrete is measured by the other accumulated marine growth. There were horizontal hairline
sensor (receiver). Knowing the distance traveled, cracks in the beginning portion of the divider wall showing
propagation velocity is calculated, and based on the signs of moisture seepage; Fig. 7. Two ceiling construction
velocity, condition of the concrete is determined. joints also showed signs of moisture seepage. Large scale,
Depending on the locations of the sensors, the procedure is significant surface deterioration was absent.
divided in to three categories: direct (sensors at opposite
ends), indirect (sensors on the same sides), and semi-direct Reinforcing Steel Layout: The steel layout was
(sensors at right angles) transmission. determined using the electronic rebar detector at several
locations. In general, no. 8, horizontal and vertical
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reinforcing steel was spaced at 0.3-m. on-center with a showed that the concrete was affected by the alkali-silica
concrete cover of at least 76-mm. At a few locations, reaction (ASR). The level of deterioration varied between
exploratory openings were made to observe the condition of moderate to severe. The ASR involves a chemical reaction
the steel. None of the bars showed signs of corrosion. between the OH- ions associated with cement paste and
certain siliceous constituents of the aggregate. The gel
Rebound Hammer Tests: Hammer soundings including formed by the chemical reaction expands and causes
rebound hammer tests were conducted on the tunnel walls concrete to crack. Some of the reactive aggregate
to determine existence of delamination and general quality constituents include opal, chalcedony, certain forms of
of concrete and strength variation. Rebound hammer quartz, pitchstone, crystobalite and tridymite. The concrete
contains a spring-controlled mass that slides on a plunger from the dividing wall contained reactive particles of
within a tubular housing. Upon the pushing action, spring- pitchstone which is a volcanic rock belonging to Ryolite
controlled mass impacts the concrete surface and the family. It is a glassy rock with characteristic luster
display indicates a whole number called a rebound number. resembling that of broken pitch appearance.
Several readings are taken and then averaged. Compressive
strength of the concrete is estimated using the calibration Recommendation: The deteriorated portion of the wall
graph provided by the manufacturer. was recommended to be removed and replaced.

Hammer soundings revealed two delaminated areas in the SUMMARY


walls of the intake chamber and the dividing wall. Rebound
hammer readings in the delaminated areas varied between The paper presented two case histories-one for the new
20 and 25 whereas the readings in the non-delaminated construction and one for the existing structure. All the test
areas were above 40 indicating concrete strength of at least methods available for evaluation have limitations and
27.5Mpa. understanding those limitations is critical. In both cases,
combination of different methods (nondestructive as well as
Impact-echo Tests: In this technique, mechanical energy in semi-destructive) was used to increase reliability and
the form of a short pulse is introduced into a member under confidence level of results. Choosing the right combination of
investigation. Reflected stress waves are monitored by a methods (which requires experience and judgment) can lead to
sensor and are transformed into a frequency domain using a conclusive results.
Fast Fourier Transform method. The resulting amplitude
spectrum is used to determine condition of the concrete. BIBLIOGRAPHY
The tests were conducted at the grid points of a 0.6 x 0.6-m
grid in five selected areas of the tunnels. With the exception 1. Braverman, J., 2000 “Assessment of Age-Related
of one area of the dividing wall, tests indicated consistent Degradation of Structures and Passive Components for U.S.
and repeatable results. The frequencies were representative Nuclear Power Plants” NUREG/CR-6679
of the thickness of the wall and none associated with the 2. Clark, R., 1958 “Radiation Damage to Concrete”, Hanford
internal flaws. One area of the dividing wall showed Atomic Products Operation report, HW-56195,
inconsistent and non-repeatable results indicating potential 3. Hilsdorf, H., J. and Kropp, H. Kock, 1978 “The Effects of
internal flaw(s). This area was the same area where surface Nuclear Radiation on the Mechanical Properties of Concrete”,
cracking was observed. Figures 8-9 show the results of the American Concrete Institute report SP-55-10
testing in the non-delaminated area. The area was marked 4. Naus,D.J., Oland C.B., and Ellingwood, B.R. 2005 “Final
for drilling and removing a core. Report Inspection of Aged/Degraded Containments Program”,
ORNL/TM-2005/170, Oak Ridge National Laboratory, Oak
Removal of Cores: Partial Depth Cores through the Walls: Ridge, Tennessee
A total of 15, 0.1-m diameter cores were drilled and 5. ACI, 2002 “Evaluation of Existing Nuclear Safety Related
removed from the concrete walls, ceiling and floor of the Concrete Structures”, 349.3R-02, American Concrete Institute,
tunnel. The cores were used for visual observation, Farmington Hills, MI
compression testing, split tensile testing, verification of 6. ACI, ”Nondestructive Test Methods for Evaluation of
NDT and petrographic analysis. Core locations were Concrete in Structures”, ACI 228.1R, American Concrete
selected on the basis of visual observations, hammer Institute, Farmington Hills, MI
soundings and impact-echo testing. The cores drilled and 7. ASTM, “Practice for Petrographic Examination of Hardened
removed in the delaminated area as identified by the Concrete”, C 856, ASTM International, W Conshohocken, PA
rebound hammer readings and the impact-echo test results, 8. Limaye H. S., 1991 “Nondestructive Evaluation of Concrete
showed vertical cracks parallel to the face of the wall. with Impact-echo and Pulse Velocity Techniques”, Third
Average compressive and split tensile strength for the cores EPRI Conference on Fossil Plant Inspections, Baltimore, MD
of the tunnel walls were 55.16and 6.03 Mpa respectively. 9. Limaye H.S. 1988,”Inspection Work on Utility Structures”,
Core removed from the suspected area of the dividing wall 2nd EPRI Fossil Plant Inspections Conference, San Antonio, TX
showed multiple interior cracks as shown in Photograph 7.
The core was selected for petrographic analysis.

Petrographic Analysis: Core from the dividing wall


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Nondestructive Evaluation

Sound Light Radiation Electromag

Time of Flight Visible Radiography Mag. Flux

Freq. Response Infrared Tomography Resistivity

Acoustic Emiss. Ultraviolet Spectroscopy Radar

Figure 1. Summary of NDE methods based on frequency


spectrum.

Figure 4. Grid pattern for the PV testing using the direct


transmission method.

Figure 2. Schematic of the STG Foundation showing the tested


columns.

Figure 5. Grid pattern for the PV testing using the diagonal


transmission method

Figure 3. NW column showing areas of deterioration

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Figure 6. Sectional plan and elevation views of the intake structure.

Figure 7. Elevation view of the dividing wall (north tunnel) showing the deteriorated area.
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Figure 8. Impact-echo results (frequency data), dividing wall-north tunnel

3125 Hz ≈ 0.6 m
3250 Hz ≈ 0.58 m

Figure 9. Representative amplitude versus frequency plots for the tunnel walls.

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Photograph 1. STG pedestal during construction. Photograph 2. Area showing the honeycombed concrete.

Photograph 3. Another example of honeycombed concrete. Photograph 4. Drilled hole to observe behind the channel.

Photograph 5. View of the intake chamber. Photograph 6. Horizontal cracking of the wall.

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Photograph 7. Core showing multiple cracks. Photograph 8. ASR affected aggregate particle.

Photograph 9. Another ASR affected aggregate particle.

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