Government of India

Ministry of Railways

Non Destructive Testing of bridge

on
river Ganga ( under construction )
at
Patna, Danapur division, E. C. Rly.

( Report No. BS 60 )

January 2004

RESEARCH DESIGNS & STANDARDS ORGANISATION

LUCKNOW 226011
 INDEX

SN Topic Page No.

1 Introduction 1 of 6
2 Objective 1 of 6
3 History of bridge 1 of 6
4 Instrumentation 1 of 6
5 Collection of data 3 of 6
6 Analysis of data 4 of 6
7 Conclusion 5 of 6
8 Recommendation 5 of 6
9 Acknowledgement 6 of 6
10 Annexure I F1/a f 1-3 of 3
11 Annexure II F2/a f 1-6 of 6
12 Annexure III T/1 7 1-7 of 7
Non Destructive Testing of bridge on river Ganga ( under
construction ) at Patna, Danapur division, E.C.Rly.

1.0 INTRODUCTION

Dy. Chief Engineer / Cons., Ganga bridge vide his letter No.
DCE/CON/GB/UPSBC dated 18/11/03, has requested to conduct the test for the
compressive strength and quality of concrete of the piers under construction.

2.0 OBJECTIVE

To find out the quality of concrete and compressive strength of the piers under
construction.

3.0 HISTORY OF BRIDGE

Ganga bridge about 5 km long is under construction, on river Ganga at Patna.

Five piers are under construction and at the time of testing construction of these
piers were completed to different RL. Out of these five piers only three piers i.e.
pier No. 3, pier No. 4 and pier No. 36 were tested. The grade of concrete used in
construction is of M25.

4.0 INSTRUMENTATION

The following three methods were used for the conducting the tests.

(a) Rebound Hammer

The concrete rebound test hammer is intended for non destructive testing of the
quality of concrete in the finished structure (ordinary building and bridge
construction). When testing, the Rebound Number is measured which depends
the strength of the mortar (concrete without coarse aggregate particles) close to
the surface. Since the strength of the mortar as a rule determines the strength of
the concrete, the rebound number gives an indication of the strength of the
concrete.

The hammer is calibrated for horizontal impact direction i.e. for testing vertical
surfaces. When using it on inclined or horizontal surfaces, the rebound value
must be corrected as per table given below.

Rebound value Correction for inclination angle

Upwards Downwards
+ 900 + 450 - 450 - 900
10 +2.4 +3.2
20 -5.4 -3.5 +2.5 +3.4
30 - 4.7 - 3.1 + 2.3 + 3.1
40 - 3.9 - 2.6 + 2.0 + 2.7
50 - 3.1 - 2.1 + 1.6 + 2.2
60 - 2.3 - 1.6 + 1.3 +1.7
(b) Pulse Velocity Meter (TICO)
The ultrasonic pulse is generated by an electroacoustical transducer. When the
pulse is induced into the concrete from a transducer, it undergoes multiple
reflections at the boundaries of the different material phases within the concrete.
The receiving transducer detects the onset of the longitudinal waves, which is the
fastest.

The principle of assessing the quality of concrete is that comparatively higher

velocities are obtained when the quality of concrete in terms of density,
homogeneity and uniformity is good.

The actual pulse velocity obtained depends primarily upon the materials and mix
proportions of concrete.

The following is for characterising the quality of concrete in structures in terms of

the ultrasonic pulse velocity.

Velocity criterion for concrete quality grading according to IS 13311 (Part I) 1992.

SN Pulse velocity by cross probing Concrete quality grading

(km/sec)
1 Above 4.5 Excellent
2 3.5 to 4.5 Good
3 3.0 to 3.5 Medium
4 Below 3.0 Doubtful

Note :- In case of doubtful quality it may be necessary to carry out further tests.

(c) Theoretical calculation of Compressive strength

This is the mostly used combined method in field. Both the methods are easy to
perform at site and one can collect large number of data in small interval of time.
This is the most economical combination. The pulse velocity and rebound
number can be combined to obtain multiple linear regression equation with
compressive strength as dependent variable in the form of

Log S = AV + BR C

Where S cube compressive strength kN/cm2

V Pulse velocity meter m/sec
R Rebound number and
A, B and C are constants

To calculate A , B and C, the value of S, R and V is taken from the data

collected. The three sets of S, R and V is taken as follows

S = 3.87, 4.24 and 3.35 V = 4700, 4790 and 4780

R = 39, 41 and 36
By putting the values of S, V and R in the above equation and solving the three
equations we get the values of constants A, B and C as follows

A = -0.00001465 B = 0.0205093 C = 0.1433

Keeping the value of constants A, B and C as above in the original equation and
putting the value of R and V as collected from the field, we get the value of
theoretical compressive strength of the concrete.

5.0 COLLECTION OF DATA

Three piers i.e. pier No. 3, pier No. 4 and pier No. 36 were tested by rebound
hammer and pulse velocity meter for assessing compressive strength and the
quality of the concrete . These three piers are still under construction. The test
was conducted on these above three piers.

5.1 Pier No. P3

Data was collected for compressive strength by rebound hammer on Patna face
and Sonpur face . Total 9 locations were taken on the top of the pier towards
Patna facing (refer annexure I - F1/a) . Similarly 9 locations were also taken on
the vertical surface towards Sonpur facing of the pier (refer annexure I - F1/b).
The distance between two consecutive locations is 100 mm . The rebound
hammer position on Patna face is vertical downward where correction factor is to
be considered and on Sonpur face , it is horizontal. The distance between the
locations is shown in annexure I - F1/a & annexure I - F1/b and the reference
point for the measurement is taken as start of the curve of the pier.

Similarly three locations on each face were tested for assessing quality of
concrete by Pulse Velocity Meter (TICO) using semi direct transmission method
on both the faces i.e. Patna face and Sonpur face. The distance between the
locations is shown in annexure II - F2/a & annexure II - F2/b and the reference
point for the measurement is taken as start of the curve of the pier.

5.2 Pier No. P4

Data was collected for compressive strength by rebound hammer on Patna face
and Sonpur face . Total 15 locations were taken on vertical surface towards
Patna facing (refer annexure I - F1/c) . Similarly 15 locations were also taken on
the vertical surface towards Sonpur facing of the pier (refer annexure I - F1/d).
The distance between two consecutive locations is 100 mm . The rebound
hammer position on both the faces is horizontal . The distance between the
locations is shown in annexure I - F1/c & annexure I - F1/d and the reference
point for the measurement is taken as the center line of the pier for Patna face
where as the reference point for the measurement is taken as the start of the
curve of the pier for Sonpur face .

Similarly five locations on each face were tested for assessing quality of concrete
by Pulse Velocity Meter (TICO) using semi direct transmission method on both
the faces i.e. Patna face and Sonpur face. The distance between the locations
and reference point for measurement is shown in annexure II - F2/c for Patna
face where as the locations and reference point for measurement is shown in
annexure II - F2/d for Sonpur face .

5.3 Pier No. P36

Data was collected for compressive strength by rebound hammer on Patna face
and Sonpur face . Total 6 locations were taken on vertical surface towards Patna
facing (refer annexure I - F1/e) . Similarly 15 locations were also taken on the
vertical surface towards Sonpur facing of the pier (refer annexure I - F1/f). The
distance between two consecutive locations is 100 mm . The rebound hammer
position on both the faces is horizontal . The distance between the locations is
shown in annexure I - F1/e & annexure I - F1/f and the reference point for the
measurement is taken as the start of the curve of the pier for Patna face as well
as Sonpur face .

Similarly two locations on Patna face and five locations on Sonpur face were
tested for assessing quality of concrete by Pulse Velocity Meter (TICO) using
semi direct transmission method. The distance between the locations and
reference point for measurement is shown in annexure II - F2/e for Patna face
where as the locations and reference point for measurement is shown in
annexure II - F2/f for Sonpur face.

6.0 ANALYSIS OF DATA

6.1 Pier No. 3

The average compressive strength by Rebound hammer is 39.6 N/mm2 on

Patna face using vertical downward position of the hammer and 55.5 N/mm2 on
Sonpur face using horizontal hammer position (refer annexure III - T1). The
Pulse Velocity Meter also gives automatically the compressive strength of the
concrete by feeding the average rebound number obtained through rebound
hammer. The value comes out to be 39.1 N/mm2 on Patna face and 47.8
N/mm2 on Sonpur face (refer annexure III - T4).

Three measurements are taken by Pulse Velocity Meter using Semi Direct
Transmission method varies from 4690 m/sec to 4830 m/sec having average
velocity of 4770 m/sec on Patna face. Similarly on Sonpur face it varies from
4710 m/sec to 4790 m/sec having average velocity of 4763.3 m/sec (refer
annexure III - T4). This shows the concrete quality is in excellent category.

6.2 Pier No. 4

The average compressive strength by Rebound hammer is 34.84 N/mm2 on

Patna face using horizontal position of the hammer and 33.13 N/mm2 on Sonpur
face using horizontal hammer position (refer annexure III - T2). The Pulse
Velocity Meter also gives automatically the compressive strength of the concrete
by feeding the average rebound number obtained through rebound hammer. The
value varies from 37.4 N/mm2 to 38.7N/mm2 on Patna face and varies from 36.5
N/mm2 to 37.4 N/mm2 on Sonpur face (refer annexure III - T5).
Five measurements are taken by Pulse Velocity Meter using Semi Direct
Transmission method varies from 4610 m/sec to 4790 m/sec having average
velocity of 4710 m/sec on Patna face. Similarly on Sonpur face it varies from
4570 m/sec to 4750 m/sec having average velocity of 4648 m/sec (refer
annexure III - T5). This shows the concrete quality is in excellent category.

6.3 Pier No. 36

The average compressive strength by Rebound hammer is 45.1 N/mm2 on

Patna face using horizontal position of the hammer and 32.9 N/mm2 on Sonpur
face using horizontal hammer position (refer annexure III - T3). The Pulse
Velocity Meter also gives automatically the compressive strength of the concrete
by feeding the average rebound number obtained through rebound hammer. The
value comes out to be 36.8 N/mm2 on Patna face and varies from 26.7 N/mm2
to 33.7 N/mm2 on Sonpur face (refer annexure III - T6).

Two measurements are taken by Pulse Velocity Meter using Semi Direct
Transmission method varies from 4440 m/sec to 4830 m/sec having average
velocity of 4635 m/sec on Patna face. Similarly on Sonpur face it varies from
4220 m/sec to 4440 m/sec having average velocity of 4305 m/sec and 4430
m/sec of two different locations (refer annexure III - T5). This shows the concrete
quality is in good category.

The comparative statement of compressive strength of the three piers by three

different methods i.e. by Pulse velocity meter, Rebound hammer and theoretical
calculation with the help of formula is shown in Annexure III T7 which indicates
that the compressive strength obtained from three different methods is almost
identical. Hence results are reliable.

7.0 CONCLUSION

The compressive strength of all the three piers by rebound hammer shows
comparatively good quality of concrete where as the pulse velocity meter also
indicates excellent / good quality of concrete.

8.0 RECOMMENDATION Nil

9.0 ACKNOWLEDGEMENT

This report is based on the field tests and investigation carried out by the
following team of RDSO research staff under the valuable guidance of Shri
S.C.Gupta, Director / Bridges and Structures (Testing) RDSO LUCKNOW.

1. Samir Paul JRE-I

2. R.R.Sinha JRE-I

We are also thankful to Shri A.K.Singh , Dy. Chief Engineer / Construction /

Ganga Bridge / E.C. Rly. and Shri Kamal Talreja, Dy. Chief Engineer /
Construction / Ganga Bridge / E.C. Rly. for their kind cooperation for conducting
the test.
 Annexure I
Rebound Hammer Locations on Pier No. 3 of Ganga Bridge

F1/a

F1/b
All dimensions are in mm
 Annexure I
Rebound Hammer Locations on Pier No. 4 of Ganga Bridge

F1/c

F1/d
All dimensions are in mm
 Annexure I
Rebound Hammer Locations on Pier No. 36 of Ganga Bridge

F1/e

F1/f
All dimensions are in mm
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 3 on Patna face

Transmitter shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/a
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 3 on Sonpur face

Transmitter shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/b
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 4 on Patna face

Transmitter shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/c
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 4 on Sonpur face

Transmitter shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/d
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 36 on Patna face

Transmitter Shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/e
 Annexure II

Pulse Velocity Meter (TICO) locations of Pier No. 36 on Sonpur face

Transmitter shown as T Receiver shown as R

Not to scale
All dimensions are in mm

F2/f
 Annexure III - T1
Bridge No. :- Ganga Bridge at Patna , ECRly.
Pier No. :- P3
Location :- Shown in annexure I F1/a
Rebound Hammer position :- Vertical downward
Face :- Patna facing

SN Location Rebound Corrected Ave. of Compressive Average

Number Rebound corrected Strength Compressive
Number Rebound (N/mm2) Strength
Number (N/mm2)
1 1 30 30+3.1=33* ----
2 2 35 35+3.1=38 37.0
3 3 33 33+3.1=36 33.5
4 4 40 40+2.7=43 46.0
5 5 38 38+3.1=41 39 42.4 39.6
6 6 34 34+3.1=37 35.3
7 7 42 42+2.7=45* ---
8 8 37 37+3.1=40 40.5
9 9 38 38+3.1=41 42.4

* Rebound number not considered as these deviates from the mean rebound
number by more than 5 units.

Pier No. :- P3
Location :- Shown in annexure I F1/b
Rebound Hammer position :- Horizontal
Face :- Sonpur facing

SN Location Rebound Ave. of Compressive Average

Number Rebound Strength Compressive
Number (N/mm2) Strength
(N/mm2)
1 10 52 63.1
2 11 44 47.9
3 12 52 63.1
4 13 37* ---
5 14 52 47 63.1 55.5
6 15 46 51.6
7 16 47 53.5
8 17 43 46.0
9 18 48 55.4

* Rebound number not considered as these deviates from the mean rebound
number by more than 5 units.
 Annexure III - T2
Bridge No. :- Ganga Bridge at Patna , ECRly.
Pier No. :- P4
Location :- Shown in annexure I F1/c
Rebound Hammer position :- Horizontal
Face :- Patna facing

SN Location Rebound Average Compressive Average Compressive

Number Rebound Strength (N/mm2) Strength (N/mm2)
Number
1 1 39 38.7
2 2 40 40.5
3 3 40 40.5
4 4 41 42.4
5 5 33 28.5
6 6 40 40.5
7 7 36 33.5
8 8 35 37 31.8 34.84
9 9 39 38.7
10 10 34 30.1
11 11 32 26.9
12 12 34 30.1
13 13 33 28.5
14 14 43* ---
15 15 38 37.0

* Rebound number not considered as these deviates from the mean rebound
number by more than 5 units.

Pier No. :- P4
Location :- Shown in annexure I F1/d
Rebound Hammer position :- Horizontal
Face :- Sonpur facing

SN Location Rebound Average Compressive Average Compressive

Number Rebound Strength (N/mm2) Strength (N/mm2)
Number
1 16 47* ---
2 17 40 40.5
3 18 43* ---
4 19 36 33.5
5 20 36 33.5
6 21 39 38.7
7 22 36 33.5
8 23 34 37 30.1 33.13
9 24 36 33.5
10 25 34 30.1
11 26 32 26.9
12 27 33 28.5
13 28 31* ---
14 29 39 38.7
15 30 34 30.1
* Rebound number not considered as these deviates from the mean rebound
number by more than 5 units.
 Annexure III - T3
Bridge No. :- Ganga Bridge at Patna , ECRly.
Pier No. :- P36
Location :- Shown in annexure I F1/e
Rebound Hammer position :- Horizontal
Face :- Patna facing

SN Location Rebound Ave. of Compressive Average

Number Rebound Strength Compressive
Number (N/mm2) Strength
(N/mm2)
1 1 41 42.4
2 2 41 42.4
3 3 43 43 46.0 45.1
4 4 47 53.5
5 5 41 42.4
6 6 42 44.1

Pier No. :- P36

Location :- Shown in annexure I F1/f
Rebound Hammer position :- Horizontal
Face :- Sonpur facing

SN Location Rebound Ave. of Compressive Average

Number Rebound Strength Compressive
Number (N/mm2) Strength
(N/mm2)
1 7 32 26.9
2 8 37 35.3
3 9 34 30.1
4 10 31 25.2
5 11 32 26.9
6 12 37 35.3
7 13 38 37.0
8 14 37 36 35.3 32.9
9 15 34 30.1
10 16 39 38.7
11 17 36 33.5
12 18 36 33.5
13 19 33 28.5
14 20 37 35.3
15 21 41 42.4
 Annexure III - T4

Bridge No. :- Ganga Bridge at Patna , ECRly.

Pier No. :- P3
Location :- Shown in annexure II F2/a
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Patna facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec ) Velocity Strength ound
second) (meter) (m/sec ) (N/mm2 ) Value
1 100041 1 103.6 0.500 4830 ---
2 100042 2 104.5 0.500 4790 4770 --- 39
3 100043 3 106.6 0.500 4690 39.1

Pier No. :- P3
Location :- Shown in annexure II F2/b
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Sonpur facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec) Velocity Strength ound
second) (meter) (m/sec) (N/mm2 ) Value
1 100044 4 104.3 0.500 4790 ---
2 100045 5 106.2 0.500 4710 4763.3 47.8 47
3 100046 6 104.5 0.500 4790 ---
 Annexure III -T5

Bridge No. :- Ganga Bridge at Patna , ECRly.

Pier No. :- P4
Location :- Shown in annexure II F2/c
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Patna facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec ) Velocity Strength ound
second) (meter) (m/sec ) (N/mm2 ) Value
1 100030 1 106.5 0.500 4700 38.7
2 100031 2 104.4 0.500 4790 ---
3 100032 3 104.6 0.500 4780 4710 --- 37
4 100033 4 107.0 0.500 4670 38.4
5 100034 5 108.4 0.500 4610 37.4

Pier No. :- P4
Location :- Shown in annexure II F2/d
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Sonpur facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec) Velocity Strength ound
second) (meter) (m/sec) (N/mm2 ) Value
1 100036 6 109.5 0.500 4570 36.5
2 100037 7 109.2 0.500 4580 36.7
3 100038 8 108.4 0.500 4610 4648 37.4 37
4 100039 9 105.2 0.500 4750 ---
5 100040 10 105.7 0.500 4730 ---
 Annexure III - T6

Bridge No. :- Ganga Bridge at Patna , ECRly.

Pier No. :- P36
Location :- Shown in annexure II F2/e
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Patna facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec ) Velocity Strength ound
second) (meter) (m/sec ) (N/mm2 ) Value
1 100052 1 112.5 0.500 4440 4635 36.8 42
2 100053 2 103.5 0.500 4830 ---

Pier No. :- P36

Location :- Shown in annexure II F2/f
Instrument :- Pulse Velocity Meter
Method :- Semi Direct Transmission
Face :- Sonpur facing

S Object Location Time Path Velocity Average Concrete Reb-

N No. (Micro Length (m/sec) Velocity Strength ound
second) (meter) (m/sec) (N/mm2 ) Value
1 100047 3 118.5 0.500 4220 4305 26.7 34
2 100048 4 114.0 0.500 4390 31.3
3 100049 5 113.4 0.500 4410 32.8
4 100050 6 112.5 0.500 4440 4430 33.7 37
5 100051 7 112.5 0.500 4440 33.7
 Annexure III T7

Comparison of compressive strength by Pulse Velocity Meter, Rebound Hammer

and Theoretical calculation.

P3 Patna face P4 Patna face P36 Patna face

PVMeter Rebound Theoretical PVMeter Rebound Theoretical PVMeter Rebound Theoretical
Hammer (N/mm2) Hammer (N/mm2) Hammer (N/mm2)
2 2
(N/mm ) (N/mm ) (N/mm2)
--- ---- ---- 38.7 38.7 38.69 36.8 42.4 42.91
37.0 36.75 40.5 40.57 42.4 42.91
33.5 33.44 40.5 40.57 46.0 47.16
--- 46.0 46.60 --- 42.4 42.40 --- 53.5 56.22
42.4 42.40 28.5 29.06 42.4 42.35
35.3 35.11 40.5 40.45 44.1 44.40
39.1 --- ---- --- 33.5 33.50
40.5 40.59 31.8 31.95
42.4 42.55 38.7 38.60
38.4 30.1 30.59
26.9 27.83
30.1 30.59
37.4 28.5 29.24
--- ----
37.0 37.03
P3 Sonpur face P4 Sonpur face P36 Sonpur face
PVMeter Rebound Theoretical PVMeter Rebound Theoretical PVMeter Rebound Theoretical
Hammer (N/mm2) Hammer (N/mm2) Hammer (N/mm2)
(N/mm2) (N/mm2) (N/mm2)
--- 63.1 71.29 36.5 --- ---- 26.7 26.9 28.26
47.9 48.86 40.5 40.75 35.3 35.79
63.1 71.29 --- ---- 30.1 31.06
47.8 --- ---- 36.7 33.5 33.72 31.3 25.2 26.80
63.1 71.29 33.5 33.72 26.9 28.10
51.6 53.70 38.7 38.86 35.3 35.58
--- 53.5 56.29 37.4 33.5 33.69 32.8 37.0 37.28
46.0 46.60 30.1 30.65 35.3 35.56
55.4 59.02 33.5 33.69 30.1 30.86
--- 30.1 30.51 33.7 38.7 39.04
26.9 27.76 33.5 33.88
28.5 29.10 33.5 33.88
--- --- ---- 33.7 28.5 29.41
38.7 38.66 35.3 35.52
30.1 30.53 42.4 42.91