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Eingeladener Vortrag
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In the framework of non-destructive-testing advanced seismic imaging techniques have been applied to ultrasonic echo data in order to examine the integrity of an engineered test-barrier designed to be used for sealing an underground nuclear waste disposal site. Synthetic data as well as real multi-receiver ultrasonic data acquired at the test site were processed and imaged using Kirchhoff prestack depth migration reverse time migration (RTM). In general, both methods provide a good Image quality as demonstrated by various case studies, however deeper parts within the test barrier containing inclined reflectors were reconstructed more accurately by RTM. In particular, the image quality of a specific target reflector at a depth of 8 m in the test-barrier has been significantly improved compared to previous investigations using synthetic aperture Focusing technique, which justifies the considerable computing time of this method.
Im Jahr 2011 hat der Bundestag in Deutschland den Ausstieg aus der Kernenergie beschlossen. Der angefallene Abfall wird mehr als hunderttausend Jahre eine derartig hohe Aktivität besitzen, dass er eine erhebliche Gefahr für nachfolgende Generationen darstellen kann. Dieser radioaktive Abfall soll in tiefen geologischen Formationen (z.B. Salz, Ton oder Kristallin) sicher endgelagert werden. Die Endlager werden mittels sogenannter geotechnischer Abdichtbauwerke (Schachtbzw. Streckenverschlüsse) verschlossen, wofür u.a. Zement- oder Sorel-basierte Baustoffe (Betone) in Frage kommen. Die Beschreibung des Dichtvermögens dieser Bauwerke ist unabdingbar. In der Forschungsphase werden verschiedene Werkstoffe untersucht und Methoden für die zerstörungsfreie Untersuchung der Bauwerke als Mittel der Qualitätsprüfung entwickelt. Hierbei ist der Nachweis der Rissfreiheit bzw. die Detektion möglicher Risse ein vorrangiges Thema. In den letzten Jahren konnten bereits umfangreiche Erfahrungen mit der Untersuchung von in-situ-Versuchsobjekten in Realmaßstab gesammelt werden. Die Messungen wurden im Endlager für radioaktive Abfälle Morsleben am in-situ-Versuch “Abdichtbauwerk im Steinsalz” und in der Grube Teutschenthal am Großversuch GV2 durchgeführt. Es ist gelungen mit einem neu entwickelten Ultraschall-Messsystem Eindringtiefen bis ca. 9,0 m zu realisieren. Die Messungen mit dem Large Aperture Ultrasonic System in Kombination mit der Rekonstruktion-Methode Synthetic Aperture Focusing Technique zeigen, dass die zerstörungsfreie Prüfung von Abdichtbauwerken möglich und die Nutzung des Messsystems zur Qualitätssicherung bei der Erstellung der Verschlussbauwerke vielversprechend ist.
Ultrasound measurements in concrete are a well-known technique in civil engineering and non-destructive testing.
For consistent monitoring of a concrete structure, the common techniques, using external sensors can often not provide the appropriate degree of repeatability, as the surface of structures changes, and comparable coupling conditions cannot be guaranteed when a measurement is repeated after some time. By embedding ultrasound transducers in concrete, we aim to develop a strategy for long-term monitoring of infrastructure, especially bridges, as a supplement and extension to other techniques. Applying the so-called coda wave interferometry to these measurements we can detect subtle changes in the medium far beyond the Resolution limit of traditional time of flight methods. A smart sensor layout enables cost-efficient sensing of the entire area of interest.
Embedding the transducers might remove uncertainties like coupling or positioning changes, while other challenges remain.
Temperature and moisture content influence the structure and the transducers. These drifts need to be recorded and removed and good coupling must be ensured while not being able to visually inspect the sensor. In a multidisciplinary research group funded by the German Research Foundation, we aim to solve these problems on the way towards an ultrasound monitoring system for reinforced concrete structures. In various experiments in the lab and field, we determine the influence of temperature variations on the measurements and the equipment. As the monitoring task is the detection of irreversible damages - not reversible changes - a smart system requires a smart way of discrimination between permanent damages and reversible changes. With the data collected in these experiments, we present an approach to an environmental correction to ultrasound data to avoid a
misinterpretation of these environmental changes as damage indicators.
Due to the importance of reinforced concrete structures for modern society, damage assessment during the entire life-cycle of such structures has become a special interest in non-destructive testing. Using embedded ultrasound sensors in combination with other measurement methods, numerical modeling and self-made data collectors, tailored specifically for monitoring tasks, the German research group DFG FOR CoDA aims to investigate and develop novel methods for damage detection and rapid model updating in reinforced concrete structures. In the first stage of the project, besides the development of custom-built, low-cost data collectors, ultrasonic transducers are embedded in a large, reinforced concrete specimen on a BAM test site near Berlin. In this experiment, the influence of changing environmental conditions (mainly temperature) on the ultrasound signal is investigated using coda-wave interferometry. The results show a correlation between changes in temperature and ultrasonic velocity. Such changes must be taken into consideration in a long-term monitoring setup to distinguish between reversible and permanent changes. By correcting the data using a linear relation between concrete temperature and velocity change to remove the seasonal trends and by low-pass filtering the data to remove daily variations can remove most of the temperature influence on the ultrasound measurements.
This paper describes a new ultrasonic measuring device called “W-Box”. It was developed based on the requirements of the DFG Forschergruppe (research unit) CoDA for a portable device for monitoring of concrete specimens, models and actual structures using embedded ultrasonic transducers as well as temperature and humidity sensors. The W-Box can send ultrasonic pulses with a variable frequency of 50–100 kHz to one selectable transducer and records signals from up to 75 multiplexed channels with a sample rate of 1 MHz and a resolution of 14 bits. In addition, it measures temperature and humidity with high accuracy, adjustable amplification, restarts automatically after a power failure and can be fully controlled remotely. The measured data are automatically stored locally on-site data quality checks and transferred to remote servers. The comparison of the W-Box with a laboratory setup using commercial devices proves that it is equally reliable and precise, at much lower cost. The W-Box also shows that their measurement capacities, with the used embedded ultrasonic transducers, can reach above 6 m in concrete.
With a goal to improve our understanding of the relationships between microstructural features and ultrasonic signal behavior, concrete specimens of varying water-to-cement ratio were imaged using X-ray computed tomography (CT), and subsequently subjected to ultrasonic testing. From the CT scans, measurements were made of cement paste density and number of interfaces. Ultrasonic signals produced using a through-transmission configuration were analyzed and fit to a diffusion model to separate absorption from scattering attenuation. The results showed that at the frequencies tested, ultrasonic dissipation rate correlated weakly with paste density, while diffusivity correlated well with number of interfaces, but only if entrained air is considered separately. Cement paste density was found to be very well predicted by diffusivity, leading to a clear power-law relationship between diffusivity and compressive strength.
Within the project SealWasteSafe, we advance construction materials and monitoring concepts of sealing structures applied for underground disposal of nuclear or toxic waste. As these engineered barriers have high demands concerning integrity, an innovative alkali-activated material (AAM) is improved and tested on various laboratory scales. This AAM has low reaction kinetics related to a preferential slow release of the heat of reaction in comparison to alternative salt concretes based on Portland cement or magnesium oxychloride cements. Hence, crack formation due to thermally induced strain is reduced. After successful laboratory scale analysis (Sturm et al., 2021), the AAM is characterised on a larger scale by manufacturing test specimens (100–300 L).
Conventional salt concrete (DBE, 2004) and the newly developed AAM are compared using two specimen geometries, i.e. cylindrical and cuboid. A comprehensive multisensor monitoring scheme is developed to compare the setting process of AAM and salt concrete for these manufactured specimens. The analysed parameters include temperature and humidity of the material, acoustic emissions, and strain variations. Passive sensor systems based on radiofrequency identification technology (RFID) embedded in the concrete, enable wireless access to temperature and humidity measurements and are compared to conventional cabled systems. Additionally, fibre-optic sensors (FOS) are embedded to record strain, but also have potential to record temperature and moisture conditions. Part of this project aims at demonstrating the high reliability of sensors and also their resistance to highly alkaline environments and to water intrusion along cables or at sensor locations. Further technical improvements were implemented so that first results clearly show the scalability of the setting process from previous small-scale AAM experiments and particularly the high potential of the newly developed approaches.
Furthermore, ultrasonic methods are used for quality assurance to detect obstacles, potential cracks and delamination. On the one hand, both active and passive ultrasonic measurements complement the results obtained from the multisensor monitoring scheme for the produced specimens. On the other hand, the unique large aperture ultrasonic system (LAUS) provides great depth penetration (up to nearly 10 m) and can thus be applied at in situ sealing structures built as a test site in Morsleben by the Federal Company for Radioactive Waste Disposal (Bundesgesellschaft für Endlagerung, BGE) as shown by Effner et al. (2021). An optimised field lay-out identified from forward modelling studies and advanced imaging techniques applied to the measured data will further improve the obtained results. To characterise the inside of the test engineered barrier and achieve a proof-of-concept, an ultrasonic borehole probe is developed to enable phased arrays that can further improve the detection of potential cracks. Modelling results and first analysis of semispherical specimens confirmed the reliability of the directional response caused by the phased arrays of the newly constructed ultrasonic borehole probe.
Overall, the project SealWasteSafe improves the construction material, multisensor monitoring concepts and ultrasonics for quality assurance. This will help to develop safe sealing structures for nuclear waste disposal. The outcomes are particularly valuable for salt as a host rock but partly also transferrable to alternative conditions.
The aim of this work is to improve the current structural health monitoring (SHM) methods for civil structures. A field experiment was carried out on a two-span bridge with a built-in un-bonded prestressing system. The bridge is a 24-metre long concrete beam resting on three bear-ings. Cracks were formed subsequently when a prestressing force of 350 kN was changed to 200 kN, so that different structural states could be demonstrated. The structural assessment of this reference bridge was accomplished by the non-destructive testing using ultrasonic devices and vibration measurements. The ultrasonic velocity variations were investigated by using the coda wave interferometry method. The seismic interferometry technique was applied to the vi-bration recordings to reconstruct the wave propagation field in the bridge. This investigation shows that the wave velocity is sensitive to the current structural state and can be considered as the damage indicator. Overall, the implementation of coda cave interferometry and seismic interferometry technique facilitates structural health monitoring (SHM) in civil engineering.
Entwicklung einer Bohrlochsonde für Ultraschalluntersuchungen an Abschlussbauwerken in Endlagern
(2021)
Für die Qualitätssicherung von Abschlusswerken für Endlager wird eine Ultraschall-Bohrlochsonde entwickelt. Mithilfe dieser Sonde, die aus einer Vielzahl von einzelnen koppelmittelfreien Ultraschall-Punktkontaktprüfköpfen besteht, soll die Rissfreiheit der Versuchsbauwerke überprüft werden.
Ein erster Prototyp der Sonde wurde mit einem kommerziellen Ultraschallgerät betrieben und bestand aus 12 Transversalwellen-Punktkontaktprüfköpfen von denen jeweils sechs als Sender und sechs als Empfänger parallelgeschaltet waren. Um den erzeugten Schalldruck der Bohrlochsonde zu steigern, wurde bei der Neuentwicklung die Prüfkopfanzahl erhöht und zusätzlich die laufzeitgesteuerte Anregung der einzelnen Prüfköpfe vorgesehen. Für die Anregung der Prüfköpfe mit programmierten Zeitverzögerungen wurde ein neuartiger mehrkanaliger Sender für bipolare Rechtecksignale entwickelt.
Durch die Entwicklung der Bohrlochsonde soll eine dynamische Anpassung der Prüfkopf-Apertur sowie eine Fokussierung des Schallfeldes in Abhängigkeit der zu untersuchenden Tiefe erfolgen. Mithilfe entsprechender Anregungsfunktionen kann das Schallfeld der Bohrlochsonde unterschiedlich geformt werden, z. B. ist auch ein Schwenken des fokussierten Schallbündels möglich. Dadurch wird das erfasste Prüfvolumen begrenzt und auf diese Weise das Signal-Störverhältnis der Empfangssignale verbessert. In Kombination mit SAFT-Rekonstruktionsrechnungen wird durch eine optimierte Abstrahlcharakteristik der Sonde mit einem hohen Schalldruck unter verschiedenen Winkeln eine verbesserte Signalqualität und damit eine erhöhte Aussagesicherheit der Ergebnisse in der Objektabbildung erwartet.
Zu jedem Endlager gehört die Entwicklung eines Verschlusskonzept. Im Endlager Morsleben und an anderer Stelle werden in Abhängigkeit vom Wirtsgestein verschiedene Materialien und Bauweisen für Streckenverschlüsse entwickelt und in großem Maßstab erprobt. Hierzu gehören auch Maßnahmen der Qualitätssicherung, die Informationen über Ausführung und Zustand der Versuchsbauwerke liefern. Hierzu werden von der Bundesanstalt für Materialforschung und -prüfung (BAM) für verschiedene Forschungsvorhaben und Prüfaufträge Methoden und Geräte getestet, verbessert und vor Ort unter Tage eingesetzt Die hier beschriebenen Verfahren lassen sich auch zu Untersuchungen im Wirtsgestein anwenden.
Acoustic emission and ultrasonic monitoring of a prestressed concrete bridge in its final years
(2021)
Many European bridges built in the 1950s, 60s and 70s must be re-placed in the next decade due to structural deficiencies, insufficient load capacity or other issues. However, the existing bridges must be used for another couple of years even if flaws and damages already have been detected.
In Germany, several prestressed concrete bridges have been instrumented with acoustic emission detection systems to detect wire breaks and to provide early warning signs before failure. To evaluate and interpret the consequences of wire breaks additional instrumentation and accompanying measures as finite element modeling are required.
At a bridge in southern Germany we have complemented such a system with active ultrasonic monitoring. Repeated ultrasonic measurements are evaluated with a very sensible algorithm called coda wave interferometry. This method, inspired by seismology, has been shown to deliver early warning signs in lab experiments. Large volumes of concrete can be monitored with a limited network of ultrasonic transducers. We will report on the installation, capabilities, and lim-itations as well as first results.
NDE 4.0 in Civil Engineering
(2021)
Civil engineering industry is one of the most important industry sectors in the worldwide economy. It contributes significantly to the gross economic product and general employment. Even more important, it provides many of the basic needs of the society (e.g., housing, infrastructure, and protection from natural hazards). The concept of “Industry 4.0” or “Smart Production” has not yet made significant progress in the civil engineering industry. The designing, building, and operating processes are still widely dominated by the exchange of printed documents and drawings. Most objects (buildings and other constructions) are unique, and a large part of the production still requires a large amount of manual labor. As-built documentation and quality assurance are often neglected. Civil engineering is among the industry sectors with the lowest level of digitalization and the lowest gain in productivity. However, this is going to change. In the past decade, several drivers have challenged the ways clients, contractors, and authorities currently operate. These drivers include but are not limited to an increasing demand for serialization and automatization or the mandatory introduction of “Building Information Modeling” (BIM) in public procurement as well as the upcoming use of digital twins. NDE plays an increasing role in quality assurance, condition assessment, and monitoring of structures. However, with very few exceptions, applications are mostly nonstandardized and performed only at selected sites. To change this, the NDT-CE community including manufacturers, service providers, clients, and the scientific community must work consistently on open data formats, interfaces to BIM, standardization, and validated ways for a quantitative use of the results in the assessment of constructions.
To provide better means for a safe and effective monitoring of cemented waste packages including prediction tools to assess the future integrity development during pre-disposal activities, several digital tools are evaluated and improved in the frame of the EC funded project PREDIS. Safety enhancement (e. g. less exposure of testing personnel) and cost effectiveness are part of the intended impact.
The work includes but is not limited to inspection methods such as muon imaging, wireless sensors integrated into waste packages as well as external package and facility monitoring such as remote fiber optical sensors. The sensors applied will go beyond radiation monitoring and include Proxy parameters important for long term integrity assessment (e. g. internal pressure). Sensors will also be made cost effective to allow the installation of much more sensors compared to current practice.
The measured data will be used in digital twins of the packages for specific simulations (geochemical, integrity) providing a prediction of future behavior. Machine Learning techniques trained by the characterization of older packages will help to connect the models to the actual data.
All data (measured and simulated) will be collected in a joint data base and connected to a decision framework to be used at actual facilities.
The presentation includes detailed information about the various tools under consideration, their connection and first results of our research.
To provide better means for a safe and effective monitoring of cemented waste packages including prediction tools to assess the future integrity development during pre-disposal activities, several digital tools are evaluated and improved in the frame of the EC funded project PREDIS. Safety enhancement (e. g. less exposure of testing personnel) and cost effectiveness are part of the intended impact. The work includes but is not limited to inspection methods such as muon imaging, wireless sensors integrated into waste packages as well as external package and facility monitoring such as remote fiber optical sensors. The sensors applied will go beyond radiation monitoring and include proxy parameters important for long term integrity assessment (e. g. internal pressure). Sensors will also be made cost effective to allow the installation of much more sensors compared to current practice. The measured data will be used in digital twins of the packages for specific simulations (geochemical, integrity) providing a prediction of future behavior. Machine Learning techniques trained by the characterization of older packages will help to connect the models to the actual data. All data (measured and simulated) will be collected in a joint data base and connected to a decision framework to be used at actual facilities. The paper includes detailed information about the various tools under consideration, their connection and first results of our research.
Long term monitoring of concrete structures using innovative NDT and SHM approaches: NDT-CE 4.0
(2021)
In Germany, a large amount of reinforced and/or prestressed concrete structures are approaching the end of their life cycle. Many of them already show a significant reduction of operability or capacity. The issue is most obvious, but not limited to traffic or energy related infrastructure. These structures have to be inspected and assessed on a regular basis. More and more permanent monitoring systems are installed to follow the degradation and to give pre-warning before failure.
While the basic mandatory inspection (e. g. of bridges) is still limited to visual examination and tap tests, more advanced investigation tools as ultrasound or radar are used more and more often. Monitoring e. g. by acoustic emission systems is increasingly used e.g. for detection of wire breaks in prestressed structures. The presentation gives an overview on the state of the art and an outlook on innovative systems, including the integration in modern data processing, evaluation, display and archive systems.
Ultrasonic monitoring, making use of the sensitivity of the coda of repeated transmission meas-urements to changes in stress, temperature, moisture, as well as localized or distributed damage, has gotten at-tention in structural health monitoring (SHM) research recently. Analysis methods such as coda wave inter-ferometry (CWI), including its nonlinear extension, have been shown to be able to measure ultrasonic wave velocity changes with a 1∙10-5 resolution, while indicators such as cross-correlation or cross-coherence have been used to distinguish between reversible and irreversible changes. Several small- and large-scale laboratory experiments have demonstrated that stress changes in structures can be captured or damage detected in a very early stage. The use of this technique for pre-warning before failure are currently under investigation, as well as detailed research on the physical causes and the connection between ultrasonic wave properties and materi-al/structural behavior. Recently, several of large-scale laboratory and real structures have been instrumented with embedded ultrasonic transducers to gather experience and evidence on how to use this technology in re-al-world applications. Preliminary results from installations on a new bridge, an existing bridge, a tunnel, a la-boratory earthquake test as well as a historic stadium in Germany, Poland, and the United States, respectively, are presented. Environmental influences (mainly temperature) and validation by load tests are discussed.
Due to increasing ageing, deterioration and loading , several prestressed concrete bridges bulit in the 1950ies and 1960ies need monitoring. Recently several bridges have sucesssfully equipped with acoustic emission sensing system. BAM works together with several universities on an add onn: Active ultrasonic monitoring combined with coda wave interferometry will help to detect subtle changes and precursors fo failure earlier than other methods.
The workpackage 7 of the EC funded project PREDIS deals with cemented low and intermediate level radioactive waste. The focus is on NDT/monitoring technologies, digiutal twins and data/decision frameworks to optimize facilitay and waste package management. The talk describes the project setup and planned activities.
News from NDT@BAM
(2021)
The presentation summarizes some recent research at BAM in the field of NDT in civil engineering. the firste xample decribes lab experiments on the degardation of concrete during tunnel fires. Radar measuremenst were sucessfully used to detect interior damage. The second example decribes the first ever experiment on using muon imaging to evaluate concrete constructions.
Die ZfP ist im Bauwesen bisher deutlich weniger reguliert (und auch akzeptiert) als in anderen Industriebereichen. Zum Beispiel gibt für die meisten Prüfverfahren weder Normen noch ein allgemein akzeptiertes Ausbildungs- und Zertifizierungssystem.
Dies hat auch Konsequenzen für die Digitalisierung. Im Gegensatz dazu wird im Bauwesen derzeit für viele Bereiche verbindlich ein neues Verfahren zur Unterstützung von Design, Planung, Herstellung und Betrieb eingeführt: BIM (Building Information Modeling). Der Vortrag beleuchtet das Spannungsfeld zwischen dem geringen Organisations- und Standardisierungsgrad und den neuen digitalen Möglichkeiten und stellt den neuen Arbeitskreis zur ZfP 4.0 im Bauwesen vor. Er beleuchtet auch, in welchen Bereichen die ZfP im Bauwesen von Entwicklungen aus „Industrie 4.0“ und der zerstörungsfreien Prüfung in anderen Anwendungsbereichen profitieren kann - z. B. bei Datenformaten, Datenarchivierung und Schnittstellen.