ML102920355
| ML102920355 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 11/24/2009 |
| From: | Williams C Progress Energy Co |
| To: | Lake L, Naus D, George Thomas NRC/RGN-II, Oak Ridge |
| References | |
| FOIA/PA-2010-0116 | |
| Download: ML102920355 (24) | |
Text
Franke, Mark From: Williams, Charles R. [Charles.Williams@pgnmail.com]
Sent: Tuesday, November 24, 2009 7:08 AM To: Lake, Louis; Thomas, George; nausdj@ornl.gov Cc: Herrin, Dennis W.
Subject:
Refute 2.7 for Review Attachments: FM 2.X.ppt; Pour7291-mechanical vibration.pdf; Pour362RB-mechanical vibration.pdf; Pour528RBElevl03-mechanical vibration.pdfPour674RB-mechanical vibration.pdf; S Pour713RB-mechanical vibration.pdf; Erlin PHike Petro report 05101976.pdf; Core Bore #5 Final CTL Petrographic Report 059169 C856 (2).pdf; Interview Willie Easman.doc 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, Vf Charles Williams 919-516-7417
2.7 Inadequate Vibration during Pour D0 May identify additional perspective on this issue as RCA related efforts proceeds
Description:
Concrete, especially low slump concrete, requires rigorous mechanical intervention in order to spread through the forms and move around tightly spaced reinforcement. Vibration helps remove excess entrapped air and water. However, excessive vibration could result in segregation of concrete constituents, while too little vibration could result in voids and aggregate pockets even when the concrete slump is within spec.
Data to be Collected and Analyzed:
(1) Vibration inspection reports. A sample is provided in Exhibit 1.
(2) Existence of voids and aggregate pockets. (Exhibit"2zand Willie Easman interview.)
(3) Segregation of concrete constituents. (Exhibit 2)
(4) Conduct interviews of former plant employees if available. (Exhibit 3)
Verified Refuting Evidence: Verified Supporting Evidence:
- 1. Adequate mechanical vibration provided. (Ex 1).
- 2. Visual and Petrographic observations show relatively dense matrix with air voids that do not appear excessive. (Ex. 2)
- 3. Although several NCRs addressed voids and aggregate pockets that required corrections and were repaired, they are more a manifestation of slump issues than vibration (See FM 2.3 and Easman interview)
Reviewed by: Dr. Avi Mor, 352-795-6486, ext 1030 -
P11 CR3 Team Office P r~ * *n fdct~ * , *0g.D 11/23/2009 net rclcase to a third Pzai*
a,-yt 1 PeFR:55$ef
Form FP-4
- PITTSBU H TESTING LABOFNORY EEiE" ESTABLISHED E oSel
,C FOR PUSLICATION OF STATEMENTS, CONCLUSIONS OR EXTRACTS FROM OR REGARDING T4R}v OUR REPORTS IS RESERVED PENDING OUR-Y'RI*EN APPROVAL. Date 2172 REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
X PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
- Arch-Engineer: Gilbert Assoc., Inc.
General Contractor: J. A. Jones A Location: Pour # 362 RB Date 1-26-72
.:-Z SUBGRADE INSPECTION: N/A 7
JOINT PREPARATION: Ki. , SCH FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
Properly Coated [] Proper Clearance __
Free From Holes jJ Proper Support ."
Seams Tight Cflean Conforms to drawings Clean No. Tie Rods OK Proper Shoring & Supports jJ Location Tie.Rods OK Alignment[]
EQUIPMENT:
No. & Size of Vibrators 3- 91500 P 1 - 11,000 Frequency Plus, Placement Equipment 1 - Witney Concrete Pump Hoppers TremieX*= -Number N/A - Size N/A Location N/A PLACEMENT:
Consolidation Procedure Vibration Sech NIAGrouted Time N/A Location N/A 18", ma.Ws" oEs Concrete - Lift Depth 18" ' Direction of Pour West to East EXCEPTIONS: Final cleanup. This item corrected prior to concrete placement.
REMARKS:
Corp.,
H..,' B' 1 -Florida Power Corp., fl.,*,Benne/t.<':. ., PITTSBU 2 - Florida Power Corp., E. ro t YRHTESTING LABORATORY I PTL- Tampa , '", //. ,
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,-,,, 7,,7 Form FP-4 PITTS P I BU H TESTING LABO ORY n ESTABLISHED 1881 A PITTSBURGH, PA.
As A MUTUAL PROTECTION TO CLIENTS. THE PUBLIC Order No. TA-7732 AND OURSELVES. ALL REPORTS ARE UBOMITTED AS THE CONFIDENTIAL PROPERTY OF CLIENTE. AND AUTHORIZATION Report No; _ _
!4, . .FOR PUBLICATION OF STATEMENTS, CONCLUSIONS OR EXTRACTS FROM OR REGARDING OUR REPORTS IS RESERVED PENDING OUR-'WRITTEN APPROVAL. .
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~Date: 2-1-72... . ,
- .. REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP..
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
Arch-Engineer: Gilbert Assoc., Inc.
General Contractor: J. A. Jones Location: ]Pour # 362 RB Date 1-26-72 SUBGRADE INSPECTION: N/A JOINT PREPARATION:.Hin SCH FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
Properly Coated Proper Clearance [ '.
Free From Holes jJ Proper Support -0" Seams Tight Clean Conforms to drawings-Clean No. Tie Rods OK Proper Shoring & Supports 01 Location Tie.Rods OK -
- Alignment EGUIPMENT; No. & Size of Vibrators 3- 9t500 11 - 11,000 Frequency Plus.
Placement Equipment -I
-Whitney Concrete Pump Hoppers TremiejC=- Number N/A Size N/A Location N/A PLACEMENT:
Consolidation Procedure Mechanicer Vibration Grouted . Time N/A Location N/A Concrete - Lift Depth 18" HSX. Direction of Pour l to East EXCEPTIONS: Final cleanup. This item corrected prior to concrete placement.
REMARKS: ECPIN , I FloridaPower Corp., H,,,Benne ,.", PITTSBURGH TESTING LABORATORY:
- 2 - F lo rida P o w e r C o rp ., E . "* :..l
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Form FP-4 PITTSBURGH ""rSTING LABORATORY PITTSBUJRGH, PA. 0rcder No. TA-7732 AU A PPOTtCTION TO Ct ?ENT%~. TF PIJOILJC ANDO 0U9~.ILVt$. ALL REPIOMT
.&Y'!.JAL AR FOR VIJSMIYItD AN THE CONFIDENTIAL PPOP94TY OF CL:CN!S. ANDO AUJTMOMIZAlioft PVIjULCATiON Or :TATIMENITS. CONdCLUSIONS 00 IN1TRACT8 PROM Oft *NSA"ON"'a R ort No.
OUR REPO 16 IP RESERVED PINDING OUIN WRITTEN APPROVAL te 7-21-72 REPU1TDe of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
Are&.Engi,,.er: Gilbert Assoc., Inc.
General Contractor: J. A. Jones I - Pour # 32., 7.B Date -25 July 72 Otton:
SUBORADE INSPECTION: IT/A JOINT PREPARATION: C FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)<
Properly Coated Procer Cearance Free Fro,-- Hoies ProDer Support r-1 Seams T"hnt Clean 1Z Cor~for-s- to davn Clean No. Tie Rods 0_
Proper Shoring & Supports Location Tie Rods_ __ _
Alignment EQUIPMENT:
6 - 10,511 Frequency Plus No. & Size of Vibrators 2 - 6" Wittney Conc~rete Puiipus Placement Equipment Tremie Pipes - Number NI Size NIA _ .Location K/A L. PLACEMENT:
Consolidation Procedure Mpcý-arllcll V:!ýZaýýior -
Grouted N/A Time NIA Location NiA A
Concrete - Lift Depth !311 ma( Direction of Pour 30'j. to N.E.
REMMKS: -EXCT -71NS: F'nal clean-.:, reno---vl c-f excess vate-. Bot~h Etemes car~rctod ?rt?
to placermwnt of comcretr.
I - Floride Pewet Coo. .4v~'
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Form FP-4 P1TTZZURZGH TESTING LA23ORATORY
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._PITTSBURGH, PA,.._0 Ortder No. TA-7732 AID A MUTUAL PROTECTION TO CLI ENT5. THE PUSLI C AND OURSELVES. ALL REPORTS ARE OU:MITTEO AS THE CONFIDZNTIAL PROPERTY OF CL.FENT&. AND AUTHORIZATION" Report No._ _ __
FOR PU LICATION OF .TATiM*EHTS, CONCLUIiON5 OR EXFIACOVS FROM OR RtGAROINO OUR REPORT IS R1RESERVEDPENDINO OUR V'RITTEN APPROVAL, te REPORT Da of CO1MCFETE PLACEMIENT REPORTED TO: FLORIDA POWER CORP.
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concreta Supplier: West Coast Concrete, Inc.
Arch-Engineer: Giibert, Assoc., Inc.
General Contractor: J. A. Jones Location: 'P01*M 714 'RR Date 111617',
SUBGRADE INSPECTION: N/A JOINT PREPARATION: OK FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
Properiy Coated Proper Clearance FR Conforms to drawings Free Frcrn Holes Proper Support CE Seams Tight Clean IN Clean No. Tie Rods OK Proper Shoring& Supports Location Tie Rods varied Alignment EQUIPMENT:
No. & Size of Vibrators 7 - 10500 Frequency Plus Placement Equipment 2 - 6" hIAteman Concrete Pumps Tremie Pipes - Number N/A Size N/A Location NIA ,, ,, , i PLACEMENT:
Consolidation Procedure Mechanical Vibration Grouted Yen Time 1:18 to 2:05 PM Location Horizontal Const. Joint Concrete - Lift Depth 18" max. Direction of Pour East to West; West to East RFMARKM Vve-nt~fnna Final ýCleantin Thlis item corrected nrior to placement oficoncrete I
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REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
PROJECT. CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier. West Cioost Concret, Inc.
Arch-Engineer: Gilbert Assoc., Inc." Inspector Generol Contractor: J. A. jones C. zý5Ol PT
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JOINT PREPARATION: OK {!
FORMS: FiEINFORCEMENTS: EMBEDDED ITEMS: (List)
Proper Clearance 17 eonfor~e d to 6_r avdin *s Properly Coated
('anform-.d to d-Aydnc-s Free Fro'm Holes Proper Support ox Seams Tight Clean ".
Clean No. Tie Rods 0LK Proper Shoring & Supports ED~I Location Tie Rods Var-i Pri Alignment EQUiPMENT:
No. & Size of V.ibrators 5 -10,500 and 1 - 12,500 Freaousncy Plus Placement Equi pmernt 2 - 6:1 %h-itecrian Concrete Pum.ps Tremie Pipes - Number NA _ size NA -Location NA PLACEMMIT:
Consolidation Procedinre 4echran~ical Vibration Grouted Yes Time 11:15 AM - 12:20 FIM Location Hor. Const. Jt.
Concrete - Lift Depth_ 18' Direction of Pour E to N; W to E REM~ARKS:- BxcptiLons: None CC: 2 -FPC Qu~alidty Recards _BTSTBURGH TMITNG LABORATORY 3- F T L Ross T. VGLlvaP
ATT.AC1MIJNENT. C"u.2 ERLIN, HIME ASSOCIATES MATERIALS AND CONCRETE CONSULTANTS
-tI *KI BOULEVARD 1312) 272.7730
,. l'* ILLINOIS 60062 /
PETROGRAPHIC STUDIES OF CONCRETE FOR CONSTRUCTION ENGINEERING CONSULTANTS
SUMMARY
AND DISCUSSION
- The specimen represented air-entrained concrete.
made with crushed fossiliferous coarse aggre-gate and'siliceous fine aggregate and a low water-cement ratio paste. There was no evidence that the aggregates had been either chemically or physically unsound.
The specimen was from an area where fractures had existed for a period of 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 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 structure of the Florida Power Corporation,'Crystal River, Unit III.
Requested by Mr. Artuso were petrographic studies for evaluating the specimen, and particularly for evidence of features that would cause volume instability.
C-12
I ERLIN, HIME ASSOCIATES - MATERIALS AND CONCRETE CONSULTANTS STUDIES Specimen - The sp~ecimen was an elongated fragment having nominal lateral dimensions of 5 inches, and a maximum thickness of about 3/4 inch.
All surfaces were fracture surfaces except for a shallow channel about 3/32 inch wide and 1/8 inchof deep. a saw The cut.
channel appears to be the terminal area 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 particdiarly 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 evidence that the aggregates had been chemically or physically unsound. Particular attention was directed to alkali-silica reactivity with respect to the coarse aggregate because a similar type of aggregate does 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 specirhen was medium dark grey', firm, and contained abundant residual and relict cement. The quality of the paste reflects a low watei-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; the irregularly shaped voids,: of entrapped air., The air content of :the specimen is estimated to be 52 percent and the parameters of the air-void system are judged to be effective for protecting critically saturated concrete exposed to cyclic freezing.
On one of the lateral surfaces were secondary deposits composed of tufts of fine aciculari-ttringit (3CaO.
A20"3CaSO4 "31H 2 0), and calcite (6TCa 3 ) *Ettringite) was also present as tufts in some air void sjust 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
ERLIN, HIME ASSOCIATES - MATERIALS AND CONCRETE 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 O"
0 0 DIRECT TENSILE STRENGTH TEST RESULTS NOMINAL TOTAL AREA - DIAMETER LOAD
- WV ,SO. TN. TN. 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 -Pr10.69 3 3/4 2500 230 All Coarse
__aggregate soft M.Pour XVIII 1-0.69 3 3/4 4600 430 Hard Coarse aggregate excepu.
two soft pieces L Pour XV 10.69 3 3/4 5400 505 All hard coarse Ln 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 3W All small soft
_ _ coarse aggregate-Average 420 p.s.i.
kote: 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 C?
greater tensile strength than the Matrix. There was no pull out of the Crystal River coarse aggregate - all fractured at the fractured surface. Ct tj
ATTACHMENT E Preliminary Report of Crystal River Coarse Aggregate ASTM Spec Sieve Wgt. Ret. % Passing # 67 1 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 Specification C-117 200 Wash Loss 1.3%(Primarily 1% Max*
dust of fracture)
C-131 Los Angeles Abrasion 42 % 50% Max C-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 Later 5.0% Max C-235 Soft Particles Later 5.0% Max C-88 Soundness (Sodium Sulphate) 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 C-16
Copy No. 1 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 R e s u I t s CTI i G~oup is a~~i r dh
Building Knowledge, Delivering Results. wwwCTLGroiup.cxo 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, ifthe 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).
Cerp;,tu Offic oi 54100 Oid (Oichwd R(oad Skokie, linois 60077-1030. Phon e: 347-965-7500 Fmx: 847-96,5-6541 Wastih~h~iS DC Ofiea: 9030 Fted 1l3iaich Road, Suite 110 Co lm~bia Maryland 21045-2003 Phone: 410-997-0400 Fax: 410-997-8480 C'ILGrorup is aoregistered iib/a of Consiructiop 7"ethnoloy, Laborawories. 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.
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 ptm (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.
Middijg Knn.vte~dqP Dr.1wricng Re-s ý vwA.,' Go i0 :_
Progress Energy Page 4 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 la. Curved surface. Outer end is to the left.
lb. Saw cut surface. Outer end is to the left Fig. 1 Side views of Core #5, as received for examination.
T"'GROUPKnewk-dqoOeAh#.vN MAJ"d~ RwwI!s
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.
G"ICROUP
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.
" 1nC*1q DMomg Rest*%~
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.
GROP Bul'dýq h ~vln Rmuft onwMd
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 6a.).
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.
6c. 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 4(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, TIGROUP
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
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 Gaild , KnrmON1goOIving Rtlw :. "ww {2 LGt ,
11/16/09 Phone Interview with original construction labor foreman for concrete work Interviewer: Marci Cooper Interviewee: Willie Easman Q. What was your role and involvement back in original construction?
" Was the labor foreman for concrete. Was also there for dome delamination problem when found the honeycomb.
" Also found voids in area around personnel hatch - had to do demolition here also.
The aggregate was too big and had voids - QC didn't give pass on it
- Had to chip it away over 4-5 weeks around hatch, maybe 20' around it, had to be careful not to get into the steel liner
" Bad bonding - steel too close together, and aggregate too large and pointed.
Pumped all in, a lot of voids and honeycomb. A lot of structural steel. Normally want pea gravel for this kind of area, but here had larger stone that didn't go through Q. Do you recall any concrete problems with any other area? With the area of containment that contains the equipment hatch?
- No, can't recall any pioblems there
- With the dome didn't find problem till electricians.were drilling and hit voids
- Need the right mix to pump - had big diesels. A lot of rock didn't go through so didn't get good bond, got honeycomb.
- Dome was also a problem with "stiff mud" - slump was way low, had to be very dry on the dome.
- There was a big laboratory, Pittsburg testing lab setup east of U I and U2 - lots of cylinder tests, 21d break and slump. Dumped in yard because slump not right.
- Honeycomb around personnel hatch and in dome
- A lot of QC control L-couldn't get right - volume, air content, slump
- Large aggregate problem around area of a lot of steel -1/2 to 3/4" where steel on 2" centers - would clog up with voids underneath
- When fixed around personnel hatch, pumped with "pump mix", smaller pea gravel, small but still strong, 3500-5000psi o Also saw some cracks in 2003 when helping with upgrade of tendons and greasing tendons - saw cracks in concrete around tendon galleries - near steel cuffs outside RB - think tension in tendons could be causing