BRIDGE: NON DESTRUCTIVE TESTING

Non Destructive Testing (NDT)

on Bridges – State of the Art

Chetan R. Raikar
Chairman & Managing Director,
Structwel Designers and Consultants Pvt. Ltd.

Abstract: Health assessment of bridges is scientific process which requires great amount of experience. Non-Destructive Testing (NDT) plays
very important role in assessing structural properties of various materials used in the bridges and also integrity of various structural members
of the bridge and the capability of these structural members to cater to the load which are expected to. Load rating of existing bridges,
structural stability for increased load, and effectiveness of repairs are some of the areas where NDT plays a major role.
There are several types of NDT to measure various properties of concrete like compressive strength, permeability, stress / strain, integrity,
homogeneity, chemical deterioration etc. There are different instruments of NDT available to assess different properties of concrete.

Preamble erties of the members, are required to be deployed. Whereas,

Non Destructive Testing (NDT) is being practised in India for
around three decades or more by now. Most of the NDT tech-
niques available across the world in developed countries are
available in India. The fact remains though, that there are very few
Laboratories which have a complete range of NDT equipments re-
quired for testing of the structures, particularly Bridges.
The more advanced countries have long adopted continuous
monitoring of stress, deflection/deformation, temperature and
other properties of bridge components; in-situ during service life.
There are very few bridges in India, where these techniques of
monitoring the bridge health have been incorporated at construc-
tion stage.
It is heartening to note the mammoth task of inventory prepa-
ration and health assessment of all the bridges across the country
by The Ministry of Transport.
NDT shall certainly play a major role in health assessment of
all existing bridges and is an important aspect of the exercise.
Unfortunately, some of the senior structural & bridge consul-
tants do not appreciate the importance of NDT. This is mostly due
to either their ignorance or lack of initiative to learn what these
magnificent techniques of NDT can do for them.
Difference Between NDT on Bridges And on Other Structures
As we all know, the major difference between loads on a
bridge and on any other structure; is the dynamic nature of the
live load a bridge is expected to cater to; during its service life.
Other structures like machine foundations, also are subjected to
dynamic loading of different levels and nature.
NDT on structures other than bridges are carried out, predomi-
nantly, to find out residual strength of material of construction like
concrete, steel, wood, stone, masonry etc. In very few structures
(other than bridges); techniques of NDT for stress measurement,
deflection measurement etc; used to measure the structural prop-
in a bridge it is equally important to know stress levels, internal
cracking and deflection checks during service life to understand
the serviceability of the bridge.
This is a major difference that makes NDT on bridges, entirely
a different gamut than the routine NDT carried out by most lab-
oratories across the country on residential and other structures.
Why NDT on Bridges?
Limitations of Inspection
Visual inspection is one of the most important aspects of
health assessment of structures. It is understood that there are
more than 2,50,000 bridges, or more, on National Highways in the
country. Surely so, India does not have so many Bridge Inspection
Experts to inspect each and every bridge in a reasonable time-
frame. The work of visual inspection of the bridges is, therefore,
going to be carried out by junior level engineers who may or may
not have sufficient and appropriate training to identify distresses
by visual inspection.
This is an important aspect and would be major lacuna, if not
addressed appropriately. Recent wash-out of a Highway bridge in
Maharashtra is a typical example of incorrect structural certifica-
tion by authorities.
Even an expert inspector will have several limitations either
of access, of time, or of light intensity etc. those that may have
limitations of visual assessment.
He/she may also want to additionally confirm the observa-
tions and quantify the areas of distresses identified by him/her.
NDT is extremely useful in these situations.
Non-availability of Drawings
This is going to be a major challenge faced by the Bridge En-
gineering Consultants. During the passage of time, important data
like drawings & maintenance registers of majority of the bridges,

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BRIDGE: NON DESTRUCTIVE TESTING
has not been retained properly by the owners and the same has
been lost.
Geometric survey of physical dimensions of superstructure of
any bridge is still an easy task and can be carried out to a great
degree of accuracy. Whereas, geometric survey of substructure of
perennial bridges and foundations; just cannot be done without
the help of NDT Unfortunately, even NDT techniques have great
limitations in supporting the bridge inspector in encompassing
this challenge.
Quantum and location of reinforcement and pre-stressing
tendons is another requirement when regression analysis of any
bridge is required to be carried out to know its load-carrying ca-
pacity or the cause of failure. This task just cannot be completed
without any of the most advanced NDT equipments.
Confirmation of Visually Observed Distresses
As mentioned above, an expert bridge inspector would ob-
serve several types of distresses in a bridge structure. He/she
may want to ignore some of the distresses which would not have
any short-term/long-term bearing on the life or performances of
the bridge. Some of the distresses found may be of critical & of
urgent / important nature, wherein he/she would suggest imme-
diate measures.
There would be a third type of distress wherein the bridge in-
spector would like to quantify or reconfirm his/her observations.
This is exactly where NDT would provide additional support.
Rather, only NDT can bring in completeness to site investigation
of health assessment of bridges. It would be prudent to mention
here that more than 60% of distress observations by an expert
bridge engineer would fall in this category which would need NDT
on the same.
To cite some examples; a bridge inspector may want to con-
firm whether the cracking observed in the wearing course extends
into the deck slab too or otherwise. He/she may also want to con-
firm the exact reason of cracking in concrete whether structural or
material, to start with.
There can be several support areas where NDT can support
the expert bridge inspector in confirming his observations and
can provide extremely valuable data to take him/her further in
concluding the health of the bridge structure.
NDT for Material Strength
NDT provides extremely useful data on strength of materials
like concrete, steel etc. used in the construction of the Bridges.
Concrete and steel both undergo macro and micro levels of crack-
ing due to various reasons. Chemical infestation, over stressing,
fatigue, other age-related distresses, fire, blast, impact due to an
accident etc. are some of the reasons that may cause distress in
a bridge. Under designed or marginally designed bridge & that
is poorly constructed will show early major distress during ser-
vice-life of the same. NDT will prove to be a useful tool in either
altering the condition assessment of the bridge or investigative
assessment in case of its early distress/collapse.
NDT for Load Rating of Bridge
There is a constant dilemma in the minds of bridge owners
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about the current rating of bridges. NDT can be a very useful tool
in upgrading or downgrading the rating of a bridge.
NDT on repaired components in Bridge Structures
Most of the bridges under health assessment would have un-
dergone some form of repair or retrofit during their service-life.
The records of location and quantum of repair may or may not
be available to the bridge inspector. NDT plays a major role in
knowing the effectiveness of earlier repair work carried out. De-
lamination of Polymer modified mortar, Epoxy mortar and other
repair mortars used, delamination and tearing of fibre-wrapping
and their effectiveness in load transfer mechanism of the bridge.
There is a rampant tendency of wrapping the bridge RCC compo-
nents with carbon / glass fibre whether it is necessary or otherwise.
The author is tempted to state that it is almost like an organized
sector of few contractors using this important repair technique of
fibre-wrapping, left–right-centre, probably in connivance with the
owners of the bridge; without checking the necessity or effective-
ness & even without any accountability for the same.
Myths about NDT in the Minds of Consultants / Bridge Inspec-
tors
Many bridge design consultants get into the profession of
health assessment of bridges. They even get empanelled with
various Government Authorities in the category of “bridge in-
spection”. Unfortunately, they neither have experience nor the
capability to carry out health assessment of bridges.
One requires totally different skills & experience for design-
ing a new bridge and to carry out health assessment of an exist-
ing bridge. Many of the new bridge design consultants are not
adequately experienced to carry out a thorough inspection of
the health of the bridges and they do not possess the ability to
predict either the structural stability or the life expectancy of
these bridges. Such consultants spread rumours about inaccura-
cy and inadequacy of NDT. Some of these consultants are senior
or very senior by age and hence the fraternity tends to believe
in their words verbatim. As a matter of fact, these consultants
do not bother to upgrade themselves with knowledge of modern
NDT and are more keen on declaring a bridge ‘unsafe’ since, it is
either safer for the consultants or it creates more projects of new
construction of bridges, of which they are capable for. Harsh re-
ality of the fraternity.
Such consultants do not bother that they are outspending
public money illegally and are committing an innocent crime in
the process. The authorities and owners of bridges also are not
trained enough to understand the opportunity and strength of
NDT, as also, the weakness and limitations of NDT.
Overall, hence, there is an aversion to using NDT sufficiently
and freely in health assessment projects of bridges.
There is a serious myth that NDT is grossly inaccurate. The
author believes that:-
“Non-Destructive Testing (NDT) is only as accurate & as useful
as are the intentions and knowledge of the consultant using the
same”
There are around 25 Non Destructive Tests available across
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 BRIDGE: NON DESTRUCTIVE TESTING

the globe on concrete and most of them are available with some C. Corrosion Potential Tests
of the advanced laboratories in India, including that of the au-
thor. Many consultants do not know about NDT altogether. Those
who claim that they know NDT, know only 5 to 7 basic tests like
Schmidt Hammer, Ultrasonic Pulse Velocity, Coring, Carbonation,
Half-cell and Chemical Analysis.
They would use only these tests to predict all the properties
of structural concrete, as a material. This is a major limitation, the
investigation suffers. Using Schmidt Hammer to predict compres-
sive strength of a carbonated concrete surface is a fundamental
mistake that would lead the entire investigation of health of the
bridge in a tangent direction. Using Ultrasonic for prediction of
compressive strength of concrete is as wrong as, using a stetho-
scope for prediction of blood pressure for blood sugar. Measurement of Potential of Corrosion Resistance of Concrete
Some consultants try to hide their inadequacy of knowledge
d. Carbonation Tests e. Core Extraction
on NDT; by spreading rumours on NDT & make this an excuse for
not using the NDT in investigations.
It may therefore be noted that the limitation of NDT in Indian
Scenario is either due to incorrect use of NDT equipments or inad-
equate sampling done for the size of the structure.

Types of non Destructive Testing

Following is the list given in Tender for consultancy in MORT

& H :-
a. Rebound Hammer Test

Pink coloration of Core Extraction of Pier – Core Extraction of Over-

concrete indicates Smaller diameter for sam- lay / Deck slab. Higher
the alkaline nature pling for Tests - Chemical / Diameter for Compres-
of the same – hence Carbonation/ etc. sive strength
absence of Carbon-
ation.

f. Transient Dynamic Tests

Rebound Hammer test on deck of the bridge using an MBIU

b. Ultrasonic Pulse Velocity

Direct Method Indirect Method (Machine in the

Inset) Test Set Up

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BRIDGE: NON DESTRUCTIVE TESTING

Underside view of the deck, showing the Average Mobility, Hollow

keyed beams Core Bridge Deck

Fixing of Prism Fixing of Dial Gauges

g. Load Test
i) Load Test of Fly Over- Physical Loading using dial gauges

Inspection Using Bucket Elevator Accuracy of a Total Station

Physical Load Test On Bridge

Fixing Inverted Dial Gauges Load on Trailers Crack Monitoring Observation, if any
ii) Load Test on Metro Structure using Total Station
h. Rebar Location Tests

Bridge View Metro Rail Bridge for Load Testing Different Types of Covermeters for Different Situations

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 BRIDGE: NON DESTRUCTIVE TESTING

i. Crack-Mapping for the Bridge b. Endoscopic Inspection

Instrument set up Inspection of Tendons using

Endoscopic technique.

Crack Width Measuring Lens

j. Pull-out Tests

Inspection of Tendons using Endoscopic technique to check the grout quality

c. I.R. Camera Thermography

Pull Out Testing In Operation

k. Chemical Analysis of Core Dust Samples

Normal Digital Photo Image Infrared Image

Lab Set Up For Chemical Analysis

l. Geometrical profiling of the bridge.

As mentioned earlier in the paper, there are around 25 Non De-

structive Tests available in the country that would assist an inves-
tigation on the structural stability of a bridge.
Some of the tests that are strongly recommended to be added in
the list above are:-

a. Radar

Utility Mapping by GPR Detection of buried ob- GPR on Wall of Metro

jects and tunnels (Hollow) structure

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BRIDGE: NON DESTRUCTIVE TESTING
d. Petrography (Microscopic Inspection)
Petrography Lab set up
Autoclam Permeability Set Permit Ion Migration Test
f. Strain Gauge Monitoring
Strain gauge monitoring of bridge
g. Vibration Monitoring
h. Vibration Monitoring of Concrete Structure
Instrument
54 JUNE 2017
Evidence of Alkali Aggregate Reac-
tivity, map cracking due expansive
reaction gel
Inspection by Drone
Discussions
Author does not believe in copy-pasting information about
usefulness of these techniques of NDT & their basic principle etc.
Volumes of such information is easily available on the net & read-
ers are requested to search themselves.
Author would like to share his personal technical and
non-technical experiences of use of these equipments in differ-
ent case studies instead. Same is covered equipment-wise in the
following paragraphs.
A. Radar
RADAR is extremely useful to assess a bridge deck for internal
cracking, voids / honey combing and other defects. This is usually
used to know the thickness and condition of wearing course, its
debonding from deck slab etc. This equipment is far superior &
accurate to Transient Dynamic Response or Ultrasonic & is a lot
more cheaper when compared to the amount of data, it can pro-
vide in a short time.
RADAR can be effectively used to know the location of re-
inforcement and pre-stressing tendons in a bridge. ‘No other
equipment…….’ the author repeats; ‘that no other equipment
is as accurate and easy as RADAR in predicting the locations of
pre-stressing tendons’.
RADAR has many other uses like prediction of underground
services, foundation sizes in-situ and depth, honey combing and
voids in concrete (almost tomography of concrete) etc. …
B. Endoscope
Endoscope is another useful tool in knowing and identifying
defects in the form of voids in concrete, hollows in pre-stressing
tendons which can be accurately photographed by the instrument
to know its extent, after the same has been identified by using a
RADAR.
Endoscope can be effectively used for inspection of expan-
sion joints, its bolts, & wear and tear of expansion joints. Endo-
scope is also useful to inspect the condition of different types of
bridge bearings not accessible to human eye.
C. In-situ Permeability
There are excellent NDT equipments like AUTOCLAM & PER-
MIT that provide very useful data on permeability characteristics
of concrete. Many of the tests on permeability suggested in Brit-
ish Standards like ISAT and other tests on air & water permeability
of in-situ concrete can be easily & accurately measured & moni-
tored using these equipments.
In-situ permeability is an important parameter that a bridge
inspector must know, particularly in corrosive environment like
coastal bridges. These tests provide extremely useful data, both
qualitative and quantitative, on permeability of concrete which in
turn, gives volumes of information on the durability of the bridge
structure.
Today there is a trend of recommending protective coatings/
paints to bridge structures without knowing their surface perme-
ability. Some paints fail on concrete with lower permeability and
recommending such paints without knowing the permeability of
the concrete surface is a criminal waste of public funds.
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D. Vibrations/Deflection and Strain Monitoring
These tests are extremely useful as every bridge has dynamic
loading and hence it constantly vibrates, deflects and undergoes
stress/strain changes. It is almost a mandatory provision in any
bridge inspection and in particular, if the bridge is recommend-
ed for demolition. Only these tests would provide correct infor-
mation on the level of distresses, the bridge has due to present
loading condition.
E. I.R. Camera
Infra Red Thermograph Camera is actually an inspection tool
and not an NDT technique per-se. This is extremely useful tool in
remote inspection and knowing the surface damage in concrete
and masonry structures. Surface cracking, delamination stones/
masonry components, cracking in arch and other concrete / ma-
sonry components of bridges, cracking in expansion joints/bear-
ings etc. are only some of the applications of I.R. Camera. This is
extremely useful in inspection of a bridge or any other structure
where approach / access is expensive.
F. Petrography
Petrography on concrete plays a major role in knowing micro
defects of concrete, if they exist. A.A.R. ( Alkali Aggregate Reac-
tivity) chemical attack on concrete and masonry mortars etc. are
some of the uses of Petrography on concrete structures.
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BRIDGE: NON DESTRUCTIVE TESTING
Conclusions
a. Consultants must come over the self-convincing ideology
of not using NDT on bridge inspection projects. Adequate
and accurate NDT must be deployed on every bridge project
whether the same is declared ‘safe or unsafe’.
b. Consultants should not restrict themselves to few basic NDT
tests, but also carry out in-depth study by deploying advanced
NDT techniques available in the country.
c. Authority must take up & ensure complete training of their
engineers/bridge inspectors in the field of knowledge of
every NDT technique that is used on bridge inspection sites
across the world.
d. Most consultants must invest in buying most of the NDT
equipments and employ technicians to use these equipments
correctly and abundantly. Only this would promote the use of
NDT sufficiently and freely on all the bridge projects.
e. Consultants must invest in training their engineers/bridge in-
spectors in inferring from NDT results.
f. Authorities and bridge owners also must invest in training
their staff for NDT and bridge inspection.
Only then, we would be able to certify the bridges either safe
or unsafe with confidence. Moreover, we would be able to avoid
instances like recent bridge wash- off in Maharashtra.
Reference: This article was published in the seminar compendi-
um of IBMS in the month of October 2016. 
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