Ultrasonic Tomography Evaluation of the Coolac Bypass Joint and Crack Subsurface Diagnostics.

Dr. Lev Khazanovich Kyle Hoegh Executive Summary Ultrasonic tomography testing was conducted March 14th and 15th, 2012 on the Coolac bypass within Chainages 77,800 and 92,000. Testing was conducted to demonstrate the ability of an ultrasonic tomography device (MIRA) in evaluating the presence and/or extent of subsurface clay balls, subsurface concrete conditions around and below joints and cracks, tie-bar location, and pavement thickness determination, as well as other general subsurface flaw analysis. This report presents results of testing with MIRA at various concrete pavement joints and cracks. The results of nondestructive testing using ultrasonic tomography gave information about the depth of surface cracks and joints as well as subsurface spalling surrounding the joints and cracks. The demonstration also showed that ultrasonic tomography testing can be used to assure properly induced crack propagation below saw cuts in contraction joints.

Introduction Ultrasonic Tomography A recently developed ultrasonic tomography device (MIRA) offers high accuracy measurements of concrete thicknesses, reinforcement or inclusion location, debonding between layers, subsurface cracking or defects, and presence of honeycombing, clay balls, or poor consolidation. MIRA is an ultrasonic tomography device that uses an array of transducers to send and receive shear waves at the surface. The array is comprised of 40 (10x4 array) touch and go transmitting and receiving dry point contact (DPC) transducers. The 10 channels utilize 45 transducer pair measurements (see figure 1) with each scan resulting in a 2D depth profile (SAFT B-scan). The DPC transducers provide the necessary consistency of impact and wavefront penetration for diagnositcs up to 1 meter deep. The multiple sensor pairs in each scan allows for the required redundancy of information to evaluate heterogeneous mediums such as concrete. Figure 1 shows a manual MIRA measurement on the right, taken at chainage 86,222. On the left of figure 1 the high redundancy of information when using a multi-static array of transmitting and receiving transducers can be observed.

Mira

45 pairs per measurement

Figure 1. MIRA ultrasonic tomography device measurement at chainage 86,222 and illustration of transmitting and receiving pair measurements. Each approximately 1 second MIRA scan gives a 2 dimensional depth cross-section (SAFT B-scan) with the vertical axis indicating the depth of any reflection (caused by any change in acoustic impedance), and the horizontal axis indicating the location along the 360 mm aperture of MIRA with 0 being the center of the scan location. Figure 2 shows an example on site SAFT B-scan output that was taken on top of a tie bar during testing at a southbound slow lane longitudinal joint at chainage 83,138. It can be observed that there is a red planar shape centered at approximately 250 mm depth indicating reflection at the interface between the PCC and the base. A green/yellow circular reflection can also be observed at approximately half of that depth indicating reflection at the metal tie bar location.

360 mm

250

Depth, mm

Tiebar

PCC/Base Interface
Figure 2. Example on-site SAFT B-scan indicating the location of a tie bar and depth of the PCC layer/sub-base interface. Any changes in acoustic impedance (material stiffness/density changes) will cause a high intensity of reflection (visualized by red) associated with the depth of this anomaly. The tie bar reflection shown in figure 2 was caused due to the higher acoustic impedance of the metal as compared to the surrounding concrete. The reflection at the concrete-base interface is caused by the lower acoustic impedance of air and sub-base material in comparison to the concrete at the layer boundary. This method can be used to detect cracks or clay balls in concrete among other subsurface anomalies due to the significantly lower acoustic impedance of air as compared to concrete. Any high intensity reflections other than at expected locations (i.e. layer boundaries, or reinforcement locations) indicate the presence of a defect. Additionally, the lack of a reflection at locations where high intensity of reflection should be expected can indicate the presence of a defect. This effect where the shear waves are blocked or scattered above an expected boundary is referred to as shadowing. More background about MIRA analysis can be found by consulting the documents in the references section. Site Specific Testing Procedure and Analysis Methods Testing with an ultrasonic tomography device (MIRA) was conducted at various locations along the coolac bypass to detect subsurface PCC layer conditions such as clay ball inclusions, cracking/spalling around and below construction joints and cracks, tie-bar location, pavement thickness determination, as well as other general nondestructive testing diagnostics. Ultrasonic tomography testing was conducted in 2 mode types including express mode testing at locations where no overlapping measurements were necessary, and detailed testing where grids were marked out for overlapping measurements in multiple rows. Detailed testing was generally carried out from left to
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right in 90 mm overlapping step sizes and moving in 100 mm step size rows. The detailed mode testing allowed for precise subsurface analysis of a general area, while express testing allowed for subsurface evaluation of specific locations such as perpendicular orientation testing along a joint or crack. The following analysis was applied at various scanned locations to obtain this information: SAFT B-scan: Synthetic aperture focusing technique cross-sections based on the absolute intensity of reflection in each 2D-depth profile (see Figure 2). These scans are available real-time at each measurement location. SAFT-Panoramic: Synthetic aperture focusing technique panoramic reconstructions based on fusing absolute intensity of reflection from multiple overlapping scans. This type of analysis was conducted at overlapping scan locations to increase the precision and coverage of the analysis. SAFT-3D: Synthetic aperture focusing technique 3-dimensional reconstructions based on interpolation of intensity reflection locations meeting specified threshold values. This type of analysis was conducted at grid locations allowing for a more intuitive visualization of subsurface conditions.

The following evaluation methods were applied to the analysis types described above to diagnose the subsurface PCC layer conditions: Direct reflection evaluation - The depth and lateral location of strong reflections within the PCC layer were evaluated. A comparison of reflection locations with the expected inclusion locations and layer boundaries gave information about the PCC condition. If no high intensity of reflection locations were observed within the concrete layer other than at the expected positions, this indicated a sound concrete condition. Locations where high intensity reflections were observed other than at the expected locations indicated a certain extent of damage (such as spalling) or need for more detailed analysis. Shadowing effect - The reflection at the depth of the PCC layer at the layer boundary with the sub-base also gave information about the condition of the PCC layer. If the concrete is in sound condition a continuous oblong reflection (backwall reflection) should be expected at the depth of the PCC. If there is a discontinuity in this backwall reflection it can be an indicator that a flaw within the PCC layer (such as a vertical crack) is blocking the wave from propagating to this interface and back to the surface. This phenomenon is referred to as shadowing in this report.

Subsurface Joint and Crack Results The evaluation techniques described in the previous section were applied for analysis of subsurface concrete condition around and below selected joints and cracks including the following cases: Properly initiated transverse contraction joint (SAFT 3D reconstruction and core) Properly formed longitudinal construction joint (SAFT 3D reconstruction) Full-Depth Crack (SAFT Panoramics and SAFT 3D reconstruction) Partial-Depth Crack (SAFT 3D reconstruction and core) Properly propagated joints MIRA measurements were taken in express mode along the transverse contraction joint shown in figure 3. Shadowing analysis of the MIRA scans indicated that the vertical crack propagated properly to the bottom of the PCC layer. Figure 4 shows the SAFT B-scan taken directly over the core location. Unlike figure 2 where a continuous backwall reflection can be observed at the depth of the PCC, there is a discontinuity in the backwall reflection observed in figure 4. This gap indicates that a subsurface anomaly (vertical crack in this case) is present which is blocking the wave propagation along this path. To confirm the MIRA diagnosis, a core was taken as shown in figure 3. It can be observed that the vertical crack does, in fact, propagate to the bottom of the PCC layer. Figure 5 shows a 3D reconstruction using the express mode measurements along the transverse joint. The continuous shadowing along the transverse direction indicates that the crack has propagated to the depth of the PCC layer throughout the measurement area initiated at the saw cut. This suggests a properly functioning joint which should allow for expansion and contraction of the concrete. Reflections can be observed along the crack path. Detailed testing with overlapping measurements should be used to separate spalling initiation at the joints versus direct reflections from jagged portions of a properly initiated crack.

Figure 3. Transverse contraction joint location and subsequent core at chainage 77,831.

Saw cut location

Shaddowing
Figure 4. SAFT B-scan at the transverse contraction joint over the core location.

(a) Side view

Crack direct reflections

(b) Top-down view

Figure 5. (a) top down and (b) side view of the PCC subsurface along the transverse joint indicating that the crack propagated to the PCC depth throughout the scanned area. MIRA measurements were also taken along the longitudinal construction joint shown in figure 6 to confirm the shadowing analysis at a known full vertical joint location. Measurements were taken in detailed mode to allow for spalling analysis as well. Figure 7 shows a 3D reconstruction resulting from detailed mode scanning along the longitudinal joint. The continuous gap along
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the PCC depth at the center of the reconstruction indicates shadowing from the longitudinal construction joint. Reflections can also be observed along the crack path indicating the locations where spalling has initiated. It can be observed that the direct reflections are generally small, shallow, and within the lateral vicinity of the joint indicating the subsurface spalling is not significant.

Figure 6. MIRA longitudinal construction joint location at chainage 86,231.

(a) Side view

Spalling Initiation

(b) Top-down view

Figure 7. SAFT 3D reconstruction indicating the spalling potential at a longitudinal construction joint.

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Crack Analysis MIRA measurements were also taken in locations where unplanned cracks were present at the surface such as the MIRA measurement grid shown in figure 8. Spalling on the surface to the left of the initial crack can be observed at the end of the MIRA grid testing area. Detailed grid MIRA testing was conducted to determine the depth of the surface crack and extent of spalling. Shadowing analysis of the MIRA scans indicated that the vertical crack propagated to the bottom of the PCC layer. Figure 9 shows a 3D reconstruction resulting from the detailed mode measurements on the area of the longitudinal crack. Figure 10 shows SAFT panoramic reconstructions at the beginning of the grid, middle of the grid, and end of the grid. The continuous shadowing observed in figure 9 along the longitudinal direction indicates that the crack has propagated to the depth of the PCC layer throughout the measurement area. The shadowing of the backwall at the panoramic reconstruction locations also indicated the location where the crack had propagated to the depth of the PCC layer. In addition to reflections along the crack path there are also significant direct reflections adjacent to the crack path indicating spalling. The spalling that can be observed at the surface resulted in a high intensity of reflection to the left of crack at the last panoramic location [see figure 10(a)] as well as a cluster of reflection intensity at the end of the grid location to the left of the crack in the SAFT 3D reconstruction. This can be observed in figure 9 at 0.8 m to 1.0 m longitudinally from the start of the test grid. Significant subsurface spalling was also indicated in the areas to the left of the longitudinal crack prior to the longitudinal location where spalling was present at the surface. These subsurface spalling initiation locations were indicated by clustered less intense direct reflections to the left of the crack path prior to the surface spalling locations in the panoramic reconstructions [see figures 9(b) and 9(c)] as well as the discrete reflection locations between 0.6 and 0.8 m from start of the testing grid in the SAFT 3D analysis. This analysis indicates that significant subsurface spalling is also occurring adjacent to the left of the longitudinal crack throughout the tested area although it has not propagated to the surface yet.

Figure 8. MIRA scanning location indicating a full depth crack and spalling initiation.

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spalling

(a) Last Row

shadowing spalling initiation (b) Middle Row

shadowing (c) Beginning Row

shadowing
Figure 9. SAFT Panoramics at the (a)end showing a full depth crack as well as spalling and (b) middle, and (c) beginning indicating a full depth crack as well as spalling initiation.

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(a) Side view

Spalling Initiation

(b) Top-down view

Spalling

Figure 10. SAFT 3D reconstruction of an unplanned longitudinal crack propagating to the depth of the PCC in (a) side and (b) top down views. MIRA measurements were also taken in the unplanned cracked location shown in figure 11. Detailed grid MIRA testing was conducted to determine the depth of the surface crack and extent of spalling. Shadowing analysis of the MIRA scans indicated that the vertical crack only partially propagated to a shallow depth (< 30mm). Figure 12 shows a 3D reconstruction resulting from the detailed mode measurements on the area of the crack. It can be observed that there is a continuous backwall reflection suggesting that there is NOT a flaw (such as a vertical crack propagating to the PCC depth) shadowing the backwall reflection. Direct discrete
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Crack Shadow

reflections can be observed in the SAFT 3D reconstruction at a shallow depth (<30 mm) in figure 11. The lack of a shadow in the backwall reflection and discrete shallow direct reflections indicated that the cracks were most likely shrinkage or shallow cracks due to a finishing problem. The core shown in figure 10(b) verified this diagnosis. It can be observed that the surface crack does not propagate to a significant depth in the PCC layer.

(a) Location

(b) Core

Figure 10. (a) MIRA scan grid location and (b) subsequent core showing no significant subsurface damage.
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(a) Side view

(b) Top-down view Partial Depth Crack Reflection

Figure 11. SAFT 3D reconstructions at the surface crack location in (a) side and (b) top-down views.

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Conclusions/Recommendations The analysis in this report showed the capabilities of the ultrasonic tomography technique in evaluating planned joints in concrete pavements as well as unplanned cracks. The forensics presented in this report verified the ability of MIRA to correctly diagnose whether or not a crack or saw cut at the surface has propagated to the depth of the PCC. As this report shows, this type of routine analysis can be done using real-time generic SAFT B-scan analysis. Therefore, it is recommended to take real-time measurements to monitor induced crack propagation in joints suspected to not propagate properly. This type of monitoring can be done using similar shadowing analysis to that provided in this report. While the generic SAFT B-scans can also be used to obtain routine information about horizontal cracking or spalling initiated at the joint, SAFT Panoramic or SAFT 3D analysis should be conducted for cases requiring detailed joint spalling and delamination monitoring. Although not the subject of this report, the ultrasonic tomography scanning of the Coolac Bypass confirmed that MIRA can also be used to determine the presence and/or extent of subsurface clay balls, locate tie-bars, and determine pavement thickness, as well as other general subsurface diagnostics.

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References Hoegh K., Khazanovich L., Yu H.T. Ultrasonic Tomography Technique for Evaluation of Concrete Pavements. Transportation Research Record: Journal of the Transportation Research Board, No. 2232, pp. 8594. 2011. Access using this link:
https://netfiles.umn.edu/users/hoeg0021/TRB_2011_MIRA.pdf

Hoegh, K., Khazanovich, L., Correlation Analysis of 2D Tomographic Images for Flaw Detection in Pavements. ASTM International. Journal of Testing and Evaluation. Volume 40. Issue 2. March 2012. Access using this link:
https://netfiles.umn.edu/users/hoeg0021/ASTM_JTE_2012.pdf

Hoegh K., Khazanovich L., Yu H.T. CONCRETE PAVEMENT JOINT DIAGNOSTICS USING ULTRASONIC TOMOGRAPHY. TRB Paper 12-4252. Accepted for publication at the Transportation Research Record: Journal of the Transportation Research Board, 2012. Access using this link:
https://netfiles.umn.edu/users/hoeg0021/TRB%20Paper%20Joint%20Diagnostics_2012.pdf

Hoegh K., Khazanovich L., Maser K., Tran N. EVALUATION OF AN ULTRASONIC TECHNIQUE FOR DETECTING DELAMINATION IN ASPHALT PAVEMENTS. TRB Paper 12-4220. Accepted for publication at the Transportation Research Record: Journal of the Transportation Research Board, 2012. Access using this link:
https://netfiles.umn.edu/users/hoeg0021/TRB_AC_Delamination_2012.pdf

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