Sustainable Bridges Sustainable Bridges Workshop I Workshop I

Inspection and Condition Assessment of Railway Bridges Inspection and Condition Assessment of Railway Bridges
Berlin, October 23 Berlin, October 23
rd rd
24 24
th th
, 2006 , 2006
Inspection of Steel Bridges
Inspection of Steel Bridges
Christian Kammel Christian Kammel RWTH Aachen RWTH Aachen
2
Content Content
Condition assessment of steel railway bridges, Condition assessment of steel railway bridges,
state state- -of of- -the the- -art art
Inspection methods for bolted, riveted and welded Inspection methods for bolted, riveted and welded
connections connections
Criteria for replacement of components and Criteria for replacement of components and
connections connections
Condition assessment examples Condition assessment examples
3
Condition Assessment o Condition Assessment of steel railway bridges f steel railway bridges
No European standard available No European standard available
Engineering Critical Assessment methods for in Engineering Critical Assessment methods for in- -service service
inspection, e.g. BS 7910 inspection, e.g. BS 7910- - or SINTAP or SINTAP- -Procedure Procedure
Assessment methods according to Assessment methods according to Ril Ril 804 and 804 and Ril Ril 805 805
Inspection plan according to Inspection plan according to prEN prEN 1090 1090- -2 2
Standardisation at the European level intended Standardisation at the European level intended
State State- -of of- -the the- -art art
4
Tasks of Condition Assessment Tasks of Condition Assessment
Allowable loads for a given defect Allowable loads for a given defect
Critical defect for a given load Critical defect for a given load
Minimum material properties for a given defect and loads Minimum material properties for a given defect and loads
Remaining life Remaining life
Determination of inspection intervals Determination of inspection intervals
Criteria to be identified Criteria to be identified
5

Conventional methods Conventional methods

(assessment based on conventional design methods) (assessment based on conventional design methods)
Outcomes of conventional inspections Outcomes of conventional inspections

Engineering Critical assessment (ECA) Engineering Critical assessment (ECA)

ECA use a combination of conventional design procedures and fr ECA use a combination of conventional design procedures and fracture acture
mechanics calculations mechanics calculations
assessment of the significance and acceptability of imperfectio assessment of the significance and acceptability of imperfections for the ns for the
strength and usability of structures strength and usability of structures
fitness fitness- -for for- -service procedures service procedures
Structure
Result of inspection Safe Unsafe
Accepted OK Customers and societys risk
Rejected Producers risk OK (but unwanted)
Table 1. Outcomes of conventional inspections
Condition assessment methods for steel railway bridges Condition assessment methods for steel railway bridges
6

Application of ECA for in Application of ECA for in- -service inspection service inspection
(deterioration may be monitored during a number of inspections i (deterioration may be monitored during a number of inspections in order to follow the n order to follow the
growth of cracks, the progress of corrosion, etc.) growth of cracks, the progress of corrosion, etc.)

Levels of Levels of
SINTAP SINTAP- -
procedure procedure
Level Title Format of Tensile
Data
Format of Toughness Data Mismatch
Allowanc
e?
0 Default Yield stress only Estimation of yield/tensile ratio (Y/T) for
FAD. Toughness from Charpy energy.
No
1 Basic Yield stress & UTS
only
Estimation of strain hardening exponent
from Y/T for FAD. Fracture toughness as
equivalent K
mat
.
No
2 Mismatch Yield stress & UTS
of Parent Plate and
weld
Estimation of strain hardening exponent
of parent plate and weld metal from Y/T
for FAD. Fracture toughness as
equivalent K
mat
for relevant zone.
Yes
3 Stress-
Strain
Full stress-strain
curve of Parent Plate
(and weld metal)
FAD determined from measured stress-
strain values. Mismatch option based on
equivalent material stress-strain curve
Optional
4 Constraint Full stress-strain
curve
Modification of FAD based on T and Q
stress approaches.
Possible
5 J-Integral Full stress- strain
curve
Estimation of J-integral as a function of
applied loading from numerical analysis.
Optional
6 LBB Yield stress & UTS
only
Application to pressurised components
with sub-critical crack growth
No
Table. The Different Levels of the SINTAP Procedure
Condition assessment methods for steel railway bridges
7
Aspect BS 7910 SINTAP
Origins Largely UK contributions 9 European countries contributed
Failure modes Brittle Fracture, Plastic Collapse,
Ductile Tearing, Fatigue,
Corrosion, Creep
Brittle fracture, Plastic Collapse,
Ductile Tearing
Structure Based on failure mode: extensive
system of annexes
Based on data quality and hierarchy
of procedure; four main chapters
Concept of
fracture and
collapse treatment
Predominantly FAD based Option of interpretation as FAD or
CDF
Fracture modes Mainly I but guidance on II and III Only Mode I
Toughness
treatment
K, J or CTOD FAD defined only in terms of
equivalent K
mat
. J used for CDF.
Allowance for ductile tearing can be
made. CTOD data converted to
equivalent K or J.
Characteristic
Input Values
Generalized guidance on
toughness treatment (Number of
tests, weld testing) and tensile
properties.
Specific sections for definition of
characteristic values of tensile
properties, fracture toughness and
imperfection dimensions, including
statistical treatment for toughness
data.
Probabilistic
approaches/safety
factors
Guidance on Reliability, Partial
Safety Factors and Reserve
Factors
As for BS 7910 but additional
guidance on probabilistic methods
and associated software.
Weld Strength
Mismatch
Qualitative guidance as an annex Inherent part of procedure with
specific recommendations.
Constraint
Treatment
No specific guidance Explicit recommendations are given.
Industry specific
guidance
Pipeline and Offshore None
Software Various systems available Demonstration software available for
levels 0-3 inclusive, and for
probabilistic analysis at level 1.
Table. Principle Differences Between BS 7910 and SINTAP Procedure
Principle Principle
differences of differences of
BS 7910 and BS 7910 and
SINTAP SINTAP
Condition assessment methods for steel railway bridges
8

Ril Ril 804 804 (defines return frequencies of (defines return frequencies of basic basic and and comprehensive comprehensive bridge inspections) bridge inspections)
standard (basic) inspection standard (basic) inspection 3 years return period: 3 years return period:
structural safety, bearings, sealing, drain structural safety, bearings, sealing, drain- -age, cracks, deformation, corrosion etc. age, cracks, deformation, corrosion etc.
main (comprehensive) inspection main (comprehensive) inspection 6 years return period: 6 years return period:
foundation, massive components, steel structure, riveted and bol foundation, massive components, steel structure, riveted and bolted connections, difficult ted connections, difficult
accessible components, rust grade, material testing etc. accessible components, rust grade, material testing etc.

Ril Ril 805 805 (defines 5 different levels of assessment intensity accounting f (defines 5 different levels of assessment intensity accounting for the individual or the individual
current condition) current condition)
Level Level 1: 1: Estimation of structural safety Estimation of structural safety
Level 2: Level 2: Approximative Approximative determination of structural safety determination of structural safety
Level 3: Level 3: Assessment of structural safety Assessment of structural safety without without consideration of consideration of fatigue fatigue
Level 4: Level 4: Assessment of structural safety Assessment of structural safety with with consideration of consideration of fatigue fatigue
Level 5: Level 5: Confirmation of assessment using Confirmation of assessment using measurement measurement in addition to level 3 and 4 in addition to level 3 and 4
For bridges in service for more than For bridges in service for more than 60 years 60 years at least at least Level 4 Level 4 or, if necessary, or, if necessary, Level 5 Level 5 is is
obligatory obligatory
Condition assessment methods for steel railway bridges Condition assessment methods for steel railway bridges
9
Operating time interval Operating time interval
( (Ril Ril 805 805- -Procedure used by German railway; if components show cracks or i Procedure used by German railway; if components show cracks or if assessment of the f assessment of the
remaining service life results in insufficient service life remaining service life results in insufficient service life < 15 years < 15 years) )
Stepwise procedure: Stepwise procedure:
1. 1. Determination of the current structural condition Determination of the current structural condition
2. 2. Determination of imposed loads Determination of imposed loads
3. 3. Structural safety assessment Structural safety assessment
4. 4. Fatigue assessment Fatigue assessment
5. 5. Assessment of operating time intervals Assessment of operating time intervals
Time interval: Time interval: depending on detectable defect during inspections (e.g. crack le depending on detectable defect during inspections (e.g. crack length a ngth a
0 0
= rivet head = rivet head
radius + 5 mm at rivet holes), stress level, radius + 5 mm at rivet holes), stress level,
tonnage, probability of failure P tonnage, probability of failure P
f f
(safety index (safety index ) )
Condition assessment methods for steel railway bridges Condition assessment methods for steel railway bridges
N
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Minimum Minimum
safety index safety index
Remaining life [years] Remaining life [years]
Individual operating time interval Individual operating time interval
Relation between probability of failure P Relation between probability of failure P
f f
and safety index and safety index ) )
10
Requirements for inspection subject to prEN 1090 Requirements for inspection subject to prEN 1090- -2 2
prEN prEN 1090 1090- -2 2
Execution of steel structures and Execution of steel structures and aluminium aluminium structures structures Part 2: Part 2:
Technical requirements for the execution of steel structures Technical requirements for the execution of steel structures Stage 49 Stage 49
Inspection plan Inspection plan
Documentation of Documentation of
a) a) scope of inspection scope of inspection
b) b) location and frequency of measurements; location and frequency of measurements;
c) c) acceptance criteria; acceptance criteria;
d) d) actions for dealing with nonconformities, actions for dealing with nonconformities,
corrections and concessions; corrections and concessions;
e) e) release/rejection procedures. release/rejection procedures.
Methods and testing devices Methods and testing devices
a) a) Visual inspection Visual inspection
b) b) NDT NDT
c) c) Inspection and testing instruments selected Inspection and testing instruments selected
from those listed in ISO 7976 from those listed in ISO 7976- -1, 1, - -2 2
d) d) Accuracy shall be assessed in accordance with the relevant part Accuracy shall be assessed in accordance with the relevant part of ISO 8322 of ISO 8322
11
Inspection and acceptance criteria available for Inspection and acceptance criteria available for
- - Bridge super Bridge super- -structure structure
- - Orthotropic decks Orthotropic decks
- - Verticality of bridge columns Verticality of bridge columns
- - Bridge supports Bridge supports
- - Hollow sections Hollow sections
- - Local Hardness and quality of cut surfaces Local Hardness and quality of cut surfaces
- - Inspection of corrosion protection Inspection of corrosion protection of members of members
incl. over incl. over- -painting, over painting, over- -coating, subsequent welding, surface repair by metal spraying coating, subsequent welding, surface repair by metal spraying
- - Inspection and repair of bolted connections Inspection and repair of bolted connections
- - Inspection and repair of hot rivets Inspection and repair of hot rivets
- - Inspection and repair of welded connections Inspection and repair of welded connections
Requirements for inspection subject to prEN 1090 Requirements for inspection subject to prEN 1090- -2 2
12
Inspection of components
Inspection of corrosion protection Inspection of corrosion protection
in accordance with EN ISO 12944 in accordance with EN ISO 12944- -7; for paints and varnishes acc. to EN ISO 19840; 7; for paints and varnishes acc. to EN ISO 19840;
defect: excessive corrosion, loss of surface treatment; defect: excessive corrosion, loss of surface treatment;
remaining thickness of the surface coating (zinc, paint etc.) ca remaining thickness of the surface coating (zinc, paint etc.) can be metered by n be metered by
magnet magnet- -inductive devices, if coating is non inductive devices, if coating is non- -ferromagnetic ferromagnetic
(alternative ultrasonic, eddy current method) (alternative ultrasonic, eddy current method)
Actions for correction Actions for correction
assessment with reduced cross section; assessment with reduced cross section;
if necessary, calculation of strengthening if necessary, calculation of strengthening
measures for members to increase their measures for members to increase their
resistance against crack growth; resistance against crack growth;
replacement by new members or replacement by new members or
components components
(
(

|
|

\
|
+

|
|

\
|
=
2
2
angle
3
req
act
lamella
h
e 8
h
e 8
2 A 2
3
t h
1
N
N
A
with
N
act
= maximum permissible number of load cycles, determined by a fracture mechanics
calculation using a certain stress range calculated with the actual cross section
N
req
= number of load cycles with a certain stress range between two inspections
A
angle
= cross section of the rolled angle profiles
e = distance between the neutral axis of rolled angle profiles to the outer edge of one of
its flanges
B < C e = 0,27B
B = C e = 0,30B
B > C e = 0,37B






Figure Calculation of the required cross section A
lamella
to strengthen a plate girder under
cyclic bending load, to increase the maximum permissible number of load cycles
Hensen Hensen 1992 1992
13
Inspection of bolted connections
Visual inspection Visual inspection
typical bolt defects: missing bolt/nut, residual gaps max. 2 mm, typical bolt defects: missing bolt/nut, residual gaps max. 2 mm, excessive corrosion, excessive corrosion,
bolt protrusion shall be not less than one full thread pitch bolt protrusion shall be not less than one full thread pitch
Sequential inspection method Sequential inspection method
acc. to ISO 8422; applicable to bolt groups or groups of rivets acc. to ISO 8422; applicable to bolt groups or groups of rivets
Inspection of bolt preload Inspection of bolt preload
defect: defect: loss loss of of preload due to relaxation and settlement; preload due to relaxation and settlement;
apply specific torque moment and inspect further rotation angle apply specific torque moment and inspect further rotation angle of the nut; of the nut;
recommended: less than 15 recommended: less than 15 rotation at 110% of specified minimum preloading force rotation at 110% of specified minimum preloading force
Ultrasonic method for direct measurement of preload force Ultrasonic method for direct measurement of preload force
Actions for correction Actions for correction
retightening up to 110% of specified minimum preloading force; retightening up to 110% of specified minimum preloading force;
replacement by new bolt assemblies, check of holes for cracks, p replacement by new bolt assemblies, check of holes for cracks, pits or hole distortion its or hole distortion
and if appropriate, reaming of holes with larger diameter and if appropriate, reaming of holes with larger diameter
14
Sequential inspection for bolted connections acc. to ISO 8422 Sequential inspection for bolted connections acc. to ISO 8422
Inspection of bolted connections
Random sample test Random sample test
type A type A
type B type B

Number of assemblies
inspected
0
1
2
3
4
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
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Minimum n of inspections : 5
Maximum nof inspections :16

0
1
2
3
4
5
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Number of assemblies
inspected
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Minimum n of inspections : 14
Maximum n of inspections : 40
15
4
0
1
2
3
4
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
A
A
R
R
A
5
Inspection of bolted connections
EXAMPLES
A The 4th and 8th bolts were found defective. Inspection was continued until crossing the vertical truncation line.
The result is acceptance of the bolt tightening operation, subject to corrective actions on the two defective bolts.
R The 2nd, 6th and 12th bolts were found defective. Exit from the uncertainty zone is into the refusal zone.
The result is negative and the inspection is extended to 100% of the bolt assemblies.
1: Refusal Zone
2: Uncertainty zone
3: Acceptance zone
4: Number of assemblies inspected
5: Number of defective assemblies
Example of sequential Example of sequential
inspection diagram inspection diagram
Random sample test (type B in case of significant effects of fat Random sample test (type B in case of significant effects of fatigue); igue);
minimum of 14 and maximum of 40 bolt assemblies to be inspected minimum of 14 and maximum of 40 bolt assemblies to be inspected
Sequential inspection for bolted connections acc. to ISO 8422 Sequential inspection for bolted connections acc. to ISO 8422
16

Relative difference of the running time (t - t
0
) / t
0
of a longitudinal and a transversal
ultrasonic wave as a function of bolt strain
developed by developed by Fraunhofer Fraunhofer- -IZfP IZfP Saarbr Saarbr cken cken

Figure Comparison of bolt strains evaluated from combined ultrasonic method and from
conventional strain gauge measurement
Advances in ultrasonic testing for bolted connections Advances in ultrasonic testing for bolted connections
Combined Ultrasonic method Combined Ultrasonic method
Innovative technique for direct Innovative technique for direct
measurement of actual bolt stresses measurement of actual bolt stresses
17
Inspection of riveted connections
Visual inspection Visual inspection
typical rivet defects: non typical rivet defects: non- -satisfactory contact, satisfactory contact,
cracks or pits, excessive corrosion, loss of pre cracks or pits, excessive corrosion, loss of pre- -stress stress
Inspection of satisfactory contact Inspection of satisfactory contact
by lightly ringing the rivet head with a hammer of 0,5 kg; by lightly ringing the rivet head with a hammer of 0,5 kg;
use use sequential sequential inspection method type A acc. to ISO 8422 inspection method type A acc. to ISO 8422
Actions for correction Actions for correction
replacement by new rivets; replacement by new rivets;
cutting out by means of a chisel or by cutting; cutting out by means of a chisel or by cutting;
check of holes for cracks, pits or hole distortion check of holes for cracks, pits or hole distortion
and if appropriate, and if appropriate, reaming of holes with larger diameter reaming of holes with larger diameter
18
Hot rivet characteristics Hot rivet characteristics
Rivet properties Rivet properties
Calculative friction coefficient Calculative friction coefficient = 0,25 = 0,25
Distinction between Distinction between load load- -bearing rivets bearing rivets in in
structural connections and structural connections and tack rivets tack rivets to to
transfer clamp forces transfer clamp forces
Pre Pre- -stress in rivets stress in rivets
Usually between 20 to 220 N/mm acc. to literature Usually between 20 to 220 N/mm acc. to literature
Average pre Average pre- -stress approx. 100 N/mm depending stress approx. 100 N/mm depending
on diameter on diameter
Clamp length has main influence on pre Clamp length has main influence on pre- -stress stress
Serviceability may be affected in case of loss of pre Serviceability may be affected in case of loss of pre- -stress stress

External loads
Stress distribution in
case of load-bearing
by bearing forces
Stress distribution in
case of load-bearing
by friction
forces
Stress distribution in plies Stress distribution in plies
of riveted connections of riveted connections

0
50
100
150
200
250
300
0 20 40 60 80 100 120 140
Clamp length [mm]
Pre-
s tres s
[N/mm]
22: maximum values
22: minimum values
25: measured values
20: maximum values
20: minimum values
20: measured values
Pre Pre- -stress depending on clamp length stress depending on clamp length
and diameter for rivet material St44 and diameter for rivet material St44
19
Defect 1: Rivet shank to long


Defect 2: Closing head to
small, Rivet shank to thin

Defect 3: Closing head to small
or offset, Rivet shank without
contact

Defect 4: Plies in skew position

Defect 5: Excentric application
of rivet header or rivet punch

Defect 6: Offset rivet heads due
to corrections

Defect 7: Rivet punch put on in
skew position

Defect 8: Rivet header put on in
skew position

Defect 9: Insufficient head
form, damage by rivet header


Defect 10: Rivet header to
small, peripheral rim at closing
head

Defect 11: Bulged-out closing
head

Defect 12: Rivet punch and
closing head in skew position

Table 1. Overview of rivet defects
Investigation on tolerable Investigation on tolerable
corrosion of rivets corrosion of rivets
Aim: Influence of rivet Aim: Influence of rivet
defects on pre defects on pre- -stress stress
Hot rivet defects Hot rivet defects
Kennel 1951 Kennel 1951
20
Effect of representative Effect of representative
corrosion damages corrosion damages
Inclined
corrosion /
deformation
(angle 22,5)
Constant
corrosion of
4 mm (56 V-%)
Constant
corrosion of
2 mm (32 V-%)
No damage
damage type 3 damage type 2 damage type 1 damage type 0

39.0
26.0
13.0
16.5
31.0
26.0
39.0
26.0
35.0
26.0
Rivet head degradation Rivet head degradation
Numerical modelling of rivet pre Numerical modelling of rivet pre- -stress stress
and decrease of resistance capacity and decrease of resistance capacity
21
Investigation on tolerable corrosion of rivets Investigation on tolerable corrosion of rivets
DT 0: Stress up to yield strength f
y
DT 1: Stress in shaft up to 170 N/mm
DT 2: Stress in shaft up to 118 N/mm - Failure by slipping
DT 3: Stress in shaft up to 101 N/mm - Failure by slipping
Influence of rivet head degradation Influence of rivet head degradation
exemplary calculation exemplary calculation
for rivets for rivets 26 26

0.0
50.0
100.0
150.0
200.0
250.0
0.00% 0.01% 0.02% 0.03% 0.04% 0.05% 0.06% 0.07% 0.08% 0.09% 0.10%
Extension of rivet shank
Stress
[N/mm]
KL=33 - S0
KL=33 - S1
KL=33 - S2
KL=33 - S3
Conclusion: Conclusion:
Constant corrosion up to 50 V Constant corrosion up to 50 V- -% %
uncritical for pre uncritical for pre- -stress stress
Inclined corrosion more critical Inclined corrosion more critical
22
Test set Test set- -up with representative rivet head degradation up with representative rivet head degradation
Direction of machining Direction of machining
Washer
Load cell
Nut for tightening
23
40
45
50
55
60
65
0 10 20 30 40 50 60 70 80 90
Zeit [min]
Nietkraft [kN]
Einbau
und
Setzung
Abfrsen in 12 Schritten
Nachspannen des Niet
auf 53 kN
Abfrsen in 6 Schritten
Rivet force [kN]
Time [min]
Installation
and
settlement
Milling in 12 steps
Milling in 12 steps
Milling in 6 steps
Re-stressing of rivet
up to 53 kN = 100 N/mm
2
Decrease of Decrease of rivet force for oblique milling rivet force for oblique milling
(inclination angle of 30 (inclination angle of 30 ) )
Remaining pre Remaining pre- -stress of rivets stress of rivets
24
Relation between rivet force and corrosion/milling Relation between rivet force and corrosion/milling
for rivet head degradation parallel to plies for rivet head degradation parallel to plies

50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Milling / Corrosion [mm]
Rivet force
[%]
Volume of rivet head
[%]
78%
50% of the
height of rivet head
42% of the
height of rivet head
Remaining pre Remaining pre- -stress of rivets stress of rivets
25
Fatigue Fatigue test:
Pre-stress of 80 N/mm
1,5 x stress amplitude (120 N/mm)
2 Mio load cycles
Result: No failure Result: No failure
Result of Result of calculation: calculation:
Inclined or constant degradation to a remaining Inclined or constant degradation to a remaining head volume of 56% is safe head volume of 56% is safe
Proposed Proposed ultimate limit for rivet head: ultimate limit for rivet head: 100 N/mm 100 N/mm
Proposed Proposed serviceability limit serviceability limit for riveted connections: for riveted connections: 90% of initial rivet force 90% of initial rivet force
Result: Inclined degradation to remaining Result: Inclined degradation to remaining head volume of 78% is tolerable head volume of 78% is tolerable
Proposed criteria for replacement of rivets Proposed criteria for replacement of rivets
Result of Result of tests: tests:
Minor corrosion: decrease of pre Minor corrosion: decrease of pre- -stress is caused by reduction of head stiffness, not by yielding stress is caused by reduction of head stiffness, not by yielding
Increased corrosion: yielding occurs locally limited with load t Increased corrosion: yielding occurs locally limited with load transfer into lower stressed areas ransfer into lower stressed areas
Recommendation: Recommendation:
Replacement of rivets, if head degradation reaches serviceabilit Replacement of rivets, if head degradation reaches serviceability limit y limit
26
Inspection of welded connections
Visual inspection Visual inspection
to be performed in accordance with EN 970; to be performed in accordance with EN 970;
typical weld defects: surface cracks, notches, cavities, slag, s typical weld defects: surface cracks, notches, cavities, slag, spatter, arc strikes patter, arc strikes
Standard NDT Standard NDT- -techniques techniques
to detect to detect internal imperfections and fatigue cracks, usually starting from internal imperfections and fatigue cracks, usually starting from HAZ; HAZ;
selection selection acc. to EN 12062: acc. to EN 12062:
a) a) liquid liquid penetrant penetrant testing (EN 571) testing (EN 571)
b) b) magnetic particle inspection (EN 1290) magnetic particle inspection (EN 1290)
c) c) ultrasonic testing (EN 1713, EN 1714) ultrasonic testing (EN 1713, EN 1714)
d) d) radiographic testing (EN 1435) radiographic testing (EN 1435)
e) e) eddy current testing (EN 1711) eddy current testing (EN 1711)
Acceptance criteria for welds acc. to EN ISO 5817 (quality level Acceptance criteria for welds acc. to EN ISO 5817 (quality level B at least) B at least)
Actions for correction Actions for correction
Weld improvement by Ultrasonic Impact Treatment (UIT) = Hammerin Weld improvement by Ultrasonic Impact Treatment (UIT) = Hammering by ultrasonic g by ultrasonic
pulses pulses fatigue resistance can be increased by 1,5 fatigue resistance can be increased by 1,5 2,1; 2,1;
crack arrest by drilling at crack tip; replacement of welds by n crack arrest by drilling at crack tip; replacement of welds by new ones ew ones
27
Visualization by Visualization by
macro specimen macro specimen
crack initiation starting crack initiation starting
from residual gaps of from residual gaps of
actual root penetration actual root penetration
Problem: Problem: Fatigue crack Fatigue crack propagation in welds propagation in welds sometimes not detectable sometimes not detectable
by traditional NDT by traditional NDT- -methods, e.g. for methods, e.g. for cruciform joints cruciform joints
Inspection of welded connections
28
Advances in ultrasonic test methods for welds Advances in ultrasonic test methods for welds
Crack detection in T Crack detection in T- -joints joints
and cruciform joints and cruciform joints
Echoes of edge waves Echoes of edge waves
at a non at a non- -penetrated weld penetrated weld
Application of acoustic lenses Application of acoustic lenses
Emitter Emitter
Receiver Receiver
Acoustic axis of the Acoustic axis of the
reflected sound beam reflected sound beam
29
x = 2a
x = a
Test setup using diagonal Test setup using diagonal
focused sound beams focused sound beams
Ultrasonic testing device Ultrasonic testing device
Innovative ultrasonic testing of cruciform joint Innovative ultrasonic testing of cruciform joint
Advances in ultrasonic test methods for welds Advances in ultrasonic test methods for welds
30
x = a
Ultrasonic testing Ultrasonic testing
of cruciform joint of cruciform joint
0
4
8
12
16
20
24
0 20 40 60 80 100 120 140 160 180 200
Testing position [mm]
F
a
t
i
g
u
e

c
r
a
c
k

l
e
n
g
t
h

[
m
m
]
line of rest 6
line of rest 5
line of rest 4
line of rest 3
line of rest 2
line of rest 1
line of rest 0
Crack length + Residual gap measurement Crack length + Residual gap measurement
Macro specimen Macro specimen
Brittle Brittle
fracture fracture
Lines of rest of fatigue crack Lines of rest of fatigue crack
Advances in ultrasonic test methods for welds Advances in ultrasonic test methods for welds
31
Example 1: Example 1: K K ln ln Hauptbahnhof Hauptbahnhof

Condition assessment examples Condition assessment examples
Condition assessment according to Condition assessment according to Ril Ril 805 805
Application of s Application of stepwise assessment procedure (Determination of current structura tepwise assessment procedure (Determination of current structural condition, l condition,
imposed loads, structural safety assessment, fatigue assessment, imposed loads, structural safety assessment, fatigue assessment, assessment of operating time intervals) assessment of operating time intervals)
Strain measurements to gain information about realistic fatigue Strain measurements to gain information about realistic fatigue loads loads
Comparison of calculated and measured fatigue stresses Comparison of calculated and measured fatigue stresses
Determination of appropriate operating time interval for individ Determination of appropriate operating time interval for individual bridge spans ual bridge spans
Single span bridge each with two riveted main Single span bridge each with two riveted main
girders and a span length of 8,35 m girders and a span length of 8,35 m
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Figure Example for a measured strain-time-history

Figure PC plug-in data acquisition device
Condition assessment examples Condition assessment examples
Example 1: Example 1: K K ln ln Hauptbahnhof Hauptbahnhof
Results of condition assessment Results of condition assessment
Measured stresses are lower than calculated ones Measured stresses are lower than calculated ones
No remedial actions necessary No remedial actions necessary
Determination of appropriate operating time interval for individ Determination of appropriate operating time interval for individual bridge spans ual bridge spans
Train type 215 Train type 215
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Condition assessment examples Condition assessment examples
Example 2: Canal bridge Example 2: Canal bridge Rendsburg Rendsburg
Condition assessment and inspection Condition assessment and inspection
Measurements to gain information about the real structural Measurements to gain information about the real structural behaviour behaviour under critical under critical horizontal horizontal loadsa loadsa
due to due to braking and traction braking and traction of of trains trains
Good agreement between calculated and measured stresses (calcula Good agreement between calculated and measured stresses (calculation under deteriorated conditions) tion under deteriorated conditions)
Inspection with NDT proves necessity of remedial measures Inspection with NDT proves necessity of remedial measures
Determination of operating time interval Determination of operating time interval
Train for braking test Train for braking test
on canal bridge (built in 1912) on canal bridge (built in 1912)
Static system Static system
Comparison of calculated Comparison of calculated
and measured stresses and measured stresses
Stress Stress- -time history measured during braking test time history measured during braking test
at diagonal bracings of longitudinal sides of piers at diagonal bracings of longitudinal sides of piers
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Available Report Available Report
Sustainable Bridges Deliverable D3.4: Sustainable Bridges Deliverable D3.4:
Condition assessment and inspection of steel Condition assessment and inspection of steel
railway bridges, including stress measurements railway bridges, including stress measurements
in riveted, bolted and welded structures in riveted, bolted and welded structures
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Related Work Related Work
NDT toolbox NDT toolbox
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Related Work Related Work
Representative of a common type of steel bridges in Europe Representative of a common type of steel bridges in Europe
- - Located in Located in Avesnes Avesnes, central France , central France
a) a) Test of damage detection and assessment methods Test of damage detection and assessment methods
(corrosion, cracking, capacity); (corrosion, cracking, capacity);
b) b) Monitoring by repeated measurements Monitoring by repeated measurements
Repair and strengthening Repair and strengthening (WP6) (WP6)
Field test of old riveted steel bridge Field test of old riveted steel bridge (WP7) (WP7)
Demonstration activities Demonstration activities - -
Bridge Monitoring Bridge Monitoring (WP8) (WP8)
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Thank you for your attention! Thank you for your attention!
Questions and comments? Questions and comments?