issued by: subject: date: i inspection procedure ... › divisions › engineering › structures...

BD 217 (1 1/84)

BRIDGE INSPECTION, INVENTORY AND LEVEL 2 LOAD RATING New York State Department of Transportation

STRUCTURES DIVISION

TECHNICAL ADVISORY ISSUED BY:

STRUCTURES DIVISION BRIDGE INSPECTION UNIT

APP~OVED BY:

J..)';(h "'"_... A • l.u.,..,_.} y

SUBJECT: LIQUID PENETRANT INSPECTION PROCEDURE

BACKGROUND

DATE:

NOVEMBER 18 SUPERSEDES :

INSP. 85-002

198

Occasionally, bridge inspectors have the need to investigate discontinuities in

metal bridge members discovered or suspected as a result of visual inspection

of metal surfaces. Liquid penetrant inspection can be performed by bridge

inspectors to determine the existence of discontinuities open to the surface

of metal members, including cracks, seams, laps, laminations, lack of fusion,

etc.

This T.A . explains the procedure to be followed for performing liquid penetrant

inspection in accordance with ASTM El65 , Method B specification.

LIQUID PENETRANT INSPECTION PROCEDURE

The success of the liquid penetrant inspection procedure is dependent on the

surface and the discontinuity being free of any con t aminant that might inter

fere with the penetrant process. All parts must be clean and dry before the

penetrant is ~pplied.

Photographic Documentation:

A general photograph and macrophotographs shall be taken of the entire test

area ·prior to preparing the surface for testing or performing liquid penet r ant

inspection. Glossy prints shall be provided and shall be of such a size and

quality that the test surface and associated detail and/or discontinuities are

easily discernable. Other photographs and macrophotographi required by this

T.A. shall- be of equal quality.

I N s p E c T I 0 N

I nsp.

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80 217 (11 /84) REVERSE CONTINUATION SHEET


DATE:

November 18, 1987

PAGE:

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SUBJECT: LIQUID PENETRANT INSPECTION PROCEDURE

Surface Preparation :

Remove all paint, rust, dirt , scale , weld i ng flux, spatter, grease, oily f i lm,

etc . that might interfere wi th the penetr ant fr om the tes t area and within

three (3) inches surrounding the test ar ea . Thi s may be accomplished by one

or more of the following methods:

* sandblasting

* power tools equipped with grind i ng discs, wire brushes,

grinding bits , sanding discs , e t c .

* hand tools , inc lud i ng pa i nt scrapers, wire brushes ,

etc.

* degreasers

* any ? t her means that wi ll remove the contaminants and

foreign mater i al without masking the discontinuity

or l eav i ng a residue on t he base metal.

In add i tion, weld profiles mus t have a smooth con t our and transition with the

base metal such that surface irregularit ies do no t i nterfere with interpretat ion

of the test indicat i ons . It may be neces sary to grind ·the weld and adjacent

base metal sur faces to provide an acceptab l e sur face for test i ng.

Care must be exerted during cleani ng and grinding pr ocedures to avoid peening ,

contaminating, or other wi se masking discontinuities such that the pene t ran t cannot

be absorbed by the discontinui ty .

Cleani ng:

After surface preparation, the area shall be cleaned with solvent c l eaner. The

cleaner may be either sprayed on the metal surface and wiped with lin t f ree

cloths or wi ped with lint f r ee cloths dampened with solvent cleaner. In ei t he r

case , the ar ea shall be a llowed to thoroughly air dry prior to· the applicat i on

of the penetrant .

80 216 (11 /84)


SUBJECT:

CONTINUATION SHEET

DATE:

NOVEMBER 18 1987


Penetrant Application:

PAGE:

3 OF 7

The penetrant shall be applied at a surface temperature between 60° F and 125°

F whenever possible. In no case shall the penetrant be applied w~en the surface

temperature is below 35° F or above 125° F .

The penetrant shall be applied such that the entire test area is covered with

a thin , even coating of liquid.

The penetrant shall remain on the test area (dwell time) in accordance with

the manufacturer's recommendations printed on the container. As a guide,

however, the minimum penetrant dwell time shall be 5 to 10 minutes at surface

temperatures between 60° F and 125° F, and 10 to 20 minutes at surface temper

atures between 35° F and 60° F . Maximum penetrant dwell time shall be 60

minutes, except that if excess penetrant materials are difficult to remove,

the penetrant shall be reapplied for the prescribed dwell time.

Penetrant Removal:

After the required dwell time, the penetrant shall be removed by wiping with

a clean, dry lint gree cloth, repeatedly until most traces of the penetrant have

been removed. Then, lightly moisten a clean, lint free cloth and wipe the sur

face until all traces of excess penetrant have been removed . Care must be

exerted to avoid the use of excess solvent. Flushing the surface of the test

area with solvent following application of the penet r ant and prior to developing

is prohibited.

After the excess penetrant has been removed, the area shall be allowed to

thoroughly dry prior to application of the developer.

Developer Application:

The developer shall be applied by spraying in accordance with manufacturer's

recommendations, such that the entire test area is covered with a thin, even

coating. It is recommended that the spraying start and stop outside the

examination area .

tl . '

BD 216 (11/84! REVERSE


SUBJECT:

CONTINUATION SHEET

DATE:

NOVEMBER 18 , 1987


PAGE:

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The minimum developing time shall be seven (7) minutes. Developing time begins

as soon as the wet developer coating is dry. If b l eedout does no t alter the

inspection results, development periods of over thirty (30) minutes are

permitted.

Inspect i on:

Visible penetrant indica t ions can be viewed in e ithe r natural or a r tificial

white light, providing the l ight intensity at the inspection site is 32 .5

footcandles minimum. This compares to the light intensity produced by one 100

watt, inside frosted general purpose incandescent bu l b at approximately two (2)

feet from the inspection si t e .

Observe the t est area while applying the developer, during the development

·time, and after the minimum development time as an aid to evaluat ing the indica

tions. I f no indications appear aft er the minimum elapsed development time , the

area is acceptable.

All indications shall be macrophotographed, then cleaned and visually inspected.

Cracks, seams, laps, laminations, lack of fusion, etc . may appear as linear

(longitudinal or transve r se) i ndications. Por osity may appear as small,

spherical indications or large bleeds depending on frequency and type. The bleed

of some indications may increase as the development time increases .

Linear indications in both weld and base metal shall be further investigat ed by

· grinding to a depth · of 1/16 inch maximum. The gr ound area must be smooth and

its sides and ends transitioned smoothly into the adjacept weld and base metal

with a slope no t exceeding 1 on 10.

If the indi cation appears to have been removed by the grinding procedure, the

ground area shall be retested using the liquid penetrant inspection procedure

described above . If the test results show no i nd ications, the area sha ll again

be macrophotographed with the developer on and documented in the inspection

report, but shall not be flagged .

BD 216 ( 11 /841


SUBJECT:

CONTINUATION SHEET

DATE:

NOVEMBER 18, 1987


PAGE:

5 OF 7

If the indication is not removed in its entirety, and remains a linear ind i ca

tion, it shall be macrophotographed after grinding is complete . The discon

tinuity shall then be retested using the liquid penetrant inspection procedure,

macrophotographed again after development, and documented in the inspection

report.

Documentation shall consist of locating each discontinuity in a sketch , dimen

s i oning its apparent size, and ·showi ng orientati on relative to t he member or

member component. In addi tion, t he entire test area shall be cleaned and a

final general photograph and macrophotographs of the entire test area shall be

taken . A detailed photograph layout sheet shall be provided showing the

specific location and orientation of each photograph and ~acrophotograph.

At the conclusion of the investigat i on, all ·cracks remaining in tension zones

of metal primary members, and all remaining indications suspected of being a

crack in tension zones of metal pr i mary members, shall be structurally flagged

in accordance with the Department's current flagging procedure. I f the

structure is painted, touch-up painting of the test area shall be done upon

completion of all testing and repair. The paint shall be a one-coat, zinc-rich

paint system selected from the Department Mater i als Bureau's latest approved

list entitled, MATERIALS AND EQUIPMENT FOR USE ON NEW YORK STATE DEPARTMENT OF

TRANSPORTATION PROJECTS, M.A. P. Code 7. 42- 3 . 1 , Materials For Use In Repa iring

Galvanized Surfaces, (B.) Paint. Attached is a copy of the October 1, 1987

edition of th i s approved list. Updated l is ts may be obtained by contacting the

Regional Materials Engineer.

Equipment Required:

* Liquid Penetrant Inspection Kit (solvent cleane r, v isible I

penetrant , developer) meet i ng the requirements of ASTM El65

* Zinc-rich paint selected from Materials Bureau approved list

M.A.P. Code 7.42-3.1

* Power Source (110 VAC minimum)

* Disc Grinder with discs or cups and wire brush

or

High Speed Die Grinder wi th as sorted bit s wire brush

80 216 (11/84) REVERSE CONTINUATION SHEET·


DATE:

NOVEMBER 18, 1987 SUBJECT:


or

Power Sander with assorted sanding discs,

.all as necessary to perform the work

* Paint Scraper

* Wire Brush

* Camera with flash and film

* Light Source capable of producing a minimum l i ght

intensity of 32 . 5 footcandles at the inspection site

* Lint Free Cloths

* Face Shield

* Gloves

* Contact Thermometer

PAGE:

6 OF 7

BD 216 (11/84)


SUBJECT:

CONTINUATION SHEET

DATE:

NOVEMBER 18 , 1987


PAGE: 7 OF 7

Manual APPROVED L!STS !code 7.42-3.1 Doteocc. l, 1987 P age 31

Subject: MATERIALS AND EQUIPXENT FOR USE ON ~EW YORK STATE DEPART~ENT OF TRANS?ORTATION CONSTRUCTION PROJECTS

7.42-3.1-1 Materials by Brand Name

(18] XATERIALS FOR USE !~ REPAIRING GALVANIZED SURFACES (cont.)

B. PAI~

Anogal

~rmor Zinc Quic (pressure spray container)

7002 Cold Galvanized Compound 7007 Cold Galvanized Compound (Spray Container)

Devcon Z (Spray Container also)

Galvanox I

LPS Instant Cold Galvanize (pressure spray container)

Q Rust

Zinc Lock 351

Zinc Re-Nu , Spray Containers only

Z.R.C. Cold Galvanizing Compound

50040 Zinc Rich Cold Galvanizing Compound (Spray Container)

SUPPLIER/LOCATION

Fred Berlage Co. Katonah, NY

Armor Research Co. Pennsauken, NJ

Cro~ Industrial Products Co. -Hebr on , IL

Devcon Corp. Danvers, MA

Subox Division Carboline Co • . Hackensack, NJ

Holt Lloyd Corp. Tucker, GA

Continental Coatings Corp . Brooklyn, NY

Port:er Coatings Louisville, KY

C. R. C. Chemicals U.S.A. Warminster , PA

Z. R. c. Chemical Products Quincy, MA

Cling-Surface Co., Inc. Angola, NY

[19] CORRUGATED METAL PIPE BITUMINOUS COATING REPAIR MATERIAL

BRAND NAME

Grundy 5X Brush

SUPPLIER/LOCATION

Grundy Industries Inc. Joliet, IL

BO 216 (11/84) REVERSE

SUBJECT:

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CONTINUATION SHEET

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