22+Apr+Manuscript (Phương Pháp Kiểm Tra Siêu Âm)
22+Apr+Manuscript (Phương Pháp Kiểm Tra Siêu Âm)
22+Apr+Manuscript (Phương Pháp Kiểm Tra Siêu Âm)
Abstract
Limited research has been performed in testing and measuring the reinforcement corrosion
levels using non-destructive tests. This research applied ultrasonic-based non-destructive test
and artificial neural network to the diagnosis and prediction of rebar’s non-uniform
tested by applying ultrasonic to reinforced concrete prisms before and after the rebar
corrosion. Input parameters including concrete strength, ultrasonic velocity, and the specimen
dimension-related variable were used for the prediction of reinforcement corrosion level
adopting artificial neural network models. Using totally 50 experimental observations, Radial
Basis Function-based model was found with higher accuracy in predicting corrosion levels
neural network
1. Introduction
Concrete structural damage due to reinforcement corrosion is not uncommon and could be
significant [1]. For example, chloride-induced durability problems shorten the service life of
concrete structures [2]. The durability of concrete materials under chloride penetration
requires particular attention [3]. However, reinforcement corrosion is not easily noticed. How
to identify and measure the rebar corrosion within reinforced concrete structure remains a key
issue in the concrete durability research. The commonly adopted non-destructive test
approaches for the measurement include half-cell potential method [4] and concrete
resistivity method (e.g, Wenner Four-Electrode Method [5]). These existing methods have
their own advantages of being easy to operate for on-site tests with simple detection facility.
However, both methods can only be used for the probability analysis of rebar corrosion
within concrete but are unable to quantify the corrosion level or the corrosion-induced
damage, especially for the non-uniform corrosion-induced damage within reinforced concrete.
A more effective approach to test the rebar corrosion level would be to separate the rebar
from concrete and measure the shape and depth of rebar etch-pits. Nevertheless, the
separation of rebar from concrete would cause further structural damage and hence being not
feasible. Therefore, it cannot be widely applied. There is hence an urgent need of developing
a more applicable and practical measurement technology for the non-destructive test of rebar
Ultrasonic measurement can be used to test concrete mechanical properties and internal
defects through the elastic wave signals sent to concrete structures. The ultrasonic test
implemented in concrete structure is based on the artificial method to generate elastic wave
signals, which contains the information of propagation time (or speed), amplitude and
impedance among its internal interfaces. The ultrasonic waves have strong reflection,
scattering, diffraction, absorption, and waveform distortion when passing through the
concrete structure. By extracting the information carried out in the signals and performing
inversion analysis, the data of mechanical properties and defect distribution of materials and
by comparing the defect size and the wave length, as the wave path would be different
depending on the defect size within concrete structures. The predication of concrete strength
by integrating ultrasonic wave and artificial neural network (ANN) has been performed in
some existing studies such as Trtnik et al. [7] and Kewalramani and Gupta [8]. However,
there has not been sufficient research on applying ultrasonic wave in measuring the rebar
corrosion within concrete structures. ANN, as one of the data mining methods that have been
widely applied in estimating concrete mechanical properties (e.g., strength) in existing studies
such as Chithra et al. [9], Omran et al. [10], Sadowski et al. [11], Wang et al. [12], Wang et al.
[13], has not been sufficiently used in the prediction of corrosion level of reinforcement in
concrete.
Non-destructive tests have been applied in the test and evaluation of properties of
construction materials, such as bond between concrete layers [11], compressive strength [12], and
other types of mechanical properties [15]. However, limited studies have been performed in
quantitative approach. Yeih and Huang [16] adopted ultrasonic testing for the non-destructive
detection of concrete reinforcement corrosion, and found certain correlation between the
from the research of Yeih and Huang [16], this study aims to apply the ultrasonic test in
measuring the corrosion level of non-uniform surfaces of rebar, and to evaluate the accuracy of
(RBF)-based and Back Propagation (BP)-based models are applied and to be compared of
their accuracies in the prediction. The study serves as the initial exploration of non-destructive
tests of rebar corrosion level in non-uniform surfaces, leading to further research in establishing
the non-destructive test procedure in measuring steel corrosion within reinforced concrete
structures.
2. Experimental program
The corrosion process of reinforced concrete was defined by Zhao and Jin [17] in terms
of three stages, namely: 1) the first stage of free expansion of rust, in which the steel
corrosion products fill the rebar/concrete interface voids; 2) tensile stress within concrete
cover, in which the concrete cover starts cracking; and 3) cracking within concrete cover,
when the cracking continues to be filled with the rust products. Empirical formulas have been
established to estimate the rebar corrosion level in concrete structures. Zhao and Jin [17, 18]
further proposed empirical formulas to estimate the corrosion depth of reinforcement. Zhao et
al [19] used stereoscopic microscope to observe the seriously corroded layer and found that
the corrosion depth was not more than 500 μm. Following Huygens-Fresnel Principle [3],
when the corrosion layer size is smaller than the wavelength, the ultrasound would diffract,
resulting in a longer receiver signal. In addition, since the acoustic impedance of the air is far
lower than that of concrete, sound energy would decrease and the sound duration would
increase resulting from the reflecting and scattering of pulse wave at the corrosion surface.
the ultrasonic velocity. The effect of test specimen size described in Fig. 1 in ultrasonic
As illustrated in Fig.1, R denotes the rebar radius, δ represents the depth of steel
corrosion layer, and L is the distance between the emission transducer and receiving
transducer within the ultrasonic generator. It was previously found by Zhang and Qiu [20]
that under the same ultrasonic velocity in concrete, the effect of rebar in ultrasonic velocity
would be reduced as the ratio of rebar to the test distance (denoted as 2R/L) decreases. When
this ratios is lower then 1/12, the effect of rebar size could be ignored according to Zhang and
Qiu [20].
Four different types of reinforced concrete specimens, namely C20, C25, C30, and C35, were
prepared by Gutetong Company from Ningbo China. The mix design details of these four
Table 1. Mix design details of four different concrete specimens in this study
Granulated
Portland Coarse Water
Specimen Fly ash blast furnace Sand Water Slump
Cement aggregate reducer
Type (kg/m3) slag (kg/m3) (kg/m3) (mm)
(kg/m3) (kg/m3) (kg/m3)
(kg/m3)
C20 182 112 26 757 1045 195 3.52 150
C25 202 87 47 762 1052 185 4.04 150
C30 220 83 58 736 1059 180 4.50 150
C35 245 78 66 695 1086 175 5.06 150
Totally 50 groups of concrete specimens were cast, among them 44 were prisms sized at
each prism was embedded with a hot-rolled round steel rebar with the diameter of 12mm.
Cured at the standard laboratory condition for 28 days, specimens were placed in the chloride
salt and stray current condition to reach different levels of rebar corrosion. Specifically, two
types of corrosion tests were adopted in this study, namely chlorine salt wet-dry cycle and
stray current method. In the chlorine salt wet-dry cycle approach, specimens after 28 days’
standard curing were soaked and placed in 5% sodium chloride solution for 12 hours, and
then oven dried in the temperature of 50±1 °C for another 12 hours. This was counted as one
wet-dry cycle. The same cycles were repeated to corrode reinforcement in the chloride salt
environment; in the stray current condition, concrete specimens after the same 28 days’
standard curing were buried in the 5%-sodium-chloride-wetted sand. Rebar was then used as
the anode with copper bars as cathodes. They were electrified with a DC power supply to
The NM-4A type of non-metallic instrument was adopted in this study to test the
ultrasonic velocity within the concrete specimen. To prevent the ultrasonic velocity being
affecting by the variation of specimens’ moisture contents, each specimen was stored indoor
under constant room temperature and dried for three days. Each specimen’s longitudinal
surface was set up with nine test areas. The average ultrasonic velocity was calculated from
the nine test areas. Test details, including specimen sections and the nine test zones are
Fig.2. Reinforced concrete specimen for ultrasonic tests with details of test specimens (Size
units /mm)
(a) Concrete curing (b) Half-cell test (c) Ultrasonic test for prisms sized at
100mm×100mm×400mm
(d) Ultrasonic test for prisms sized (e) NM-4A type of non-metallic (f) Specimens after testing
at 150mm×150mm×550mm ultrasonic instrument
Before the ultrasonic test had been performed in concrete specimen, the effect of
concrete moisture content on ultrasonic velocity was examined. Mix design targeting on C30
ordinary concrete was adopted to cast two standard prisms, with the dimension at
100mm×100mm×400mm. Cured at the standard condition on Day 28, the reinforced prism
was connected to electrical circuits to achieve different degrees of corrosion severity. Later,
following the procedure described by Liu et al. [21], the corroded specimens were immersed
in water for three days to reach full saturation. The saturated specimens were then removed
from water, surface dried, and weighted. The specimens were then put in ovens to be
gradually dried with lower moisture content. After each drying period, the specimen was
removed from the oven, weighted, and retested of the ultrasonic velocity until it reached its
constant weight when fully internally dried. The test setup is illustrated in Fig.4.
Fig.4. Test setup to studying the influence of moisture content on ultrasonic velocity
Data obtained from the test setup described in Fig.4 would then allow the correlation
Artificial neural network (ANN) was applied in this research to analyzing the rebar
corrosion, based on the three following features of ANN [22]: 1) it has strong
it is able to store the damage-related information in the learning stage and compare the
predicted data with the measured outcomes; 3) it is robust with its non-linear mapping
capacity to establish the relationship between the rust damage related value and the
non-destructive parameters. In this study, ANN was modeled using the NeuroSolutions [23]
as the tool.
The Back Propagation (BP) and Radial Basis Function (RBF) were the two ANN models
that were adopted in this research to link the non-destructive parameters to corrosion levels of
BP has been widely applied in the field of civil engineering [24-27]. The topology
As displayed in Fig.5, the data samples start from the input layers, passing the hidden
layer until they reach the output layer. In Fig.4, ij and ij represent the connection
weightings when data is moving forward from the input layer to hidden layer, and from the
hidden layer to the output layer respectively. During the learning and training process, the
error would be passed backwards through hidden layer to input layer if the actual output
value does not match the expected value. Then the error is spreading to all cells in the input
layer illustrated in Fig.5. The error signal serves as a basis for modifying the weighing of
each cell. The weightings will be adjusted through a new cycle by passing the data forward
from input to output layers. This kind of cycle can be reprocessed until the error is reduced to
a tolerable level, or the learning process has completed certain specified number of cycles.
Detailed process of running BP-based models can be found in Buscema [28] and
Hecht-Nielsen [29].
RBF’s topology structure can be described in Fig.6. Differing from BP, the input layer in
RBF only passes information, with the connection weighting at 1.0. The radial basis function
is incorporated in the hidden layer. Linear weightings are adjusted in the output layer. The
steps to perform RBF-based network can be found in Billings et al. [30] and Chen et al. [31].
Although RBF has not been widely applied in predicting steel corrosion levels, certain
relevant existing studies can be found, such as Chou et al. [32] and Pai et al. [33].
The main difference between BP and RBF lies in that BP model utilizes the S-type
hyperbolic function in its hidden layer. In comparison, RBF is a non-linear network, with its
hidden layer utilizing Gaussian function. Both BP and RBF were adopted in the prediction of
rebar corrosion levels in this research. Both types of ANN models contain the three layers
(i.e., input, hidden, and output layers). Applied in the predication of rebar corrosion levels,
three nodes were included in the input layer for both models, namely compressive strength of
concrete specimens (X1), average ultrasonic velocity (X2), and the ratio (i.e., 2R/L) of rebar
diameter to test distance illustrated in Fig.1. Four treatment nodes were set in the hidden layer.
Rebar corrosion level was set as the single node in the output layer. The
Levenberg-Marquardt algorithm was adopted in the data training. The maximum training
time was set at 1,000. After the networks were established, data sample could be used for the
training. The data sample was divided into training sample and the cross-validation sample.
When the training was complete, the error was reduced and eventually approached 0, and
Under the laboratory condition, the interfaces between concrete and corroded reinforcements
The development of steel corrosion led to defects in the interfaces between reinforcement
and concrete as shown in Fig.7. To further identify the defect size of corrosion layers formed
in reinforced concrete prisms, the element distribution of the corrosion area was analyzed
adopting scanning electron microscopy (SEM) and electron probe. Adopting C30 specimen
Element content(%)
50 150
Element content(%)
Element content(%)
125 40
40
100 Fe
30
30
75 Ca
20
20
50
10
10 25
0 0
0
0 100 200 300 400 500 600 0 50 100 150 200 250 300 350 0 20 40 60 80 100 120 140
Distance(m) Distance(m) Distance(m)
The black-colored line denoted with Fe in Fig.8 represents the rebar, and the red-colored line
denoted with Ca is concrete. Both lines underwent sudden sharp drops of their element
content as it can be seen in Fig.8, indicating the occurrence of corrosion. The length of the
overlapping zones of the two lines shows the corrosion depth. It is found from Fig.8 that the
corrosion depth was between 80μm~200μm, below the maximum depth of seriously corroded
The experimental data of water content corresponding to the ultrasonic velocity is described
in Fig.9. Various moisture contents ranging from 0 to 2.5% in concrete were included.
4.1
4.0 Specimen 1#
Specimen 2#
Acoustic velocity (km/s)
3.9
3.8
3.7
3.6
3.5
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Water content (%)
Fig.9. Relationship between ultrasonic velocity and moisture content
can be found from Fig.9 that under both corrosion levels, ultrasonic velocity would not be
significantly affected when the moisture content in concrete is not higher than 1.5%. As the
moisture content increases from 1.5% in concrete specimens, the ultrasonic velocity would
grow more significantly to be 8% higher compared to that when concrete is fully dried. The
effect of moisture content in ultrasonic velocity could be due to the heterogeneous feature of
concrete structure. Voids and cracking in corroded concrete members are filled with air or
moisture. The moisture content in concrete structure would affect the air percentage in
significantly faster in liquids than in the air, it would be significantly increased when concrete
cracking was filled with more moisture. The experimental tests indicated that the moisture
content lower than 1.5% could be considered as dry condition when the moisture is not
continuously or evenly distributed within concrete internal voids. As a result, the ultrasonic
velocity would not be significantly changed. This initial study of moisture content’s effect in
ultrasonic velocity provides the threshold value that in conducting the ultrasonic tests within
concrete structures, concrete should be kept dry with the moisture content below 1.5%.
3.3. Ultrasonic test results
Ultrasonic velocities were tested within different types of specimens under different
corrosion levels before and after corrosion. Four typical types of recorded acoustic velocities
along the nine locations within the same specimen are showcased in Fig.10.
4.2 4.2
4.0 4.0
3.6 3.6
3.4 3.4
3.0 3.0
0 2 4 6 8 10 0 2 4 6 8 10
Measuring location Measuring location
4.2 4.2
4.0 4.0
Acoustic velocity (km/s)
3.8 3.8
3.6 3.6
3.4 3.4
All the four examples in Fig.10 demonstrate that ultrasonic velocity was significantly higher
in concrete before rebar corrosion. The velocity tested at the nine different areas of the same
specimen was generally stable with little variation before corrosion. After the rebar corrosion,
the ultrasonic velocity was significantly reduced, and the nine tested velocities within the
same concrete specimen had a larger variation. The variation of ultrasonic velocity could be
explained by the micro-structure of the concrete specimen. The number and size of defects
(e.g., pores and micro-cracks) within concrete structures are relatively small before rebar
corrosion, and the ultrasonic wave would mainly be transmitted with high velocity in a stable
way. Following the rebar corrosion, the corrosion products increase creating defects at the
concrete cracking and diffraction of ultrasonic wave. The reflection and scattering of
ultrasonic waves would then result in significant reductions of velocity according to Wang et
al. [34].
Totally 50 observations were used as the data sample in applying BP and RBF models.
Among them 45 observations were adopted as the training set, and the rest five were used as
complete the data training and predict the rebar corrosion level based on the three input
parameters (i.e., X1, X2, and X3), where X1 stands for the design compressive strength pf
concrete, X2 is the average ultrasonic velocity within each observation sample, and X3 means
the ratio of rebar diameter to the test distance (denoted as 2R/L) as shown in Fig.1. The
dependent variable (i.e., corrosion level) was measured by the reinforcement mass loss ratio
as shown in Equ.(1).
m o m1
S 100%
mo
Equ.(1)
where S denotes the mass loss ratio of reinforcement, m0 is the mass of the originally
non-corroded specimen, and m1 represents the mass of the corroded specimen after de-rusting.
Upon the end of each ultrasonic test in this research, corroded reinforcements were washed
using de-rusting solution to remove corrosion products after the corrosion process. The
The removal solution applied in the de-rusting of rebar was prepared by mixing 3% of
hexamethylene tetramine with 97% of diluted hydrochloric acid by weight. The relative errors
It can be found from Table 3 that the RBF model had a superior performance in terms of
generally lower relative errors. Several significantly large relative errors were found in the
validation sample adopting BP, such as data set 2 and 5 related to C30. The comparison
between BP and RBF showed that RBF had the lower standard error. Compared to BP, RBF
could better detect the non-linear relationship between the input and output layers with an
overall higher prediction accuracy, due to its own advantages in network structure, training
1) BP network applied weightings from its input layer to the hidden layer. It is not easy to
determine the number of hidden layer units in BP network. The network structure will not
be changed once it is confirmed in the training process. In comparison, the RBF network
utilizes the direct connection between its input and hidden layers, but weightings are
applied between its hidden layer and the output layer. RBF is capable of adjusting the
2) theoretically, both BP and RBF models are capable of providing the non-linear prediction
uses the approximation of the nonlinear mapping. The RBF network is a network derived
from the regular theory. It uses the locally exponentially decaying Gaussian function to
locally approximate the nonlinear mapping and has the best approximation Nature
the sum of the squared deviations of each output node. The trained network can only be a
compromise between different tasks, and the best effect cannot be achieved for one task.
In comparison, the distribution of hidden layer units in RBF network can be decided
according to the capacity, category and distribution of training samples. Based on the
distribution of hidden layer units, the mapping relationship between input and output can
be achieved by adjusting the mapping between the hidden layer’s and output layer’s units.
The impact of different tasks is relatively small, and the network resources can be fully
utilized.
It should be noted that the neural network models established in this study of
steel corrosion levels. Continuous data training will be performed as the sample size increases.
The future work will focus on building a more comprehensive prediction system with more
ANN models or data mining methods, as well as further improving the prediction
performance.
4. Conclusion
This study aimed to adopt the ultrasonic test as the non-destructive approach in
measuring the corrosion level of non-uniform surfaces of rebar within the reinforced concrete
structure. Then the artificial neural network was applied in training the experimental data for
the prediction of rebar corrosion level. Based on the experimental investigation and the neural
(1) The rebar-concrete interface was observed using scanning electron microscopy
(SEM) and electron probe. The corrosion depth in the reinforced prism was identified
between 80μm~200μm;
(2) The effect of water content in concrete specimens’ ultrasonic velocity was studied
before conducting the corrosion tests. It was identified that moisture content below 1.5% in
concrete would not cause significant increases of ultrasonic velocity. Moisture content over
1.5% would cause more significant increase (i.e., up to 8%) of ultrasonic velocity;
(3) Rebar corrosion would cause significant reductions in ultrasonic velocity in concrete
specimens. Compared to the ultrasonic velocity before rebar corrosion, the ultrasonic velocity
tested at different zones of the same concrete specimen also tended to vary more significantly.
The larger variation of ultrasonic velocity after rebar corrosion was due to the
(4) two types of artificial neural network models (i.e., BP and RBF) were applied in
predicting the rebar corrosion level based on 50 experimental observations. RBF was found
outperforming BP in predicting the rebar corrosion level due to the smaller average relative
The current study is limited in its data sample size and the types of neural network
models. Future research would recruit a larger data sample and more neural models to further
explore the application of artificial neural network and other data mining methods in
members. More future research needs to be performed to extend the current study, which only
adopted a single rebar in the test specimen. The current study adopted the average velocity of
nine test areas within the same specimen to estimate the overall corrosion level of
reinforcement. But the current study can lead to future research if different test areas of the
same specimen are recorded and input for data analytics. Overall, this research serves as the
initial movement towards applying the ultrasonic test as one non-destructive method to
The authors wish to acknowledge the financial support of National Natural Science
Foundation of China (Grant No. 51778577), Zhejiang Provincial Natural Science Foundation
(Grant No. LY15E080025 and Grant No. LY16E020014), and the Ningbo Natural Science
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