Ultrasonic Testing Supports Steel Bridge Connection

BDI partnered with the U.S. Army Corps of Engineers (USACE) to perform advanced nondestructive testing (NDT) on critical steel bridge connections at multiple bridges across the United States. The project aimed to identify cracking, weld defects, and other internal flaws within steel connection components to support informed maintenance and repair decisions.

BDI evaluated steel connections on six bridges using Phased Array Ultrasonic Testing (PAUT) as a primary screening method. The team used PAUT to detect, characterize, and size potential flaws within welds and structural steel elements. When PAUT identified areas of concern, BDI applied Total Focusing Method/Full Matrix Capture (TFM/FMC) technology to further refine flaw sizing and improve defect characterization.

BDI’s engineers and field technicians conducted all field inspections, data collection, and engineering analysis. The team compiled the results into detailed reports that documented the location, size, and severity of identified indications across each bridge and connection type.

By providing highly accurate flaw detection and characterization, BDI helped USACE and its project partners develop targeted repair and retrofit strategies, allowing them to efficiently address areas requiring additional strengthening, maintenance, or rehabilitation while supporting the long-term reliability of these critical infrastructure assets.