Evaluation of the feasibility for detecting hidden corrosion damage in multi-layer gusset plates using multiple inspection techniques

Gusset plates are used to connect the members in truss bridges and they are usually inspected using calipers or conventional thickness measurement ultrasonic testing (UT) devices. The damage mechanism of particular concern in gusset plates is corrosion and the regions most susceptible to corrosion damage are on the gusset interior surface where it intersects the chord, diagonal, and vertical members from water collecting at the interfaces. For heavily loaded gusset plates, one or more shingle plates are used to reinforce the gusset plate, creating a multi-layer structure. While the areas with corrosion damage remain near the members on the gusset plate, the shingle plates cover the gusset plate and greatly limit the surface access to the gusset plate, making UT thickness measurement impractical. Because of the critical nature of the gussets, a viable inspection strategy for multi-layer gusset assemblies must be developed. The premise of this research and development effort was to develop viable, field-deployable inspection approaches for this problem area. This paper presents three separate inspection approaches: two ultrasonic-based techniques and one radiographic approach. Each of these techniques was evaluated on a mock-up specimen provided by the Federal Highway Administration (FHWA) that is representative of gusseted connection from a truss bridge.