ML102920138

5.1 Exhibit 6A Petrographic Mactec

ML102920138
Person / Time
Site:	Crystal River
Issue date:	12/08/2009
From:	Dilek U, Denise Wilson MACTEC Engineering & Consulting
To:	Chris Miller Progress Energy Co, Office of Information Services
References
FOIA/PA-2010-0116
Download: ML102920138 (12)

Text

FM 5.1 Exhibit 6a Page 1 of 12 SMACTEC engineering and constructing a better tomorrow December 8, 2009 Mr. Craig Miller Progress Energy (352) 795-6486 ex 1026 Craig.miller@pgnmail.com

Subject:

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

Reference:

Report of Petrographic Observations Crystal River Containment Wall and Dome Concrete Samples Steam Generator Replacement Project Crystal River Nuclear Generating Facility, Florida MACTEC Project No. 6468-09-2535 Dated November 11, 2009

Dear Mr. Miller:

MACTEC Engineering and Consulting 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. One core, Core #7 (MACTEC laboratory number 21271 A), was previously analyzed and the results were contained in our November 11, 2009 report. An additional core, identified as core #87 was received under chain of custody for petrographic analysis. Core #87 was assigned MACTEC laboratory number 21329. It is our understanding that sample 21271A is from the containment wall near the fracture (as referenced in our November 11, 2009 report. It is our understanding that sample 21329 is from an area in the dome that was repaired several years ago. The purpose of our observations was to evaluate the similarities and/or differences in the coarse aggregate of the two samples to attempt to determine if the coarse aggregate used in sample 21329 is similar to coarse aggregate used in sample 21271A.

Additionally, as requested, parameters of the air void system were evaluated for sample 21271A in general accordance with the ASTM C 457-08 Standard Test Method for Microscopial Determination of Parameters of the Air-Void System In Hardened Concrete.

MACTEC Engineering and Consulting, Inc.

9177 Sky Park Court, San Diego, CA 92123

• Phone: 858-278-3600 ° Fax: 858-278-5300 www.mactec.com Page 1 of 16 DCN CR-017 G9i(10

FM 5.1 Exhibit 6a Page 2 of 12 Crystal River Steam GeneratorReplacement Project December 8, 2009 Report of PetrographicObservations MACTEC Project No. 6468-09-2535 Crystal River Nuclear GeneratingFacility, Florida In addition to the petrographic observations, the Mohs hardness of the coarse aggregates in samples 21271A and 21329 was evaluated using picks of known hardness.

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 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 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 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 of the coarse aggregate and discussion are as follows.

2 Page 2 of 16 DCN CR-017

FM 5.1 Exhibit 6a Page 3 of 12 CrystalRiver Steam GeneratorReplacement Project December 8, 2009 Report of PetrographicObservations MACTEC Project No. 6468-09-2535 Crystal River Nuclear GeneratingFacility, Florida Aggregate Sample 21271A 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, fosiliferous 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. The coarse aggregate had a moderate amount of void space. The limestone and fosiliferous limestone had a Mohs hardness of approximately 3.

On sample 21271, there were 4 coarse aggregate pieces on the cut surface of the core that retained moisture longer than other portions of the sample. A thin section was prepared from one of these pieces and this piece contained microcrystalline quartz and radial silica and exhibited localized evidence of alkali silica reaction Sample 21329 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 and fosiliferous limestone. 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. The coarse aggregate had a moderate amount of void space. The limestone and fosiliferous limestone had a Moh's hardness of approximately 3.

DISCUSSION Photographs comparing the features of the coarse aggregate in samples 21271A and 21329 are shown on pages 10 and 11.

The aggregates from both samples have the same general similarities.

• Both coarse aggregates have a Moh's hardness of about 3

" Both coarse aggregates are a fosiliferous limestone with similar fossils

• Both coarse aggregates have some particles with a moderate amount of void space

" Both fine aggregates are predominately quartz with a similar particle shape A few limestone particles were observed in sample 21271A that contained microcrystalline quartz and radial silica (chert). Chert was not observed in sample 21329. Chert is found in association with some limestones in Florida. The material is formed by the replacement of calcium carbonate with silica that is carried in the ground water. The lack of chert in sample 21329 does not necessarily mean that the coarse 3

Page 3 of 16 DCN CR-017

FM 5.1 Exhibit 6a Page 4 of 12 Crystal River Steam GeneratorReplacement Project December 8, 2009 Report of PetrographicObservations MACTEC Project No. 6468-09-2535 Crvstal River Nuclear Generating Facility, Florida aggregate in sample 21329 is from a different source than the coarse aggregate in sample 21271A. In MACTEC's November 11, 2009 report, a petrographic analysis was performed on two samples (2127 IA and 21269A). It is our understanding samples 21271A and 21269A (both from the containment wall) are expected to be from the same source, however, chert was observed in sample 21271A and was not observed in sample 21269A.

It appears the coarse aggregate in both samples (21271 A and 21329) could be from the same source or from the same general geologic deposit. It cannot be said with 100% certainty that both coarse aggregate samples came from the same source, however, we didn't see indications to suggest they are from different sources.

PARAMETERS OF THE AIR VOID SYSTEM The parameters of the air void system were evaluated in general accordance with the ASTM C 457-08 Standard Test Method for Microscopial Determination of Parameters of the Air-Void System In Hardened Concrete. For this evaluation the modified point count method was utilized.

In our analysis, a total of 1,667 points were counted and each point was classified as a void, paste, coarse aggregate, or fine aggregate. Additionally, the number of voids that were traversed when going from point to point was recorded. The results are as follows:

Number Of Voids Intersected 327 Points In voids 52 Points In Paste 434 Points In Coarse Aggregate 683 Points In Fine Aggregate 498 Total Number of Points 1667 Following the calculations in ASTM C 457-08, the parameters of the air void system are as follows:.

Air Content = 3.1%

Air content is the proportion of the total volume of the concrete that is air voids; expressed as a percentage by volume.

Void Frequency = 3.1 per inch Void frequency is the voids per unit length of traverse; the number of air voids interceptedby a traverse line divided by the length of that line; the unit is a reciprocallength.

4 Page 4 of 16 DCN CR-017

FM 5.1 Exhibit 6a Page 5 of 12 CrystalRiver Steam GeneratorReplacementProject December8, 2009 Reportof PetrographicObservations MACTEC ProjectNo. 6468-09-2535 CrystalRiver Nuclear GeneratingFacility,Florida Paste Content = 26.0%

Paste content is the proportionof the total volume of the concrete that is hardenedcement paste expressed as percentage by volume Paste-Air Ratio = 8.34 Paste-Air ratiois the ratio of the volume of hardened cement paste to the volume of the air voids in the concrete Average Chord Lengthr= 0.002 inch Average chord length is the average length of the chordsformed by the transactionof the voids by the line of traverse;the unit is a length Specific Surface = 2000 per inch Specific surface is the surface area of the air voids divided by their volume, expressed in compatible units so that the unit of specific surface is a reciprocallength.

Spacing Factor = 0.0029 inch Spacingfactor is a parameterrelated to the maximum distance in the cement pastefrom the periphery of an air void, the unit is length In addition to the above calculated values, by dividing the points in coarse aggregate by the points in coarse and fine aggregate (added together) we can calculate the volume of aggregate that is coarse aggregate. Based on this, the coarse aggregate fraction as 58% of the total aggregate volume similarly and the volume of aggregate that is fine aggregate as 42%. To equate these values to relative weight (for comparison to a mix design) the specific gravities of the aggregates would need,-to be known and additional calculations would need to be performed.

We trust this information meets your current needs. If more information is needed, or if you have any questions, please contact us.

Sincerely, MACTEC ENGINEERING AND CONSULTING, INC.

David C. Wilson u ilek Ph.D.

Senior Principal Professional ior Principal Professional DCW/UD:pcc Attachments: Photographs #1 - #4 Photomicrographs for Samples 21271 A and 21329 Summary of Petrographic Observations for Cores 21271 A and 21329 5

Page 5 of 16 DCN CR-017

FM 5.1 Exhibit 6a Page 6 of 12

%/MACTEC

SUMMARY

OF PETROGRAPHIC OBSERVATIONS OF HARDENED CONCRETE - ASTM C-856-04 PROJECT NAME Crystal River Core Petrography Project nI PROJECT NUMBER 6468-09-2535 DATE SAMPLED RECEIVED 10-25-09 SAMPLE I.D. 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 IICHRACTERISIC OBSERVATIONS COARSE AGGREGATE:

Shape Angular to sub rounded Grading Approximately 3/ 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 Coatings 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 PetrographicObservations,Sample LD. 21271A Page 1 of4 Form Reviewed andApproved for Use on CrystalRiver Cores Project 6468-09-2535 J. Allan Tice, ProjectPrinci*al

-- -- DCNCR-017---

FM 5.1 Exhibit 6a Page 7 of 12 0MACTEC 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

[ Contamination

__mall amounts Not observed resent.

FINE AGGREGATE:

Shape Generally sub-rounded to sub-angular Grading #4 and smaller Distribution Even Texture Fine Composition Siliceous Rock Types Quartz Alteration: Not Observed

- Degree

- Products Coatings Not Observed Rims Not Observed Internal Crirking A fei *wev, ra fractures were observed FContamination Not observed CHARACTERISTISI OBSERVATIONS CONCRET E:

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 erimeter of the PetrographicObservations, Sample LD. 21271A Page 2 of4 Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, ProjectPrincipal P ,DCNCR-071f1

FM 5.1 Exhibit 6a Page 8 of 12

%MACTEC 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 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 1/22 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

- Intificatio-fn Contamination:

- Size.

- Abundance

- Identification PetrographicObservations, Sample LD. 21271A Page 3 of4 Form Reviewed and Approvedfor Use on CrystalRiver Cores Project 6468-09-2535 J. Allan Tice, ProjectPrincipal

= of 16

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FM 5.1 Exhibit 6a Page 9 of 12 AMACTEC 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 ID. 21271A Page 4 of4 Form Reviewed and Approvedfor Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, ProjectPrincipal

• nC 1f.3 nf l1 F

FM 5.1 Exhibit 6a Page 10 of 12 SMACTEC 1,- 1.ffm I, ,I,

SUMMARY

OF PETROGRAPHIC OBSERC-8ONS6 HARDENED CONCRETE PROJECT NAME

- ASTM C-856-04 VA Crystal River Core Petrography Project O

I PROJECT NUMBER 6468-09-2535 DATE SAMPLED RECEIVED 11-20-09 SAMPLE I.D. '21329 SAMPLE SIZE AND DESCRIPTION Concrete core, approximately 1 3/4 inches in AS RECEIVED diameter, 2 pieces, each approximately 6 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 and fossiliferous limestone.

Alteration: Not observed

- Degree

- Products Coatings Not observed Rims Not observed Internal Cracking Not observed L Contamination Not observed FINE AGGAy_,GA 1I*:

Shape Generally sub-rounded to sub-angular Grading #4 and smaller Distribution Even Texture Fine Composition Siliceous Rock Types Quartz Alteration: Not Observed PetrographicObservations, Sample ID. 21329 Page 1 of 3 Form Reviewed and Approvedfor Use on Crystal River Cores Project 6468-09-2535 J. Allan Tice, Project Princa DCN CR-017

FM 5.1 Exhibit 6a Page 11 of 12 OMACTEC

- Degree

- Products Coatings Not Observed Rims Not Observed Internal Cracking. A fPw internal fracture,, were. onherved Contamination Not observed ICHARACTERISTICS CONCRETE:

OBSERVATIONS 4 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. Generally

- Shape fairly evenly distributed

- Size

- Distribution 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 Not observed Embedded Items Not observed

- Shape

- Size

- Location

-Type _________

Alteration: Not observed

- Degree & Type

- Reaction Products

- Location

- Identification Nature and Condition of Surface Not observed Treatments 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 PetrographicObservations, Sample ID. 21329 Page 2 of3 Form Reviewed and Approved for Use on Crystal River Cores Project 6468-09.2535 J. Allan Tice, P P

- - - - - DCN CR-017

FM 5.1 Exhibit 6a Page 12 of 12 3MACTEC with a hardened steel noint Porosity Did not appear very porous.

Carbonation The '/2 inch of the exterior surface was 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 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 H 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. 21329 Page 3 of 3 Form Reviewed andApproved for Use on Crystal River Cores Project6468-09-2535 J. Allan Tice, Project Principal

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