REPORT ON “NON-DESTRUCTIVE TESTING ON W.I.P.

SHED
COLUMNS” FOR HINDALCO INDUSTRIES LTD, UNIT-BIRLA
COPPER

PO-20108486

MARCH 3, 2020
PROSAVA PVT LTD
0|Page
Sl. No. Chapters; Page No.
1 INTRODUCTION 3
2 SCOPE OF WORK 4
3 NON-DESTRUCTIVE TESTING 4
3.1 GENERAL INFORMATION 4
4 RESULTS AND DISCUSSIONS 14
4.1 UPV TEST 14
4.2 REBOUND HAMMER TEST 16
4.3 HALF CELL POTENTIAL TEST 17
4.4 CORE COMPRESSION AND CHEMICAL TESTS 19
5 CONCLUSIONS 20
6 REFERENCES 21

1|Page
GOOGLE MAP LOCATION OF THE STRUCTURE

Longitude and Latitude: 21.703938,72.541279

2|Page
1.0 INTRODUCTION
Hindalco Industries Ltd, Unit Birla copper has mandated Prosava Pvt. Ltd to carry out
NDT test of existing RCC columns that it proposes to reuse for newly proposed WIP
storage shed at its Dahej Plant in District Bharuch, Gujarat.

VISUAL DEFECTS ON SURFACE

PHOTOGRAPHS OF THE SITE

3|Page
2.0 SCOPE OF WORK
This document covers details of Non-destructive tests conducted on concrete along with
observations and conclusions in conjunction with respective Indian/Foreign Codes.
3.0 NON-DESTRUCTIVE TESTING
4.1 GENERAL INFORMATION ULTRASONIC PULSE VELOCITY (IS 13311 Part
I: 1992):
The ultrasonic pulse velocity measurement technique involves determination of velocity of
ultrasonic pulse through solid material. The velocity of these pulses depends upon the
density and elastic properties of the material. The quality of some materials is sometimes
related to their elastic stiffness so that measurement of ultrasonic pulse velocity in such
material can often be used to indicate their quality as well as to determine their elastic
properties.
Materials that can be assessed in this way include, in particular, concrete and timber, but
exclude metals.
The pulse velocity is determined by the equation: -
Pulse Velocity = 𝑃𝑎𝑡ℎ 𝑙𝑒𝑛𝑔𝑡ℎ/ 𝑇𝑟𝑎𝑛𝑠𝑖𝑡 𝑡𝑖𝑚𝑒
The path length and transit time are measured to determine the pulse velocity. The velocity
of longitudinal pulse in elastic solids.

It can be shown that the velocity V, of pulse of longitudinal ultrasonic vibration traveling
in an elastic solid is given by: V2 = E (1-) / p (1+) (1-2) (B.S. 1881 Part 203 - 1986)

Where, E is the dynamic elasticity modulus,

P is the density,
µ is the Poisson’s ratio.

4|Page
The instrument indicates the time taken for the earliest part of the pulse to reach the
receiving transducer measured from the time it leaves from a suitable point on the surface
of the material.

Sr. U.P.V. Quality of Concrete for Direct Method

No. (km/sec)
1 Above 4.5 Excellent Good
2 3.5 to 4.5 Medium
3 3.0 to 3.5 Doubtful.
4 Below 3km/sec.

Table 1 (As per IS 13311 (Part I) 1992)

Note: - Readings of semi direct & indirect methods are generally less than direct
method by 1km/sec

Pulses are not transmitted through large air voids in a material and if such a void lies
directly in the pulse path, the instrument will indicate the time taken by the pulse, which
followed quickest route. It is thus possible to detect large voids when grid of pulse velocity
measurement is made over a region in which voids are located.

The pulse velocity method of testing may be applied to the testing of plain, reinforced and
pre-stressed concrete whether it is pre-cast or cast in-situ. The measurement of pulse
velocity may be used to determine.
a) The homogeneity of the concrete.
b) The presence of void, cracks or other imperfections.
c) Changes in the concrete, which may occur with time or through the action
of fire, frost or chemical attack.
d) The quality of concrete in relation to specified standard requirement, which
generally refer to its strength.

5|Page
Homogeneity of the concrete
Measurement of pulse velocities at points on regular grid on the surface of a concrete
structure provides a reliable method of assessing the homogeneity of the concrete. The size
of the grid chosen will depend on the size of the structure and the amount of variability
encountered.

Detection of defects
When an ultrasonic pulse travelling through concrete meets a concrete air interface, there
is a negligible transmission of energy across this interface so that any air-filled crack or
void lying directly between the transducers will obstruct the direct beam of ultrasound
when the void has a projected area larger than the area of the transducer faces. The first
pulse to arrive at the receiving transducer will have been diffracted around the periphery
of the defect and the transit time will be longer than in similar concrete with no defect.

Detection of large voids or cavities

A large cavity may be detected by measuring the transit times of pulses passing between
the transducer when they are placed in suitable positions so that the cavity lies in the direct
path between them. The size and position of such cavities may be estimated by assuming
that the pulses pass along the shortest path between the transducers and around the cavity.
Such estimates are more reliable if the cavity has a well-defined boundary surrounded by
uniformly dense concrete. If the projected area of the cavity is smaller than the diameter of
the transducer, the cavity cannot be detected.

REBOUND HAMMER TEST (IS 13311 Part II: 1992):

Rebound Hammer Tests shall be carried out in accordance with I.S. 13311 (Part 2) – 1992
in order to determine
• Assessing the likely compressive strength of concrete.
• Assessing the uniformity of concrete.
• Assessing the Quality of concrete with respect to standard requirements.

The apparatus used consists of a spring-controlled mass that slides on a plunger within a
tubular housing. The impact energy required for rebound hammers is 2.25 Nm.

6|Page
Methodology:
For testing, smooth, clean and dry surface will be selected. If loosely adhering scale is
present, this should be rubbed of with a grinding wheel or stone. Rough surfaces resulting
from incomplete compaction, loss of grout, spalled or tooled surfaces do not give reliable
results and should be avoided.
For taking a measurement, the rebound hammer is held at right angles to the surface of the
concrete member. The test can thus be conducted horizontally on vertical surfaces or
vertically on horizontal surfaces. If the situation demands, the rebound hammer can be
held at intermediate angles also, but in each case, the rebound number will be different for
the same concrete.

Interpretation of results:
The rebound hammer method provides a convenient and rapid indication of the
compressive strength of concrete by means of establishing a suitable correlation between
the rebound index and the compressive strength of concrete. The rebound number
increases as the strength increases. It is also pointed out that rebound indices are indicative
of compressive strength of concrete to a limited depth from the surface. If the concrete in
a particular member has internal micro cracking, flaws or heterogeneity across the cross
section, rebound hammer indices will not indicate the same.
Note: The probable accuracy of prediction of concrete strength in a structure is + 25
% (tolerance).

7|Page
HALF CELL POTENTIAL TEST (ASTM C876 09):

Half-cell potential method is used to delineate those portions of the structure where there
is a high likelihood of corrosion activity. Using half-cell potential, we are measuring that
negative charge, which gives an indication of the corrosion activity. Methodology

• Measuring the concrete surface electrical potentials relative to that of a standard

electrode.
• Copper-Copper sulfate electrode or Silver-Silver chloride electrode commonly used.
• Measure the potentials on a predetermined grid on the surface of concrete structure.
• If bar corroding, electrons flow from bar to half-cell.
• At half-cell, electrons transform Cu2+ ions in the CuSO4 solution to Cu atoms and
deposit on the rod in the half cell.
• Voltmeter then indicates a negative value.
• The more negative the value, higher is the likelihood of corrosion.  There is NO
current in the circuit.
• The half-cell potential readings are indicative of the probability of corrosion activity of
reinforcement located beneath the reference cell.
• True only if all of the reinforcement is electrically connected.
• To ensure that this condition exists, electrical resistance measurements between widely
separated reinforcing bars should be carried out.
• The method cannot be applied to concrete with epoxy-coated reinforcement.

Potential difference levels Chance of re-bar being

(mV) corroded
Less than -350 More than 90% probability
that reinforcing steel
corrosion is occurring.
-200 to -350 Corrosion Activity of the
reinforcing steel is uncertain.
More than -200 More than 90% probability
that reinforcing steel
corrosion is not occurring.

8|Page
 Half Cell Potential Arrangements

Advantages

• Method and equipment simple to use.

• Non-destructive survey of the concrete member to produce potential maps.
• Zones of corrosion can be identified.

Limitations

• Cannot indicate the actual corrosion rate.

• Not applicable to epoxy coated steel bars.
• For conclusive results, need other techniques like chloride content, carbonation depth
etc. in conjunction.

CORE COMPRESSION TEST (IS 516 – 1959):

The existing concrete shall be tested for its various strength and durability properties.
Concrete shall be cut in the form of cylindrical cores of appropriate length so as to maintain
the L/D Ratio of 2.0 with core diameter of 50 mm. Casting date of the concrete shall be
determined for its age at testing. Irregular faces of the concrete core shall be furnished by
cement mortar paste or suitable grouts and shall be cured up to curing cycle. Concrete core
can also be furnished by cutting & finishing the faces at perpendicular to the length axis.
Compressive strength test is performed as per IS: 516 Clause no. 5.
Concrete core shall be tested in compressive strength machine, capable of producing
strength as per stipulated concrete grade. Core shall be measured for its dimensions and

9|Page
L/D Ratio is determined. If the L/D ratio is less or more than 2.0, appropriate correction
factor shall be applied as per Clause no. 5.6.1 of IS: 516.
Corrected Compressive strength of the cylinder for L/D Ratio shall be further corrected for
Equivalent cube strength by multiplying by 5/4. Entire calculation steps are mentioned
below with e.g.
Step 1: Dimensional Measurements of Length and Diameter and determine L/D Ratio.
Step 2: Load at which core fails to take load, W
Step 3: Breaking Load shall be corrected for the occurrence of reinforcing steel
Wc = W x Steel Factor
Steel Factor = 1 + 1.5 x (Steel Dia. x Cover Height) / (Core Dia. x Core Length) Step
Step 4: Determine Compressive Strength C as:
C = Wc / (Core Area)
Step 5: Cs = Corrected Compressive Strength C shall be corrected for the L/D Ratio
Step 6: ECS - Equivalent cube strength is obtained multiplying Cs by 5/4.

SULPHATE TEST:

The presence of soluble sulphates (principally those of sodium, calcium and magnesium)
is common in areas of mining operations, chemical and paper milling industries.
All sulphates are potentially harmful to concrete. They react chemically with cement
paste’s hydrated lime and hydrated calcium aluminate. As a result of this reaction, solid
products with volume greater than the products entering the reaction are formed.
Sulphate resistance of the concrete is improved by a reduction in water-cement ratio and
an adequate cement factor, with a low tricalcium aluminate and with proper air entrainment.

10 | P a g e
As per table clause 8.2.5.3 of IS 456 excessive amounts of water-soluble sulphate from
these or other mix constituents can cause expansion and disruption of concrete. To prevent
this, the total water-soluble sulphate content of the concrete mix, expressed as SO3 should
not exceed 4 percent by mass of the cement in the mix. The sulphate content should be
calculated as the total from the various constituents of the mix.

11 | P a g e
CHLORIDE CONTENT:

Determination of chloride ion content in the extract samples were found out by the titration
methods (laboratory) as per IS 14959(part 2)-2001. The limits of chloride content of
concrete as given in IS 456-2000 is as follows.

Sr. Use of Concrete Max. Total Acid

No. Soluble chlorides as
kg/m3

1 Concrete containing Metal and steam cured at 0.4

elevated temperature and pre-stressed concrete

2 Reinforced concrete or plain concrete containing 0.6

metal

3 Concrete not containing embedded metal or any 3.0

other material requiring protection from corrosion

British Standard BS 8500 suggests that the maximum acceptable percentage of chloride ion
by mass of cement is 0.1% for pre-stressed concrete and 0.4% for reinforced Concrete.
However, it is now generally accepted that as little as 0.25 % chloride ion by mass of
cement ingressing into hardened concrete may be sufficient to DE passivate the steel
reinforcement.

12 | P a g e
DEPTH OF CABONATION:

Carbonation of concrete occurs when the carbon dioxide, in the atmosphere in the presence
of moisture, reacts with hydrated cement minerals to produce carbonates, e.g. calcium
carbonate. The carbonation process is also called DE passivation. Carbonation penetrates
below the exposed surface of concrete extremely slowly.
The significance of carbonation is that the usual protection of the reinforcing steel generally
present in concrete due to the alkaline conditions caused by hydrated cement paste is
neutralized by carbonation. Thus, if the entire concrete cover over the reinforcing steel is
carbonated, corrosion of the steel would occur if moisture and oxygen could reach the steel.

Methodology:
The core extracted during core cutting shall be tested for carbonation by using
Phenolphthalein indicator. If the color of the concrete surface turns to pink the concrete is
free of carbonate contents. And if the indicator shows colorless indication, the concrete is
carbonated.

13 | P a g e
4.0 RESULTS AND DISCUSSIONS
The columns have been identified for NDT on a random basis as per attached Site survey
and lay out drawing WIP-A1001-GA. Interpretation of columns are as follows:
11B-L refers to Column No. 11 in as per general arrangement. "B" refers to Row of
Column. "-U" refers to upper half of column and "L" refers to lower half of column.

4.1 UPV TEST

Following table gives the results of UPV test conducted on structure and interpretation of
results in terms of concrete quality grading as per IS Code.
UPV RESULTS
Corrected Concrete
Path
Type of Transit Pulse Quality grading as
Sr. No. Element ID Length
Transmission Time (µs) Velocity per IS 13311 (Part
(mm)
(km/s) I) 1992
1 11B-L Direct 460 115.3 3.99 Good
2 13B Direct 460 298 1.54 Doubtful
3 6D Direct 460 115.3 3.99 Good
4 10D Direct 460 117 3.93 Good
5 11B-U Direct 460 128.6 3.58 Good
6 12B-U Direct 460 129.8 3.54 Good
7 9C Direct 600 326 1.84 Doubtful
8 7C Direct 600 148 4.05 Good
9 5C Direct 600 169.3 3.54 Good
10 6A Direct 600 150.5 3.99 Good
11 4A Direct 600 173.8 3.45 Medium
12 3C-U Direct 600 179.8 3.34 Medium

Colour Coding Identification

Excellent Good Medium Doubtful

Note: As per IS 13311 (Part I): 1992, Indirect Velocity in general gives lower pulse velocity than in
case of Direct Velocity. The difference could be of the order of about 1 km/sec.

14 | P a g e
 UPV Results (km/s)
0%

17%

17%

66%

Excellent Good Medium Doubtful

15 | P a g e
 4.2 REBOUND HAMMER TEST
Following table gives the results of Rebound Hammer test conducted on structure.
REBOUND HAMMER RESULTS

Rebound Numbers
Sr. No. Element ID
1 2 3 4 5 6
1 11A-L 44 48 44 40 42 40
2 13B 24 26 28 26 26 26
3 6D 44 42 40 38 40 42
4 10D 42 42 40 40 38 46
5 11B 42 46 42 42 46 38
6 12B 34 34 32 34 32 34
7 9C 36 34 36 42 38 36
8 7C 40 38 38 42 38 40
9 5C 38 40 42 38 40 36
10 6A 38 36 20 38 38 42
11 4A 36 36 40 34 40 42
12 12A-U 36 40 44 42 42 40

Colour Coding Identification

< 20 20 to 30 30 to 40 >= 40

Notes:
1) Higher rebound numbers suggest possibility of carbonation in concrete. 2) As per IS 13311 (Part II) 1992,
following are the limitations of Rebound Hammer Test:
a) rebound numbers are indicative of compressive strength of concrete to a limiting depth from the surface.
If the concrete in a particular member has internal micro-cracks, flaws or heterogeneity across c/s, rebound
hammer indices will not indicate the same.
b) Probable accuracy of rebound hammer results is ±25%.

16 | P a g e
 Rebound Numbers
0%

10%

51%
39%

< 20 20 to 30 30 to 40 >= 40

4.3 HALF CELL POTENTIAL TEST

HALF CELL POTENTIAL TEST RESULTS

Element Potential Chance of Rebar being corroded

Sr. No.
ID Difference (mV)
More than 90% probability that
1 7C -364 reinforcing steel corrosion is
occurring.
More than 90% probability that
2 6C -385 reinforcing steel corrosion is
occurring.
Corrosion Activity of the
3
4D -330 reinforcing steel is uncertain

17 | P a g e
 Half Cell Potential Test Results
0%

33 %

67 %

∆V>= -200 mV -200 mV>∆V >= -350 mV ∆V< -350 mV

18 | P a g e
4.4 CORE COMPRESSION AND CHEMICAL TESTS

CORE COMPRESSIVE STRENGTH RESULTS

Equivalent
Max cube
Height Dia L/D Correction
Sr. No. Core ID Load strength
(mm) (mm) ratio Factor
(kN) (MPa)

1 18B 84 44 1.909 0.991 31.4 25.57

2 13B-L 87 44 1.977 0.998 37.4 30.69
3 14B 72 44 1.636 0.961 37.7 29.79
4 13B-U 86 44 1.955 0.996 59.4 48.62
5 10D 85 44 1.932 0.993 22.9 18.70

CORE CHEMICAL TEST RESULTS

Carbonation
Sulphate
Sr. No. Core ID Height pH Chloride (%)
(%)
(mm)

1 18B - 10.93 0.600 -

2 13B-L - 10.88 0.700 -
3 14B - 9.72 2.500 -
4 13B-U - 11.10 0.400 -
5 10D - 11.43 0.600 -

19 | P a g e
5.0 CONCLUSIONS
UPV result: More than 60% results are falling in good category as per IS 13311 (Part I) 1992. About 34%
results are falling in medium to doubtful category which is the indication of internal voids/micro-cracks.
Rebound Hammer test : Almost 90% results are falling above 30 in case of Rebound Hammer test which
indicates that surface hardness of concrete is good.
Core Compression test : Except one result, remaining are falling above 25 MPa
Half-cell potential test : Out of three results of done on site, 2 results are indicating that there is more than
90% probability that reinforcing steel corrosion is occurring.
Chemical tests: PH for good alkaline concrete should be in the range from 11 to 13.5. Of the five
representative samples taken four results are close to 11 and one result is falling significantly below 11.

No carbonation is detected in concrete.

No Sulphate content is detected in concrete.

Chloride content in concrete should not be more than 0.6% as per IS. However, 80% results are crossing
the same limit.

Recommendations

There is a distinct possibility of high chloride content in concrete which is also collaborated by
half- cell potential test results which indicate possible corrosion in reinforcement in majority of
samples.

Also during visual examination of concrete surface we have also noted that in some places
sufficient cover is lacking in reinforcement. Accordingly the first line of defense should be carry
out a hammer and delamination survey to check all the column surfaces for adequacy of cover,
loose/laminated concrete and possibility of voids between reinforcement and concrete. Exposed
reinforcement at all spots with defects should be should be fully exposed, coated with epoxy
based Zinc rich primer and covered with thick cover of dense, highly impermeable concrete
maintaining minimum the water-cement ratio (workability to be improved by addition of water
reducer or super plasticizer (or both) after providing a bonding coat .

20 | P a g e
REFERENCES
• IS: 456 – 2000 – Indian Standard Plain and Reinforced Concrete, Code of Practice, BIS.
• IS: 14959 (part 2): 2001- Determination of water soluble and acid soluble chlorides in mortar
and concrete — method of test. -
• IS: 516-1959 – Methods of Tests for Strength of Concrete.
• IS 13311 (Part 1): 1992, Non-Destructive Testing of Concrete – Methods of Test, Part – 1,
Ultra Sound Pulse Velocity, Bureau of India Standards.
• IS: 13311 (Part 2) – 1992 - Non-Destructive Testing of Concrete Methods of Test Rebound
Hammer, Bureau of India Standards.
• ASTM C876-09 - Standard Test Method for Corrosion Potentials of Uncoated Reinforcing
Steel in Concrete

21 | P a g e
22 | P a g e