ML102870892
| ML102870892 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 01/16/2010 |
| From: | Chris Miller Progress Energy Co |
| To: | Robert Carrion, Lake L, George Thomas Office of New Reactors, NRC/RGN-II |
| References | |
| FOIA/PA-2010-0116 | |
| Download: ML102870892 (12) | |
Text
Franke, Mark From:
Miller, Craig L [Craig.Miller@pgnmail.com]
Sent:
Saturday, January 16, 2010 1:10 PM To:
Lake, Louis; Thomas, George; Carrion, Robert; 'trowe@wje.com' Cc:
Williams, Charles R.
Subject:
RE: Failure Mode 5.1 for Review and Commet Attachments:
FM 5.1.pdf; FM 5.1 Exhibit 1 - SP5618 and JAJ-W5 clean forms.pdf; FM 5.1 Exhibit 2 - QC ProceduresPTL-10.pdf; FM 5.1 Exhibit 3 - Pour52ARIb-NCR213 sand in joints.pdf FM 5.1 is being re-sent due to "mail delivery problems" associated with file size. There will be three emails to cover all the attachments. Please let me know if you have any questions.
Thank you, Craig From: Miller, Craig L Sent: Saturday, January 16, 2010 1:02 PM To: 'louis.lake@nrc.gov'; 'George.Thomas2@nrc.gov'; 'nausdj@ornl.gov'; 'rpcl@nrc.gov'; Souther, Martin;
'trowe@wje.com' Cc: Williams, Charles R.
Subject:
Failure Mode 5.1 for Review and Commet Mr. Lake and others, Attached for your review is the draft of FM 5.1 and its exhibits. If you have any questions, please contact Charles Williams or myself.
Thank you, Craig Miller I
cP~qu
5.1 Contamination During Construction
==
Description:==
During construction operations it is possible for contaminants to get mixed with the fresh concrete. Some of these materials have the potential to weaken the concrete and/or affect its durability. Source of contamination can be dirty aggregate that may include organic material, fine dust, or other reactive elements. Another source is construction related material such as grease/oil, nails/ties, tools and safety items, clothing, cigarettes, food, and other debris.
Foreign material can impact the concrete by either replacing sound concrete with weak/incompatible filler, or by adding reactive elements that react inside the concrete. Contamination can be detected by inspections during construction, visual inspections for signs of distress such as spalls and cracks, and analysis of concrete removed from the structure (during demolition and coring).
Precautions involve strict control of aggregate sources, good construction and safety practices, and an effective Quality Control (QC) program that monitors potential for contaminations.
I Data to be collected and Analyzed:
- 1. Review project specifications for requirements.
4
- 2. Review project QC procedures.
- 3. Review aggregate evaluation from original construction (FM 5.1 Exhibit 5 is a report by Law Engineering)
- 4. Review Non Compliance Reports. (NCRs)
- 5. Review Petrographic reports for signs of contamination.
- 6. Review inspection records (IWL), observations during demolition, and core inspections for indications of contamination.
Verified Supporting Evidence:
- a. Exhaustive review of NCR reports revealed an incidence where sand was found inside concrete forms. (FM 5.1 Exhibit 3) QC procedures failed to detect the contaminant (FM 5.1 Exhibit 4) and corrective measures were needed to repair the problem.
Verified Refuting Evidence:
- a. Project specifications included cleaning requirements. (FM 5.1 Exhibit 1)
- b. Project QC specifications provided requirements for preventing contaminations and for proper inspections and reporting. (FM 5.1 Exhibit 2)
- c. Tests on original aggregate by Law Engineering (FM 5.1 Exhibit 5) found no clay lumps. There was no mention of any organic impurities or excessive dust.
1/13/2010 DRAFTPage 1 of 2 DRAFT] Io~trIiet hr ot, Aih~
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5.1 Contamination during construction (cont.)
- d. Multiple Petrographic reports on concrete cores taken in 1975 and 2009 did not encounter contaminants (FM 5.1 Exhibit 6). The Erlin Hime report (FM 5.1 Exhibit 6b) noted dusty aggregate and recommended that it be washed prior to use.
- e. Exhaustive review of inspection reports (IWL) found no indication of spalling or cracking that could be attributed to contaminants.
- f. Detailed review of cores taken during 2009 found no indication of contaminants. Thorough analysis of photos taken during and after the SGR hole cut demolition did not detect any signs of contamination in the concrete.
Discussion:
The evidence presented above describes a system that provided guidelines and inspection tools needed to prevent contamination of the concrete. The single report discussed in FM 5.1 Exhibits 3 & 4 of contaminant in the concrete also describes the methodology for removing and repairing the contaminated concrete.
==
Conclusion:==
There is no evidence of undetected contamination during construction and it was not a contributing factor to the delamination.
I 1/13/2010 I UL I ~Ie~:o to third party ~~;thcut pcrmi:cinIi Page 2 of 2 DRAFT I
FM'5.1 Exhibit 2 Page 1 of 1 PTL-QIO t., 1972 ge 4 C. Field Placement Inspection
- 1.
Testing laboratory inspectors shall perform the following inspections and shall document this inspection on each placement.
(Sample Inspection form attached.)
- a.
Formwork for cleanliness, tight joints, form oiling and exposed edges chamfered.
- b.
Reinforcement for cleanliness, adequate securing and clearances to forms and subgrades.
- c.
Construction joint surfaces except as noted otherwise hereinafter shall be prepared for the placement of concrete there on by cleaning thoroughly with wire brushes, water under pressure, or by other means to remove all coatings, stains, debris, or other foreign material.
- d.
Horizontal and vertfcol construction joints in the reactor building cylinderical shell below 250'0 lewl shall be prepared for receiving next pour by either sandblasting, air water jet, bush hammering, or other means to remove all coatings, stains, debris or other foreign material.
The horizontal joints shall be dampened, then thoroughly covered with cement - sand mortar, of similar proportions in concrete, of approximately 1/2 inch thick ard concrete placed before initial set of mortar.
Vertical joints shall be dampened before concreting.
- e.
Construction joint surface in the Ring Girder an Dow at and above 250'0 of the Reactor Bldg. are to be prepared by sandblasting to produce a clean rough surface and the applying an evenly distributed film of Colma Fix 8% adhesive.
- f.
Conveyance equipment in accordance with ACI 301 Chapter 8 and ASTM C94.
All transporting to point of deposit to be without segregation of concrete.
S.
- g.
Concrete deposited in horizontal layer not exceeding 18m -
avoiding inclined joints with maximum free fall of 3 feet.
Each layer vibrated together.
- h.
Placing of concrete shall not cause movement or damage to emledded i temrs.
- i.
Concrete vibrated adequately and concrete of proper workability to avoid seams or planes of wekness.
-4
FM 5.1 Exhibit 1 Page 1 of 3 S P-5 181 1-22-69 5:01.2 The COETRACTOFR shall be responsible for the pr,,,,ration of written procedure(s) to set forth how the work to be performed under the specification will be carried out.
The party performing the work shall also.prepare a ri*tten.-.quality..contrcl.-procedure st forth vhat tests will be executed to substantiate coliance with the specification.
Such written procedures $sall be submitted to iMU*O
-for review adcent.
Thýee oe s s lbe written yrior to the starting of any of the work.
- -01.3 Prior to placing of concrete on compacted fill, the fill shall be checked for the percentage compaction required under Section 2:01.1.
The subgrade shall be free ot debris and organic material and shall be vetted thoroughly.
5:01.4 Before concrete is placed on a hardened concrete surface, it shall be free of laitance and foreign material.
Horitontal and vertical construction joints in the reactor building cylindrical shell and doae shall be prepared for receiving the next pour by either snd-.
blasting, air water jet, bush hammeriug, or other means to remove ad1 coatings, stain, debris, or other foreign material.
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5:01.5 In conveying of concrete from mixer to concrete in place, only those methods and arrangements of equipment should be used which will re-duce to a minimum any separation of coarse aggregate from the concrete.
Equipment should be capable of expeditiously handling and placing concrete of such a proper consistency, grading, and maximum sia of aggregate, at the rate most favorable to good quality and woromnshp.
The conveying equipment shall be in accordance with ACI 301-67.
Chapter 8 and AS*M C-9L-67.
5:01.6 If concretekis deposited on a hardened concrete surface, a 1/2 inch layer of neat grout shall be applied before concrete is deposited.
Concrete shall be deposited continuously and in horizontal layers not exceeding 18 inches, avoiding inclined construction Joints.
It is important that each layer be shallow enough so as to be placed vhle the previous layer is still soft and that the two layers be vibrate together.
No concrete shall be deposited in concrete which has hardened sufficiently to cause the formation of seams or planes of weakness within the section.
Concrete shall be placed with the re-quired consistency to assure proper workability.
The placing of concrete around reinforcing azd embedded items shall be by methods that will not cause movement or damage.
The maxi-m-free fall of concrete shall be three feet.
5:01.7 All concrete shall be consolidated by vibration, spading, or roddjing so that the concrete is thoroughly worked around the reinforcemnt, embedded items, and into corners of forms, eliminating all air or rock pockets which may cause honeycoibing, pitting, or planes of weakness.
If vibrators are used, they shall have adequate power and be of high frequency, rugged, and reliable.
When immersed in concrete, the vibrator shall have a minimum frequency of 7000 rpm.
Over-vibrating and the use of vibrators to transport concrete within the
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FM 5.1 Exhibit 1 Page 2 of 3 sP-5618 1-22-69
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4:01.2 Horizontal and vertical construction Joints in the reator building Acylindrical shell and dome shall be prepared for receivix* the next 4Z pour by either sandblasting, air water jet, bush hamerl*n, or other meens..t.o. r e gl coat l
,.___n-sldebris or other.
._o..._I matl.al.
The horizontal.ointd~shall be dampened (but not saturated), then thoroughly covered with a coat of nes cement mortar of iailwl pro--
-tio-n to t oe-ta..' in the concrete -- Th"..
rt iall.. be.t lea t 1/2 inch thick and fresh concrete shall be placed before the mortar has attained its initial set.
The vertical joints shall be damened (but not saturated) before concrete is placed.
4:02 Expansion Joints 4:02.1 Premolded expansion joint filler shall conform to "Spec. for Pre-formed Expansion Joint Fillers for Concrete Paving and Structural Construction (Mon-extruding and Resilient Non-bituminous Types),"
ASTM D 1752-66.
4:02.2 The location size and detail of fillers shall be as shown on the Drawings.
4:02.3 The expansion Joints shall be sealed with a material compatible with the premolded expansion Joint filler.
4:03 Water Stops 4:03.1 Water stops shall be polyvinyl chloride water stop of the dumbbell, bulb or serrated type as manufactured by W. R. Grace & Co. or ap-proved equal.
The location, size and detail of water stops will be as shown on the Drawings.
4:03.2 Vulcanizing of water stop shall be inspected and approved by the Inspector or OWNER.
Nailing of water stop shall be free of o1i,
- i k
" "rease, grout, or any other material that prevents good sel.
5:00 QUAITY CONTROL 5:01 Concrete 5:01.1 Each week the CONTRACTOR shall submit to the ENGINE a concrete pour schedule.
(This schedule will give the ENGINEER advance notice so he may check the drawings ahead of time and help eliminate possible problems before pour time.)
The CONTRACTOR shall initiate a concrete pour checkout form to assure that all crafts have completed their work prior to concrete placement.
After the form has been signed by each craft, it shall be given to the TESTING LABORATORY and/or ENGINEER prior to concrete placement.
This form shall be kept as a record for that pour.
Each pour shall have a checkout form.
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FM 5.1 Exhibit 1 Page 3 of 3
- 2.
Do not remove forms in less time than shown, unless approved by the FPC Structural Supervisor.
6.4 Joints A. Locate Construction Joints as shown on drawings or as directed by the FPC Structural Supervisor.
B. Clean horizontal, vertical and/or overhead concrete surfaces, against which fresh concrete is to be placed, by sandblasting, bush-hammering or high pressure water jet.
- 1.
For Reactor building shell Joints below elevation 250';
dampen Joints and remove standing water, place 1/2" thick cement mortar on the horizontal joints, prior to placing the concrete.
- 2.
For concrete other than Reactor building shell, 1/2",iortar "buttering" is not required.
C. Construct Expansion Joints according to the location and of materials shown on the drawings or as directed by the FPC Siructural Engineer.
D. Construct water stops of WR Grace PVC mterial as shown on the drawings or as directed by the FPC Structural Supervisor.
I.
Obtain FPC Structural Supervisor's approval of vulcanization of water stop.
- 2.
Do not make penetrations through or allow objectionmble materials on water stop.
6.5 Placement A. Place slabs on grade, supported basement floor slabs, and slabs on structural steel framing as shown on the drawings with the top of all finished slabs a true plane with a tolerance of 1/8" in 10' unless otherwise noted.
B. Place concrete walls as shown on the drawings with a mxmuma deviation of 1/4" In any bay of 20' maximum.
C.
Place concrete in such a manner to facilitate bulkheadlng and covering should the pour be terminated before completion.
- 1.
Have sufficient materials readily available to bulkhead and/or cover pour.
- 2.
Have a spare gas powered vibrator available on the job site.
5-8-70 J. A. JONES CONSTRUCTION CO.
JAJ-W5 ORIGINAL DATED
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REVISION EFFECTIVE FORM JAJ 101
FM 5.1 Exhibit 3 Page 1 of 5
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.. i PROJECT:
FLORIDA POWER CORPORATION DISTRIBUTION:
CRYSTAL RIVER UN IT NO. 3 NONCONFORMANCE AND White:
Quality Engineer Green:
Dir. Gen. Construction CORRECTIVE ACTION REPORT Pink:
Mgr. Gen. Q. & S.
Blue:
Extra Copy Goldenrod: Extra Copy ITEM:
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RMR NO.:
- re. 7SPEC. NO:
-WG, NO.:Sc q O'a NONCONFORMING OiARACTERISTICS:{ NONCONFOR**ANCE DESCRIPTION:
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DATE:
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REQUIRED DISPOSITION AND CORRECTIVE ACTION:
DISPOSITION:
Waiver #243 was issued to permit exploratory concrete removal; end produ-ct is "as built" shown on dwg. CR3-S-30286, sheet 1 of 2.
Required disposition is method of repair, as outlined on sheet 2 of 2, copy attached.
OORMCTIVE ACTION:
Instructed foremen, PTL & QC to perform final cleanlneass insption immediately before concreting.
See copy of letter attached.
ATTACH REQUEST FOR WAIVER FORM NO. 0-010 IF APPLICABLE WAIVER SER. NO.
SITE ACCEPTANC SITE REVIEW APPROVAL:
BOARD REVIEW APPROVAL:
DI.W 0
DIR. GEN CONST.
QUALITY ENGR.
?ALITY ENGR.
DIR. GEN. ENG'RG.
ACONIR. - MGR, MGR. GEN. 0. & S.
REPAIR/REWORK-ENGRG. APPROVAL:
REPAIR CO-"
UATY ACCEPTA CE BYJ-NoneINSPECT R
DATE!
REPAIR/REWORK PROCEDURE REQUIRED:
REPAIR/REWORK P CEDURE NO.:
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FORM NO: G-086
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FM5:1 Exhibit 3 Page 4 of 5 FLORIDA POWER CORPORATD(
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INTER-OFFICE CORRESPONDENCE Generation Construction I WV~ I~DI 4 oIff jc !
$UJS9CT DAix Jan=ar 10, 1973 To General Foremen & Foremen PTL QC ATTI[RTIOM Oil Pour #528 R.B. buttress 3 to 4, 0 el. 98, contained a "lens" type void, approximately 6' long x 1" thick x about 12" deep.
Thils"lena" was caused by failure to remove sand blast sand from the depression into which it accumulated,prior to con-creting.
Similar condition occurred in pour ;644 R.B.
To avoid recurrence, it is vital that a final thorough caeanli-ness inspection be made immediately before actual placement of concrete.
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FM 5.1 Exhibit 3 Paqe 5 of 5 FM 5.1 Exhibit 3
Paqe 5 of 5 FLORIDA POWER CORPORATION CRYSTAL RIVER UNIT #3 I REQUEST FOR WAIVER THE UNDERSIGNED REQUESTS TO PERFORM THE FOLLOWING ACTIVITY Jt W I T H / 0 N CeZo
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FPC -POWER CONSTRUCTION ASSUMES RESPONSIBILITY FOR ANY AND ALL CONSEQUENCES OF THIS ACTION AND UNDERSTANDS THAT, EXCEPT FOR THE ABOVE ACTIVITY, SUBJECT ITEM REMAINS IN A "H 0 L D" STATUS UNTIL SUCH TIME AS A "R E L E A S E" TAG REPLACES THE "H 0 L D" AND "W A I V E R" TAGS.
RESPONSIBILITY:
7e" FPC/PC APPROVED:
FPC/QP DISTRIBUTIONi WhIt.* rlglotal FPC SITE QUALITY ENGIIIEER oreen FPC CONSTRUCTION SUPT.
G0.Id1n'o FPC MOR. -QUALITY PROGRAMS N9 243 FORM NO. 0 -010 3/18/71