ML102871040

Email - from: Williams, Charles R. (Charles.Williams@Pgnmail.Com) to: Lake, Louis; Thomas, George; 'Nausdj@Ornl.Gov'; Carrion, Robert; Souther, Martin; 'Trowe@Wje.Com' Cc: Miller, Craig L Dated Wednesday, January 06, 2010 4:51 PM, Subject:

ML102871040
Person / Time
Site:	Crystal River
Issue date:	01/06/2010
From:	Williams C Progress Energy Co
To:	Robert Carrion, Lake L, George Thomas Office of New Reactors, NRC/RGN-II
References
FOIA/PA-2010-0116
Download: ML102871040 (20)

Text

Sengupta, Abhijit From: Williams, Charles R. [Charles.Williams@pgnmail.com]

Sent: Wednesday, January 06, 2010 4:51 PM To: Lake, Louis; Thomas, George; 'nausdj@ornl.gov'; Carrion, Robert; Souther, Martin;

'trowe@wje.com' ,I,-

MleCraig L '*,

Cc:

Subject:

FM 5.5 - Corrosion of Rebars adSleeves t-,,

Attachments: FM 5.5 - Corrosion Rebars a; Sleeves.pptx; FM 5.5 Exhibit 1 Permeabili v w2c from /

Mehta.pdf; FM 5.5 Exhibit 2'Mix Design- from Dome Repair Report-cgp df; FM 5.5 Exhibit 3a Petrographic Erlin Hime May 1976-1.pdf; FM 5.5 Exhibit 3b Petrograp c CTL.pdf; FM 5.5 Ehibit 3c Petrographic Mactec 2009-1-*1-1 .pdf; FM 5.5 Exhibit 4 WC ratio RB-1 5.pdf; FM 5.5 hibit 5 Cover (etail - Plan 421-036-SHOOO.pdf; FM 5.5 Exhibit 6 Cover photos.pdf\

Mr Lake and Others, Attached for your review is the draft of FM 5.5 and its exhibits. I you have any questions, please contact me or Craig Miller.

Charles Williams 1

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FM 5.5 Exhibit 6 01/02/10 page 2 of 2

FM 5.5 Exhibit 4 page 1 of 1 Measured Water/Cement Ratio in concrete during construction - RBCN-0015 mix DM-5 modified I

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........... mix 727550-2 mod tmix 727550-2 CR3 - , 12/18/2009 11:34 AM test data original filled vl.xls FM 5.5 Exhibit 4 01/01/10 page 1 of 1

FM 5.5 Exhibit 3c page 1 of 5

< MACTEC engineering and constructing a better tomorrow November 11 2009 Mr. Craig Miller Progress Energy (352) 795-6486 ex 1026 Craig.miller@pgnmail.com Su.biject: 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 Numberl' Laboratory Number Description of the Core Assigned by MACTEC 5 - 2Q269 From an area where the fracture. had. occurred .

2 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 B 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 2127 IA 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 www.mactec.com FM 5.5 Exhibit 3c 01/01/10 page 1 of 5

FM 5.5 Exhibit 3c page 2 of.5 CrYWial River Concrete Core Obseraotions Nov*ember 1I, 2009 Report oa Pettvgraphic Observations

• A CTEC Project NA\,6468-09-2535 Cr-Ystal River Nuclear Generating F*cilitv. Fhlorida relative to the age of the fractured surfaces on samples 21269A and 2127 IA. 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 cementitous 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 8OX.

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 O.f concrete. examines the constituents of the concrete including coarse aggregates, fine dagregates,: 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 petrograph ic examination can also estimate the. water to cement ratioi, look for. indications of mineral:additives and unhydrated cement 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 finishino, observe micro cracking present and other conditions within the concrete:which might give infortnation 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 C(oncrete. Photographs From our examination are attached. A summary of oui' observations and discussion are as follows.

FM 5.5 Exhibit 3c 01/01/10 page 2 of 5

• - -FM 5.5 Exhibit 3c page 3 of 5 Crystal River Concrete (ore Obse,-vations ,November 1/, 2009 Report of PetrographicObservations tIAT(7 Proie! No, 6468-09-2535 Crystal River Nuclear Generating FocilitY, Florida APggregate 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 cutsurface 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 8K 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 containedmicrocrystalline 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 T.he 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 beair entrained' and had a total air content estimated to bearofUnd2 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 lackedair-entrainment: There was limited.mineral growth observed in some of the air. voids. Calcium hydroxide was observed lining some air voids.

3 FM 5.5 Exhibit 3c 01/01/10 pageý 3 of 5

FM 5.5 Exhibit 3c page 4 of.5.

IMACTEC

- Location

- T yp e . ............. .

Altertion: Not observed

- Degree & Type

- Reaction Products

- Location

- Identification Nature and Condition of Surface There appeared to be white paint on the.

Tra*tm-nt ' -*-vtnir c-Ar:- -F 1,-t-h .r, Estimated water-cement ratio (based on Appeared to have a moderately low w/c

[visual. . observations only) rato p bly in the range of 0.4 to .5.

Lunrted cernett cu,,tent (bacsd 66 6saal Appeared to have a iiomu.eiaiy high observations only) cement content PASTE: .....

Color (GSA rock color chart 1991) Medium lightgray .

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 droAn of water.

The outer 1/4/4 to 1/22 inch of the exterior surface was carbonated. The fractured surface was not carbonated.

1 J*l

• I I . I I .I il l q _ Jl Kesiouai un-nyorateo Cement: i Sorne un-niyarated/partanly nydrated

- 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 II polarized light microscope Aven Digital Microscope Starrett 6 inch rule SN 109000003 Note: No M&TE used is subject to calibration requirements.

PetrographicObservations, Sample LD. 21269A rge 3of 3 Form Reviewed and Approvedfor Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, ProjectPrincipal V I/U IV I/t lIU payt '-t VI ~

I Ml 3.J L -AI MAL~ OU u I/V PJCI3JtE -t" UI

FM 5.5 Exhibit 3c page 5 of 5 SMACTEC particle.

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 previouslv.

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 exteror surtace ot hte 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 Fsti-nmated rmnipcnmcattnt (hsed oun "ilsl Appeaed to hu"e a wIodvrateIy high observations only) cement content PASTE:

Colo0r (GSA irock .color.cliarl 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 or water.

Carbonation

-ResidLuai uii-liydiaid Distribution Particle Size Ccmiut.

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

SUiii& ut1-hydratedipaitialty liydiated cement particles were observed I

- Abundance

-__COMposition __________________

Mineral AIdnmI ixtires*: .Fl.y .-ash was not observed

-Size

-Abundance

-Identification_________________

Contamination: Not observed

-Size

-Abundance

- Identification______________ _______

PetrographicObservations,Sample ID. 21271A Page 3 of4 Form Reviewed and Approvedfor Use on CrystalRiver (ores Project 6468-09.2535 .. Allan Tice, Project Principal i Lf .11v, .. ,J I IV I _;./* , LJ L I_ I  %.#*, k,/ Ilk/ II IU la ZI

-M. 5.5 Exhibit 3a ~ATTAC11MEN'*.page 1 of 3.

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ERLIN, HIME ASSOCIATES MATERIALS AND CONCRETE CON.SULTANTS l St%C.KtlE BOULEVARD 03121 272-7730 ILLINOtS60062 PETROGRAPHIC STUDIES OF CONCRETE FOR CONSTRUCTION ENGINEERING CONSULTANTS

.1.

SUMMARY

AND DISCUSSION

• The specimen represented air-entrained concrete.

made with crushed fossiliferous coarse aggre-water-cement ratio paste. There was no. evidence that the aggregates had een either chemically or physically unsound.

. The: specimen: was.from an ,are:a where fractures%

had existed for a periodof time and where:,

moisture had been present, That was demon-strated by secondary deposits on fracture surfaces.. .

The specimen was. relatively small. Larger-specimens fr.om ,different areas of. the struc-ture would be desirable for examination in order to obtain a, better representation of. the-concrete.

INTRODUCTION "Reportied herein are the results of petrographic studies of a concrete fragment submitted by*J. Artuso of Con.-

Struction Engineering Consultants. The specimen is from the dome of the containment structure of the Florida Power Corporation, *Crystal River-, Unit. III.

Requested by Mr. Artusowere petrographic studies for evaluating: the specimen, and particularly for evidence of features that would cause :volume instability._

C-12 FM 5.5 Exhibit 3a 01/01/10 page 1 of 3

"F--.---

F 5.5 Exhibi[.3apage2of page 2 of 3 ERLIN, HIME ASSOCIATES - MAT*RIALS.ANO oCOCRETE COwSULTANTS STUDIES-Specimen -The sgecimen was an elongated fragment having nominal lateral dimensions of 5 inches, and a maximum thickness of about 3/4 inch.

All surfaces were fracture surfices except for a shallow channel about 3/32 inch wide and 1/8 inch deep., The channel appears to be the terminal area of a saw cut, Petrographic Studies - Coarse aggregate of the specimen was a buff to light brown, fine-grained, fossiliferous limestone, having a maximum nominal size of 3/4 inch.

The fine aggregate was a siliceous sand composed prin-cipally of quartz.

The aggregates were not partichlarly well graded, as evidenced by deficiencies of the finer sizes of the coarse aggregate and the coarser. sizes -of the fine aggregate.

There was%: no -vidence, that.the aggregates had.,been chemically or physically unsound. Particular attention

• .. directed to alkali-silica reactivity with respect. to

• the coarse aggregate because;'a similar type. of. aggregate doest, contain a highly reactive variety of chert. Neither the.chert nor the product of the reaction of the chert with alkalies (alkali-silica gel) was present.

.Paste of the specimen was, medium dark grey,, firm, and contained abundant residual and relict cement. The+

quality of the paste reflects a low wate+/--cement ratio.

Air occurred-as small, discrete, spherical voids that bccasionally were very slightly distorted, and as coarser irregularly shaped voids. The spherical voids are characteristic. of entrained air voids; thel irregularly.

shaped voids,, of ent-rapped.air.. The air content of :the specimen is estimated to be 51/2 percentand the parameters of the air-void system are judged to be effectiv-. for protecting-critically saturated concrete exposed to cyclic freezing.

On one of the lateral surfaces were secondary deposits composed of tufts of fine.acicularettr1ngit j (3aO .

A120 3 3CaSO 4 '31H 2 0), and7 calcite (CaCO 3 ) . [Ettring-te) was also present as tufts in some air voidsý.juSt below the fracture-surface..-

• The fragment was not uniformly thick; it tapered to a knife-like edge. Along that edge, were fine fractures C-13.

FM 5.5 Exhibit 3a 01/01/10 page 2 of 3 FM 5.5 Exhibit 3a 01/01 / 10 page 2 of 3

FM 5.5 Exhibit 3a page 3 of 3 ERLIN, HIME ASSOCIATES. - MATERIALS ANO CONCRETZ CONSULTANTS oriented subparallel to the long axis: of the fragment.

The fractures transected coarse aggregate particles. On those fracture, s-urfaces were secondary deposits similar to those described above.

The secondary compounds demonstrate that the fragment was from, an area where fractures present for a period of time had been exposed to moisture.

May 10, 1976 Erlin, Hime Associates, Inc.

by Bernard Erlin, President Petrographer c-14 FM 5.5 Exhibit 3a page 3 of 3

page 1 of 1 113

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04 0.5 0,6 0,7080-91,0 SWater/Cement Ratio (b)

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)f water through concrete in cubic*

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FM 5.5 Exhibit 3b page 1 of 3 Copy No. I Report for Progress Energy CTLGroup Project No. 059169 Petrographic Examination of Concrete Half Core from Delaminated Containment Wall, Crystal River, Florida November 2, 2009 Submitted by:

Derek Brown COA #4731 5400 Old Orchard Road:.

Skokie, Illinois 60077-1030 (847) 965-7500 9030 Red Branch Road, Suite 110 Columbia, Maryland 21045 www.CTLGroup.com K *o w I :&" ýd: -q 1ý D p Ii Ro ut~Jrnc CTLGroup is a registered d/b/a of.Construction Technology Laboratories, Inc.

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FM 5.5 Exhibit 3b page 2 of 3 Progress Energy Page3of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 For thin-section study, small rectangular blocks were cut from the core inner surface fracture region and within the body of the core. One side of each block was lapped to produce a smooth, flat surface. The blocks were cleaned and dried, and the prepared surfaces mounted on separate ground glass microscope slides with epoxy resin. After the epoxy hardened, the thickness of the mounted blocks was reduced to approximately 20 Pm (0.0008 in.). The resulting thin sections were examined using a polarized-light (petrographic) microscope at magnifications up to 400X to study aggregate and paste mineralogy and microstructure.

Estimated water-cement ratio (w/c), when reported, is based on observed concrete and paste properties including, but not limited to: 1) relative amounts of residual (unhydrated and partially hydrated) portland cement clinker particles, 2) amount and size of calcium hydroxide crystals,

3) paste hardness, color, and luster, 4) paste-aggregate bond, and 5) relative absorbency of paste as indicated by the readiness of a freshly fractured surface to absorb applied water droplets. These techniques have been widely used by industry professionals to estimate w/c.

Depth and pattern of paste carbonation was initially determined by application of a pH indicator solution (phenolphthalein) to freshly cut and original fractured concrete surfaces. The solution imparts a deep magenta stain to high pH, non-carbonated paste. Carbonated paste does not change color. The extent of paste carbonation was confirmed in thin-section.

Derek Brown Senior Microscopist Microscopy Group DB/DB Notes: 1. Results refer specifically to the sample submitted.

2. This report may not be reproduced except in its entirety.

3. The sample will be retained for 30 days, after which it will be discarded unless we hear otherwise from you.

F.Jldin9 CnWedMeKOerhqResUt www..TLGroupcorn FM 5.5 Exhibit 3b 01/01/10 page 2 of 3

4, FM 5.5 Exhibit 3b page 3 of 3 Progress Energy Page 10 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 to 0.4 in.). Somewhat uneven distribution of voids. Marginally air entrained based on the very low volume of moderate to small sized spherical air voids in the hardened cement paste.

Depth of Carbonation: 4 to 5 mm (0.16 to 0.20 in.) as measured from the outer surface.

Negligible when measured from the inner fractured core surface.

Calcium Hydroxide*: Estimated 6 to 12% of small to medium sized crystals evenly distributed throughout the paste, and around aggregate to paste interfaces. Estimation of the volume is difficult due to the presence of calcite fines in the cement paste.

Residual Portland Cement Clinker Particles*: Estimated 4 to 8%. Some large cement particles, particularly belite clusters, of up to 0.15 mm in size suggest a portland cement as produced more than 30 years ago.

Supplementary Cementitious Materials*: None observed by the core supplied.

Secondary Deposits: None observed either in the body of the core and or near the fracture surface.

MICROCRACKING: A small number of medium length (5 to 10 mm), randomly orientated microcracks are evenly distributed throughout the body of the core. At the fractured end of the core there was no observed increase in microcracking relative to the body of the core.

ESTIMATED WATER-CEMENT RATIO: Moderate to moderately high (0.50 to 0.60) but estimation may be biased upwards due to the well advanced degree of hydration / apparent old age of the concrete.

MISCELLANEOUS:

1. Water droplets applied to freshly fractured surfaces were somewhat slowly absorbed by the hardened cement paste.

2. Some small areas of the inner fractured surface of the core, as received, exhibit a thin white haze of efflorescence-like substance suggesting leaching of lime in solution from within the core, or alternatively, moisture on or flowing past the fractured surface at the delamination position within the wall.

3. A moderate volume of fine calcite particles is present within the hardened cement paste, most likely from coarse aggregate crusher fines.

percent by volume of paste B.-dngKnM1g ;D"" Res:*

ýexA ~W GTtGroupxcin FM 5.5 Exhibit 3b 01/01/10 page 3 of 3

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