GO2-83-839, Responds to NRC Re Violations Noted in IE Insp Rept 50-397/83-38.Corrective Actions:Honeycombed Areas in Beams 2B11 & 2B25 Excavated to Sound Concrete & Will Be Repaired.Destructive Exam & Documentation Review Conducted
| ML20078G474 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 09/16/1983 |
| From: | Carlisle C WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | Martin J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| Shared Package | |
| ML20078G469 | List: |
| References | |
| GO2-83-839, NUDOCS 8310120250 | |
| Download: ML20078G474 (133) | |
Text
_ _ _
- .,b Washington Public Power Supply System
- _ P.O. Box 968 3000 GeorgeWashingtonWay Richland, Washington 99352 (509)372 5000 t*
Docket No. 50-397 September 16, 1983 G02-83-839
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in N m y - -* ly Mr. J. B. Martin o a @9 Regional Administrator 'l @
U. S. Nuclear Regulatory Commission : E Region V ~
1450 Maria Lane, Suite 210 -
Walnut Creek, CA 94596 "
Subject:
NUCLEAR PROJECT 2 EC INSPECTION REPORT 50-397/83-38 NOTIT OF VIOLATION
Reference:
- 1) Letter, D. M. Sternberg to C. S. Carlisle, dated Av]u.t 30, 1933 h
Washington Public Power Supply System hereby replies to the Notice of Viola- -
i tion designated "E" in Appendix A of the referenced letter dealing with con-crete reinforcing steel placement, For your information, the Supply will be responding to Items A through F via several letters rather than a single transmittal.
Statement of Violation i
" Washington Public Power Supply System Docket No. 50-397 P. O. Box 968 Construction Permit No. CPPR-93 '
Richland, Washington 99352 e -
3 As a result of the special inspection conducted by the E C Construction Ap-praisal Team on May 16-27 and June 6-22, 1983, and in accordance with the E C '
Enforcement Policy,10 CFR, Part 2, Appendix C, the following violations were identified:
Critation V of 10 CFR 50 Appendix B requires, in part, that ' Activities affec-ting quality shall be prescribed by documented instructions, procedures, or drawings of a type appropriate to the circumstances and shall be accomplished 1 in accordance with these instructions, procedures or drawings. . Instructions, procedures or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satis-factorily accomplished'.
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0310120250 030928 PDR ADOCK 05000397 0 PDR
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Mr. J. B. Martin Page 2 September 16, 1983 i]<
G02-83-839 The FSAR for the WNP-2 project, Section 17.1.1.5, accordingly describes that activities affecting quality are described in procedures, instructions, and drawings and that activities are conducted in accordance with these docu-ments. Procedures, instructions, and drawings include adequate quantitative and qualitative acceptance criteria to ascertain that the prescribed activi-ties have been satisfactorily accomplished."
"E. The WNP-2 project design and placement drawings (S-707, S-710, S-712, S-715, S-721, S-749, BS-RB-63, -73, -84, -125, -132) define reinforcing steel placement requirements. These include placing of lap splices ver-tically and required number of bars.
- 1. ' Contrary to Criterion V, 10 CFR, Appendix B, cited above, and the 9bove requirement,1 of 8 reinforcing steel dowels was apparently omitted from Beams 2811 and 3B18, as observed in excavations during the inspection.
- 2. Contrary to Criterion V, 10 CFR 50, Appendix B, cited above, and the
, above requirement, reinforcing steel bars, for concrete beams 2B3, 285, 2Bll, 2B25, 3810, 3818, and 6B9 were placed with lap splices
. horizontally and with horizontal and vertical clear space between
?n. -V bars of a little as 1/8". As a result, honeycomb and voids had occurred in the concrete, as observed in excavations during the inspection. ,
This is a Severity Level IV Violation, (Supplement II)." ,
Supply System Response In order to resolve the items addressed in the Notice of Violation, a formal destructive examination and documentation review was conducted.
o Eight beams with congested rebar were selected for review. In addition, two exterior walls, a pilaster, a wall of the dryer separator pool, a fuel pool wall / beam, the foundation mat and a slab were selected. The sample was representative of the Quality Class I work done by three con- -
tractors during a three-year time period, during which the majority of concrete work for the project was accomplished. The sample was biased because members with congested reinforcing bar were specifically selected.
o As-builts of the reinforcing steel exposed by the excavations were pre-pared, checked, and compared with fabrication drawings. Photographs of each excavation were prepared. The E C was contacted to view each ex-cavation and questions of the accuracy of two as-built sketches were raised by the inspectors, as noted in Inspection Report 83-36. The sketches have been reviewed, revised, and discussed with the Resident Inspector. It is our understanding that this issue is resolved.
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Mr. J. B. Martin Page 3 September 16, 1983
$)" G02-83-839 o In Item 1, the Notice of Violation notes one of eight dowels as appar-ently omitted from beams 2811 and 3818. Supplementary excavation in beam 2811 has exposed all eight dowels in that beam. Supplementary excavation in beam 2B5 and the north wall of the spent fuel pool also exposed steel initially thought to be missing. Additional review of the design and placement drawings for beam 3818 indicates that the dowel apparently missing may be there, but not exposed. Engineering analysis of beam 3818 demonstrates that if the dowel were assumed to be missing, the strength of the beam as bJilt would still meet the design objective. These facts support a project conclusion that further excavation of beam 3818 is not warranted.
o Rein' forcing steel bars for the concrete beams identified in Item 2 of the Notice of Violation are located closer than specified and this resulted in honeycomb and volds in two of the beams. Investigation has found good bond between the concrete and reinforcing steel in all the sample excava-tions except beams 2811 and 2B25. The honeycombed areas in these beams have been excavated to sc<;nd concrete and will be repaired. Engineering analysis of beams 2811 and 2B25 show that their strengths meet the design objectives, o The findings of the formal destructive investigation program briefly set forth above are that the deviations noted in the Notice of Violation have ,
no detrimental impact on the biased sample of structures eveluated and these conclusions have been reviewed by consultants considered expert in their knowledge of reinforced concrete structures. Their written assess-ments are appended to the attached report. The structural capacity of all 17 members evaluated fully meet the original design objectives. The Supply System, therefore, concludes that the quality of reinforced con-crete placed in the project is adequate. .
Corrective Action to Preclude Repetition
. Corrective action included the examination of concrete beams and structures other than those identified in the Notice of Violation. This examination has not identified any deviation which would cause any beam or structure evaluated to be of questionable adequacy; therefore, no additional actions are planned.
Date of Full Compliance Submission of the attached report completes action on this item.
Our detailed reply, pursuant to the provisions of Section 2.201 of the MiC's
" Rules of Practice", Part 2 Title 10 Code of Federal Regulations, consists of this letter and Attachment 1, which contains our detailed response to the Notice of Violation.
h
i e Mr. J. B. Martin Page 4 September 16, 1983 eQ' G02-83-839 l
If you have any questions or desire further information, please contact Hugh Crisp at (509) 377-2501, extension 2795.
. 901A Program Director, WNP-2 i HAC/1kh ;
Attachments: Attachment 1 Appendix A, B, C, and D cc: Mr. R. C. DeYoung, M C IIE Mr. R. T. Dodds, EC RV Mr. R. F. Heishman, MC QASIP IE Mr. 8. D. Toth, MC Resident, WNP-2 2-)
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e i
19
Attachment 1
!.b WASHINGTON PUBLIC POWER SUPPLY SYSTEM NUCLEAR PROJECT NO. 2 DOCKET NO. 50-397 LICENSE NO. CPPR-93 RESPONSE TO INSPECTION REPORT 83-38 NOTICE OF VIOLATION EVALUATION OF CONCRETE AND REINFORCING STEEL FOR WASHINGTON PlBLIC POWER SUPPLY SYSTEM UNIT 2 Executive Summary This report describes the results of an evaluation performed to assure the adequacy of the design and construction of the reinforced concrete structural members in the iteactor Building. This program was commenced during the spe-cial investigation conducted by the NRC Construction Appraisal Team (CAT) who were on site during May 16 through 27 and June 6 through 22, 1983. The pro-gram was further reviewed with NRC personnel on site on July 25 through 27, 1983. This report specifically addresses Section E of the Notice of Violation which was issued following the CAT inspection and stated:
Q "The WNP-2 project design and placement drawings (S-709, S-710, S-712, S-715, S-721, S-749, BS-RB-63, -73, -84, -125, -132) define reinforcing steel placemnt requirements. These include placing of lap splices vert-ically and required number of bars.
- 1) Contrary to Criterion V, 10 CFR, Appendix B and the above require-ment,1 of 8 reinforcing steel dowels was apparently omitted from Beams 2B11 and 3818, as observed in excavations during the inspection.
- 2) Contrary to Criterion V,10 CFR 50, Appendix B . . . and the above requirement, reinforcing steel bars, for concrete beams 283, 285, 2Bll, 2B25, 3810, 3B18, and 689 were placed with lap splices hori-zontally and with horizontal and vertical clear space between bars of as little as 1/8". As a result, honeycomb and voids had occurred in the concrete, as observed in excavations during the inspection."
In order to address these items, a formal destructive examination and documen-tation review was conducted. Eight beams with congested rebar were selected for review. In addition, two exterior walls, a pilaster, a wall of the dryer separator pool, a fuel pool wall / beam, the foundation mat and a slab were selected. All of the items listed above were evaluated in detail and were checked. The sample was a biased one because members with congested rebar were selected.
b Page 1 of 9 Evaluation of Concrete and Reinforcing Steel
The reinforcing steel dowels identified in Item 1 of the violation as appur-
_ ently caltted were investigated furtner. Additional excavation of Beam 2B11 9 located the apparently omitted dowel.
Excavation of beam 3818 did r >t locate one of the dowels. The beam wss eval-uated conservatively assuming that the dowel was missing rather than just mis-located. This evaluation showed the beam to be adequate for all specified loads.
Reinforcing steel bars for the seven concrete beams identified in Item 2 of the violation are located closer than specified. The minimum spacing is spec-ified to permit concrete to flow between the bars such that concrete could be placed without honeycomb or volds. Investigation of five of the beams showed no honeycomb or voids and demonstrated good to excellent bond between the con-crete and reinforcing steel. Honeycomb and voids had been reported in prior nonconformance reports in the other two beams (2811 and 2825). These two l
beams were heavily reinforced, because of the demand generated due to con-struction loads greater than those specified during operation. Evaluation of the structural members demonstrated adequate structural capacity of all mem-bers for the specified loads.
j 1
The evaluation has been reviewed by Lewis Tuthill and Westinghouse as jndepen-dent third parties. Lewis Tuthill inspected each of the excavations. West-inghouse inspected the excavations a,d performed a detailed review cf all the documentation. Both parties concurred with the general conclusicn of the evaluation. l
-}. In summary, the questions raised in the Notice of Violation have been ad-dressed. The detailed evaluation of 17 structural elements with 23 discrete excavation locations indicates that the as-built structures are structurally adequate for all specified loads. In many cases there is substantial margin, since the future operating loads are lower than those specified and experienced during construction.
- 1. Introduction Beams 283, 2811, and 2825 were constructed in May 1976 and were the sub-ject of Nonconformance Report 6426-01851 dated August 4,1976. This non-conformance report identified honeycombing in each of the beams, which were subsequently repaired. When these repair patches were reinspected and sounded in 1983, it appeared that the patches were deficient and it was decided to perform destructive examination of these beams. The con-crete was partially excavated when the CAT visited the site. CAT expres-sed concerns after viewing the exposed reinforcing steel. These concerns led to the additional excavation and evaluation described in this re-port. Some of this work was performed while the CAT team was originally
._ on the site. Additional axcavation performed after the CAT team left the site was inspected in a subsequent NRC visit on July 25 through 27, 1983. Further examination and evaluation was performed subsequent to this visit.
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Page 2 of 9 Evaluation of Concrete and Reinforcing Steel
- 2. Structural Members Evaluated
[] A total of 17 members with 23 locations was selected for evaluation.
These were members with congested rebar. Based on past experience, it is known that structures with congested rebar are the ones most susceptible to lack of bond, hoaaycomb area, misplacement of reinforcement, changes from design drawings in preparing shop drawings, and changes in design drawings from calculations. The samples are thus biased in the direction of those most likely to show deviations from the original design.
To illustrate the method of selection, the concrete beam schedule for elevation 471'0" is shown in Table I. The beams selected at elevation 471'0" were 283, 285, 2B11, and 2B25. In addition, three excavation locations were selected for 2B11 and two excavation locations were selected for 2B25. It should be noted that rebar dowel splicas were re-quired, so a total of 48 bottom bars were required for beams 2811 and 2B25. The design drawings called for three layers of bottom bars for 2B11 and 2825. With these closely-spaced bars and dowels, if lack of consolidation wers to occur, this would be the most likely locatinn.
A similar selection procedure was used to select the following structural elements:
- a. Beams 3810, 3818 (four excavation locations), (Elevation 501'0")
- b. Beam 4830 (Elevation 522'0")
- c. Beam 6B9 (Elevation 572'0")
}
- d. West and east exterior walls (Elevations 493'0" and 476'0").
l
- e. Pilaster / column of column lines 3.4 and M (Elevation 448'0").
- f. Dryer separator pool, north wall (Elevation 578'7 1/2").
- g. Fuel pool 0;rth wall / beam (Elevation 588'2 1/2").
j h. Foundation mat (three excavation locations) (Elevation 422'3").
- 1. Slab (Elevation 471'0").
- 3. Details of the Evaluation i The detailed procedure for evaluation of structural elements (Appendix B) f called for a review of documentation and physical destructive examina-tions. The documentation review consisted of:
i a. The design drawings on each member were checked against the design calculations.
I
- b. The shop drawings were checked against the design drawings.
- c. The excavated areas shown on the as-built drawings were checked (g against the shop drawings.
Page 3 of 9 Evaluation of Concrete and Reinforcing Steel
- d. For the cases where reinforcing bars were not found or where bond was determined to be questionable in the excavated areas, the struc-h, tural capacity was checked against the structural design loads,
- e. The pour records were reviewed for Requests for Information (RFIs) and Nonconformance Reports (NCRs) indicating changes to design or shop drawings.
The physical inspection consisted of excavating the concrete in the selected locations and preparing as-built sketches. The results of the evaluation including the "as-built" sketches for each beam are included in Appendix C.
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- 4. Desian and Construction Process This section describes the process fnllowed during the original design
( and construction in order to show the relationship between the various design and construction documents. These documents were prepared sequen- ,
tially and the predecessor documents such as the design drawings were not l l
required to be updated to reflect changes incorporated in the later docu-ments such as shop drawings, RFIs or NCRs. The as-designed condition is i j represented by the latest dccuments in the total documentation package.
a) Design computations were prepared and checked by structural engineers.
b) Design drawings were prepared and checked by design draftsmen and i.
@ were approved by the structural engineer, c) Shop drawings were prepared by the reinforcement steel fabricator and were checked and approved 'oy the structural engineer in accor-dance with approved procedures. Design draftsmen checked the shop drawings against the design drawings and detailing requir+ments of the ACI Code. The structural engineer coordinated this review as well as checked any areas of reinforcing not delineated on the design drawings.
The shop drawings represent the input provided to construction. At each step of the design process, additional detail is defined.
Approval by the structural engineer confirms that the additional detail conforms to his design computations.
d) During construction, the contractor requested changes to resolve interferences, ease of placement or other construction reasons.
These changes were documented on Requests for Contract Change (RCCs) or Requests for Information (RFIs) which were reviewed and approved by the structural engineer, e) If nonconformances were identified after the construction work was completed, it was documented in a nonconformance repor t which required review and disposition by the structural engineer.
h Page 4 of 9 Evaluation of Concrete and Reinforcing Steel
y 1 f) Each contractor furnished his own quality control inspection. Each completed checklist, covering all phases of concrete construction
@' prior to, during and after concrete placement, was signed off by quality control personnel. The contractor was responsible for as-suring that all approved changes were incorporated in the construc-tion.
- 5. As-Designed Versus As-Built Comparison The comparison of the design documentation against the as-built condition revealed a few discrepancies which are detailed for each structural mem-ber on the evaluation sheets in Appendix C. The comparison confirmed that the as-designed condition was adequately supported by design calcu-lation. Discrepancies in the as-built condition identified in the EC Notice of Violation were in one of the following categories:
a) Clear spacing between horizontal bars was less than that required by Paragraph 7.4.1 of ACI-318. This was particularly noted in the dowel region of heavily reinforced beams, where the dowels were 10-cated in the same horizontal layer as the main bars, and was aggrd vated by inserts also located in these regions.
b) Poor band, honeycomb and volds were found in two beams at the loca-tion that had been repaired in response to the prior nonconformance reports. No lack of bond or voids were found in structural members '
that had not previously been identified in nonconformance reports.
One dowel bar was not located in beam 3818.
] c)
- 6. Evaluation of As-Built Discrepancies The evaluation sheets for each structural member in Appendix C show the results of the evaluation of each discrepancy. All members were found to be a&quate. This section describes the consideration in performing these evaluations.
6.1 Rebar Spacing Rebar clearance has been discussed among structural engineers and constructors for decades. ASCE has a committee to study the prob-lems related to nuclear power plants. Nuclear power plants are usually built to ACI 301, ACI 318, ACI 349, or ACI 359. All of the codes specify clearances that are desirable. For example, it is desirable that the maximum-size aggregate pass between the rebar.
This is rarely practical on all parts of the plant. For example, at containment openings, shell-to-base mat intersections and on heavily reinforced plates and beams so much rebar is required that the spac-ing is very close. Beam 2B11 is a good example of the problems that are often encountered in heavy-engineered construction.
The clear distance limitations in ACI 318 were establiched to permit concrete to flow readily into spaces between bars a::d to insure against concentration of bars on a line that may cause shear or h
Page 5 of 9 Evaluation of Concrete and Reinforcing Steel
shrinkage cracking. The code permits lesser spacing if, in the
_n
- judgment of . the engineer, workability and methods of consolidation
- *- :are such that' concrete can be- placed without honeycomb or volds.
Rebar spacing should, therefore, be evaluated in terms of the re-sulting quality of concrete placement. The excavations have shown that, with only a few exceptions, the final structure is free of ,
honeycomb ~ and voids. The average spacing across the full width of '
the beam meets ACI Code ininimum requirements. The low stress in the rebars under operating loads, together with the closely-spaced stir-rups 'in each beam, will mitigato any tendency to crack along the plane of the rebar.
6.2. Rebar Solicina The WNP-2 project design and shop drawings did not clearly define whether the splices of the dowels at the bioshield wall should be oriented vertically or horizontally. This left the option to the :
constructor to splice the bars in either orientation. Splicing of dowels above or below the bar being spliced is good practice in the case of one layer of rebar. In the case of multiple layers, the practice _ comes into question because of the almost vertical cut, with essentially zero clearance, produced in the concrete at the ,
rebar location.. Hcrizontal dowel splicing is not unusual in this type of multiple-layer construction. Various placing techniques are used to minimize lack of consolidation. Often bars are left loose or moved until the lower elevations are filled with concrete. Pea gravel; mixes or grout are sometimes used. Field changes in mixes M may be allowed .to produce _ the best possible consolidation.
of _ all the precautions, lack of consolidation exists on all pro-In spite ,
jects; It is for this reason that patching procedures are covered in the ACI Code and project procedures.
6.3 General Comments on Desian and Desian Criteria .
During the review of the design calculations, it became clear that the structures with the congested rebar were generally governed by the construction load case. The operating load case that governed consisted of dead load, live load, seismic and thermal. For this
- case, the amount of rebar required was generally much less than that required for the construction load case. Since it is difficult to estimate -the construction loads early in the project, conservative -
i loads and methods of analysis were- generally used. In addition, as r
is -usually the case, the actual concrate strengths (including bond,
- t shear and tensile strength) greatly exceeded the minimum specified strengths.
p 6.4 Beam 2811 This section describes the evaluation for - a typical beam in which a number of discrepancies were identified. The design drawings for
,- beam 2B11 called for a width of 3'-6" and 'for 24-#11 bottom bars to be placed in three layers. Although the ACI Code only requires that
, g1 one-fourth of the positive moment reinforcement be extended into the
- i r
Page 6 of 9 Evaluation of Concrete and Reinforcing Steel
l biological shield, the shop drawings call for dowels for all 24 n bars, resulting in a total of 48 bars specified at the section ex-t> cavated (section B-B on sketch #SK-3 in Appendix C). In addition, inserts were specified that prevented the bars from being uniformly ;
spaced.
1 The excavation at section B-B exposed 24-#11 bars. The bottom layer shows 16-fil bars (8 main bars plus 8 dowels from the bioshield wall). Bars are placed close together in some cases to clear the inserts. The ACI Code permits contact splices between the main bars and corresponding dowel but imposes a minimum clear distance between the contact lap splices and adjacent bars or splices. This minimum clear distance is not satisfied at some locations at the excava-tion. On the botbm layer, seven of the dowels are placed alongside the main bars and one above; on the second layer, eight #11 bars are exposed of which two are dowels located aboye the main bars.
After concrete placement, honeycombing was reported in the dowel region. This honeycombing was repaired, although the recent re-excavation of the deficient patch indicated minor honeycombing. It was not determined whether this honeycomb was in the original con-crete or in the patched area.
Review of the design calculations for the beam indicated that loads during construction determined the reinforcement required (24-#11 bars). Review of all load conditions subsequent to construction
) shoved that only 8-#11 bars are required at mid-span and only 2 of these are required to extend into the biological shield wall. An investigation of the actual loads experienced during construction concluded that the beam experienced loads during construction that exceed those specified during operation.
In summary, the evaluation of beam 2B11 has shown that there was honeycombing and voids during construction, primarily due to the close spacing of the reinforcing steel. However, due to the fact that the beam has experienced significant construction loads and that the number of bars required for operating loads is signifi-cantly less than the as-built condition, it is concluded that the beam is structurally adequate.
- 7. Summary and Conclusions The purpose of this evaluation was to assure the adequacy of the design and construction of the concrete structural members in the Reactor Build-ing.
A total of 17 structural members with 23 discrete excavation locations were conservatively selected. A detailed destructive examination was performed at each location and an analysis was made on each structure to determine the as-built capacity. In all cases, the structures were found to be achquate. The results show that for two cases some bond was not available on all the bars. This inadequacy occurred at dowel splice m
a&
Page 7 of 9 Evaluation of Concrete and Reinforcing Steel
r 1 locations where honeycomb and voids would be most likely. Of all the cases studied, only one bar may be missing (limited excavation was done h" in this area). Minor relocation of rebar from the placing drawings was to be expected with the very congested design which was dictated by the construction loads. The method of rebar placement for multilayer splices is not unique for this type of construction.
In conclusion, all of the members examined are adequate and there is rea-sonable assurance that all of the design and construction of concrete in the Reactor Building is adequate to meet the design conditions. This conclusion is endorsed by the independent reviewers, as shown in their letter reports in Appendix A (Lewis Tuthill) and Appendix D (Westing-house).
.h Page 8 of 9 Evaluation of Concrete and Reinforcing Steel j i
L. 1
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TABLE I SQ l l I I I I l MARK l WIOTH l OEPTH I _B0TTOM BARS l TOP BARS l l l l l l l l l l l l I 1 2B1 1 l'-0" l 2'-6" l 3-#8 l 3-#6 l l 282 l 2'-0" l 3'-0" l 4-#9 l 3-#10 l l *2B3 l 2'-6" l 4'-2" l 14-#11 1 7-#11 l l 284 l l'-4" l 2'-6" l 3-#8 1 3-#8 l l *285 l 2'-6" l 4'-6" l 14-#11 l 7-#11 l l 2B6 1 3'-0" l 4'-6" l 12-#11 l 6-#9 l l 287 l 2'-0" l 3'-4" l 6-#11 1 4-#9 l l 288 l l'-6" l 2'-6" l 4-#7 l 2-#6 l l 2B9 l l'-6" l 3'-0" l 6-#11 1 4-#9 l i 2810 l 2'-0" l 4'-0" l 5-#9 l 3-#7 l l *2811 l 3'-6" l 5'-0" l 24-#11 l 12-#11 l l 2812 l 2'-6" l 4'-2" l 8-#8 1 4-#11 l l 2813 l 3'-0" l 2'-6" l 4-#6 l 2-#6 l l 2B14 l l'-6" l 3'-0" l 4-#11 l 3-#10 l l 2B15 l 3'-0" l 4'-2" l 6-#11 1 3-#10 l l 2B16 l 3'-0" l 4'-0" l 6-#9 l 4 19 l l 2B17 l 2'-2" l 4'-2" l 8-#10 l 4-#9 l l 2B18 l l'-6" l 2'-6" l 4-#9 l 4-#9 l l 2B19 l l'-6" l 3'-0" l 3-#9 l 2-#8 l l 2820 l 3'-0" l 5'-0" l 17-#9 l 7-#9 l l 2821 l 2'-0" l 3'-0" l 4-#10 l 3-#8 l l 2822 l 3'-0" l 3'-4" l 7-#9 l 3-#9 l
.Q>
- l .2823 l 3'-0" l 3'-6" l 5-#9 1 3-#9 l l 2B24 l 3'-0" l 3'-6" l 6-#8 l 3-#7 l l *2825 1 3'-6" l 5'-0" l 24-#11 l 12-#11 l l 2B26 l 2'-6" l 4*-2" l 8-#9 l 4-#7 l l 2B27 l l'-9" l 2'-0" l 3-#8 l 3-#6 l 1 2B28 l l'-0" l l'-6" l 2-#6 l 2-#6 l l 2B29 l 3'-0" l 2'-0" l 6-#9 l 4-#9 1 l 2830 l 2'-0" l 3'-0" l 5-#10 1 5-#10 l l 2B31 l 2'-6" l 3'-6" l 6-#11 l 4-#10 l i 2832 l 2'-0" l 2'-6" l 4-#10 l 4-#10 l l 2D33 l 4'-8" l 2'-0" l 8-#8 l 8-#8 l l 2B34 l 2'-0" l 3'-0" l 4-#10 l 4-#9 l l 2B35 l 2'-0" l 3'-6" l 6-#11 1 4-#9 l 1 I I I I i
- Beam selected (bottom reinforced in two or more layers) h Page 9 of 9 Evaluation of Concrete and Reinforcing Steel J
ac APPENDIX A x ' *: . ..
LEWIS H. TUTHILL Concrete Engineering Consultant
4617 Cabana Way Sacramento, California 95622 (916) 457-9007 June 11, 1933 To: Neil Powell Project Engineering Manecer Bechtel Power Corporaticn WNP-2 P. O. Box 600 Richland, Washington 99352 From: Lewis H. Tuthill
Subject:
Washington Public Porer Supply System ViNP-2 Huclear Project Feview of Concrete Placing on Beauc 2B11 and 2B25 73 1. Questiona as to the adequacy and accurity of the subject beamn a >' have been rained by a final inopoction team representing the Nuclear Pegulatory Commincion (NRC). Apparently for several feet near one support of the subject two beams, it was evident when the support forms were removed that concrete in the under face was not well consolidated. Repairs of reported poor quality were made that looked good but on counding, nome areas proved to be drummy. Some of the No. 11 bars, at least in the vicible lower two of three layers are rather close together. Thus, i t was not easy to get concrete down and around them without special precautions not pro-vided initially. Removal of this poor and questionable concrete has continued until only a cmall portion of questioned value remains between and above this middle layer of bars.
- 2. Of course this is not the first time in the construction industry that such imperfecticns have occurred in the underside of a concrete beam. It is by no monna unique. The 'atate-of-the-art '
procedure has been to remove the imperfection back up to sound concrete and replace it with a suitable repair. Even though many repairs auch as those could have been done better, there is no record of failure in cervice because of them. Many rere not an strongly designed as the subject beams. Earthquakes may wreck buildinga and bridgen but in auch canca there are vaatly more structural failures than where nome of the beama have been repaired, or even poorly repaired. This all leads to the following conclu-ciona and opinion:
s
- v. p ~.,: - APPENDIX A 2
h a) That when such underside imperfection in the subject beams has been visibly fully removed as discucced above, it may well be presumed, certainly for all practical purposes, that no significant, invisiblo, unsound concrete exists above such.a lower zone of replacement, that will impair its intended perfor-mance.
.b) That when on all form removal, concrete beams exhibit on all faces, fully consolidated concrete without other than super-ficial imperfections, they can be considered solid and without-voids other than some entrapped air bubbles. With proper curing such beams are widely considered ready to carry their design loads with ammle safety. If they do not, something other than the work-manship in placing the concrete will be at fault. If for some reason there is doubt, sounding in those areas might be reassuring.
c) hiithin the facility, enroute to inspect the questioned bottom areas of the subject beams, it was noted from its general appearance that workmanship in forming and placing the concrete had been amply good. Installation of reinforcement could be judged only from job photographs and the few square feet where it was exposed at the underside of those two beams. Nothing unfavor-
. able could be identified in the photographs as there were none of detail placement in critical or congested places. The general if,) grids appeared to be evenly spaced and uniform. That exposed under the beams could have been more uniformly spaced but the two hanger inserts required, caused much of the crowding. Robars are: under-stood to perform fully as well despite some variation in spacing.
3 I trust the foregoing adequately covers the principal points in question which we observed and discussed during my visit June 9 and 10. If further clarification or amplification is desired, please advise.
- w .
Lewis H. Tuthill LHT:at
I
]
-: .- APPENDIX A LEWIS H. TUTHILL Concrete Engineering Consultant 4617 Cabana Way Sacramento, California 95822 (916) 457-9007 Jt11y 19, 1983 To: Heil-Powell Project En6 ineering Mana6er Bechtel Power Corporation WHP-2 P. O. Box 600 Richland, rachington 99352 From: Lewis H. Tuthill
Subject:
Washington Public Power Supply Synten WNP-2 Huclear Project
- Review of concrete placing in beamn and clner:horo, exponed cince June 9, 1983.
. .:x
'+'
-Since my report of June 11, 1983, dincunning beams 2B11 and 2B25, ac noted during my innpoetion of them June 9, a number of expocures of concrete at reinforcing in other beams and locations were made in annvier-to certain questions rained by the NRC repre-sentatives.
As requested, I visited the project July 18 to examine those new exposuroc. It ic my observation and opinion after looking closely at each of them, that
- 1. - All concrete made vinible since my visit May 9 is perfectly sound and without imperfection. It is well-consolidated and therefore well-bonded around the reinforcing bars.
- 2. The overall quality of yorkmanship to cood.
3 ,Th re is no reason to question the integrity of the structure.
-4 Apparently overything that should be there is in there exposed features of the structure, and, by the implicationn of this generous sampling, elsewhere as well'.
r *
$ ) b Lewin H. Tuthill
].--
LHT:at
l .
" ~, . APPENDIX B - Paga 1 of S M
BURNS AND ROE, INC.
PROCEDURE FOR EVALUATION OF CONCRETE FOR WASHINGTON PUBLIC POWER SUPPLY SYSTEM UNIT 2 AUGUST 24, 1983
- 1. PURPOSE The purpose of this evaluation is to assure the adequacy of the
, design and construction of the concrete structural members in the Reactor Building.
- 2. DOCUMENTATION TO BE EVALUATED
- The following docuraentation will be evaluated in detail to deter-ig mine the structural adequacy of the members. The selection of specific members will be discussed in Section 4 of this procedure.
- a. The design drawings on each member will be checked against the design calculations.
- b. The shop drawings will be checked against the design drawings.
- c. The excavated areas shown on as-built sketches will be checked against the shop drawings (as practical and to determine where f
rebar placement is adequate).
l
- d. For the cases where reinforcing bars appear to be missing or where bond is questionable in the excavated areas, the structural capacity will be checked against the structures' design loads.
- e. The pour record will be reviewed for RFIs and NCRs indicating changes to design or shop drawings.
1
APPENDIX B - Page 2 of 5
' .: .~~
- 3. PHYSICAL INSPECTION A detailed physical inspection will be made of each excavation in each structure to be evaluated. The results of the physical inspection will be recorded on as-built sketches which show:
number, size, spacing and location of rebar.
- 4. STRUCTURES TO BE EVALUATED _
The structures selected for detailed review were chosen because they represent the part of the structures with the most complex and congested rebar details. It is known from past experience that such structures are the ones most susceptible to lack of bond,' honeycomb areas, misplacement of reinforcement, changes from design drawings in preparing shop drawings, and changes in design drawings from calculations. The samples are thus biased in the direction of those that are most likely to show deviations
, from the original design. In addition, the structures selected represent beams, pilasters, walls, foundation mat, and slabs.
_.b 1:
The selected members are:
- a. Beams 2B3, 285, 2B11 (3 locations), 2825 (2 locations), 3B10, 3B18 (4 locations), 4B30, 6B9.
- b. West and east exterior walls.
- c. Pilaster / column at column lines 3.4 and M.
- d. Dryer separator pool, north wall.
- e. Fuel pool north wall / beam at elevation 588'-21s".
- f. Foundation mat (3 locations).
l 1
- g. Elevation 471' slab. l l
1 2 l l
. ~:
- APPENDIX B'- Paga 3 of 5 0
- 5. DOCUMENTATION An evaluation form, Attachment I, will be completed for each member.
The results of the evaluation, including the evaluation forms, the as-built drawings and the computations, will be kept for future evaluation and examination.
- 6. REPORT A repo'rt will be prepared to summarize the evaluation. The report l will contain the following sections:
s
- a. Executive Summary
- b. Purpose
- c. Events that led up to evaluation
- d. Documentation evaluated ,
- e. Members evaluated
- f. Study of reinforcing bar clearance and substitution of alternate -
concrete mixes
- g. Results of evaluation l
- h. General comments on design and design criteria
- 1. Summary and conclusions
$)
3
'l: -
APPENDIX B - Page 4 of 5 ATTACHMENT I b Date: Rev.
STRUCTURAL MEMBER IDENTIFICATION
- 1. Design drawings checked against design calculations, and code / standard requirements:
,_ Engineer checker Comments:
b
- 2. Shop drawings checked against design drawings:
Engineer Checker Comments:
- 3. As-built sketches of excavated areas checked against shop drawings:
Engineer Checker Commants:
Nh 4
'4
- APPENDIX B - Page 5 of 5 Date: ,
Rev.
fh 4. Concrete consolidation and bond Engineer . . _
Checker
~ Comments:
i
- 5. Member as-built:
(Adequate or Inadequate)
Engineer Checker
. List Discrepancies Engineering Disposition i
3 9
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.l Appendix C i STRUCTURAL COMPONENT BEM 2B3, ELEV 471'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETCH NO. SK 1) SHEET 1 0F 1 l I REIWmCEMENT l REIW m CEMENT l l l REQUIRED BY mIGINAL l REQUIRED BY ANALYSIS I AS-BUILT COWITIONS (SEE SKETCH NOTED) l DISCREPANCIES I DESIGN AND SHOWN ON l Fm MOST CRITICAL I I ;
1 DESIGN DRAWINGS I OPERATING /SSE LOAD l LOCATION OF l BOTTOM BARS I DOWELS I C0f0ITION l EXCAVATION EXPOSED EXPOSED SECTION A-A I SECTION A-A l l ALL EXCAVATIONS I i i i l l l Bottom Bars: 14-#11 l Bottom Bars: 7-# 11 l 2'-0" East l 7-#11 i None - l 1) Rebar spacing deviation partly to I in 2 layers l l of column i i Not requiredi accommodate installation of 2 rows l l l line 7.7 l l 1 of Richmond inserts parallel to l Bottom Bar Dowels: l Bottom Bar Dowels: l l l 1 axis of beam.
I Not required l Not required l l l l l l l 1 1 I l Top Bars: 7-# 11 1 Top Bars: 5-#11 l l l l l l l l l l l l l l l l l l l 1 1 I l l l l 1 l l l l l l l 1 l l l 1 I I I i 1 l l l l l l l l l l l l l l l l 1 l l l 1 I I l l l l l l l l 1 1 I I I ,
I l RESOLUTION OF DISCREPANCIES: l COMENT:
I I i 1) Excavation demonstrated that concrete is fully consolidated and is l 1) Beam 2B3 has been reanlayzed and checked and I tightly bonded to rebars. The rebar spacing deviation has not ad- I found to be structure 11y adequate. Reanalysis I versely affected placement of concrete and is acceptable. I indicates a large design margin.
l 1 l l 2) Dimensions and bar sizes shown on as-built l l cAetch SK-1 have been verified.
l l l l 3) Honeycomb, which was originally identified in l l Nonconformance Report 1851, was repaired prior l l to the NRC CAT inspection.
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Appendix C -
) STRUCTURAL COMPONENT BEAM 2BS, ELEV 471'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETOi NO. SK 2) SHEET 1 OF 2 i REIWmCEMENT I HEIWmCEMENT I l
.1- REQUIRED BY- MIGINAL l REQUIRED BY. ANALYSIS I AS-BUILT C0f0ITIONS (SEE SKETCH NOTED) I DISCREPANCIES l DESIGN AND SHOWN ON l Fm MOST. CRITICAL l l l DESIGN ORAWINGS l OPERATING /SSE LOAD l LOCATION OF l BOTTOM BARS l DOWELS' I I C0tOITION ' EXCAVATION EXPOSED l EXPOSED SECTION A-A l SECTION A-A ) -
! ) ALL EXCAVATIONS
!l I I- 1 I I i l Bottom Bars: 14-#11 l Bottom Bars: 4-#11 l 7'-0" West l 14-#11 in l None i 1) Bottom bars in 3 layers instead of l In 2 layers l l of column i 3 layers I required i 2 layers.
il l 1 line 8.3 l l l l Top Bars: 7-#11 l Top Bars: 5-#11 l l l l 2) NRC Ccnstruction Appraisal Team
,I l l l l l noted as discrepancies:
I I I I I I
'I l
>l l l l l a) 2 of 7 bars missing from l l l l l bottort rchar layer.
.I I I l l l l l l l l l b) Spacing deviation between
{l i l ji l l l first and second layers and l
4 l
l l l l second layer bars not directly I
1 l l l l above first leyer bars.
I I I I I I I I I I I jl l l l l l 4
I I I I I I 4 I I I I I l
!l l l l l l 4l l l l l !
l RESOLUTION OF DISCREPANCIES: I COPNENT:
l
'l I I
- I 1) Further excavation after NRC CAT inspection found 5 bars in bottom- l 1) Beam 285 has been reanalyzed and checked and i
- I most layer, 5 in middle layer, and 4 in top layer as shown on SK-2. l found to be structurally adequate. l
'l The deviation in bar and layer spacing would be acceptable provided l I
,I the concrete was adeqmtely consolidated. Beam 285 was found to i 2) Dimensions and bar sizes shown on as-built I have fully consolidated concrete tightly bonded to the rebars with I sketch SK-2 have been verified. I no honeycomb. Placement of the rebar in 3 layers did not change l l jl the conservative effective depth used in the original calculations. l l 1I l I i l 2) a) See 1) All bars have been found; none are missing. l l il l 1
- I I I il i1
-{
b 'h [
Appendix C I STRUCTURAL COMPONENT BEAM 2BS, ELEV 471'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETW NO. SK _2) SHEET 2 0F 2 I REIW m CEMENT l REIWORCEMENT l l l REQJIRED BY ORIGINAL I REQUIRED BY ANALYSIS I AS-BUILT COPOITIONS (SEE SKETCH NOTED) I DISCREPANCIES I DESIGN AND SHOWN ON I Fm MOST CRITICAL l l l DESIGN DRAWINGS l OPERATING /SSE LOAD I LOCATION OF I BOTTOM BARS I DOWELS I COPOITION EXCAVATION i EXPOSED f EXPOSED l l l I l i I l' I I I I I I I I I I I I I I I I I I I I I i 1 1 I I I 1 I I 1 I I I I I I I I I I I I I I I I I I I I l I I I I I I I I I I I 1 I I I l I
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I I I I I I I I I I I I
.I I I I I I I I I I I I I I I I I I
- I I I I I I i
l RESOLUTION OF DISCREPANCIES: I C0tHENT:
ii l I b) ACI 318-71 (7.4.2) requires only one inch clear distance be- I I tween layers. NRC CAT noted that 1 1/2" was furnished, there- l l fore there lo no discrepancy. I I I l It is apparent that the staggered spacing of bars in the levels l l (with a maximum of 5 bars in a 30 inch beam width) did not ad- l l versely affect concrete placement. l I I 1 I t
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l Appendix C
'l STRUCTURAL C(NPONENT BEAM 2811. ELEV 471'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETCH NO. SK 3) SHEET 1 0F 2 ~'
l REIWmCEMENT l REIWORCEMENT l l l REQUIRED BY mIGINAL l REQJIRED BY ANALYSIS l AS-BUILT COWITIONS (SEE SKETCH NOTED) l DISCREPANCIES l DESIGN AND SHOWN ON l FOR MOST CRITICAL- l l l DESIGN ORAWINGS l C?ERATING/SSE LOAD l LOCATION OF l BOTTOM BARS l DOWELS l l C0f0ITION ' EXCAVATION EXPOSED EXPOSED SECTION A-A SECTION A-A I l 1 ALL EXCAVATIONS il ,l l" l ,l l
- 1 Bottom Bars
- 24-#11 l Bottom Bars: 8-#11 l Near exter- l 7-#11 l 7-#11 l 1) Deviations in rebar spacing partly
, I in 3 layers l l lor face of l (see Com- l (see Com- I due to relocation of bars to l l l the bio- I ment 5) I ment 5) l accommodate installation of 2 rows i i Bottom Bar Dowels: l Bottom Dowels: 2-#11l shield wall l l l of Richmond inserts parallel to l 24-#11 in 3 layers I (code minimm) l l l l the axis of the beam.
ll l l l l l
- -l Top Bars
- 12-#11 l Top Bars: 7-#11 l l l l 2) Honeycomb in dowel splice area.
l in 2 layers l l l l l
- l l l l l l 3) Defective patch.
jl SECTION B-B l SECTION B-B l l l l
,l l l l l l 4) Richmond inserts were not tagged 1 l Bottom Bars: 24-#11 l Bottom Bars: 8-#11 l 7 '-6" Eas t i 8-#11 l 8-#11 l to derate capacity.
I in 3 layers l l of colmn l 1 l l l l line 8.3 l l l 5) Stirrup exposed in Section A-A has l Bottom Bar Dowels: l Bottom Dowels: 2-#111 l l l inadequate cover, j l 24-#11 in 3 layers l (code minimum) l l l l l l l l l l
- l Top Bars: 12-#11 l Top Bars: 7-#11 l l l l
- l in 2 layers l l l l l
- I l l l l l 4
i RESOLUTION OF DISCREPANCIES: l COM4ENT:
,l l .
l l 1) The deviations in rebar spacing would be acceptable provided that l 1) Beam 2B11 has been reanalyzed and checked and
!l concrete was adequately consolidated around the bars. As noted I found to be structurally adequate.
kl in Nanconformance Report 1851, honeycomb and volds were observed i 1l after stripping the forms. Upon completion of patching, the con- l 2) ACI 318-71 requires that only one-fourth of the iI crete will be adequately consolidated and the discrepancy, there- l positive moment reinforcement (bottom bars) ex-ll fore, will be resolved. I tend into the support. The shop drawing shows 1
l l dowels for all (24) bottom bars which is in ex-
! l 2) Honeycorao has been removed and its effect has been evaluated. I cess of minimum requirements.
iI l 4 l 3) The &fective patch has b&n completely removed. l 3) A dowel which appeared to be missing or mislo-l l cated during the NRC CAT inspection has been j l 4) Derating tags will be re-attached to pertinent inserts upon com- I found after further excavation and is shown on jl pletion of patching. I SK-3.
-r o. c
,d G V Appendix C 1 STRUCTURAL COMPONENT BEAM 2Bll, ELEV 471'-0", WNC/REINF BY CONTRACT 6426 (SEE SKETCH NO. SK 3) SHEET 2 0F 2 l REIW m CEMENT l REIW M CEMENT l. 1 I REQUIRED BY mIGINAL l REQUIRED BY ANALYSIS l AS-BUILT CONDITIONS (SEE SKETCH NOTED) I DISCREPANCIES l DESIGN AND SHOWN ON l Fm MOST CRITICAL l 1 l DESIGN ORAWINGS l OPERATING /SSE LOAD l LOCATION OF I BOTTOM BARS I DOWELS I l COPOITION l EXCAVATION EXPOSED l EXPOSED SECTION C-C l SECTION C-C 1 l .I ALL EXCAVATIONS I I I I I l I Botte Bars: 24-#11 1 Bottom Bars: 8-# 11 1 2'-6" West l 8-#11 l -
l 6) NRC Construction Appraisal Team l in 3 layers i l of column i I I identified as a discrepancy the-l l l line 8.3 l l l placing of the lap splices in a l Top Bare: 12-#11 1 Top Bars: 7-#11 l l l l horizontal plane instead of a l in 2 layers l l l l l vertical plane.
I I I I I I l Bottom Bar Dowels: l Bottom Bar Dowels: l I l l 7) NRC CAT identified as a discre-l None required l None required l l l l pancy the size and spacing of I l l 1 l l stirrups shown on the drawings l l l l l l did not agree with those shown l l l l l l In the calculations.
1 I I I i l l 1 1 I I I I I I I I I I I l l l !
I I I I I I ,
I I I I l l I I ! I i 1 I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: l COP 94ENT: l l l l l 5) During patching, adequate cover will be provided over the stirrups. l 4) Dimensions and bar sizes shown on as-built i I
l sketch SK-3 have been verified. l l 6) The orientatiori of lap splices was not clearly defined on the l l l shop drawings and was left to the contractor. Lap splices can l 5) As noted on sketch SK-3, two bars exposed in l
,I be in either plane. This does not represent a discrepancy. l the area at Section B-B slope upward. The l
<l l slope prevented their exposure in the relatively I i l 7) A checked and approved original calculation sheet, not viewed by I shallow excavation of Section A-A. I
'I the NRC CAT, notes size and spacing of stirrups for 2B11 which I i l agree with those shown on the design drawings. l l l
lll l l
'I jl 4
._J
9.
.- f r, .;
D V O .
NOTES N - , ' -
ET -
4 l
@% cnneg 3.c Powtn coR outs.oa Paca M' .
BCSHitkD WALL
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SEE McTE #2 (*5
& ConJCEPTUAL LAvour or Beam STutt -_
esv pr.wmPTied - le== **s == G enoVtp
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6 chair'tp wo mo P'cTo"o^. n~r R' ( *8 @ P A ve,
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--K) f 2%ET'1%TIRRuss e uCTE: 8 *st taatu SARS wlTH 6 **t DowrLS r ea,c - '* SoTTo% moST LavsER NOTE: 6 'stIAksu BARS BOTTOM-moST LaTER CMyp C"$N SECTION A-A SECTION B S ball a I'-o" 5,CALE g*e l o*
BEAM 2625 As-sui v vww avicu en iomt ecc. 63 e.tr.w ign A wr*
.w. < .e eraovea ars ya/r @ r;wu d F d fa e ,N/n VAlf*-2 61<-4 at<
1
- ~
. m. . .._m - - - - - .- - - - - - - -
Q. ,
' A:cendix C l STRUCTUR4 COMPONENT BEAM 2B25. ELEV 471'-0", CONC /EINF BY CONTRACT 64?6 (SEE SKETCH NO. SK 4) SHEET 1 0F 2 ll REIW m CEMENT l REIWmCEMENT l l
' l REQUIRED BY MIGINAL I REQUIRED BY ANALYSIS I AS-BUILT COPOITIONS (SEE SKETCH NOTED) l DISCREPANCIES
' l DESIGN Af0 SHOWN ON l Fm MOST CRITICAL l l DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF l BOTTOM BARS l DOWELS ll' SECTION A-A i C0f0ITION SECTION A-A l l EEAVATION '
1 EXPOSED
.)
[ EXPOSED l
l ALL EXCAVATIONS
,I I '!- 1 I I_
! l Bottom Bars: 24-#11.l Bottom Bars: 9-#11 l 9'-0" East _
l 8-#11 ;l 8-#11 l 1) Deviations in rebar and layer
! I in 3 layers l l of column l l l spacing partly due to relocation l l l line 8.3 l l l of bars to accommodate installation l l l l l of 2 rows of Richmond inserts lllBottomBarDowels:l Bottom Bar Dowels:
j .l l l l parallel to the axis of the beam.
- I 24-#11 in 3 layers l 3-#11 l l l l 4l i l l l l 2) Bars in second layer were not.dir-l Top Bars
- 12-#11 l Top Bars: 9-#11 l l l l ectly above bars in the first
, l in 2 layers 4
l l l l l layer.
,I I _
l l l 1
- 1 SECTION B-B 1 SECTION B-B l l l l 3) Honeycomb visible in local area ii l l l l l concentrated between bars; local
- I Bottom Bars
- 24-#11 l Bottom Bars: 9-#11 1 6'-6" West l 8-#11 l None l void visible above bars.
1 1 in 3 layers l l of column i l required l
- l l l line 8.3 l l l 4) Defective patching.
.I I I l l l i~l Top Bars: 12-#11 i Top Bars: 9-#11 l l l l 5) Richmond inserts were not tagged l l in 2 layers l l l l l to derate capacity.
1 1 I I I I I ii I I I I ~
I l RESOLUTION OF DISCREPANCIES: 1 COPO4ENT:
'l l
! l 1) The deviations in rebar and layer spacing would be acceptable pro- l 1) Beam 2825 has been reanalyzed and checked and 1l vided the concrete was adequately consolidated around the bars. I found to be structurally adequate.
!l l jl2) See 1) above. I 2) Dimensions and bar sizes shown on as-built il I sketch SK-4 have been verified.
j l 3) Honeycomb has been removed. Effect of honeycomb and void on struc- l 1l tural adequacy has been evaluated. I il l j l 4) The patch has been removed completely and will be replaced. l l l
- I 5) Derating tags will be reattached permanently to pertinent inserts l
{l upon completion of patching.
lI i
i
$99
$k IMAGE EVALUATION (d8g,
[jgf j t k/j ig f>/ TEST TARGET (MT-3) % f
++** %#.4 i 1'0 MH L3a I l5 9 BlE i,i [E !!!M l
l.8 1.25 1.4 1.6 4 150mm >
< 6" *
- r % + /4 4// '4M<yh k>///// ,-
D's Q?r
- W Q. Q App?ndix C l STRUCTURAL COMPONENT BEAM 2B25, ELEV 471'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETCH NO. SK 4) SHEET 2 0F 2 I REIWmCEMENT l REIWORCEMENT l l l REQJIRED BY mIGINAL l REQUIRED BY ANALYSIS I AS-8UILT C0mITIONS (SEE SKETm NOTED) I DISCREPANCIES I DESIGN AND SHOWN ON I Fm MOST CRITICAL i I I DESIGN DRAWINGS I OPERATING /SSE LOAD l LOCATION OF i BOTTOM BARS l DOWELS I l COPOITION l EXCAVATION ~l EXPOSED EXPOSED
- I l l i ALL EXCAVATIONS I I I I I ,i l l l l l l 6) NRC Construction Appraisal Team l l l l l 1 indicated the following discre-1 I I I I I pancies:
I l i I I I I l l l l l a) Reinforcement lapped horizon-1 I l l l l tally instead of vertically.
l l l l l l l l l l l l b) Nonconformance Report 1851 did l l l l l l not indicate adequate investi-1 I I l l l gation of initial honeycomb l l l l l l and did not identify deviations l l l l l l In rebar placement.
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: l COMENT:
I I l 6) a) The orientation of lap splices was not clearly defined on the l l shop drawings and was left to the contractor. . Lap splices can l l be in either plane. I I I l b) See 1) and 3) above (on preceding page). I I I I I I I I I I I I l l
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Appendix C I STRUCTURA. C[NPONENT BEAM 3B10, ELEV 501'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETOi NO. SK 5) SHEET 1 0F 1 1 REIW m CEMENT I REIWORCEMENT I l l REQUIRED BY ORIGINAL I REQUIRED BY ANALYSIS I AS-BUILT COPOITIONS (SEE SKETCH NOTED) l DISCREPANCIES l DESIGN AND SHOWN ON l Fm MOST CRITICAL I I I DESIGN DRAWINGS I OPERATING /SSE LOAD .I LOCATION OF 1 BOTTOM BARS I DOWELS I C0f0ITION l EXCAVATION EXPOSED EXPOSED 1 l SECTION A-A I SECTION A-A i 1 - ,
l ALL EXCAVATIONS I I I I I I i l Botte Bars: 7-#10 l Bottom Bars: 4-#10 1 4'-9" West l 7'-#10 I None - l 1) One bar spacing deviation.
l l . I of column l I Main bars l
,I Top Bars: 4-#9 l Top Bars: 3-#9 I line 8.3 l l extend dir- 1 I I i l I ectly into l l l l l l supports. I I I I I I I I I I I I I I I I I I I I l 1 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I i 1 1
'I I I I I I
.I I I I I I
'I I I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: I C0fMENT:
I I i 1) Excavation demonstrated that concrete is fully consolidated and i 1) Beam 3810 has been reanalyzed and checked and
, I tightly bancbd to rebars, indicating that the deviation has not I found to be structurally adequate.
I adversely affected concrete placement. l l l 2) Dimensions and bar sizes shown on as-built
!l l sketch SK-5 have been verified.
I I l iI i l i I l I l 1
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O O h'd Appendix C
] STRUCTURAL COMPONENT BEAM 38-18, ELEV 501'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETCH NO. SK 6) _ _ .
SHEET 1 0F 2 l REIWmCEMENI l REIWORCEMENT l l l REQUIRED BY mIGINAL l REQUIRED BY ANALYSIS l AS-BUILT C0f0ITIONS (SEE SKETCH NOTED) I DISCREPANCIES l DESIGN AND SHOWN ON I FOR MOST CRITICAL l 1 l DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF I BOTTCM BARS l DOWELS l l l C0f0ITION EXCAVATION EXPOSED '
EXPOSED l SECTION A-A l SECTION A-A I j i
l 4 ALL EXCAVATIONS I 1 l l I i l Bottm Bars: 24-#11 l Botts Bars: 17-#11 l 5'-6" West l 8-#11 l 5-#11 11) Rebar spacing deviations.
l in 3 layers 1 in 2 layers I of column l l (None l I l I line 7.7 l l requied) l 2) One of 8 dowels was not located.
I I I I I I l Bottcm Bar Dowels: l Bottm Bar Dowels: I l l l 3) NRC Construction Appraisal Team '
l None required l None required i
l l l l noted that reinforcement was
1 l Top Bars: 16-#10 i Top Bars: 8-#10 l 1 l l lapped horizontally, contrary to !
l in 2 layers J l l l l required vertical lapping. l l l l l I 1:
I I I I I I il SECTION B-B l SECTION B-B l l l l l l Bottom Bars: 24-#11 i Bottom Bars: 17-#11 l l'-0" East i 8-#11 l 7-#11 l l 1' 1 l of colmn i I (None l l l l l line 7.7 *l l required) l l 1 I l i I I l l Bottom Bar Dowels: l Bottom Bar Dowels: l l I None required ' l None required l l l.
l l l 1 l l l l 1 I I I l Top Bars: 8-#10 l Top Bars: 8-#10 l l l l l l 1 l l l l l 1 I I I I l l RESOLUTION OF DISCREPANCIES: COMMENT: l
'1 l l 1 1) The deviation in spacing would be acceptable if the concrete were l 1) Beam 3B-18 bes been reanalyzed and checked and l l adequately consolidated. The concrete is fully consolidated and I found to be structurally adequate. ]
l the concrete is tightly bonded to the rebar. The deviations are l l acceptable.
l l
l 2) Dimensions and bar sizes shown on as-built I l sketch SK-6 have been verified. I l 2) ACI 318-71 requires that only one-fourth of the positive moment l l l reinforcement (bottom bars) extend into the support. The number 1 3) Contractor provided extra-long dowels (25'-0") l l of dowels observed exceeds the number required by code. Therefore, I to insure proper development length in both the I l even if the bar is assumed to be missing the beam would be accept- l beam and the bioshield wall. The dowels appear l l able. ~1n Section A-A and B-B but are not required.
I l
- w
g .*
~
Appendix C l STRUCTURAL COMPONENT BEAM 38-18, ELEV '501'-0", WNC/REINF BY CONTRACT 6426 (SEE SKETOi NO. SK 6) SHEET 2 0F 2 l REIW m CEMENT l REIWORCEMENT l l l REQUIRED BY.mIGINAL l REQUIRED BY ANALYSIS l AS-BUILT C0tOITIONS (SEE SKETCH NOTED) l DISCREPANCIES I DESIGN MO SHOWN ON l .Fm MOST CRITICAL I l l DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF l BOTTOM BARS l . DOWELS l C0tOITION EXCAVATION EXPOSED -EXPOSED SECTION C-C l SECTION C-C . l , ALL EXCAVATIONS I l l l l l l Botte Bars: 24-#11 l Bottm Bars: 17-#11-l 5'-0" East .1 8-#11 l 7-#11 l l in 3 layers I.in 3 layers I of column l l l l l l line 7.7 l l l l l l l l l l Botte Bar Dowels: l Botte Bar Dowels: l l l l l 8-#11 into bioshield l 5-#11 into bioshield I 'l l l l walls l gall (code minimun) l l l l l l l l l l l Top Bars: 8-#10 l Top Bars: 8-#10 l l l l l l l l l l l SECTION 0-D l SECTION D-D l l l l l l l' l l l l Botte Bars: 8-#11 l Bottm Bars: 8-#11 l 3'-3" East i 8-#11 l -
1 i l l of column l l l
- l l l line 8.3 l l~ l .
l I l l l l l Botte Bar Dowels: l Botta Bar Dowels: l l l l l No dowels required l None required l 1 l l l at supporting beam l l l l l l l l l l l l Top Bars: 16-#10 l Top Bars: 8-fl0 l l l l
-l in 2 layers l l l l l l 1 -l l 1 l l l l l l l RESOLUTION OF DISCREPANCIES: i COPNENT:
l l l 3) The orientation of lap splices was not clearly defined on the l l placement drawings and was left to the contractor. Lap splices l ,
l can be in either plane. This does not represent a discrepancy. l I .I I l' l l l
l 1
W. r u, Q,/ & .
N - @TES:
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SEC TIOM A-A 3 BEAM 4 B30 A4-I%h6r VERtPet.ATeeM DT MI FWT., N ssnt w M we thW ce.a:. A f*PhE D Ewfs di .M k ' 9/Ob A h QG,c thG;h 4All'-2 SK ~ 7l?
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Appendix C '
I STRUCTURAL COMPONENT BEAM 4830, ELEV 522'-0", CONC /REINF BY CONTRACT 206A (SEE SKETCH NO. SK 7) SHEET 1 0F 1
'I REIW m CEMENT l REIWORCEMENT l l l REQUIRED BY mIGINAL I REQUIRED BY ANALYSIS l AS-BUILT C0f0ITIONS (SEE SKETCH NOTED) l DISCREPANCIES I DESIGN AND SHOWN ON I Fm MOST CRITICAL i i i DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF 1 BOTTOM BARS I DOWELS I C0bOITION EXCAVATION 1 EXPOSED l EXPOSED i SECTION A-A l SECTION A-A I I- 1 ALL EXCAVATIONS I I ,I I I I I Bottom Bars: 7-#11 l Bottom Bars: 2-#11 1 4'-9" North l 7-#11 I None - Main l 1) 1 1/2" aggregate concrete was I l I of column l l bottom bars I substituted for 3/4" aggregate l l l line H.7 l l extend dir- I concrete (required by specifica-l l l l l ectly into I tion) without a Request for In-l Top Bars: 5-# 11 l Top Bars: 3-#11 l l l supports. I formation.
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I' I I I I I I I I I I I I I I -
l RESOLUTION OF DISCREPANCIES: l COP 44ENT:
1 I I 1) Excavation demonstrated that the concrete is fully consolidated, 11) Beam 4830 has been reanalyzed and checked and I as evidenced by aggregate penetration, especially into the bottom I found to be structurally adequate.
I corners of the beam, and that the concrete is tightly bonded to l I rebars. It is apparent that the use of 1 1/2 inch aggregate did I 2) Bar sizes and dimensions shown on as-built I not adversely affect concrete placement. I sketch SK-7 have been verified.
I I I I I I I I I I I I I
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Appendix C -
l STRUCTURAL COMPONENT BEAM 6B9, ELEV 572'-0", CONC /REINF BY CONTRACT 206A (SEE SKETCH NO. SK 8) SHEET 10F 1 l REIW m CEMENT I REIW m CEMENT I l l REQUIRED BY ORIGINAL i REQUIRED BY - ANALYSIS l AS-BUILT C0f0ITIONS (SEE SKETCH NOTED) I DISCREPANCIES-I DESIGN AND SHOWN ON I Fm MOST CRITICAL I I I DESIGN ORAWINGS l OPERATING /SSE LOAD I LOCATION OF l BOTTOM BARS l 00WELS I l COPOITION EXCAVATION EXPOSED I EXPOSED SECTION A-A l SECTION A-A l ,
l l ALL EXCAVATIONS I I I I I I l Bottom Bars: 4-#10 i Bottom Bars: 2-#10 l 12'-6" SouthI 4-#10 l 4-#10 1 1) Rebar spacing deviation.
l l l of column l I l l l l line .] l l l 2) 1 1/2" aggregate was substituted l l l l l l for 3/4" aggregate without a Re-l Bottom Bar Dowels: I Bottom Bar Dowels: I I I I quest for Information.
l 4-#10 into bioshield I l-#10 (code minimum) l l l l l call l I l l l l l l 1 I I l Top Bars: 5-#10 1 Top Bars: 2-#10 l l l l l l l l l l 1 1 I I I I I I I I i I I i i I i i I I I I I I I I I I I I I I I I I l I I I I I I I I I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: I COPNENT:
I I I 1) The deviation in spacing would be acceptable if the concrete were l 1) Beam 689 has been reanalyzed and checked and I adeqmtaly consolidated. The concrete is fully consolidated and I found to be structurally adequate.
I the concrete is tightly bonded to the rebar. The deviation is l l acceptable. I 2) Dimensions and bar sizes shown on as-built i I sketch SK-8 have been verified.
I 2) Excavation demonstrated that the concrete is fully consolidated; 1 I specifically, that there was good penetration of large aggregate l l throutf1 rebars and that the concrete was tightly bonded to the - 1 I rebars. It is apparent that the use of 1 1/2 inch aggregate did l l not adversely affect concrete placement. 1 I I I
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Appendix C -
I STRUCTURAL COMPONENT PILASTER /COLtNN, EVEL. 448'-0" CONC /REINF BY CONTRACT 206 (SEE SKETW NO. SK 9) SHEET 10F 1 1 REIWmCEMENT l REIWORCEMENT l l l REQUIRED BY ORIGINAL I REQUIRED BY ANALYSIS I AS-BUILT C0tOITIONS (SEE SKETCH NOTED) I DISCREPANCIES I DESIGN AND SHOWN ON I Fm MOST CRITICAL l l l DESIGN DRAWINGS I OPERATING /SSE LOAD l LOCATION OF I BARS l DOWELS .I C0tOITION EXCAVATION EXPOSED EXPOSED VIEW A-A l l l VIEW A-A - ALL EXCAVATIONS I I I I I I l Colunn Bars: I Same as original I Column i 11-#11 with I N/A l None 1 11-f11 in each I design i M-3.4 at I alternate l l l 7'-0" face l l elev. I staggered I l l l l 448'-0" I lap splice l I l Ties: #4 at 24' O.C.l i l l i l l I I I I I I I I I I I I I I I l l I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I i l RESOLUTION OF DISCREPANCIES: l C0tNENT:
I I l N/A I 1) Excavation demonstrated that the concrete is l l fully consolidated and tightly bonded to the l l rebar.
I I l l 2) The dimensions and bar sizes shown on as-built i I sketch SK-9 have been reverified.
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Appendix C * '
l STRUCTURAL COMPONENT WEST EXIT-HIm WALL ELEV. 493'-0", CONTRACT 6426 (SEE SKETCH NO. SK.10) SHEET 1 0F 1 i REIWmCEMENT I REIWORCEMENT l l l REQUIRED BY ORIGINAL l REQUIRED BY ANALYSIS l AS-BUILT CONDITIONS (SEE SKETCH NOTED) I DISCREPANCIES l DESIGN Af0 SHOWN ON I Fm MOST CRITICAL l l l DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF.l BARS I DOWELS I i WPOITION EXCAVATION EXPOSED EXPOSED i ELEVATION VIEW A-A l ,
ELEV VIEW A-A. l ALL EXCAVATIONS I l l~ l l I l (Interior face) l Same as original i Interior I (Interior l N/A l None l l Vartical Bars: I design i face of walll face) Ver- l l l l #11 at 9" 0.C. l I on column I tical Bars: l l l l each face l l line 9.4, I #11 at 9" l I i l l l 4'-0" North l 0.C. l l l l l l of column l l l l l Horizontal Bars: l l line N.8 i Horizontal l I l l #11 at 12" 0.C. I I I Bars: #11 l l I I sch face l l l at 12" and 1 I I l l l l 13" 0.C. l l l l l l l l 1 l I I I I I I I I l' I I I I 1 I I I I I I I I I I I I I I i i I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: ! COM ENT: l I I I I N/A I 1) West exterior wall has been reanalyzed and l I I checked and found to be structurally adequate. l I I I l l 2) Exposed concrete is adequately consolidated with l 1 some evidence of very minor air pockets. The l
! l concrete is tightly bonded to the rebar. l I I I l
l 3) Dimensions and bar sizes shown on as-built l I I sketch SK-10 have been verified. I I I I I I I I
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d b. Appendix C - l STRUCTURAL COMPONENT ORYER-SEPARATE POOL WALL, ELEV 578'-7 1/2", CONTRACT 206A (SEE SKETCH NO. SK-ll) SHEET 1 OF 1 ! I REIWmCEMENT l REIWmCEMENT l l l REQUIRED BY WIGINAL l REQJIRED BY ANALYSIS I AS-BUILT COFOITIONS (SEE SKETm NOTED) l DISCREPANCIES I DESIGN AND SHOWN ON l Fm MOST CRITICAL l l l DESIGN ORAWINGS l OPERATING /SSE LOAD 1 LOCATION OF l BOTTOM BARS l DOWELS l l COM)ITION EXCAVATION EXPOSED EXPOSED SECTION A-A & B-B 1 SECTION A-A & B-B , 1 ALL EXCAVATIONS I I I I I I l Beam i Beam l On column l Beam l N/A l None l Bottom Bars: 36-410 l Same as original I line K l Bottom Bars:l I i l in 3 layers l design l 10'-0" East l 12-J10 in l I l l l of column I bottom l l l l l line 4.3 l layer i i l I I I I I l Slab l Slab l l Slab I l l Bottom Bars: #11 l Same as original l l l-#11 and l l l st 10" 0.C. each way I design l I l-#9 (or l l l l l l #10) bars l l l l l l were ex- 1 I l l l l posed l l 1 I I I I I I I I I I I I I I I I I l l l l l l l l l l l l l l l l l 1 I I I I I I l i l I I l l_ RESOLUTION OF DISCREPANCIES: l COPNENT: l l l N/A I 1) No discrepancies noted, tnerefore, no reanalysis l I is required. The bar spacing is acceptable. I I l l 2) Dimensions and bar sizes shown on as-built i i sketch SK-ll have been verified. I I l l 3) Excavation demonstrated that exposed concrete l l 1s adequately consolidated and tightly bonded l l to the rebar. I I I I I C _ __U
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h Appendix C l STRUCTURAL COMPONENT FUEL POOL WALL ELEV. 588'-2 1/2", CONC /REINF BY CONTRACT 206A (SEE SKET W NO. SK-12) SHEET 1 0F 2 l REIWORCEMENT l REIW ORCEMENT l l l REQUIRED BY mIGINAL l REQUIRED BY ANALYSIS l AS-BUILT COIOITIONS (SEE SKETm NOTED) l DISCREPANCIES l DESIGN MO SHOWN ON l Fm MOST CRITICAL l l l DESIGN ORAWINGS I OPERATING /SSE LOAD l LOCATION OF l BARS l DOWELS l l COM)ITION EXCAVATION l EXPOSED EXPOSED SECTION A-A l SECTION A-A l . l l ALL ETCAVATIONS I I I I I .I l Vertical: Outer l Same as original l On column l Vertical: l l 1) The 22-#10 bars were not placed I layer: #11 at 9" l design l line K l #11 2 layersl l in accordance with RFI 206A-1672. l 0.C., lap splices l l 2'-8" East I see SK-12 l l l start at Elev 588'- l l of column l l l 2) Bar spacing in Section E-E,. I 2 1/2" l l line 8.3 -l l l (SK-12). l Imer Layer: #11 at l l l l l l 9" 0.C., up to Elev i l l l l 3) NRC CAT Representative noted that l 599'-10 1/2" +/- l l l l l third layer of relocated 22-#10 l l I l l I bars was not visible as directed l Horizontal Bars: i Same as origint.- l l Horizontal: l l in answer to contractors Request l #11 at 10" 0.C. I design' l l #11-1 layer l l for Information 206A-1672. I each face l l l See SK-12 l l l l l l l l l Additional Bars: l Additional Bars: l l Additional l l l 22-#10 as a con- l At construction l l Bars: l l l struction aid during i joint: Not required l l 7-#10 l l l placing of concrete l l l exposed l l l in the upper wall l l l l l l above Elev 588'- l l l l l l 2 1/2" l l l l l l RESOLUTION OF DISCREPANCIES: I COP 44ENT: 1 I . I 1) RFI 206A-1672 permitted contractor to revise placement of the i 1) The fuel pool wall has been reanalyzed and l 22-#10 bars from 2 layers to 3 layers (of 8,8 and 6 bars) in order I checked and is structurally adequate. I to provide access through the middle of the wall for tremie and l l vibrator use. The depth of the excavation for the #10 bars is l 2) Subsequent to the PRC Representative's visit, I approximately one-fourth the width of the wall (60 inches). Ex- l placement procedures were discussed with the I trapolation of this qmntity would provide reasonable assurance l Foreman of reinforcing during concrete placement. ' I that 22-#10 bars were placed. l He indicated that the bars were relocated to l I provide access for a tremie in order to properly 1 2) The spacing deviation would be acceptable provided that concrete i place the concrete in the wall below the bars. l tras adeqtately consolidated around the bars. Excavation demon- l strated that the exposed concrete is fully consolidated and is l
- lI tightly boncbd to the rebar.
- I
g Appendix C ' I STRUCTURAL COMPONENT FUEL POOL WALL ELEV. 588'-2 1/2", CONC /REINF BY CONTRACT 206A (SEE SKETCH NO. SK-12) SHEET 2 0F 2 I REIWmCEMENT l REIWORCEMENT I l l REQUIRED BY ORIGINAL I REQUIRED BY ANALYSIS I AS-BUILT COBOITIONS (SEE SKETOi NOTED) l , DISCREPANCIES I DESIGN AND SHOWN ON I Fm MOST CRITICAL l 1 l DESIGN DRAWINGS I OPERATING /SSE LOAD I LOCATION OF I BARS I DOWELS I l l COPOITION EXCAVATION EXPOSED l EXPOSED I l l l l l I I I l l I I I I I I I I I I I I I I I I I I I I I I I I I I I 'l i I I I I I I I I I I I I i i i l I I I I I I I I I I I I I I I i 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I RESOLUTION OF DISCREPANCIES: 1 C0bNENT: I I I 3) Excavation subsequent to the NRC CAT Representative visit exposed l 3) Excavation demonstrated that the exposed concrete I the third layer of #10 bars as shown on as-built sketch SK-12. I is adequately consolidated and is tightly bonded l l to the rebars. I I I l 4) Dimensions and bar sizes shown on as-built l l sketch SK-12 have been verified. I I I I I I
! I I I I
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_ . _ _ . _ _m-- ._. _- ~ . _ . _ _ .. _ . _ _ . . _ y h b_ , i Appendix C l STRUCTLRAL COMPONENT FOUt0ATION MAT, ELEV. 422'-3", CONC /REINF BY CONTRACT 205 (SEE SKETW NO. SK-13) SHti.I 1 OF 1 1 REIWmCEMENT l REIW m CEMENT l l l l REQUIRED BY ORIGINAL l REQUIRED BY ANALYSIS I AS-BUILT CONDITIONS (SEE SKETW NOTED) l DISCREPANCIES l - DESIGN AND SHOWN ON l Fm MOST CRITICAL 1 l l DESIGN DRAWINGS I OPERATING /SSE LOAD l LOCATION OF l BOTTOM BARS I DOWELS I
- I COPOITION l EXCAVATION EXPOSED l EXPOSED PART PLAN AT ELEV. i I -
i l ALL EXCAVATIONS i l'422'-3" l I I I I Top bars: #18 at l Same as original .1 5'-0" North l _ Top bars: I N/A l 1) Spacing deviation between E-W bars , l1 18"+/-6" 0.C. each I design I of north l E-W: #18 l l partly due to need to avoid inter-I way l l face of walll at 141/2", I l ference with 12-2 inch ' diameter - 1 l l l on column l 7", 5" and l l anchor bolts in a 30 inch diameter
;I l l line N and l 16 1/2" 0.C.l l bolt circle.
l l l 8'-0 1/2" l N-S: #18 I I 1 l l East of I at 16" 0.C. l l '2) NRC Construction Appraisal Team . l l column line i l I identified one #11 sump face re-- lll Additional #11 and l l 9.4 l Additional l I bar a:, not located in accordance l l- #18 bars around l l l #11 E-W bar l I with concrete shop drawing. t I openings and at facesl l I from North l l ! , I of sump and elevator l l I face of l I l
- I pit. l l l sump and l l 1 l l l l #11 N-S l l l il i l I bar from l l l l l l l elevator l l l
'l 1 l l pit. l I l !I I I I I I ll l l l l l i 1-4 I I I I 3 I I I I RESOLUTION OF DISCREPANCIES: I CDP 44ENT: I' l1 l l-i l 1) -The spacing deviation would be acceptable provided that concrete i 1) The dimensions and bar sizes shown on as-built I !I was adeqtately consolidated around the bars. Excavation demon- l sketch SK-13 have been verified. l l strated that the exposed concrete is fully consolidated and is l l 1 tightly banchd to the rebar. l l l l 1 l 2) Both the design drawing and the shop drawing called for a vertical l l I configuration of #11 stsnp face bars but neither dimensioned their i l l location. The location of the top #11 is acceptable for design, I l l therefore, the discrepancy is resolved. l l l l l 1 I I I l l s
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q , b b b,., , Appendix C - I STRUCTURAL COMPOWENT FOUPOATION MAT, EEV 422'-3", CONC /REINF BY CONTRACT 205 (SEE SKETm NO. SK 14) SHEET 10F 1 1 REIWmCEMENT l REIWORCEMENT I l l REQUIRED BY ORIGINAL I REQUIRED BY ANALYSIS I AS-BUILT COPOITIONS (SEE SKETCH NOTED) I DISCREPANCIES l DESIGN AND SHOWN ON l Fm MOST CRITICAL l l l DESIGN DRAWINGS I OPERATING /SSE LGra l LOCATION OF l BARS l DOWELS l C0tOITION l EXCAVATION EXPOSED EXPOSED ' TPART PLAN AT EWV. ) - l ALL EXCAVATIONS I 422'-3" l l ,l 1 1 I Top bars: #18 at 1 Same as original l 5'-3" East l Top bars l N/A I None i 18" +/- 6" O.C. I design I of column l E-W" #18 at i I l each way l l line 7 and I l'-8" 0.C. l l l l l 3'-9" South I N-S: #18 I I l l l of south I at l'-7" l l l l l face of wall 1 0.C. 1 I l l l an colunn l l l l l l line N l l l l l l l l l l l l l l 1 1 I I I I I I I I I I I I I I I I I l l 1 I I I I I I I I I I I I I I i 1 I I I I I I I I I I I I I I I I I I I I I - 1 i 1 RESOLui10N OF DISCREPANCIES: l COWENT: 1 I l N/A l 1) The exposed concrete is fully consolidated and l l 1s tightly bonded to the rebar. I I I I 2) The dimensions and bar sizes shown on as-built l l sketch SK-14 have been verified. I I I I I I { l i I I I l ( l
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A .. h Appendix C I STRUCTURAL COMPONENT F0utOATION MAT, EEV 422'-3" CONC /REINF BY CONTRACT 205 (SEE SKETm NO. SK 15) SHEET 1 0F 1 l REIWORCEMENT l REIWORCEMENT l l l REQ'JIRED BY MIGINAL I REQUIRED BY ANALYSIS I AS-BUILT CONDITIONS (SEE SKETm NOTED) l DISCREPANCIES i. l DESIGN AND SHOWN ON l Fm MOST CRITICAL I I i-l DESIGN DRAWINGS I OPERATING /SSE LOAD l LOCATION OF 1 BARS DOWELS I l 'l C0bOITION EXCAVATION EXPOSED EXPOSED l l PART PLAN AT EEV. l l i ALL EXCAVATIONS l l 422'-3" l l l l l 1 I Top bars: #18 at I Same as original l 7'-6" South l Top bars I N/A l 1) Spacing deviation between #18 l. l 18"+/-6" 0.C. each I design I of column I N-S: #18 l l bars. l l way I l line K and I at l'-5" 0.Cl l l l 1 1 4'-6" East i E-W and l l l l Additional Bars: #18 l l of east i Additional l l l l at faces of pump pit l I face of ex- I bars at l l l l l l terior wall l pump pit l l l: l l l on column I face: #18 l l l l l l line 9-4 l at 5", 8" l l l l l l l and 41/2" i l l I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I l I I I I I I I I I I I I I I .I I I I I I I I I RESOLUTION OF DISCREPANCIES: l C0>e4ENT: I l l I i 1) The spacing deviation would be acceptable provided that the con- l 1) The dimensions and bar sizes shown on as-built l l crete was adeqmtely consolidated around the bars. Excavation I sketch SK-15 have been verified. l l demonstrated that the exposed concrete is fully consolidated and l l l 1s tightly bonded to the rebar. Upon completion of patching, the l l l discrepancy will have been resolved. I l l l I I I I I I I I I I I I I I I I I I
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j h . Anendix C l STRUCTURAL COMPONENT FL0m SLAB ELEV 471'-0", CONC /EINF BY CONTRACT 6426 (SEE SKETCH NO. SK-16) SHEET 10F 1 I REIWmCEMENT l REIWmCEMENT [. l l REQUIRED BY W IGINAL l REQUIRED BY ANALYSIS l AS-BUILT C0tOITIONS (SEE SKETCH i NOTED) DISCREPANCIES I DESIGN AND SFOWN ON l Fm MOST CRITICAL I l DESIGN ORAWIt'GS l
' l OPERATING /SSE LOAD l LOCATION OF 1 BARS I DOWELS l C0tOITION 1 EM'AVATION EXPOSED EXPOSED PLAN AT ELEV 471'-0" { { j -
l 1 Top BARS: #6 at l Same as original ALL EXCAVATIONS 1 i 12" 0.C. mch way l 3'-6" South l Bottom bars: 1 N/A 1 None I design I of column l Not exposed l l l l l l line H.3 andl l 1 1 I l l 2'-0" West l Top bars: l l l 1 l l of column l E-W: #6 I I l 1 I line 6 I at l'-1 1/4"l l l l-l l 1 I I I I l i l I l N-S: #6 at l l l I i l l'-0 1/4" l l l I l l l l and l'- l I 1. l l l l 0 1/4" l l l 1 l l l 1 I I I I I I 1 I I I I I I I I I l I I. l ~! i l I I I I I I I I I i I I I l I l l 1 l I I 1 I I I l I I I I l l l l 1 l I I I i l l rtESOLUTION OF DISCREPANCIES: I COWENT: 1 1 1 I N/A I I l 1) Excavation demonstrated that exposed concrete l l i is fully consolidated and is tightly bonded l l l to the rebar. l l 1 I l 2) Dimensions and bar sizes shown on as-built l I I sketch SK-16 have been verified. l I I I I I ' I I i I l I i I i I 1
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O Q2 & Appendix C ' l STRUCTURAL COMPONENT EAST EXTERIM WALL ELEV 476'-0", CONC /REINF BY CONTRACT 6426 (SEE SKETCH NO. SK-17) SHEET 1 0F 1 l REIW mCEMENT l REIWORCEMENT l l l REQUIRED BY ORIGINAL l REQUIRED BY ANALYSIS l AS-BUILT C0tOITIONS (SEE SKETm NOTED) l DISCREPANCIES l DESIGN AND SH3WN ON l Fm MOST CRITICAL l l l DESIGN DRAWINGS l OPERATING /SSE LOAD l LOCATION OF l BARS I DOWELS l C0tOITION EXCAVATION EXPOSED EXPOSED l ELEVATION A-A & B-B l l ! INTERIM FACEI i ALL EXCAVATIONS l Vertical bars: #11 l Same as original l On column l Vertical: 1 N/A l 1) During NRC CAT visit on July 25 l at 9" 0.C., each faceI design I line 3.4 andl #11 at l l and 26, 1983, the CAT Representa-l l l 8'-6" North l 7 1/2" l l tive postulated that every hori-l l l of column I to 10 1/4"0Cl l zontal rebar is spliced on the l Horizontal bars: l l line N l Horizontal: l l exterior face. I #11 at 12" 0.C. each l l (South of I #11 at l'- l l l face, south of I l column line l 0 5/8" to l l 2) "C1" splice length call-out noted l colunn line M l l M) l l'-0 7/8" l l at interior face is in error. I I I l 0.C. l I , I I I l l l l l l l EXTERIOR l l ,I l l l FACE l l l l l l vertica': 1 I l #11 at 11" 0.C., l l l #11 0 -l'- l l '.1 North of column line l 4 l l 0 5/8" to l l lM l l l l'-0 7/8" l l J ~ l l l 0.C. l l l l l l Horizontal: l l l l l l #11 varies l l
, I l l l from 9" to l l l l l l 12" l l l RETLUTION OF DISCREPANCIES: l C0tNENT:
l . l l 1) Vendor Drawing BS-RB-33 shows staggered laps of #11 bars spaced at l 1) Excavation demonstrated that the exposed concrete l 11" 0.C. to #11 bars spaced at 12" 0.C. As shown on sketch SK-17A l 1s fully consolidated and tightly bonded to the
! (detailed layout of bars), the spacing of bars is such that some I rebar.
I bars will not be contact or non-contact spliced. Request for In- l l formation 6426-329 was submitted by the contractor requesting tech- l 2) Dimensions and bar sizes shown on as-built I nical direction to resolve the problem. In response, the engineer i sketch SK-17 have been verified. I directed the contractor to add 2xB3 splices at such locations. The l l add 2 *lonal bars are shown on sketch SK-17B, and are the additional l
! hor. ontal bars fomd in the excavation. These additional bars l l satisfy the original tbsign intent. l I I l 2) The'use of "Cl" splice (11'-9") instead of an embedment "E3" (5'-6")
! is conservative and does not represent a deficiency in this case.
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APPENDIX D PAGE 1 of 2 WCQAP-007
@ Westinghouse Water Reactor Ri:h:and P;cgram 0mce Electric Corporation Divisions sexeos Richland Washington 99352 509 375 5223 September 15, 1983 Mr. H. A. Crisp, WNP-2 Construction Manager Washington Public Power Supply System 3000 George Washington Way Richland, Washington 99352
Subject:
EVALUATION OF REINFMCED CONCRETE STRUCTURAL MEMBERS IN WNP-2 REACTOR BUILDING The Westinghouse Construction Quality Assessment Team nave completed review of the Supply System evaluation of concrete structures as described in the Supply System Report " Evaluation of Concrete and Reinforcing Steel for Washington Public Power Supply System Unit #2". We have reviewed the excavations as well as all documentation related thereto and concur with the conclusion of the report that the as-built structures are structurally adequate for all speci-fled loads. The Westinghouse review was performed by Mr. H.P. Bonnet and Mr. R.S. Orr. Mr. H.P. Bonnet has thirty-four (34) years of experience in Structural (.. r Engineering. His specific experience related to concrete structures in-cludes four (4) years field engineering for concrete bridges and founda- . tions , complete supervision of design, drafting and review of, shop draw-ings for some very heavily reinforced concrete structures including Titan 1 mdergromd missile bases, heavy machinery foundations for the steel indJstry, paper machine structures, turbine generator foundations, an extremely large prestressed concrete building and many very large rein-forced concrete chimneys, silos and their foundations. Mr. Bonnet has ! been a member of ACI Committee 307 (Reinforced Concrete Chimneys) for the i past ten (10) years. l l Nr. R.S. Orr has twenty-one (21) years experience in all structural as- ' pects of nuclear power plants. His specific experience related to con-
~ cret'e structures includes design and construction inspsection for fossil power plants, design evaluation of prestressed concrete reactor vessels l and prestressed and reinforced concrete containment,and technical super-
! vision of all concrete structures design and licensing for the Floating l Nuclear Plant. Mr. Orr has participated on concrete code committees since 1968 and was Chairman of ACI Committee 349, Concrete Nuclear i Structures from 1977 to 1982. l The Westinghouse review covered the following items significant to the evalua-l tion of the seventeen (17) structural members investigated in the Supply
- System Program. -
l
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APPENDIX 0 PAGE 2 of 2
- 1. Westinghouse reviewed the Inspection Reports and Notices of Violations g issued by the NRC as well as participating in the site meetings with NRC between July 25-27.
- 2. Westinghouse made a detailed survey of all the concrete excavations (23).
This survey included a location check of the excavation, a complete dimensional check for each rebar exposed, and a size check for rebar (where possible).
- 3. In addition a complete survey was made at every excavation to check for concrete consolidation and bond to rebar.
- 4. All as-built drawings made by Burns and Roe were verified for dimensions and size of rebar. -
- 5. All as-built drawings were reviewed against the design drawings, shop drawings and any Requests for Information which affected the reinforcing steel placement.
- 6. The design criteria being used by Burns and Roe in their re-analysis of the structural beams was reviewed against the commitments of the FSAR.
- 7. Design philosophy and methodology used by Burns and Roe for re-analysis of the beams was reviewed.
- 8. The Burns and Roe calculations for three beams 285, 2B11 and 2825 were g' verified in detail. (Design loads were taken from previously verified Burns and Roe calculations and were not verified in the Westinghouse review.) Other calculations were reviewed for methodology.
- 9. Burns and Roe evaluations of the impact of differences between design, shop and as-built drawings were reviewed for concurrence and completeness.
- 10. Procedures for patching of all excavated ares except 2B11 and 2B25 have been reviewed. The procedure for patching 2811 and 2B25 will .be reviewed as soon as it is finalized by the Supply System.
The above review was commenced at the beginning of July and was performed in parallel with the Burns and Roe evaluation. WestinghaJse provided comments on the program during the course of the review and all comments have bet.n ade-quately adfressed in the final report. i l u!vu H.'P. Bonnet M 0rr Manager, Construction Quality Assessment Program s O
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