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In 1882, the East-West suburban train viaduct was built through Berlin as part of the public traffic solution in the late 19th Century. Today, the only left over iron arch bridge is a pair of two arches Crossing the Spree river in the middle of Berlin. Before dismantling the former parallel two original pairs of iron arches and rebuilding new arches for the high-speed railway line through Berlin in 1997, BAM was involved in an extensive test program of the heritage iron arch structure. Especially the estimation of accumulated damage in critical details and the verification of the old material properties at early stage was important information to the bridge owners. The testing program included two strain and displacement measurement campaigns, non-destructive testing, materials testing and microscale metallographic analysis of critical details. The measured strain cycles were significant lower in number and size than expected. Most of the cycles were compression stress cycles only. The work was planned in Cooperation with the Berlin consultancy Professor Hilbers that was responsible for the design and calculation of the reconstruction measures. Additionally, after calculation of the possible reuse of the old arches, we compared measured data from strain measurements with the results from calculation.
The measured data and the calculated data show a good qualitative correlation.
Ultrasound sensors should be embedded into concrete for monitoring concrete properties. These new longitudinal wave sensors with a center frequency of 60 kHz were examined regarding their suitability for ultrasonic measurements in concrete structures in terms of emission characteristics, sensitivity and frequency ränge.
For the measurement of the radiation patterns, the sensors were embedded vertically and horizontally in concrete cylinders. The directivity pattern was measured using a laser vibrometer.
The sensitivity of the sensor was determined in water using different sensors of the same type. It shows changes in the signal amplitude as well as variations in the frequency ränge for different transmitter-receiver combinations.
The attenuation of the concrete affects the achievable resolution of the measurements and thus, the maximum possible spacing of the sensors within a concrete element. Experimental tests helped optimizing the distances with respect to the required resolution and the effort of embedding the sensors. The signal attenuation in the concrete was measured in the frequency ränge of 60 kHz in response to various degrees of reinforcement and grain size. For this purpose, the sensors were cast at different distances in the specimens studied. The recorded Signals were evaluated for their amplitude and frequency spectrum.
Following the long tradition of the Federal Institute for Materials Research and Testing (BAM) since Adolf Martens has created first routines in failure analysis (Ruske, 1971), BAM has been frequently called-in by the Berlin Traffic Association (BVG) to carry out root-cause analyses of the Berlin suburban train line (Frahm, 1902), reported in Helmerich and Herter (1999), Helmerich (2000), Nega and Winkler (1998), Helmerich et al. (2002) and Herter et al. (2002). This was also the case in the 1990s, when BVG-inspectors found cracks in hanging, barrel-like shaped ballast plates of the Berlin underground steel viaducts during regularly scheduled inspections. Cracks were located parallel to the riveted connection between the ballast plates and the upper chord of the viaduct cross girder steel profiles. For safety reasons, the operator BVG immediately stopped the cracks by means of drilling stop holes at the crack tips. As intermediate measures, longitudinal steel profiles were spanned below the rail axes between the cross girders affected to stabilize the track in longitudinal direction. The inspection period was shortened from years to few weeks. BAM was mandated to measure strains under regular train traffic to analyze the cause of the cracks. Strains were measured in identical connections as the damaged details, which did not suffer from cracks at the time of the measurement. The traffic-induced strain cycles and thus the resulting strain differences in the questionable cross sections were higher than expected and resulted in stresses of max. 85.8 MPa. Calculations showed that the credible remaining fatigue life for this particular structural detail was exceeded after 68 years according to nowadays standards. Extensive discussions, further field and laboratory tests followed to develop a rehabilitation plan for retrofitting the structure with minimum interference of the traffic. Finally, a method with minimum intervention to the structure was elaborated by a consortium of the operator BVG, BAM and producers based on further laboratory and field tests at BAM. Now, the viaduct is saved for the future.
The reliability of data, obtained from nondestructive testing depends on many different factors as e.g. the equipment, the human factor, the influence of material properties, geometrical accessibility of the given detail, the structure of the detail, but also from data acquisition, processing and interpretation. The presentation introduces to current possibilities for the quantification of measurement results received during nondestructive testing.
The active approach for non-destructive-testing in Civil Engineering (NDT-CE) with infraredthermography (IR), developed at the Federal Institute for Materials Research and Testing (BAM), is described in part one of this contribution. The active IR-approach is based on the principles of impulse- (IT) and pulse-phase-thermography (PPT). The concept is a direct result of a research project at the BAM in cooperation with the Technical University of Berlin (TUB) and was funded by the Deutsche Forschungsgemeinschaft (DFG). In the second part results of the new thermography-scanning system (thermo-scanner) of BAM on debonding of multi-layered structures, especially carbon fibre reinforced plates (CFRP) on concrete are presented. Both, the thermo-scanner developed at BAM, and the investigations carried out, are part of the
EU-Project Sustainable Bridges. In the third part of the paper the characteristic frequency of the optimum phase-contrast as a means for the characterization of defects depth in CE by means of PPT is introduced. A new quantitative approach is tested and discussed on concrete structures with defects of polystyrene and gas concrete.