THERMAL NONDESTRUCTIVE TESTING (TNDT) OF ADHESIVELY BONDED

COMPOSITE REINFORCEMENTS APPLIED TO CONCRETE CIVIL STRUCTURES

Douglas Burleigh, TNDT Consultant
Richard Bohner, William P.Young Construction, Inc.

ABSTRACT

Thermographic nondestructive testing (TNDT) was performed on composite reinforcements applied to two concrete civil
structures:

1. Caltrans Qualification Test —University of California, Irvine - A reinforced cement column, which represented a freeway
support column, was fabricated with a 14 inch square cross section. Fiberglass laminate shells up to 1/2 inch thick were
adhesively bonded to the concrete column to simulate a proposed seismic retrofit. TNDT was used to evaluate the entire
area ofthe fiberglass laminate.

2. Navy Pier 12, San Diego Naval Station - This structure is 50 years old and was rated for 30 ton loads. It was required
that the deck loading capacity be upgraded from 30 to 50 tons. Several types of Graphite and Glass fiber reinforced
composites were adhesively bonded to the concrete substructure to achieve the desired increase in deck loading capacity.
TNDT evaluations were performed on a "random spot check" basis along typical sections of the each of the composite
systems which were used to reinforce the concrete deck structure

TNDT provided both qualitative and quantitative information. TNDT was successful in detecting both simulated and actual
disbonds in several types of composite reinforcements. TNDT was an effective technique for inspecting some of the
composites, but was unsuccessful in inspecting some of the thickest (1/2") composites. In several cases, it was possible to
perform destructive investigations to confirm the results of TNDT testing. TNDT standards were created "in situ" for two of
the composite materials used on these composite upgrades, and free standing TNDT standards were fabricated for several
more.

Information on the types of defects which occur in these structures and their locations has led to process improvements in the
application of adhesively bonded laminated composites to steel reinforce concrete structures.

Key Words: TNDT, concrete, composite reinforcement

STRUCTURES TESTED

Caltrans Column Confinement Qualification Test.

A steel reinforced concrete test column was clad with adhesively-bonded fiberglass shells for structural reinforcement as part
of a column confmement qualification program for CalTrans (California Department of Transportation) at the University of
California at Irvine. The column was rectangular in cross section having dimensions of approximately 1 8 inches x 24 inches.
Layers of fiberglass shells were adhesively bonded to the concrete column to simulate a 40% scale seismic retrofit of a
typical rectangular shear column.The column confmement jacket was supplied by Hardcore DuPont Composites L.L.C. of
New Castle, Delaware. The composite jacket system was comprised of 8 "L" shaped shell components epoxy bonded in
place around the concrete column creating an overlapping configuration. This provided a minimum of 2 shells thickness', or
0.30 inch, at any given location and exceeded the minimum structural design requirements of the Caltrans retrofit. In areas
where corner angles overlapped, the total thickness including bond line was approximately 0.60 inches. Figure 1.

Part of the SPIE Conference on Nondestructive Evaluation of Bridges

and Highways Ill • Newport Beach, California • March 1999 105
SPIE Vol. 3587 • 0277-786X1991$l0.O0

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 U, RND CORNER (TYP)

FILL GAPS
SECTION VITH ADHESIVE
A—A

L
QUMN RETROflI
NO

Figure 1. Column Confinement Configuration

The fiberglass jacket components were fabricated using SCRIMP (Seeman Composite Resin Infiltration Manufacturing
Process). Each shell thickness was .15 inch and was layed up using three individual layers of 0.05 inch unidirectional
fiberglass cloth. The infiltrated resin system was a modified vinyl ester. The procured shells were delivered to the test site
and bonded in place by William P. Young Construction Inc.. The bonding operation was performed using a two part epoxy
paste applied with notched trowel. Minimum bond line thickness was .05inch with maximum corner fillets in gap areas of
up to .20 inches.

U.S Navy Pier 12 San Diego

The Naval Engineering Facilities Support Center (NEFSC) has, for the past 10 years, performed design, development, and
structural testing activities on applications of composite materials to water front civil structures. The Pier 12 project was
designed to examine the performance of several structural design approaches incorporating composite material systems to
upgrading of concrete civil structures. The pier selected for this project was a 50year old concrete structure with minimal
steel rebar reinforcement. This active pier in the heart of the Navy's San Diego Naval Base is limited in utility by low deck
loading capacity. The Navy's design goal was to increase the capacity of the crane positions from 30 to 50 tons. This was
accomplished by the addition of 5 structural reinforcing systems fabricated with 5 different composite materials. Figure 2
shows a diagram of the deck structure and the location of each composite material system. A description of each material
follows.

r—o

12 lSeotions
0.30 tn1ft (8.2$cn/m)
C.rbov/Epoz7 LamIn.te . 13. Wide Strips
RelotoreemeM
UPgT$de BOth Side.)

yjço1 Longitudinal Positive Moment Reiniorcemeni

Jpgmde At Midineji

Figure 2. Application of Composite Material to Pier 12

1. Pultruded Graphitefiber rods embedded into slots saw cut into the top deckfor increased negative moment capacity.

The pultruded rods were supplied by DFI of Louisville, Kentucky. These components are comprised of 65% Graphite fiber
and 35% epoxy resin. The rods are typically 10 feet long and are placed into 5/8" wide by 7/8" deep grooves saw cut into
the top deck on 4" centers. The rods were epoxy bonded in place using SikaDur 32, made by the Sika Corp. of Santa Fe

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 Springs, California, with a mixture of 20% #60 mesh sand. A 1/8" top coat of SikaDur 22 with a mixture of 3 :1 (sand to
epoxy) #30 sand was troweled on top to provide a barrier to prevent UV (ultraviolet) degradation ofthe epoxy.

2. Pultruded fiberglass I beams bolted and epoxy bonded to the under deck surface for increased shear strength and
positive moment capacity.

Fiberglass I beams 12"x 6"x V2, supplied by Strongwell, Rancho Cucamonga, California, provide increased punching shear
and positive moment capacity enhancement when bonded directly to the under deck surface and anchored to the pile caps.
These materials are superior to conventional steel I beam due to their superior corrosion resistance in salt water
environments. Additionally, since the composite beams weigh 70 % less than steel beams of the same stiffness, the 12 foot
long composite I beams could be lifted into place by 2 men without the aid ofjacks or heavy lifting equipment.

3. Pultruded Graphitefiber strips epoxy bonded to the under deck surfacefor increasedpositive moment capacity.

The pultruded Graphite fiber strips, whose trade name is CarboDur, were supplied the Sika Corporation, Santa Fe Springs,
California. They were bonded to the under deck surface using approximately 1/8" of SikaDur 30 epoxy material. This
system has a high loading of sand aggregate as supplied by the manufacturer. The SikaDur 30 epoxy was first troweled on to
the under surface of the deck to provide a level surface by filling the undulations in the concrete surface caused by the
original concrete board forms. The Graphite fiber strips were cut to length, adhesive was applied to both the strips and the
cement surfaces, the strips were positioned in place and then a roller was applied over the strips to ensure consistent bond
line pressure and thickness. Strips were placed in multiple rows of 2, 3, and 4 inch wide configurations to provide the
specified width of reinforcement.

4. Laminated Graphite/epoxy fabric adhesively bonded to the under deck surface for increased positive moment
capacity.

A rectangular area 4.5 feet by 9 feet under the 24 inch thick section of the deck has been strengthened by the addition of a
wet epoxy laminated Graphite fiber system supplied by the Fyfe Co., San Diego, California. The system selected was a 4 ply
unidirectional Graphite fabric laminated with the Tyfo S epoxy resin system. Total laminate thickness was approximately
0.4 inches. The dry unidirectional fabric was processed using an on-site impregnator to saturate the fabric with a uniform
content of epoxy resin. The saturated fabric was then carried to the application site on rolls that were used to place the
material on the area requiring reinforcement. Between the layers of fabric a "tack" coat of Tyfo WC was applied. This tack
coat is based on the same TYFO S resin system with the addition of a thickener of cabosil or milled fiber to enhance the
viscosity of the material. Tack coat thickness averaged 0.05 inches. Subsequent layers of 0.05 inch fabric were carefully
applied to preclude entrapment between plies.

5. Laminated vinyl ester/fiberglass shells installed on selected vertical piles to provide improved ductility and side load
capacity

Selected bearing and batter piles of Pier 12 were retrofitted with the confmement composite jacket system supplied by Hardshell
Composites (formerly Hardcore Dupont Composites L.L.C. of New Castle, DE). The system, originally developed to meet
stringent Caltrans column casing requirements, was used to provide improved ductility and side load capacity to the original 45
year old steel reinforced rectangular concrete piles.

The Hardshell System designed for this project was a vinyl ester/fiberglass composite jacket approximately 0.45 inches thick.
The jacket consists of two half shells that are joined using composite "H" connectors. A complete "H" connector is factory-
installed on one side of the half shell, with a male tab on one side of the connector and a female mate on the otherside. On the
opposite side of the shell, the two halves are both female, and a flat, full-length insert serves as the male connector for both
halves. In the field, adhesive is applied to both the male and female sides ofthe joints and the assembly isjoined around the pile.
After the jacket is installed, a cementitious grout is poured in the gap between the composite shell and the pile. The goal of
inspecting this material system was not to fmd voids in the grout, but to fmd voids in the adhesive of the "H" connector.

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 PRINCIPLES OF THERMOGRAPHIC TESTING

Thermography is a process that produces a mapping of the distribution of temperature on a surface. This is usually done by
the use of an infrared scanner that provides a video image of the temperature distribution. The image is constructed of many
thousands of pixels, each of which represent the level of infrared energy radiating from a point on the surface. The images
are usually displayed in black and white (gray scale, where white is hot and black is cold) when used for NDT.

Thermographic nondestructive testing (TNDT) techniques have been developed, primarily in the aerospace industry, for
evaluating the quality of coatings, composite materials, and bonded structures. TNDT is generally done by applying a
uniform heat pulse to the surface of a material and thermographically monitoring the temperature distribution of that surface
for a short time. Where the structure is uniform and free of disbonds or defects, the temperature distribution will change as
the surface heats and cools, but will remain uniform. Disbonded or delaminated areas however, will warm up relative to the
adjacent bonded areas since they lack contact with underlying material, which acts as a heat sink in well-bonded material.
Disbonds and delaminations therefore, appear in a thermographic image as light areas in a darker field. In an alternate
technique, heat is applied to one surface while monitoring the temperature distribution on the opposite surface; this is a
"through-transmission" method. This latter method is not possible with most concrete structures.

The change in surface temperature required for a TNDT inspection such as those described in this paper is on the order of ten
to 20 degrees Fahrenheit.

There are numerous choices of test parameters and configurations for TNDT testing. The selection of a technique depends on
the dimensions of the part to be tested, the size (critical flaw size) and type of defect sought, the thermal properties (specific
heat, thermal conductivity, thermal diffusivity, thermal effusivity, density, etc.) and optical properties of the material to be
inspected, whether one-sided or two-sided access is available, which thermographic camera is used, and which heating
options may be employed. The selection of heating is based on the requirements for the energy and duration of the heat
pulse, the surface properties of the subject (emittance, etc.), portability, power consumption, safety, cost, and availability.
Some examples are hot air guns, quartz lamps, Xenon flash lamps, laser, hot or cold water, vortex tubes, sprayed liquid
nitrogen, and others. The selection of the camera is based on requirements for spatial resolution, thermal resolution, speed
(frame rate-measured in Hertz), wavelength sensitivity, selection of appropriate lenses, portability, cost, and availability.

It is the selection of technique and the interpretation of the images that allow the operator to detect defects by TNDT (or any
other NDT method).

Thermography does not detect defects directly; it detects thermal patterns and the change of thermal pattern as a function of
temperature. To use thermography for NDT, the proper conditions must be provided; the heat pulse energy and duration must
be appropriate to create a thermal gradient which will reveal a defect of a certain type. Other variations in the structure may
create thermal gradients that may be misinterpreted as defects. For example, a thin layer of a insulating material, such as
foam or plastic, when included in a laminate, would cause a gradient which could be misinterpreted as that of a delamination,
which is a thin layer of insulating air.

The operator must understand not only the TNDT process and equipment, but also the structure and materials to be
inspected. The structure may contain built-in features that may be falsely identified as defects. Variations in the structure
may require a corresponding variation in the test technique.

As test materials increase in thickness and thermal mass, and br thermal conductivity decreases, the minimum detectable
defect size increases. While in thin materials, defects as small as 0.01 inch (or smaller) across may be detected, in the
relatively thick composite materials used to reinforce concrete structures, such as .50 inch thick fiberglass, the smallest
detectable defect may have a minimum dimension of .25 to 1 inch or more.

The question of whether the resolution of the TNDT technique for a specific application is sufficient frequently has no
answer. The inspector is rarely provided information on critical defect size, i.e., what is the minimum size defect that will
lead to (catastrophic) failure?

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 The use of NDT standards is highly recommended. An NDT standard is a representative piece of the structure to be inspected
and contains built-in defects as similar as possible to those sought. An NDT standard was not originally available for the
inspection discussed, but several were constructed during the course of the work. Note that TNDT. as with all other fonns of
NDT, does not evaluate the strength of an adhesive bond. It may only indicate whether or not there is a bond, not how strong
It is. Evaluation of bond strength must be accomplished by other methods, most of which are not nondestructive.

TNDT TESTING OF A CONCRETE COLUMN

Before testing of the large surfaces of the reinforced colunin began, preliminary testing was concentrated on areas where
suspected disbonds had been previously located by tap testing with a ball peen hammer. This preliminary testing was
performed to verify that TNDT could detect disbonds and to develop a procedure for that purpose.

Several methods of heating for TNDT were tried. In the first, an industrial heat gun (1 50() Watt Master or equivalent) with a
spreader attachment was used to heat the panel. This was successful, but the slow thermal response of the thick fiberglass
plates required diligence and control ("art") by the operator to be successful. This method would be of questionable
reliability in the hands of an inexperienced operator.

The second method used a 1000 Watt quartz lamp (Smith Victor). This was moved across the specimen to heat it. This
technique was successful also, but, as with the heat gun, a lot of "art" was required. Also, the use of quartz lamps is
accompanied by several safety constraints which make their use less attractive than the use of a heat gun.

Voids in adhesive layers were detected through two and three layers of 1/8 inch thick fiberglass with a layer of adhesive
between each. Defects detected by TNDT were marked on the surface of the composite by the use of a grease pencil.
Whenever possible, each marked defect was tested by tapping with a small hammer built specifically for that purpose. In
some cases, tapping on defects located by TNDT caused obvious, hollow-sounding, indications of defects when compared to
tapping on "good" material. However, in many defects located by TNDT there was no anomaly detected by tap testing. This
was attributed to the inherent unreliability of tap testing, which has been documented previously (reference Burleigh. 1995).

Figure 3 shows the thermal image of a disbond approximately 6 inches long under the half-inch thick fiberglass adhesively
boded to the column. The centered vertical line identifies the free edge of the corner shell, it is not indicate a disbond. The
area on the left of the figure is thicker and the disbond extends under this thicker area. This was apparent during the
inspection, but difficult to capture in a still image. Several smaller disbonds are also visible in the upper part of the Figure.
Figure 4 shows a photograph of the area shown in Figure 3. The disbonds shown in Figure 3 are visible in the lower part of
Figure 4.

Figure 3. Thermal Image of a Disbond in Half-inch Thick Fiberglass Adhesively bonded to a Concrete Column

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 This column was built for destructive testing as part of a seismic event structural simulation. After the TNDT inspection, the
colun-m was subjected to a dynamic forced displacement with dead load until structural failure occurred. This afforded the
opportunity of examining some areas where defects had been marked. In all areas examined, outlines marked on the surface
were accurate (+/-l/4 inch) representations of a loss of bonding between the fiberglass and cement.

Figure 4. Photograph of the Column tested in Figure 3. The Disbond shown in Figure 3 is at the lower left of this Figure.

TNDT TESTING OF A NAVAL PIER

TNDT testing of the composite reinforced pier was more challenging than the testing of the column, which was in an indoor
laboratory. Access to the pier was more difficult. Most of the adhesively bonded composite reinforcements were overhead.
Work was performed while standing on a plywood-covered scaffolding system that was accessible only at low tide. In addition,
there was a fairly constant and cold wind of —50F and 10-15 mph., which interfered with the process of heating the surface to he
inspected. This was especially true of the thickest composites, which required heating times of up to one minute to allow
detection of the defects below them. It is possible to protect against the wind, but this would have required devising a structure
around the test area and this was not possible within the time and budgetary restraints of this work.

Several NDT standards were fabricated. Defects were simulated by inserting thin, 0.05 to 0.10 inch thick, closed cell foam
pieces into the bondline between the composite and cement.

Five different composite materials were used as detailed above.

1. Pultruded Graphite fiber rods

This system was not considered to be a reasonable candidate for TNIDT, and was not tested.

2. Pultruded fiberglass I beams

This material is 0.50 inch thick and relatively dense. The pultruded system is made of approximately 55% glass fibers with a
vinyl resin system. "I" beams and angle shapes were bonded to the pier with sand-filled epoxy. These components were also
mechanically fastened using epoxy bonded anchor rods.

An NDT standard was constructed with defects ranging m size from 0.25 to 1.0 square inches. Testing of this material was
unsuccessful in detecting simulated disbonds.

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 3. Pultruded Graphite fiber strips
Stnps of this matenal were bonded adjacent to one another m numerous areas of the pier in areas approximately I x 12 feet. The
thickness of the unidirectional Graphite fiber stnp is approximately 0.05 inch. One strip was applied to the concrete as an NI)'F
standard. This contained numerous disbonds. As the materials are relatively thin, TNDT was very effective. Figure 5 is a
composite of two thermal images of the standard. Figure 6 is a photograph of the standard. All simulated defects were easily
detected.

Figure 5. Composite of Two Thermal Images of Simulated Defects in an NDT Standard of Pultruded Graphite Fiber Strips

Figure 6. Photograph of the NDT standard in Figure 5

Figure 7 is a thermal image of two disbonds along the edges of adjacent strips. Figure 8 is a photograph of the same area
showmg markings of the disbonds.

Figure 7. Thermal Image of Two Disbonds on the Edges of Pultruded Graphite Fiber Strips

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 Figure 8. Photograph of the Area in Figure 7

4. Laminated Graphite/epoxy fabric

Laminated Graphite/epoxy fabric was applied to 4.5 x 12 foot areas of the pier. The total thickness of the four ply laminate
material was approximately 0.4 inches.. Two square composite pieces, approximately 8 x 8 inches, were applied to the concrete
as NDT standards. There were several simulated defects inserted in the bondime, ranging in size from 0.25 to 1 .0 inch square.
Testing of the standard indicated that defects larger than 1 inch square could be detected. Figure 9 shows a thermal image of
such a defect. Figure 10 shows a photo of the standard.

Figure 9. Thermal Image of a 1 inch Square Simulated Defect in the Bondline of an ND1' Standard of 0.5 inch Thick Laminated
Graphite/Epoxy Fabric

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 Figure 10. Photograph Showing the INDT Standard in Figure 9

Two areas of this material were inspected using TNDT. In the first. delaminations were detected. Figure 11 shows the thermal
image of the area containing delaminations, which is approximately 3 x 3 feet in size. Figure 12 shows a photograph of the area.
Marking the delaminations was not attempted, as the shapes were complex, and repairs were not planned as the size, quantity.
and type of the defects was not judged to compromise the integrity of the structure.

Figure 11. Thermal Image of Delaminations in the Laminated Graphite/Epoxy Fabric. The Area Pictured is Approximately 3x3 feet

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 Figure 12. Photograph of the Area in Figure 12

In the second area, hammer tap testing had detected a hollow-sounding area. TNDT tests of this area were not conclusive. Two
possibilities were considered: first, that TNDT had failed to detect the disbond, and second, that the adhesive disbond was intact.
but there was a defect in the concrete. Further analysis, by ultrasonic testing or by destructive analysis involvmg cutting a hole
into the structure was recommended.

Some time later the destructive analysis was performed. This revealed that the TNDT was correct, in that there was no disbond
between the composite and the concrete. There was, however, a sub-surface anomaly that explained the hammer tap test finding.
There was a layer of 0.05 inch thick metal approximately 0.1 inch under the surface of the concrete, and there was a void behind
the metal. Apparently this metal was installed during the construction of the pier. While itis possible that TNI)l could detect
this type of disbond, it would require a different technique than that used for finding the composite dishonds.

Testing of this material was hampered by a cold, stiff wmd as discussed earlier.

5. Laminated Graphite/epoxy fabric

The thermographic inspection performed on this component on Pier 12 was intended to detect voids in the adhesive layers within
the field bonded "H" joints. Since the joints have an "H" configuration, there are two adhesive bond layers in each joint. One
adhesive layer is below the outer surface by approximately one third of the thickness of the material; the second is below the
outer surface by approximately two thirds of the thickness of the matenal. In this structure, the depths of the hondlines are at
approximately 0.15 and 0.3 inch below the surface. Due to the process of putting the joints together, it is much more likely that
voids in the adhesive layer will appear in the first bondline.

After the therniographic inspection of several of these Joints in the field, a single one inch diameter void was detected. There
were no planned disbonds m the field bonded joints.

As with the other material systems, an NDT standard was made and tested. The testing of the standard verified that the TNDI
process used would reliably find disbonds in the "H" connector at the adhesive bondline closest to the surface. l)isbonds in the
second bondline can be detected, but not with good reliability, as this requires thermal energy to pass through the first bondline.
which has variable thickness and thermal properties.

The inspection of these piers was made extremely difficult by limited access and environmental conditions. The inspection was
performed after the scaffolding had been removed from under the pier, and was done floating under the pier on a raft made of
railroad ties! There was a cold wind blowing, the raft was rocking, and nearby was a leaking steam fitting which provided a
constant source of damp fog. No attempts were made to exclude these environmental hindrances. [his work is sometimes
challenging, but this is the nature of field inspections!

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 CONCLUSIONS
1) The ability of TNDT to fmd defects and anomalies in the structure of the composite reinforcements adhesively bonded
to reinforced concrete has been demonstrated, though techniques have not been optimized. As the thickness of the
composite increases the minimum detectable disbond size increases.

2) Defects found were apparently smaller that the "critical flaw size" for the column structure. When the column failed, at
ductility 7 in accordance with the CalTrans requirements, failure did not initiate in the vicinity of a defect detected by
TNDT.

3) Further development and refinement of TNDT test methods would be beneficial. Other heating methods have being
considered.

4) Additional NDT standards should be designed and built of representative materials and thicknesses.

5) Information on the types of defects that occur in these structures and their locations has led to process improvements in
the application of laminated composites adhesively bonded to concrete structures.

6) Environmental problems sometimes made the inspection difficult, but never made it impossible in the work described in
this paper.

7) Secondary NDT methods for this application should be identified to verify the results of TNDT testing. Candidate
methods may include ultrasonic testing, laser shearography, vibration pattern imaging, and others.

REFERENCES
1. "Thermographic Nondestructive Testing (TNDT) of Honeycomb Composite Structural Parts of Atlas Space Launch
Vehicles," D.D. Burleigh, D.R. Kuims, S. Cowell, & J.E. Engel, Thermosense XVI, April 1994, SPIE Volume 2245,
p.152-163
2. "Practical Aspects ofThermal Nondestructive Testing," D. Burleigh, Thermosense XVIII, April 1996, SPIE Volume 2766,
p.158-163
3. "Practical (Nontechnical) Aspects ofNDT, Using Thermographic NDT as an Example," D. Burleigh, Materials Evaluation
(ASNT), November 1996, Vol. 54, No. 11, p. 1266-1269.

4. "Thermal Nondestructive Testing (TNDT) of Composite Reinforcements Adhesively Bonded to Concrete Civil
Structures," R. Bohner and D. Burleigh, Proceedings of the 431X1 International SAMPE Symposium, May 31- June 4, 1998,
Materials and Processes Affordability Keys to the Future, Volume 43, Book 2, Pages 1847-1857, edited by Kliger et al.,
1998

ACKNOWLEDGEMENTS
The authors would like to acknowledge the support of Peter Bliven of PBA Instruments, La Jolla, California. Peter assisted in
printing thermal images and providing the Inframetrics equipment used to inspect the Naval Pier 12 in San Diego.

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