Field test of internal visualization of deep-water pile foundation using ultrasonic waves

Early-age internal visualization is critical for timely assessing the quality of pile foundations, especially as super cross-sea bridges increase the diameter and length of pile foundations beyond the capabilities of traditional cross-hole sonic logging (CSL). This article introduces two innovations. First, ultrasonic instruments are specially developed to transmit waves through a concrete pile with a diameter of 4 m, a length of 92 m, and a water depth of 63 m, before the full hardening of concrete. Second, an imaging method is proposed to upgrade traditional CSL from 1D detection to 3D visualization. Both large-scale experiments and field tests are tested in the first 7 days after the concrete casting. The experiments successfully visualize typical construction defects, achieving a detection resolution of 18 cm for layered defects and 15 cm for void defects. During the field test, a low-pixel region is observed at the pile head, extending approximately 2.1 m deep, attributed to mud floating up during concrete casting into the steel casing. These developments in instrument technology and visualization methods provide essential tools for the quality evaluation of super pile foundations. Furthermore, the visualization data can support digital twin modeling in subsequent stages of construction and maintenance planning.