ML102720498

3.4 Exhibit 7a, Petrographic Report

ML102720498
Person / Time
Site:	Crystal River
Issue date:	11/11/2009
From:	MACTEC Engineering & Consulting
To:	Chris Miller Progress Energy Co, Office of Information Services
References
FOIA/PA-2010-0116
Download: ML102720498 (16)

Text

FM 3.4 Exhibit 7a Page 1 of 17

,8MACTEC engineering and constructing a better tomorrow November I 1 2009 Mr. Craig Miller Progress Energy (352) 795-6486 ex 1026 Craig~miller@pgnrnail.com

Subject:

Report of Petrographic Observations Crystal River Containment Wall Steam Generator Replacement Project Crystal River Nuclear Generating Facility, Florida MACTEC Project No. 6468-09-2535 Dear Mr.

MACTEC Engineering and Consulting, Inc. (MACTEC) is pleased to present this report of our petrographic observations performed on two concrete cores that were shipped to our laboratory under chain of custody. An additional core was received under chain of custody for limited observations. It is our understanding the two cores submitted for petrographic observations are from an area of the containment wall where a fracture was discovered, running parallel to the surface at a depth of' approximately 8 to 9 inches. We understand the core that was submitted for limited observations was from an area where the subject fracture had not occurred.

The cores submitted are as follows:

Core Number Laboratory Number Description of the Core Assigned by MACTEC 5

21269 From an area where the fracture had occurred 52 21270 From an area where the fracture had not occurred 7

21271

] From an area where the fracture had occurred Each core was photo documented as received and then saw cut longitudinally into halves. Each half was labeled with the same sample number and than A and B were added to designate the halves. As requested the H half for cores 21269 and 21270 were shipped to CTL Group in Skokie Illinois. The B half of core 21271 is being held for possible future use. The A half's of the cores were used for our analysis.

The purpose of our work was to perform a petrographic analysis of samples 21269A and 21271A and limited observations of sample 21270A. It is our understanding that you also require specific information MACTEC Engineering and Consulting, Inc.

9177 Sky Park Court, San Diego, CA 92123

• Phone: 858-278-3600 - Fax: 858-278-5300 wwwmactec.com

FM 3.4 Exhibit 7a Page 2 of 17 Crstal River Concrete Core Obsen,ations November II, 2009 Report of Petrographic Observations MACTEC Project No, 6468-09-2535 Crystal River Nuclear Generating lariity, Florida relative to the age of the fractured surfaces on samples 21269A and 2127IA. Sample 21270A was used as a control sample that did not have a fractured surface.

Petrographic Observations A Petrographic Analysis is a visual and microscopic analysis of cernentitous materials performed by a qualified petrographer.

Petrographic examinations are typically performed on polished sections or thin sections. Polished sections are generally cut sections that have been lapped (ground flat and smooth) and polished and are observed using reflected polarized light microscopes at magnifications of up to 80X.

Thin sections are samples mounted to glass slides and ground to specific thicknesses (generally 20, 30, or 40 microns depending on the application) and observed using transmitted polarized light microscopes at magnifications of up to 600X.

A petrographic evaluation may be performed to identify and describe a specific item of interest such as the presence or extent of distress in concrete, or to provide a general characterization and measure of quality of the materials being evaluated.

The petrographic evaluation of concrete examines the constituents of the concrete including coarse aggregates, fine aggregates, embedded items, hardened paste, and air void structure. The examination identifies cracking present in the concrete, indications of corrosion, extent of damage from external sources, aggregate reaction, chemical attack, sulfate attack, freeze thaw cracking, acid attack, and other mechanisms of deterioration. The petrographic examination can also estimate the water to cement ratio, look for indications of mineral additives and unhydrated cernent particles in the paste, look for indications of bleed water and excess porosity in the concrete, look for indications of curing procedures used and methods of finishing, observe micro cracking present and other conditions within the concrete which might give information on the overall quality or the quality of any particular constituent material. Aggregate mineralogy, rock types, and mineral crystal structure can be identified when thin sections are viewed under a transmitted polarized light microscope.

TEST RESULTS AND OBSERVATIONS PETROGRAPHIC OBSERVATIONS The petrographic analysis was performed in general accordance with the applicable sections of ASTM C 856-04 Standard Practice for Petrographic Examination of Hardened Concrete.

The results of our petrographic analysis are on the attached sheets, Summary of Petrographic Observations of Hardened Concrete.

Photographs from our examination are attached.

A summary of our observations and discussion are as follows.

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FM 3.4 Exhibit 7a Page 3 of 17 Crvstal River Concrete Core Observations Report of Peirographic Observations CoYstal River Nuclear Generating Facility. Florida November I/, 2009 AM CTEC Project No. 6468-09-2535 Apmreaate The coarse aggregate generally consisted of a natural carbonate crushed rock with a maximum size of 3/4 inch. The rocks types observed included limestone, fossiliferous limestone, and a few particles of chert and/or limestone and chert. The particles were generally angular to sub-rounded in shape and fairly evenly distributed. The coarse aggregate appeared to comprise approximately 50% of the total aggregate quantity with the remaining fraction being fine aggregate.

On sample 21271, there were 4 coarse aggregate pieces on the cut surface of the core that retained moisture (and moisture in the surrounding paste) longer than other portions of the sample. These pieces are shown in Photographs 5, 6, 7, and 8. One of the pieces (Photograph 5 for core 21271) had a darkened rim. A thin section was prepared from the piece in photograph 7 and this piece contained microcrystalline quartz and radial silica and exhibited localized evidence of alkali silica reaction.

The fine aggregate was observed to be a natural siliceous sand consisting mostly of quartz. The particles were generally sub-angular to sub-rounded in shape and fairly evenly distributed.

Cement Paste The cement paste was medium light gray (Reference colors from The Geological Society of America Rock-Color Chart, 1991). The paste appeared moderately hard and not easily scratched with a hardened steel point.

The concrete appeared to have been placed at a moderately low water to cement ratio, possibly in the range of 0.4 to 0.5. Indication of placement at a high water to cement ratio such as significant bleed channels and water gain voids were not observed.

Air Voids, Voids, and Cracks The concrete appeared to be air entrained and had a total air content estimated to be around 2 to 3%. The voids were generally small and spherical. Some air void clustering was observed around a few coarse aggregate particles. The air void distribution was moderately un-even and some small areas lacked air entrainment. There was limited mineral growth observed in some of the air voids. Calcium hydroxide was observed lining some air voids.

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FM 3.4 Exhibit 7a Page 4 of 17

%FMACTEC U

SUMMARY

OF PETROGRAPHIC OBSERVATIONS OF HARDENED CONCRETE - ASTM C-856-04 I

PROJECT NAME Crystal River Core Petrography Project PROJECT NUMBER 6468-09-2535 DATE SAMPLED RECEIVED 10-21-09 SAMPLE I.D.

21269A SAMPLE SIZE AND DESCRIPTION Concrete core, approximately 3 3/4/ inches in AS RECEIVED diameter, approximately 7 to 8 inches long.

OBSERVATIONS BY David Wilson CHARACTERISTICS.

OBSERVATIONS COARSE AGGREGATE:

Shape Angular to sub rounded Grading Approximately 3/4 maximum size Distribution Even. Approximately 50% of the aggregates appeared to be coarse aggregates with the remaining fraction being the fine aggregate.

Texture Fine Composition Carbonate Rock Types Limestone, fossiliferous limestone Alteration:

Not observed Degree Products Coatings Not observed Rims Not observed Internal Cracking Generally not observed except in the vicinity of the fractured surface Contamination Not observed FINE AGGREGATE:

Shape Generally sub-rounded to sub-angular Grading

1. 4 and smaller Distribution Even Texture Fine Composition I Siliceous Petrographic Observations, Sample LD. 21269A Page I of 3 Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, Project Principal

FM 3.4 Exhibit 7a Page 5 of 17 SMACTEC Rock Tyies Ouartz I

Alteration:

Not Observed Degree Products Coatings Not Observed Rims Not Observed Internal Cracking A few internal fiactures were observed Contamination Not observed CHARACTERISTICS OBSERVATIONS CONCRETE:

Air-Entrained or Not Appeared to have some air entrainment.

Total air content based on visual observations appeared to be 2 to 3%

Air Voids:

Mostly small and spherical. Some air void Shape clustering was observed around a few Size coarse aggregate particles. The air void Distribution distribution was moderately un-even, some small areas lacked air entrainment. There was some limited mineral growth observed in some of the air voids. Calcium hydroxide was observed lining some air voids.

Bleeding Not Observed Segregation Not Observed Aggregate-Paste Bond Coarse and fine aggregates appeared to have a good bond to the cement paste with few openings. Some aggregate particles had increased calcium hydroxide in the paste surrounding the perimeter of the particle.

Fractures One end of the core contained a fractured surface. There were some other minor fractures on the end with the fractured surface. On the fractured surface there was a white deposit in a few areas. The deposit exhibited desiccation cracking and appeared to contain fine cement paste particles and some angular quartz fragments. This deposit is expected to be

_ drilling slur Embedded Items Not observed Shape Size Petrographic Observations, Sample I.D. 21269A P,

Form Reviewed and Approved for Use on Oystal Rivetr Cores Project 6468-09-2535 J. Allan Tice, Project Principal zge 2of 3

FM 3.4 Exhibit 7a Page 6 of 17

%MACTEC Location Type Alteration:

Not observed Degree & Type Reaction Products

- Location

- Identification Nature and Condition of Surface There appeared to be white paint on the Treatments exterior surface of the core Estimated water-cement ratio (based on Appeared to have a moderately low w/c visual observations only) ratio possibly in the range of 0.4 to 0.5 Estimated cement content (based on visual Appeared to have a moderately high observations only) cement content PASTE:

Color (GSA rock color chart 1991)

Medium light gray Hardness Appeared moderately hard when scratched with a hardened steel point Porosity Did not appear very porous. It took from 10 minutes to over 20 minutes to absorb 15 micro liter drops of water.

Carbonation The outer 1/4 to V2 inch of the exterior surface was carbonated. The fractured surface was not carbonated.

Residual un-hydrated Cement:

Some un-hydrated/partially hy-drated Distribution cement particles were observed Particle Size Abundance Composition Mineral Admixtures:

Fly-ash was not observed Size Abundance Identification Contamination:

Not observed Size Abundance Identification Equipment Used:

Cannon EOS Digital Rebel with 50mm macro lens and microscope adapters AmScope 7X to 45X stereo zoom microscope (with and without polarized light)

Olympus BH-2 polarized light microscope Zeiss Photomicroscope 1I polarized light microscope Aven Digital Microscope Starrett 6 inch rule SN 109000003 Note: No M&TE used is subject to calibration requirements.

Petrographic Observations, Sample LD. 21269A Page 3 of 3 Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, Project Principal

FM 3.4 Exhibit 7a Page 7 of 17 SMACTEC Q 11F i EN q "ps I

SUMMARY

OF PETROGRAPHIC OBSERVATIONS OF HARDENED CONCRETE - ASTM C-856-04 Il PROJECT NAME Crystal River Core Petrography Project PROJECT NUMBER 6468-09-2535 DATE SAMPLED RECEIVED 10-25-09 SAMPLE I0D.

21271 A SAMPLE SIZE AND DESCRIPTION Concrete core, approximately 3 3/4 inches in AS RECEIVED diameter, approximately 7 to 8 inches long.

OBSERVATIONS BY David Wilson

• CHA C..

TICS OBSERVA. TLONS COARSE AGGREGATE:

Shape Angular to sub rounded Griading.

Approximately 3/4 maximum size Distribution Even. Approximately 50% of the aggregates appeared to be coarse aggregates with the remaining fraction being the fine aggregate.

Texture Fine Composition Carbonate, a few with siliceous deposits Rock Types Mostly limestone and fossiliferous limestone. 4 coarse aggregate particles on the cored surface retained moisture much longer than the other particles and one of these particles had a darkened rim Alteration:

Not observed Degree Products Coafingý Not observed Rims Not observed except for one particle Internal Cracking Generally not observed except in the vicinity of the fractured surface. One of the particles that retained moisture longer than the other particles (referenced in rock type section) was observed in thin section and contained microcrystalline quartz and Petrographic Observations, Sample I.D. 21271A Page I of4 Form Reviewed and Approvedfor Use on Crystal River Cores Project 6468-09-2535J. Allan Tice, Project Principal

FM 3.4 Exhibit 7a Page 8 of 17 SMACTEC radial silica (essentially chert) with the limestone, several cracks were observed going through the portion which was predominately chert. There appeared to be minor amounts of ASR gel but a positive identification could not be made due to the small amounts present.

Contamination Not observed FINE AGGREGATE:

Shape Generally sub-rounded to sub-angular Grading

1. 4 and smaller Distribution Even Texture Fine Composition Siliceous Rock Types Quartz Alteration:

Not Observed Degree Products Coatings Not Observed Rims Not Observed Internal Cracking A few internal fractures were observed Contamination Not observed I-CHARACTERISTICS OBSERVATIONS CONCRETE:

Air-Entrained or Not Appeared to have some air entrainment.

Total air content based on visual observations appeared to be 2 to 3%

Air Voids:

Mostly small and spherical. Some air void Shape clustering was observed around a few Size coarse aggregate particles. The air void Distribution distribution was moderately un-even, some small areas lacked air entrainment. There was some limited mineral growth observed in some of the air voids. Calcium hydroxide was observed lining some air voids.

Bleeding Not Observed Segregation Not Observed Aggregate-Paste Bond Coarse and fine aggregates appeared to have a good bond to the cement paste with few openings. Some aggregate particles had increased calcium hydroxide in the paste surrounding the perimeter of the Petrographic Observations, Sample LD. 21271A Form Reviewed and Approved for Use on Crystal River Cores Page 2 of4 Project 6468-09-2535 J. Allan Tice, Project Principal

FM 3.4 Exhibit 7a Page 9 of 17 SMACTEC Darticle.

Fractures One end of the core contained a fractured surface. There were some other minor fractures on the end with the fractured surface. There were some fractures associated the chert particle discussed previously.

Embedded Items Not observed Shape Size Location Type Alteration:

Not observed Degree & Type Reaction Products

- Location

- Identification Nature and Condition of Surface There appeared to be white paint on the Treatments exterior surface of the core Estimated water-cement ratio (based on Appeared to have a moderately low w/c visual observations only) ratio possibly in the range of 0.4 to 0.5 Estimated cement content (based on visual Appeared to have a moderately high observations only) cement content PASTE:

Color (GSA rock color chart 1991)

Medium light gray Hardness Appeared moderately hard when scratched with a hardened steel point Porosity Did not appear very porous. It took from 10 minutes to over 20 minutes to absorb 15 micro liter drops of water.

Carbonation The outer 1/4 to '/2 inch of the exterior surface was carbonated. The fractured surface was not carbonated.

Residual un-hydrated Cement:

Some un-hydrated/partially hydrated Distribution cement particles were observed Particle Size Abundance Composition Mineral Admixtures:

Fly-ash was not observed Size Abundance Identification Contamination:

Not observed Size Abundance Identification Petrographic Observations, Sample I.D. 21271A Page 3 of4 Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09-2535 j. Allan Tice, Project Principal

FM 3.4 Exhibit 7a Page 10 of 17 SMACTEC Equipment Used:

Cannon EOS Digital Rebel with 50mm macro lens and microscope adapters AmScope 7X to 45X stereo zoom microscope (with and without polarized light)

Olympus BH-2 polarized light microscope Zeiss Photomicroscope 1I polarized light microscope Aven Digital Microscope Starrett 6 inch rule SN 109000003 Note: No M&TE used is subject to calibration requirements.

Petrographic Observations, Sample I.D. 21271A P

Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, Project Principal

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FM 3.4 Exhibit 7a Page 11 of 17 C*ystal River Concrete Core Observations, Sample.1D. 21271 Report of Petrographic Observations CrYstal River Nuclear Generating Facility, Florida November 1I, 2009 MACTEC Project No. 6468-09-2535 U

Photograph #5 Remarks An aggregate particle on the cored surface.

This particle has a darkened rim and the area around the particle appeared to retain moisture longer than the rest of the core.

Marks on the ruler are

0. 1 inch.

Photograph #6 Remarks Photograph #6 Remarks An aggregate particle on the cored surface.

This particle has a darkened rim and the area around the particle appeared to retain moisture longer than the rest of the core.

Marks on the ruler are 0.1 inch.

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FM 3.4 Exhibit 7a Page 12 of 17 COystal River Concrete Core Observations, Sample ID. 21271 Report of Petrographic Observations Crystal River Nuclear Generaatlng Facility, Florida November 11, 2009 MA CTEC Project No. 6468-09-2535 Photo ra h #7 Remarks An aggregate particle on the cored surface.

This particle has a darkened rim and the area around the particle appeared to retain moisture longer than the rest of the core.

Marks on the ruler are

0. 1 inch.

Photograph #8 Remarks An aggregate particle on the cored surface.

This particle has a darkened rim and the area around the particle appeared to retain moisture longer than the rest of the core.

Marks on the ruler are

0. 1 inch.

4

I.

FM 3.4 Exhibit 7a Page 13 of 17 C('vstal River Concrete Core Obsenoatiion, Sample L), 21271 Report of Petrog raphic Observations Crystal River Nuclear Generating Iarwility, Florida Notemrber I 1, 2009 A ICTEC Project No. 6468-09-2535 Photo ra h #9 Remarks Close up of the polished sections showing voids in the coarse aggregate.

Width of view is approximately 0.8 inch.

Photograph #10 Remarks I Close up of the polished sections showing the fracture surface (top of photograph). Note uneven distribution of air voids. Width of view is approximately 0.4 inch.

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FM 3.4 Exhibit 7a Page 14 of 17 Crystal River Concrete Core Observations, Sample 1.1. 21271 Report of Petrographic Observations Crystal River Nuclear Generating Facilit. Florida November 11, 2(0)9 MACTEC Project No. 6468-09-2535 I PhotoziraDh #17 Remarks Remrk II Close up of the polished sections showing clustering of air voids around an aggregate particle.

Width of view is approximately 0.2 inch.

Photograph #18 Remarks Close up of the polished sections showing uneven distribution of air voids. Width of view is approximately 0.2 inch.

9)

FM 3.4 Exhibit 7a Page 15 of 17 Crystal River Concrete Core Observations, Sample ID. 21271 Report o[Petrographic Observations Crystal River Nuclear Generating facility, Florida Novemnber /I/, 2009J MACT1UIC Project No. 6468-09-2535 Phot a h #23 Remarks Photomicrograph of thin section in plane polarized light. Note the mineral growth in the air void that was exposed at the fractured surface (red arrow).

Note lack of mineral growth on fractured surface (blue arrow).

Width of view is approximately 0.3 inch.

Photograph #24 Remarks Photomicrograph of thin section using plane polarized light. Note fractures (red arrows) coming out of chert deposit (blue arrows) in a limestone particle.

Width of view is approximately 0.5 inch.

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FM 3.4 Exhibit 7a Page 16 of 17 C,3,stol River Concrete Core Observations, Simple.)D. 21271 Report of Petrographic Observations CrYstal River Nuclear Generating Facility. Florida Noveember / 1, 2009 MACfIEC Project No. 6468-09-2535 Photograph #25 Remarks Same view as photograph #24 taken with cross polarized light. Width of view is approximately 0.5 inch.

Photo ra h #26 Remarks Cracking in a chert deposit in a limestone particle (red arrows).

Width of view is approximately 0.5 inch.

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