ML102920266

Email - Subject: Refute 3.1 for Review

ML102920266
Person / Time
Site:	Crystal River
Issue date:	11/24/2009
From:	Lake L NRC/RGN-II
To:	Robert Carrion NRC/RGN-II
References
FOIA/PA-2010-0116
Download: ML102920266 (20)

Text

Lake, Louis 0 ".

From: Lake, Louis Sent: Tuesday, November 24, 2009 9:25 AM To: Carrion, Robert

Subject:

FW: Refute 3.1 for Review El ,'A Attachments: -- FM 3.1.ppt; Exhibit 4 - Graph of air from tickets.pdf; Exhibit 1 - Erhn Hime Petro report, .- , ,

05101976.pdf; Exhibit 2 - Core Bore #5 Final CTL Petrographic Report 059169 C856.pdf; Exhibit 3 - pour ticket samples - Pour666RBElevl6O.pdf S/,

From: Williams, Charles R. [1]

Sent: Tuesday, November 24, 2009 7:12 AM To: Lake, Louis; Thomas, George; nausdj@ornl.gov Cc: Herrin, Dennis W.

Subject:

Refute 3.1 for Review Mr Lake, I am resending due to difficulty with opening/reading the previous attachments. Again, this is prelim. Call me with questions. It looks'like I will need to send each one as separate emails to keep from mixing documents.

Thank you, Charles Williams 919-516-7417 K'

3.1 Inadequate Air Content May identify additional perspective on this issue as RCA related efforts proceeds

Description:

Excessive amount of uncontrolled air contained within the concrete as a result of mixing/placing operations could cause voids. These voids of variable size and shape create weakness in the matrix.

Excessive volume of air voids (entrained and entrapped) can weaken the concrete, provide an initiation zone for cracks, and increases potential for shrinkage/creep.

Data to be Collected and Analyzed:

(1) Petrographic analysis (Exhibits 1 & 2)

(2) Review pour tickets for measured air during construction (Exhibit 3). Exhibit 4 is a graph of the data from those pours.

Verified Refuting Evidence: Verified Supporting Evidence:

1. Amount of entrained air is within acceptable range according to Petrographic analysis.

2. Pour ticket review shows the air entrained admixture (DAREX) was used in all concrete pours in accordance with the design specifications.

3. Analysis of measured air confirmed that air content was within specifications.

Reviewed by: Dr. Avi Mor, 352-795-6486, ext 1030 -

P11 CR3 Team Office a

neot receaso to a third part, withm~t- I 11/23/2009 11/232009*

StT 5i7A/i0 ERLIN, HIME ASSOCIATES MATERIAL. ANO CONCRETE CONSULTANTS ISKCtKtE BOULEV'ARD (312) 272.7730 "LL."NOtS 60062 " , .. :r : --:

PETROGRAPHIC' STUDIES O0F COG0NCRET'E FOR CONSTRUCTION ENGINEERING CONSULTANTS SUMMU'ARY AND DISCUSSION..

-The specimen represented~ air-entrained concrete.

made with, crushed fossiliferous coarse aggre-gate and'siliceous fine aggregate arnd a low water-cement ratio paste. There was no evidence that the aggregates had been either chemically

,or physically unsound.

'~The specimen was from a~n area, where fractures~

had existed for a period of time and where moisture had been present. That was demon-k strated by secondary deposits on fractur~e surfaces.

The specimen was relatively small. Larger specimens fr.orn diffqrent areas of the struc-ture would be desirable for examination in order to obtain abetter representation of. the concrete....

INTRODUCTION Reported 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 structuire of' the Florida Power Corporation, Crystal River, Unit III .

S .Requested by Mr. Artuso. were petrographic studies for evaluating the specimen, and particularly for evidence of-f£eatures~that' would cause 'volume instability.

C-12

9..

ERLIN. HIME ASSOCIATES 'MATERIALS ANO CONCRET, CONSULTANTS STUDIES-/

Specimen - The sp-ecimen was an elongated fragment having nominal lateral dimensionsa. of 5 'inches, and a maximum thickness of about 3/4 in.ch.

All *surfaces were fracture' surfaces except for a shallow channel about 3/32 inch wide and 1/8 tinch deep. The channel appears to be the terminal area of' a saw cut.

.PetrograDhic Studies - Coarse aggregate, of the specimen.

wasa buff t:o 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. pa~rticliiarly 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 Ovide~nce that 'the aggregates had been S::chemically ,or physically unsound. ,Particular attention was directed to alkali-silica reactivity with respect to the oar-se aggregate because *a similar type ofI aggregate.

does co,ntain a highly reactive' variety of chert. Neither the chert nor the pr6duct of the reaction of the chert  :

with alkalies (alkali-silica gel) was present.

Paste of the specitfien was medium dark grey', firm,' and contained abundant ~residual and relict c~ement. The quality of the ~paste reflects a low watei-cement ratio.

Air occurred as small, discrete, spherical~voids that bccasionally were very slightly distorted, aind as coarser irregularly shaped voids. The spherical v'oids are characteristic of entrained air voids; the irregularly shaped1 voids,: 'of' entrapped air., The" air .conten~t of' the specimen is""estimated to be 512 percent and the parameters of' the air-void system are judgred to be effective: for protecting 'critically saturated concrete exposed" to cyclic f'reezing.

On one of the lateral surf'aces were secondary deposit's composed of 'tufts of fine acicularettri'ngit. ý (3aO.

A1203.3CaSO 4 .31H 20), and calcite (6 aCO 3 ). -Ett5Hngit e was also present as tufts in some air voids'-just belo-w the fracture-surface. ' -

V The fragment was not uniformly thick; it tapered to a knife-like edge. Along that edge, were fine fracture Is

• c-u

ERLINK, HIME. :ASSOCIATES. MATERIALS-ANO CONCR*TE 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, i-rime Associates, Inc.

by Bernard Erlin, President Petrographer

~EF c-14

n ninn

• 0 DIRECT TENSILE STRENGTH TEST RESULTS NOMINAL TOTAL AREA.- DIAMETER LOAD CORE SQ. IN. IN. LBS. P.S.I REMARKS Granite aggregate 8.19 3 1/4 3400 415 concrete 5000 p.s.i, value ________ ______ _________

8.14 3 1/4 3200 390 Crystal River Cores Average 400 p.s.i.

N Pour XVI - 10.69 3 3/4 2500 230 All Coarse

....... _ __ __._aggregate soft M.Pour XVIII 10.69 3 3/4 4600 430 Hard Coarse aggregate exceDt.

two soft pieces I

L Pour XV 10.69 3 3/4 5400 505 All hard coarse

______aggregate L Pour 9B 10.69 3 3/4 5400 485 Most coarse

._ _,._aggregate hard' P Pour XIII 10.69 3 3/4 5400 505 All hard coarse -

____ _,,_ _ ,aggregate Pour XII 10.63 3 3/4 3800 3 All small soft coarse aggregate' Average 420 p.s.i.

6ote: The Granite Aggregate concrete cores fractured surfaces indicated all coarse aggregate was hard and dense and several pieces of the CA pulled out of the Matrix, indicating rt

.greater tensile strength than the Matrix. There was no pull out of the Crystal River coarse aggregate - all fractured at the fractured surface. M

A&

ATTACHMENT E pr eliminary Report of Crystal River Coarse Aggregate ASTM Spec Sieve Wgt. Ret.  % Passing # 67 J.0 100 100 3/4 1.0 97 90-100 1/2 .15.8 58 3/8 28.4 24 20-55 4 35.8 4 0-10 8 ~ 36.3.3 0-5 Pan .37.3 Test Result ASTM Specificati...

C-ll 200 Wash Loss 1.3% (Primarily 1% Max*

dust of fr;acture)

C-131 Los Angeles Abrasion 42 % 50% Max Cý-123 Lightweight Pieces in Aggregate 0.*2% 0.5% Max C-29 Unit Weight of Aggregate 85.68 lbs/cu. ft. No Spec

• C-142. Friable Particles .tater 5.0% Max C-235 .Soft Particles Later 5.0% Max C-88 'Soundness (Sodium -8ulphat~e) Later 12.0% Max C-127 Specific Gravity and Absorption Later No Spec

• This limit may be increased to 1.5% if the material finer than a No. 200 consists essential of dust from fracture Oz C-16

• Copy No. I Report for Progress, Energy CTLGroup Project No. 059:169 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 GROUP K. a f wi1 e 'd q ý'ý. D~e II' a ri ResuP t a ;:.

CTLGroup is a registered dib/a of Construction Technology Laboratories, Inc.

qBuilding K edge, Delivering Resuls., www.CTLGroup.com REPORT OF PETROGRAPHIC EXAMINATION Date: November 2, 2009 CTLGroup Project No.: 059169 Petrographic Examination of Concrete Half Core from Delaminated Containment Wall, Crystal River, Florida One saw cut half concrete core labeled Core #5 (Figs. 1 and 2) was received on October 27, 2009 from Mr. Jerzy Zemajtis, Project Manager, CTLGroup on behalf of Mr. Paul Fagan of Progress Energy, Crystal River, Florida. According to Mr. Zemajtis, the core represents the outer portion of concrete from a containment wall and the core is fractured at its inner surface at a delamination that was found to be present when access was gained to the wall interior. The delamination is approximately at a depth of 200 mm (8.0 in.) where horizontal post tensioning ducts are present.

Petrographic examination (ASTM C856-04) of the core was requested in order to determine, if possible, if the delamination is a recent feature, or alternatively if it occurred at some earlier time in the age of the structure.

FINDINGS AND CONCLUSIONS The following findings result from the petrographic examination.

Based on the general appearance, and both the physical and microstructural properties, the fracture at the point of delamination is most likely a fairly recent event. However, it is not possible to be completely definitive about the time frame since an older fracture, if subsequently well protected from air and moisture ingress, may also have similar characteristics.

The fracture surface passes through, not around the aggregates particles, is moderately hard, and does not exhibit loose surface debris. There is an absence of significant microcracking in the general vicinity of the fracture, and only limited evidence of surface deposits (slight efflorescence).

Corporate Office: 5400 Old Orchard Road Skokie, Illinois 60077-1030 Phone: 847-965-7500 Fax: 847-965-6541 Washington D.C. Office: 9030 Red Branch Road, Suite 110 Columbia. Maryland 21045-2003 Phone: 410-997-0400 Fax: 410-997-8480 CTLGroup is a registered d/bla of Construction Technology Laboratories, Inc.

Progress Energy Page 2 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 Carbonation to any significant depth from the fracture surface into the outer concrete is not observed (Fig. 3). Incipient carbonation is exhibited in thin section at the immediate fracture surface (Fig. 6a). However, an older delamination surface that was not exposed to air due to the depth of outer concrete, and other possible wall coverings, may also have such an absence of carbonation.

The cement hydration adjacent to the fracture is well advanced and comparable to that of the body of the core (Figs. 6b and 6c). This suggests that there was no moisture ingress to the fracture surface, over a period of time long enough, to change the general degree of hydration.

This is supported by an absence of secondary deposits within air voids adjacent to the fracture surface.

Additional Comments The concrete represented by Core #5 is well consolidated and free of any cracks or excessive microcracks (Fig. 4). The concrete consists of crushed carbonate rock coarse aggregate and natural sand fine aggregate, well distributed in a portland cement paste. No evidence is exhibited of any deleterious chemical reactions involving the cement paste and / or aggregates.

The concrete could be considered marginally air entrained based on an approximate volume of 1 to 2% of small, spherical entrained air voids in the hardened cement paste (Fig. 5).

Based on the physical properties and microstructure of the hydrated cement paste, and the tight aggregate to paste bond, lack of major cracks and microcracks, and absence of a materials-related distress mechanism, the concrete is considered to be in good condition.

Further details of the petrographic examination are given in the following image and data sheets.

METHODS OF TEST Petrographic examination of the provided sample was performed in accordance with ASTM C 856-04, "Standard Practice for Petrographic Examination of Hardened Concrete." The core was visually inspected and photographed as received. The core half was ground (lapped) on the saw cut surface to produce a smooth, flat, semi-polished surface. Lapped and freshly broken surfaces of the concrete were examined using a stereomicroscope at magnifications up to 45X.

Ct ROUP. Oft~fes*ft, ~wwwCL1U.~

B0gnede

Progress Energy Page 3 of 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 gim (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.

" g!:'cc

' Oe gRAi.s , wv,.CTL GOU p.co

Progress Energy Page 4 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 Ia. Curved surface. Outer end Is to the left.

lb. Saw cut surface. Outer end Is to the left Fig. I Side views of Core #5, as received for examination.

www.CTLGmup~com

Progress Energy Page 5 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 2a. Inner end.

2b. Outer end.

Fig. 2 End views of Core #5, as received for examination.

SB KIJ*U .OIdnwIIR www.CTLGinup.com

Progress Energy Page 6 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 3a. Saw cut side. Outer surface is to the left.

3b. Fractured Inner end.

Fig. 3 Views of the portions of Core #5 treated with phenolthalein, a pH Indicator. All the pink regions exhibited denote the limits of where the Indicator was applied. No colorless, low pH (carbonated) regions were observed at the fractured end regions.

lD.ll *I www.CTLGroup.comn

Progress Energy Page 7 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 Fig. 4 View of the lapped surface of a portion of Core #5 showing the general appearance of the concrete.

Fig. 5 View of the concrete hardened air-void system of Core #5 illustrating the moderate quantity of both coarse and fine air voids.

Scale Is millimeter Increments.

a Io uýn-s- DI.I P*Isu A www.CTLGroup.com

Progress Energy Page 8 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 6a. Crossed-polarized light view of the paste adjacent to the Inner fractured surface. Only incipient carbonation Is indicated by the speckled high birefringence colors in the paste. Carbonate fines are arrowed yellow. Width of view is approximately 0.5 mm.

6b. Plane-polarized light view of the paste adjacent to the inner fractured surface (same field of view as Ga.).

A low to moderate number of unhydrated and partially hydrated cement particles (arrowed red) are exhibited by the paste. The amount is comparable to that in the body of the core in Fig.

Sc. below. Width of view is approximately 0.5 mm.

6c. Plane-polarized light view of the paste in the body of the core. A low to moderate number of unhydrated and partially hydrated cement particles (arrowed red) are exhibited by the paste. The amount is comparable to that near the fracture surface in Fig.

6b. above Width of view is approximately 0.5 mm.

Fig. 6 Transmitted light photomicrographs of the thin sections of Core #5 illustrating significant features.

Buo ig. O"16ýftk-iuw.f www CTLGroup.com

Progress Energy Page 9 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 PETROGRAPHIC EXAMINATION OF HARDENED CONCRETE, ASTM C 856 STRUCTURE: Containment wall DATE RECEIVED: October 27, 2009 LOCATION: Crystal River EXAMINED BY: Derek Brown SAMPLE Client Identification: Core #5.

CTLGroup Identification: 2452601.

Dimensions: Core diameter = 95 mm (3.75 in.). Core length = approximately 197 mm (7.75 in.); partial wall thickness.

Top End: Even, slightly rough formed surface.

Bottom End: Uneven and rough, fractured core end.

Cracks, Joints, Large Voids: Text.

Reinforcement: None observed in the core supplied.

AGGREGATES Coarse: Crushed rock composed of carbonate rock type.

Fine: Natural quartz sand.

Gradation & Top Size: Visually appears evenly graded to an observed top size of 18 mm (0.75 in.).

Shape, Texture, Distribution: Coarse- Sub rounded to angular, slightly irregular to rough, evenly distributed. Fine- Rounded to sub angular, slightly smooth to somewhat rough, evenly distributed PASTE Color: Medium gray, uniform coloration throughout the length of the core.

Hardness: Moderately hard at the outer surface and in the body of the core. At the fracture surface the paste is also moderately hard.

Luster: Subvitreous.

Paste-Aggregate Bond: Tight. Freshly fractured surfaces pass through aggregate particles.

Air Content: Estimated 2 to 4% total. Approximately 1 to 2% of the total air is larger entrapped air voids of up to 3 mm (0.12 in.) in size, plus a few large voids of 4 to 10 mm (0.16

~i1CROUP 9tM,~ K,,wiedg Oeeu1ngoemi

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

.... g . . ~s

... !A wwwCTLGioup.cofn w.

.NfJ11M a kIWI VV sed 81No es0 REPORTED TO: FLORIDA POWER CORP.

PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Suppler: West Coast Concrte, Inc.

Arc/.Englnoor: Gllbert Assoc., Inc.

I K_ jaas Dalle 22 Time Loaded Class Eý Mau Ow Twdc No. Load No. P- Cu. Yds.--d C2101"10

%4X*L. Lbs;, C.A. us.

Cu.. Cu. YdLJf2JLF kbistuie: F.-k .1.

7 .1 Ossip SML. WtL Adj. B"tc IL CammIt (TWpe)

C.A. (Sie.-dV-(Sze )

F.A. Total2.

nDatod I4CF I I OW LbsL _ _ Gals.

Ice C Ls Lbs.___

TOWa Meon*U Total wale 4L~________GALs Rev. d Whoan SOW Finish .7 ev -- Diff. -0 R (10 M")

Sipiwe of Bath Plot In~ector e.~

g-!2Total Tmdk. Rev.- (300 VAIL)

Agied Tp ~-OJ-.- OF Concete TM -.r OF

¶ M (1411)

Wft AMdd inPlFtidd Gd/Cu. Yd.(3 k Am, "t tl. Finish:  ? DetfnsruceŽ-

011 3 W.

Raft nkwbm , --- II ý ý

• .- P.ITTSBURGH TESTING LABORATORY PlITTSUNGN, PA.

Saltim's DOWNlY REPORTED TO; FLORIDA POWER CORP.

PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Conurete Suupim: West Cesot Comete., In..

Auch.Effoonew Gilbert Ass.... In..

G.enera Cowruvws: J. A. Jameg

/t . fLL fimeuLaski lss ~ . u 0 OIEi.

TPA* .i.

lk Load ko Cu. Y 4Z..-Countylo0-M CoCLg Yd OF bgW~x .. A___ S LCF Lb.; C.A. A&-.. U/~Lb Cou(Twer W Dam uAEA Ptthieic-PuN., me -uim m ..

P...TO A Tiilir Til R LbL ToldumtCrn. L . Iu Tim" L'L_ _I 1*.Mm