ML102990361
| ML102990361 | |
| 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: ML102990361 (26) | |
Text
Lake, LoUis From: Lake, Louis Sent: Tuesday, November 24, 2009 9:26 AM To: Carrion, Robert
Subject:
FW: Refute 2.7 for Review / K -
Attachments: FM 2.7.ppt; Pour729RB-mechanical vibration.pdf; Pour362RB-mechanical vibration.pdf; Pour528RBElev1 03-mechanical vibration.pdf; Pour674RB-mechanical vibration.pdf; Pour713RB-mechanical vibration.pdf; Erlin Hime Petro report 05101976.pdf; Core Bore #5 Final CTL Petrographic Report 059169 C856 (2).pdf; Interview Willie Easman.doc From: Williams, Charles R. [1]
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 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 1.2
2.7 Inadequate Vibration during Pour May identify additional perspective on this issue D eýnar 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 2 and 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 P1 *~.tr~ Co "n .!nta!, 20C9. Do 11/23/2009 iot-re ..... t,, a t,,,,d part7 w,,tlUut 1
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- PIT,'rsURGH. PA. O ier No. TA-7"232
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C ^Lt.. fl1.IP SitiUgU4itiro
- i P,it( c-ir tawrTA L rom pp.CV i c'rov, tV, Vr-. ^Nf AtoTI4OINIZAlaOK OCRruM.LCArtO" or. rr v,,-.!o.rs COC.on9 x.r.TMvcs i4OM O an ZARDING OUR RIEVONTS 15 I1L8IA'. ED LNOING, OUR V 4ITrTLM &PPROVALL..
~E P0#r RT of -CC i.-T Z Af-L4 C62 LI ENT REPORTED TO: .2' C~
P&OJ~ECC' : 72AL P.: TV.L 2IT
'7 140. 3 Concrete Surmlier: 'V2" C-st C,-:r--retc, Inc.
- Archza,:nqinccr: Cio.'-rt Assoc.. Inc. Inspector.
General Ccrlliac+/-or: J. A..~.Owes Lccation:- F OUR: 729 RB Date 3-1-73 SUCGRADE. INSPECTION:NA JOINT PREPARATION: OK FORMS: Y=EllNF C .ý` . .. ' 73: EMBEDDED ITEMS: (List)
Properly Coated Proper Clearance (] rnflfr7-Tniq +.n Awane Free From Holes Proper Support (]
Seams Tight Clean Clean No. Tie Rods OW Proper Shoring & Supports ] Location Tie Rods mr-,ried Atignment EQUIPPi','T:
kv a- 01 Zw 0 9 -1In L_ 5 -. 1fl3~flO ulpvnlmq
- 0. GU-- 6 - 10 -- -MFemrn lu Placement Equipment 2 - 6" 1'ihiteman Concrete Pups and 1 - 5 yd. bucket Tremie Pipes - Number NA Size NA Location NA PLACE1:ENT:
Consolidation Procedure Mechanical Vibration Groutcd Yes Time 12:2,0- 2--5 E Location Lower Const. Jt.
Concrete - Lift Depth. I8"! max.. Direction of Pour N to S; S to N.
REMARKS: Exce-tpozpps_ None CC:
T:3- 14 isoZ3 T.-ZIU~iL vvxaL,ý-41i
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Form FP-4 PITTSBU H TESTING LABOIFTORY ESTABLISHED 1to1 PITTSBURGH, PA. arcler No. TA-7732 AS A MUTUAL PROTECTION TO CLIENTS. THE PUBLIC AND' OURSELVES. ALL REPORTS ANE SUBMITTED AS THE CONFIDENTIAL PROPERTY OF CLIENTS. AND AUTHORIZATION Re*
FOR PUBLICATION OF STATEMENTS, CONCLUSIONS OR EXTRACTS FROM OR REGARDING *ort No.
OUR R RT, IS RESERVED PENDING OUR-W'RITTEN APPROVAL.
Dal e 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 Plus" A 1&9 UK Date 1-26-72 LA.MOaL4ll -
.SUBGRADE INSPECTION: N/A JOINT PREPARATION: Min. k SCH FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
- Properly Coated U] Proper Clearance Free From Holes Proper Support Q Seams Tight V. Clean Q Conforms to dravings' Clean No. Tie Rods OK Proper Shoring & Supports Location Tie-Rods OK Alignment EQUIPMENT:
No. & Size of VI L. I - 9A00 1 - ll.~OOO Preauancv Plus 3Irw
- 9 500' 1- 11 00 --.----- Plu r Iacemellt CqIuipIIFI I,- WIhiInev Concrete Pumn Hoppers Tremie mc- Number N/A Size N/A Location N/A PLACEMENT:
Consolidation P[ocdu~re MIA i~a~~A
~ ~ TF-1 ffk VA 641I
&M-I. 114 11,31UU L4U N/A
-. Time N/A Location X/A Concrete - Lift Depth 18" Max. - Direction of Pour Wiest to East REMARKS: EXCEPTIONS: Final cleanup. This item corrected prior to concrete placement.
A5 7'ý fC~-y ~it,::;~, '2 I- Florida Power Corp., i/.'iBenvee/..><.. ".
Florida Power Corp., E."-rraa.,z ..
I - PTL - Tampa /
'-PTL-W.T .Hurst I4 .E.
-ANSLEY9 I - PTL-Pg'. -.
PITTSBURGH
- T"ESTING LABORATORY PITTSBURGHP. p A: ASU.Ji'UAL PPO? LOTION TO CLI[NS. T,4L PWSL1CAND Oun3KLV[6. ALL RIPO-OrY ASS*USM YSD AS T149 CONTIIE[N1-At. FPPOPSIr OP CLIENTS. AND AWTHONIZATION Pre PUOLIATION OP STAISMLNTrs. comeLUSsows o: txnUAcT@ saou on 401*ADNrn.
OURn SEP01. to RZAg4vto PENDING uu WRITTEN AIP0Ov^L.
T Re ler No. TA-7732 Date No.__
7-28-72 Form FP-4 I
REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
Ar&.Engin*@r: Gilbert Assoc., Inc.
General Contractor: J. A. Jones 1 Z Four #~328 '.B DOte 25 July 72 SUBGRADE INSPECTION: IT/A&
JOINT PREPARATION: C.'
FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
Properly Coated 5 Proper C earance C Free From Hoies S Proper Support r-1 Seams TaUnt 0 Clean 1Z Corifor-s to drav.in.-s Clean No. Tie Rods 0__
Proper Shoring & Supports 0 Location Tie Rods CV-Alignment S EQUIPMENT:
6 - 10),5W)§ Frequency Plus No. & Size of %'IF. &U awt 2 - 6" *taIney Cocerete Pumps Placement Equipment Temie Pipes - Number N/A Size K/A Location 11/A RlACEMENT:
Consolidation Procedure Xe-ý--4ewl ';-b-at4or MIJA Time N/A Location MIA Unruluia '
Concrete -Lift Depth 13" 1mix. Direction of Pour REMAfXS:_YXCF .1S: F'.nal cleanu, rtno;-e1 of excess ¶vater. Both ttems cart.ected prtor to oIacam~at of conerete.
to o1scemput of concrete.
-PITTSBURGH TRSTIIO LABORATMY I2FPwi~d.Power Co'rP ff E." ees /
'~ -PT-W..Dfrst~i.. WASLEY PZ UK.. KcGILLIVRAY, P!AIAGSER P7L - Ith
.t * .. -St...
Form FP-4 PITTSBURH TESTING LABOFOTORY ESTABLISHED 1021 PITTSBURGH, PA. Orcder No. TA-7732 AD A MUTUAL PROTECTION TO CLIENTS. THE PUBLIC AND OURSELVES. ALL REPORTS ARE SUBMITTED AS THE CONFIDENTIAL PROPERTY OF CLIENTS. AND AUTHORIZA.TION FOR PUELICATION 07 S'TATEMENT'S. CONCLUSIONSl OR EXTRACTS FROM OR REGARRING Rer >ort No.__ __
OUR REPORTS IS RESERVED PENDIN* OUR-WRITTEN APPROVAL te 2-1-72 REPORT Da of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
5~ PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
Arch-Engineer: Gilbert Assoc., Inc.
General Contractor: J. A. Jones
"& l99
ýUL V'" Date. 1-26-72 M4 SUBGRADE INSPECTION: N/A JOINT PREPARATION: Min. k SCI4 FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List)
- Properly Coated iJ Proper Clearance
'U Free From Holes Seams Tight Clean Proper Shoring & Supports Alignment U Proper Support Clean No. Tie Rods Location Tie.Rods
[]
OK OK Conforms to drawings EQUIPMENT:
No. & Size of V ;hrtfnre 3 - 9.500 . 1 - 11.000 Frequency Plus 4 s--- ~
Placement Equipment I. - WhitnUy Coucrete rump Hoppers Tremiemlnm- Number N/A Size N/A Location N/A-PLACEMENT:
1a~k*A Wk..&4 Consolidation rrocedure ~UME-WILAlma. -h *a m -"
N/A Time __._ I - + l N/A
.JIU~gU N/A-N/A Concrete - Lift Depth 18" xa". Direction of Pour West to last REMARKS: " EXCEPTIONS: Final cleanup. This item corrected prior to concrete placement.
I- Florida Power Corp.,P. n. t! -j...
2 - Florida Power Corp., E-.ro "Ivy I1 PTL - Tampa,/
1- PTL - W. T..Hurst , P.R,Z*S I - PTL - Pgh. ,f
Form FP.4 PITTSBURGH T7ESTING LABORATORY PITTSIBURGH.1 pA.Or fer No. TA-7732 As A UWV.UALPPOltCION YO CL2UdTS. TWE P~ubL£C asgO OPIJ9CfLV9. ALL 01IOWOS A49SUS14" AS TNX CONVIDEN1,At. PROPICH$VOF CLIKNT, AftOOAUjTHOM12ATIO9 0UM~
P00 PUS61CATI*F4 Or STAT9ME0NTU.CONCLUSIOW N$ 046TIACS lPOOMOR 49"ARDIN4 Re o No....
QUN ISPONOC 10 RZUAXV40 PCP40 0NQ OUR 'IRSN PIC P0VA4.
Del t 7-28-72 REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3 Concrete Supplier: West Coast Concrete, Inc.
Arh.Engin..: Gilbert Assoc., Inc.
General Contractor: J. A. Jones Pour # 328 RB 25 July 72 LUiIW1lu. Date SGRAOE INSPECTION: T11 A JOINT PREPARATION: C.'..
FORMS: REINFORCEMENTS: EMBEDOED ITEMS. (List)
Properly Coated Proper Cearance :
Free Fro- Hoies Proper Support Seams Thunt Clean I Cornior-a to dravin~a i ;
- Clean 0 No. Tie Rods 0_,
Proper Shoring & Supports [] Location Tie Rods CK.
Alignment EQUIPMENT:
No. & Size of V ,maaauu U 6 - 10.5Tl) Frequency Plus aw Placement Equipment 2 - 6" *'.ttuey Concrete Purrps Tremie Pipes - Number N/A Size N/A Location IXA FLACEMON:
Consolidation M'aP*-a mT PD 1 'aT."% .- D f.' J n*
Rrgceuure .~- ...--. - -
.-- 64 N41%mlIll -
K/A
. . Time N/A Location W/A Concrete - Lift Depth 12", Mix. Direction of Pour S.W. to b?.!.
1NUAftXS:-EXC1TIT!C!S: Ftnal cleanup, rrmo-,-il o'f excess ¶.ate'r. soth items carrected prtor to a1*cerna~nt of coswrete.
to olacement of cmcretv.
flTMSURCK TRSiTOG LASINATOY Floid Pedowew or.$ E. .1Prowes
- I1PTL -Tamps I. - PT1L - w. r. Hurst iE.J. WIWSLLY P./ X.. KeGILLIVRAY, K~MAGERt I -PTL - Fo.
Form FP-4 PITTSOURGH TESTING LABORATORY EDTABLI.HI S031 PITTSBURGH, PA. Order No. TA-7732 AS A MUTUAL PROTECTION To CLIENTS. THE puBLIC AND* OURSELVES. ALL REPORTS
.ARK SUMITT"O AS THE CONFIDENTIAL. PROPERTY OF CtICNTS. ANO AUTHORIZATION R'nort NO._ _ _
,FOR PUSIICATION OF 8IATiM6,TS. CONCLUriONS OR EXTRHACS FROM OR REGARDING .'
-"OUR REPORTE IS RESERVED PENOIN- OUR Y'RItiEN APPROVAL. "
REPORT D"te_______________
of CON1CRETE PLACEMENT REPORTED TO:` FLORID,A POWER CORP.
PROJECT:- CRYSTA L RIVER PLANT UNIT NO. 3 Concreta Supplier: West Coo st Concrete, Inc.
Arci,-Engineer:. Gilbert A ssoc., Inc.
.,General.Contractor:J. J-A. Jonies
- Location. Date 1./!1 SUBGRADE INSPECTION: NIA JOINT PREPARATION: : . UJL%
FORMS: REINFORCEMENTS: EMBEDDED ITEMS: (List).
- Properiý, Coated Proper Clearance [] .. Conforms: to dir" W1T12A Froe Frcm- Holes- Proper Support IN Seams Tight: Clean . P1 Clean No. Tie Rods OK Proper Shoring & Supports Location Tie Rods varied Alignment tEUWPMENT.-
No. & Size of Vibrators 7 l.500.FrequeneX Plus 1-
.'-Placement Equipment .H 2 - 6" Whiteman Concrete Pumus Tremie Pipes - Number. N/A Size N/A Locationi IA PLACEM0NT:
Consolidation Procedure +Mechanical Vibration iGrouted .Y n- . .
Time 1I188 to 2#05 PIM Location .Hortizoital Const Concrete - Lift Depth ."" max.'
415 Direction of Pour East to WWest- West: to.East--
NFU Afh'1 C~
H;+C.+8enntt::.::! :.:::"! . .. :"I*: -4,'!* TITSBURGdf TESTING LABORATORY"i:. .:"' "- "
'1:.
- i:- Florida Pow*eje C0rp:,'H.
- L.PTL: N-kFnp T.. M,+G'li~v~ry, P .L:
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" II-*M.," SIR. 1.1 7* .N."
Form' FP-4 SPITTSBURGH TESTING LABORATORY
, PITTSBURGH" PA. Orderý No. rA-7732 AL X MS.UuTUALPROTECTION 740 CLICTrS. T~t P..s'-?C AOP OUPSKLVES. ALL REPORTS AAXEI1UD1M1TTWrAS Trs CONrI*O'TIAL Pqo0 EOTVyOF Cu. ZNTS. AN10 &UTHORI2tTION FOX VIUSLJCA1801 OF S T&TfKTTS. CCN=LIS.ON*S 0-7 EXTRACTS FRSOMOR ACOAR I NO
-li a OURt wErC.1T wIKTW~ PvOirmO Oug "Wflrtw ^OPp~vAL.
RLS REPORT of CONCRETE PLACEMENT REPORTED TO: FLORIDA POWER CORP.
PROJECT: CRYSTAL RIVER PLANT UNIT NO. 3
- Concrete Supplier: West Ctoast Concrete, Inc.
Arch.Engineer: Gilbert Assoc., Inc.' Inspector :I General Contractor: J. A. Jones C. i0. o T L
.1- F2UR--;-,-- 7 RB -:2- 7 3- ..
"*-U ,GRAD ." NA: . ""NSPECTION.
JOINT PREPARATION: OK FORMS: REINFORCEMENTS: EMBEDDED ITEMS: {Listf Properly Coated Proper Clearance R Lonforned to dra*j *,n Free From Holes Proper Support R Seams Tight Clean _ _ _:__ _ _"
Clean No. Tie Rods OK_ _ __ _ __ _
Proper Shoring & Supports EJ Location Tie Rods "wrPpd _ _ _,_ _
Alignment .
EQUiPMENT:
No. & Size of Vibrators 5 - 10,500 and 1 - 12,500 Freou-ncy plus Placement Equipment 2 -61 Whiteman Concrete Pumps Tremie Pipes - Number NA Size NA Location NA PLACEMENT:
Consolidation Procedure M4echanicaJ Vibration Grouted Yes Time 11 :15 A9 12:20 Fill Location Hor. Const. Jt.
Concrete - Lift Depth 18' Direction of Pour E to W; W to E REIJARKS. ExceRtions. None ,v CC: 2- FPC Qual.ity Records -J.*TSBURGH TESTING LA-BORATORY `4 3R-ssT.L * /-.*.- r-., P. E
- . *Ross T. McGillivraY, P. -*......
ATTACý1)'MENT ERLIN, HIME ASSOCIATES MATERIALS AND CONCRETE CONSULTANTS i.O ml SC+IE VOULEVARO 43121 272.7730 ILLINOIS 60062 PETROGRAPHIC STUDIES OF *CONCRETE 4.
FOR CONSTRUCTION ENGINEERING CONSULTANTS I
SUMMARY
AND DISCUSSION
-The specimen represented air-entrained concrete.
made with. crushed fossilif'erous coarse aggre-gate and siJliceous fine aggregate and a low water-cement ratio paste. There was no evidence
- that the aggregates had. been either chemic ally
,or physic~ally unsound.
~ The specimen was- from -an area where fractures
'had existed for a period of time and where
- . moisture had been present. That was demroni-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 r~esults of petrographic s-tudies 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
ERLIN, HIME' ASSOCIATES *,MATERIALS ANO CONCRETE CONSULTANTS STUDIES.
Specimen scimen was an elongated -Thefragment. 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 inch deep. The, channel appears to be the terminal area of a saw cut.
~PetrogravhicStudies, - Coarse aggregate, of. the sp.eciznen.
was a buff to light brown, fine-grained, fossiliferous limestone' having a maximum nomin~al size of 3/4 inch.
The fine aggregate was a siliceous satid composed prin-cipally of quartz.
The aggregates were not partichlar'ly well graded, as~...
evid'enced 'by deficiencies of the finer sizes of the coarse .aggregate and, the coarser sizes of the fine.
aggregate.
There was no 6vidence 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 s'imilar 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 speclimen was medium dark, grey, firm, and contained "abund~ant ~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, arnd as coarser irregularly shaped voids. The spherical vo'ds are characteristic of entrained air voids; the irregularly shaped voids,, of entrapped air.. The' air content of~th1e specimen' is estimated'to be 512 percent and the parameters of the ai'z-v'oid 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 acicular -ttriin~giteI(3CaO.
A1203-3C'aSO 4 -31H20), and calcite (6 aCO 3 ). IEtltr~igj~)
'was also present as tufts in,some air voids-Jusit be~low the' fracture-surface.
The fragment was not uniformly thick; it tapered to a knife-.like edge. Along that edge, were fine fractures C-13
- , .ERLIUN, HIME*ASSOCIATES - MATERIALS ANO .CONCRT: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 c~ompounds 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
0 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
... *Average 400 p.s.i.
Crystal River Cores 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 excepr.
....... __two soft pieces L Pour XV 10.69 3 3/4 5400 505 All hard coarse IL 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 All small soft
_coarse aggregate-Average 420 p.s.i.
Lote: The Granite Aggregate concrete cores fractured surfaces indicated all coarse aggregate P-I, 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 p3 coarse aggregate - all fractured at the fractured surface. 0 M:
ATTACHMENT E Preliminary Report of Crystal River Coarse Aggregate ASTM Spec Sieve Wgt. Ret. % Passing 0 100 100 3/4. 1.0 97 90-100 1/2
- 15-8. 58 3/8 28.4 .24... 20-55 4 35.84 0-10
.8 36.33 0-5 Pan 37.3 Test Result ASTM Specification C-117~ 200 Wash Loss. 1.3% (Primarily 1% Max*
C-131 Los Angeles Abrasion 42 % 50% Max C-ý123 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 Sul~phate) Later - 12.0% Max 0-127 Specific Gravity and Absorption Later No Spec
- This limit may be increased to. 1.5% if the material finer than a-No. 200 consistsý 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.CTLGro.Up.corn IT GROUP
.:.:!, 3. I, d, n. I~ a~e~~ eIiv.. ig JS R es J CTLGroup is a registered dibla of Construction Technology Laboratories, Inc,
~GROUP uIldh Knowledge. Oelvertng Resulti. 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/b/a 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.
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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.
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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. 1 Side views of Core #5, as received for examination.
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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.
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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 phenoithalein, 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.
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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.
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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 (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.
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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 si nIg l Reml*, ww, CTLGroup. C0o1
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
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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 problems 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 1 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 - couldn't get right - volume, air content, slump
- Large aggregate problem around area of a lot of steel -1/2 to 3/" 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
- 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