Introduction

In the complex world of engineering, where structures are continuously subjected to diverse loads, environmental stressors, and the ravages of time, ensuring Structural Integrity is paramount, and understanding Failure Analysis is critical for preventing catastrophic events, extending service life, and improving future designs. The ability to predict potential weaknesses, assess remaining life, and meticulously investigate the root causes of failures provides invaluable insights that directly impact public safety, economic stability, and the advancement of engineering practices across industries like civil, aerospace, and mechanical engineering. This training course is meticulously designed to equip civil, structural, mechanical, aerospace, and materials engineers, quality control professionals, forensic investigators, asset managers, and researchers with cutting-edge knowledge and practical skills in understanding the fundamental principles of structural integrity, mastering various modes of failure (e.g., fracture, fatigue, buckling, corrosion), applying advanced analytical and experimental techniques for failure investigation, assessing structural reliability, performing remaining life prediction, and leveraging modern tools for diagnostics and prognostics. Participants will gain a comprehensive understanding of how to proactively manage structural risks, conduct thorough failure investigations, and implement effective strategies to enhance the safety, reliability, and durability of engineering structures.

Target Audience

• Civil Engineers (Structural, Forensic)
• Structural Engineers
• Mechanical Engineers
• Aerospace Engineers
• Materials Engineers
• Quality Control / Quality Assurance Professionals
• Forensic Engineers & Investigators
• Asset Managers & Owners
• Reliability Engineers
• Researchers in Structural Mechanics
• Advanced Engineering Students

Objectives

• Understand the fundamental principles of structural integrity and factors affecting it.
• Master various modes of structural failure, including ductile, brittle, fatigue, creep, and buckling.
• Learn about common deterioration mechanisms affecting materials and structures.
• Develop proficiency in conducting root cause analysis for structural failures.
• Explore advanced analytical and experimental techniques for failure investigation.
• Understand the concepts of structural reliability, risk assessment, and remaining life prediction.
• Learn about non-destructive testing (NDT) methods for detecting defects and damage.
• Develop skills in applying relevant codes, standards, and guidelines for structural integrity.
• Understand the legal and ethical considerations in structural failure analysis.
• Explore strategies for enhancing structural robustness and resilience.
• Formulate comprehensive approaches to prevent and analyze structural failures.

Course Content

Module 1. Fundamentals of Structural Integrity and Reliability

• Defining Structural Integrity: Concepts, importance, and objectives
• Reliability Engineering: Probability of failure, safety factors, load and resistance factors
• Risk assessment and management in structural engineering
• Role of design, construction, and maintenance in integrity
• Lifecycle management of structures

Module 2. Material Behavior and Failure Modes

• Stress-Strain Relationships: Elastic, plastic, and viscoelastic behavior
• Ductile vs. Brittle Failure: Mechanisms and characteristics
• Yielding and Ultimate Strength: In metals and concrete
• Stress Concentration and its effects on failure
• Introduction to fracture mechanics

Module 3. Fracture Mechanics and Brittle Fracture

• Linear Elastic Fracture Mechanics (LEFM): Stress intensity factor, fracture toughness
• Crack Propagation: Stable vs. unstable fracture
• Fracture Modes: Mode I, II, III
• Elasto-Plastic Fracture Mechanics (EPFM): J-integral, Crack Tip Opening Displacement (CTOD)
• Preventing brittle fracture in structures

Module 4. Fatigue and Fatigue Failure

• Fatigue Phenomenon: Cyclic loading, crack initiation, and propagation
• S-N Curves (Wöhler Curves): High cycle and low cycle fatigue
• Fatigue Crack Growth Laws: Paris Law
• Factors affecting fatigue life: Stress range, mean stress, surface finish
• Design for fatigue resistance and inspection methods

Module 5. Creep and Creep Rupture

• Creep Mechanism: Time-dependent deformation under sustained stress (especially at elevated temperatures)
• Creep Stages: Primary, secondary (steady-state), tertiary
• Factors influencing creep: Temperature, stress level, material type
• Creep rupture and design against creep failure
• Applications in high-temperature environments (e.g., power plants)

Module 6. Buckling and Instability Failures

• Column Buckling: Euler buckling, critical load, effective length
• Local Buckling: Flanges, webs of steel sections
• Lateral-Torsional Buckling of Beams
• Plate Buckling and Shear Buckling
• Stability analysis for frames and arches

Module 7. Corrosion and Environmental Degradation

• Corrosion Mechanisms: Electrochemical process, types of corrosion (uniform, pitting, crevice, galvanic)
• Stress Corrosion Cracking (SCC): Combined effects of stress and corrosion
• Hydrogen Embrittlement
• Environmental effects on concrete: Carbonation, chloride attack, sulfate attack
• Corrosion protection strategies for metals and concrete

Module 8. Deterioration of Concrete Structures

• Cracking in Concrete: Shrinkage, thermal, structural cracks
• Alkali-Aggregate Reaction (AAR): ASR, ACR
• Freeze-Thaw Damage
• Sulfate Attack and Acid Attack
• Spalling and delamination in concrete

Module 9. Root Cause Analysis (RCA) for Structural Failures

• RCA Methodologies: 5 Whys, Fishbone (Ishikawa) diagram, Fault Tree Analysis (FTA)
• Data collection and evidence preservation at failure sites
• Failure reconstruction and sequence of events
• Identifying direct, contributing, and root causes
• Documenting and reporting failure investigations

Module 10. Non-Destructive Testing (NDT) for Damage Detection

• Visual Inspection (VT): Tools and techniques
• Ultrasonic Testing (UT): Crack detection, thickness measurement
• Magnetic Particle Testing (MT) and Liquid Penetrant Testing (PT) for surface defects
• Radiographic Testing (RT) and Eddy Current Testing (ET)
• Acoustic Emission (AE) and Infrared Thermography

Module 11. Structural Health Monitoring (SHM)

• SHM Principles: Sensors (strain, acceleration, displacement), data acquisition
• Data processing and analysis for damage detection
• Vibration-based SHM and impedance-based SHM
• Remote monitoring and wireless sensor networks
• Applications of SHM in bridges, buildings, and other structures

Module 12. Structural Reliability and Probabilistic Methods

• Basic Probability Theory: Random variables, probability distributions
• Reliability Index: First-Order Reliability Method (FORM), Second-Order Reliability Method (SORM)
• Monte Carlo Simulation for reliability assessment
• Target reliability levels and their implications
• Load and resistance factor design (LRFD) as a reliability-based approach

Module 13. Remaining Life Prediction and Asset Management

• Damage Accumulation Models: For fatigue, corrosion, creep
• Prognostics and Health Management (PHM)
• Service life prediction techniques
• Risk-based inspection and maintenance planning
• Economic considerations in asset management and life extension

Module 14. Forensic Engineering and Legal Aspects

• Role of Forensic Engineer: Investigation, analysis, expert testimony
• Ethical Considerations: Objectivity, professional responsibility
• Legal framework: Contracts, negligence, liability
• Report writing for forensic investigations
• Case studies of high-profile structural failures and their legal outcomes

Module 15. Repair, Strengthening, and Future Trends

• Repair Materials: Composites (FRP), epoxies, high-strength concrete
• Strengthening Techniques: External bonding, post-tensioning, section enlargement
• Disaster resilience and robustness in design
• Self-healing materials and smart structures
• AI and Machine Learning in failure prediction and prevention.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 7 working days before commencement of the training.