RS-14-338, Byron/Braidwood Nuclear Stations, Updated Final Safety Analysis Report (Ufsar), Revision 15, Appendix B - Construction Material Standards and Quality Control Procedures
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B/B-UFSAR B.0-i REVISION 1 - DECEMBER 1989 APPENDIX B - CONSTRUCTION MATERIAL STANDARDS AND QUALITY CONTROL PROCEDURES TABLE OF CONTENTS PAGE B.0 CONSTRUCTION MATERIA L STANDARDS AND QUALITY CONTROL PROCEDURES B.1-1 B.1 CONCRETE STANDARDS B.1-1 B.1.1 General B.1-1 B.1.2 Material Requirements and Quality Control B.1-1 B.1.2.1 Cement B.1-1 B.1.2.2 Aggregates B.1-2 B.1.2.3 Heavy Weight Aggregate B.1-4 B.1.2.4 Fly Ash B.1-4 B.1.2.4.1 Fly Ash In P rocess Testing B.1-4 B.1.2.5 Admixtures B.1-6 B.1.2.6 Water and Ice B.1-7 B.1.2.6.1 Water and Ice, C hloride Ion Content B.1-7 B.1.3 Concrete Properties and Mix Design B.1-8 B.1.3.1 Trial Mi xtures B.1-9 B.1.3.2 Design M ixtures B.1-9 B.1.3.3 Adjustment of Design Mixtures B.1-9 B.1.3.4 Grout B.1-10 B.1.3.5 Additional Concr ete Testing for Concrete Used in Cont ainment B.1-11 B.1.3.6 Heavyweight Concrete B.1-11 B.1.4 Formwork B.1-11 B.1.5 Joints and Emb edded Items B.1-12 B.1.6 Bar Placement B.1-13 B.1.7 Bending or Straighte ning of Bars Partially Embedded in Set Concrete B.1-13 B.1.8 Batching, Mixing, De livery, and Placement B.1-14 B.1.9 Witness and In spections B.1-15 B.1.10 Concrete Placement B.1-15 B.1.11 Concrete Con trol Tests B.1-18 B.1.11.1 Fresh Concre te Testing B.1-18 B.1.12 Evaluation and Acceptance of Fresh Concrete B.1-19 B.1.13 Evaluation and A cceptance of Concrete Compression Results B.1-19 B.1.13.1 In-Process Concrete Comprehensive Testing B.1-20 B.1.14 Consolidation of Concrete B.1-21 B.1.15 Concrete Finishes B.1-21 B.1.16 Curing and Protection B.1-22 B.1.17 Preplaced Aggr egate Concrete B.1-23 B.1.18 Evaluation a nd Acceptance of Concrete B.1-23 B.2 REINFORCING STEEL B.2-1 B.2.1 Requirements for Category I Materials B.2-1 B.2.2 Reinforcing Bar Fabrication B.2-3
B/B-UFSAR B.0-ii REVISION 7 - DECEMBER 1998 TABLE OF CONTENTS (Cont'd)
PAGE B.2.3 Cadweld Splicing B.2-3 B.2.3.1 Qualification of Operators B.2-3 B.2.3.2 Procedure Sp ecifications B.2-3 B.2.3.3 Visual E xamination B.2-4 B.2.3.4 Sampling and Tensile Testing B.2-6 B.2.4 Reinforcing Steel Repa ir for Steam Generator Replacement Project Co ntainment Opening B.2-7 B.3 POST-TEN SIONING TENDONS B.3-1 B.3.1 General B.3-1 B.3.2 Materials B.3-1 B.3.2.1 Tendon M aterial B.3-1 B.3.2.2 Button heads B.3-1 B.3.2.3 Tendon S heathing B.3-1 B.3.2.4 Permanent Corrosion Protection B.3-1 B.3.2.5 Anchor Heads B.3-2 B.3.2.6 Bearing Plates and Shims B.3-2 B.3.3 Quality Control B.3-2 B.3.3.1 Testing B.3-2 B.3.3.1.1 Tendon Tests B.3-2 B.3.3.1.2 Tests on Wires and Buttonheads B.3-2 B.3.3.1.3 Tests on Corrosion Preventative Grease B.3-3 B.3.3.1.4 Anchorage Hardware Tests and Inspections B.3-3 B.3.3.2 Fabrication Tolerances B.3-3 B.3.3.3 Field Installation Tolerances B.3-3 B.3.3.4 Corrosion Protection B.3-4 B.4 STRUCTURAL STEEL B.4-1 B.4.1 Structural Steel Materials B.4-1 B.4.2 Structural Steel Connections and Connection Material B.4-1 B.4.2.1 Bolted C onnections B.4-1 B.4.2.2 Welded C onnections B.4-1 B.4.3 Quality Control B.4-1 B.4.3.1 General B.4-1 B.4.3.2 Testing and Inspection of Weldments B.4-2 B.4.3.3 Fabric ation B.4-2 B.5 CONTAINMENT LINER WI THIN THE CONTAINMENT BACKED BY CONCRETE B.5-1 B.5.1 General B.5-1 B.5.2 Materials B.5-1 B.5.3 Quality Control B.5-1 B.5.3.1 Testing of Welds B.5-1 B.5.3.1.1 General B.5-1 B.5.3.1.2 Liner Plate Seam Welds B.5-1 B.5.3.1.2.1 Radiographic Examinations B.5-1
B/B-UFSAR B.0-iii REVISION 3 - DECEMBER 1991 TABLE OF CONTENTS (Cont'd)
PAGE B.5.3.1.2.2 Ultrasonic Examinations B.5-2 B.5.3.1.2.3 Magnetic Parti cle Examination B.5-2 B.5.3.1.2.4 Liquid Penet rant Examination B.5-2 B.5.3.1.2.5 Vacuum Box S oap Bubble Test B.5-2 B.5.3.1.3 Leak Test Channels B.5-2 B.5.3.2 Fabrication and Installation B.5-2 B.5.3.2.1 General B.5-2 B.5.3.2.2 Welding Qualification B.5-3 B.6 CONTAINMENT STEEL BO UNDARY NOT BACKED BY CONCRETE B.6-1 B.6.1 Materials B.6-1 B.6.2 Quality Control B.6-1 B.6.2.1 Testing B.6-1 B.6.2.1.1 General B.6-1 B.6.2.1.2 Testing of Welds B.6-1 B.6.2.2 Fabrication and Installation B.6-2 B.6.2.2.1 General B.6-2 B.6.2.2.2 Qualification of Welders B.6-2 B.7 STAINLESS ST EEL POOL LINERS B.7-1 B.7.1 Materials B.7-1 B.7.2 Welding B.7-1 B.7.3 Erection Tolerances B.7-1 B.8 OTHER STAINLESS STEEL ELEMENTS B.8-1 B.9 NUCLEAR STEAM SUPPLY SYSTEM (NSSS) COMPONENT SUPPORT STEEL B.9-1 B.9.1 General B.9-1 B.9.2 Steel Materials B.9-1 B.9.3 Welding Qualif ications B.9-1 B.9.4 Quality Control B.9-1 B.9.4.1 General B.9-1 B.9.4.2 Lamination Tests B.9-1 B.9.4.3 Nondestructi ve Examination of Welds B.9-1 B.9.5 Fabrication and Installation B.9-1 B.9.5.1 Installation Tolerances B.9-2
B/B-UFSAR B.0-iv APPENDIX B - CONSTRUCTION MATERIAL STANDARDS AND QUALITY CONTROL PROCEDURES LIST OF TABLES NUMBER TITLE PAGE B.1-1 Air Content B.1-24 B.1-2 Limits for Slump B.1-25 B.1-3 Placing Temperature B.1-26 B.1-4 Concrete Compression Testing B.1-28 B.1-5 Concrete Testing B.1-31 B.1-6 Gradation of Heavyweight Aggregate B.1-32 B.9-1 Material for NSSS Component Supports B.9-3 B/B-UFSAR B.1-1 REVISION 7 -DECEMBER 1998 APPENDIX B CONSTRUCTION MATERIAL STANDARDS AND QUALITY CONTROL PROCEDURES B.0 CONSTRUCTION M ATERIAL STANDARDS AND QUALITY CONTROL PROCEDURES B.1 CONCRETE STANDARDS B.1.1 General
All concrete work do ne conformed to the requ irements as cited from the codes, standards, and recommended practices as listed in Table 3.8-2 with the exceptions and addit ional requirements indicated in this Section B.1. For the restoration of the containment opening following steam generator replacement, current versions of the cited standards and recommended practices listed in the following sections were used. If the referenced standards or recommended practices were no longer in use, appropriate replacement sta ndards or recomm ended practices were used.
B.1.2 Material Requirements and Quality Control
B.1.2.1 Cement
Portland Cement, Type II, was used and conforms to all applicable requirements of "Specification for Portla nd Cement" (ASTM C150). Portla nd Cement, Type I, c onformed to all the standard chemical requiremen ts and stand ard physical requirements listed in T ables 1 and 2 respective ly of ASTM C150.
Type I cement was us ed on a limited basis in Category I structures other tha n the containment.
Qualification Tests prel iminary to mix design were p erformed on every source of ceme nt for conforman ce with ASTM C150.
The cement supplier furnished certificat ion with each shipment of cement to the project site for the following ASTM tests:
- a. ASTM C114, "Chemical A nalysis of Hydraulic Cement," including actual Na 2 O content and re quirements for tricalcium silic ate and tricalcium aluminate as specified in Table 1A of ASTM C150, b. ASTM C109, "Test for Compressive Strength of Hydraulic Cement Mortars" (results were forwarded within 30 days a fter delivery), c. ASTM C204, "Tests for Fi neness of Portla nd Cement by Air Permeability Apparatus," and
B/B-UFSAR B.1-2 REVISION 7 -DECEMBER 1998 d. ASTM C266, "Tests for Time of Setting of Hydraulic Cement by Gilmore Needles," or C191, "Te sts for Time of Setting of Hydraulic Cement by Vicat Needle." Control testing was perf ormed for the following ASTM tests, based on a frequency of every 1200 tons:
- a. ASTM C114,
- b. ASTM C266 or C191,
- c. ASTM C151, "Test for A utoclave Expansi on of Portland Cement," and
- d. ASTM C204.
All cement was store d in accordance with the applicable requirements of Section 2.5.1 of ACI 301, "Specification for Structural Concr ete for Buildings." B.1.2.2 Aggregates
Fine and coarse aggregat es conformed to "Sta ndard Specification for Concrete Aggrega tes" (ASTM C33) and to the following.
- a. Size Numbers 57 or 67 were used for grading of coarse aggregates (ASTM C33).
- b. Coarse aggregate con tained less than 15% (by weight) flat and elongated parti cles as determined by CRD-C119, "Method of Test for Flat and Elongated Particles in C oarse Aggregate."
Samples of aggregate were obtained in accordance with ASTM D75, "Sampling Aggregates," and the following qualification tests, preliminary to mix desig n, were performed on each source and type of aggregate proposed for use:
- a. ASTM C136, "Sieve or Screen Analysis of Fine and Coarse Aggregates," b. ASTM C117, "Materials Finer Than No. 200 Sieve in Mineral Aggregat es by Washing,"
- c. ASTM C40, "Organic Imp urities in Sands f or Concrete,"
- d. ASTM C87, "Effect of Organic Impurit ies in Fine Aggregate on Strength of Mortar," e. ASTM C88, "Soundness of Aggregates by Use of Sodium Sulfate or Magne sium Sulfate,"
- f. ASTM C142, "Clay Lumps a nd Friable Particles in Aggregates,"
B/B-UFSAR B.1-3 g. ASTM C123, "Lightwei ght Pieces in Aggregate," h. ASTM C131, " Resistance to Abra sion of Small Size Coarse Aggregate by Use of t he Los Angel es Machine,"
- i. ASTM C235, " Scratch Hardness of Coarse Aggregate Particles," j. ASTM C127, "Specific G ravity and Absor ption of Coarse Aggregate,"
- k. ASTM C128, "Specific G ravity and Abs orption of Fine Aggregate," l. ASTM C29, "Unit Weight of Aggregate,"
- n. ASTM C289, "Potentia l Reactivity of Aggregates (Chemical Method)," o. ASTM C295, "Petrographic Examination of Aggregates for Concrete," and
- p. CRD-C119.
The following control te sts were performed during periods of casting of concrete to ascertain conformance with ASTM C33, "Specifications for Conc rete Aggregates," at the frequencies indicated:
- a. ASTM C117 and C29 - daily;
- b. ASTM C136 and C40 (C 87 if C40 failed) - daily;
- c. ASTM C566, "Total Mois ture Content of Aggregate by Drying" - tw ice daily;
- d. CRD-C119, C142, C123, C235, C127 and C128 are performed monthly during production; and
- e. ASTM C131 or C535, "Re sistance to Abra sion of Large Size Coarse Aggregate by Use of the Los Angeles Machine," C289, and C88 every 6 months.
If an aggregate sample f ailed any of these t ests, two additional samples were taken i mmediately and the test for which the original sample did not meet specificati on requirements was repeated on each. If both sampl es met requirements, the material was accepted. If one or both of the retests failed, production was halted and Sargent
& Lundy was notified, and determined the necessary action required.
B/B-UFSAR B.1-4 REVISION 7 - DECEMBER 1998 Samples for tests were in accord ance with ASTM D75, Paragraph 3.3.3, with the following modification: the gradation tests for each source and type of aggregate proposed f or use that day were performed on samples collected and blend ed into one combined sample from four locations in th at portion of the stockpile intended for use that day.
Control, handling and storage of aggregates, were in accordance with Section 2.5.2 of ACI 301.
The fine and coarse aggregates used in the c oncrete mix for restoration of the ste am generator repla cement project (SGRP) containment opening conf ormed to ASTM C33. The maximum size of coarse aggregates was 3/8 inch. The qualifi cation tests, prior to mix design, were performed in accorda nce with the above listed standards (No te: ASTM C235 standard has been withdrawn).
In addition, ASTM C1218, "Standa rd Test Method f or Water-Soluble Chloride in Mortar and Concrete," and ASTM C586, "Test Method for Potential Alkali Reactivity of Carbonate Rocks for Concrete Aggregate (Rock Cylinder Method)
," tests were also performed.
B.1.2.3 Heavy We ight Aggregate
Heavy weight aggregate conformed to ASTM C63 7, "Aggregates for Radiation-Shielding Conc rete," Sections 5 and 6, except that at the Byron Station a larger per centage of material finer than sieves No. 100 a nd No. 200 was allowed, based on Section 4.1 of ASTM C637 and actual placing t ests. Heavy wei ght aggregates also conform to the following.
Test Frequency: One complete set of qua lification tests of each type of aggregate and one complete test at the time aggregate was delivered at the project site were performed.
Sampling was performed in accorda nce with Paragraph 7
.1 of ASTM C637.
B.1.2.4 Fly Ash Fly ash conformed to the Class C and F m andatory requirements of ASTM C618, "Standard Specifications for Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Miner al Admixture in Portland Cement Concrete
," except that in Table 1, "Chemical Requirements," the loss on ignition was a maximum of 6%.
Qualification tests prel iminary to mix design were p erformed on every source of fly ash for conformance with the above specification.
Certified material test reports were furnish ed by the fly ash supplier who certified that delivered fly ash had been tested and did meet the mandatory r equirements of ASTM C618, as modified above. This certification included the test results and was supplied with de livery of fly ash fo r mix designs and with each 2000 tons de livered to the project.
B/B-UFSAR B.1-4a REVISION 7 - DECEMBER 1998 Storage of fly a sh was as specified in S ection 2.5.1 of ACI 301.
B.1.2.4.1 Fly Ash In Process Testing
ANSI N45.2.5 Table B requires in-process testing of fly ash per ASTM C618 with a frequency of ev ery 200 tons. F ly ash was not used in Braidwood Stat ion concrete, except for the restoration of the containment following steam gener ator replacement. It was used on a limited basis at B yron Station. In-process testing at Byron Station was per formed by the fly ash supplier and by Commonwealth Edis on's testing laborat ory. Fly ash was tested and cer tified by the
B/B-UFSAR B.1-5 REVISION 3 - DECEMBER 1991 supplier for conformance with ASTM C618 at a fre quency of every 2000 tons. The following tests were p erformed every 2 000 tons by the supplier:
- c. Amount retained on No. 325 sieve, d. Sum of the oxides (SiO 2 + A1 2 O 3 + Fe 2 O 3),
- e. Moisture content, f. Pozzolanic act ivity with cement,
- g. Pozzolanic a ctivity with lime, h. Water requirement, i. Soundness, and
- j. Specific gravity.
The Applicant's testing laboratory tested the fly ash at a frequency of every 200 tons for the fo llowing tests:
- a. Loss on ignition,
- c. Amount retained on No. 325 sieve.
In-process concrete co ntrol testing by the Applicant's testing laboratory at a frequency of 200 tons includ e chemical and physical tests for whi ch correlation with concrete properties has been established.
Any test resu lt that cannot be correlated with concrete properti es serves no useful concrete quality control function.
Prequalification tests w ere performed for ev ery source of fly ash for full compliance with ASTM C618.
Once fly ash from a power plant using a specific coal is qualified by ASTM C618, testing for loss on igni tion, sulfur trioxid e, and the amount retained on No. 325 sieve perf ormed every 200 tons are sufficient to ensure the uniformity of t he fly ash.
Uniformity of fly ash can be c orrelated to con crete quality.
When fly ash was used, it was ad ded in the propo rtion of 20% by weight of cement. F ly ash was n ot used as a substitute for cement.
B/B-UFSAR B.1-6 B.1.2.5 Admixtures Air-entraining admixtu res conformed to " Specification for Air-Entraining Admixture for Concrete" (ASTM C260), including "Optional Uniformity Requirement s" in Section 5. Air-entraining admixtures containing more than 1% chlor ide ions were not used.
The air entrained admixture su pplier furnish ed certified material test reports wh ich state that the a dmixture was tested in accordance with ASTM C260 and satisfied both of these above additional requirements. This certification included the manufacturer's statements as described in Sections 4.1, 4.2, and 4.3 of ASTM C260 , and also included the results of the following tests performed on a composite sample from each shipment:
- a. infrared spectrophotometry, b. pH value, c. solid content, d. chloride ion content, and
- e. specific gravity.
Chemical admixtures conformed to "Specification for Chemical Admixtures for C oncrete" (ASTM C494).
Type A, water-reducing admixtures were permitte d, subject to the fo llowing requirements:
- a. The material was either a hydroxylated carboxylic acid base or a modif ied salt thereof, or a hydroxylated polymer base.
- b. The material was not p repared by the addition of any chloride ions. The supplier certified that the admixture did not contain from all sou rces more than 1%, by weight, of chloride ions.
- c. The supplier furnished certified test results of specific gravity, viscos ity, infrared spectro-photometry, pH value and solids content of the material used for the pr oject, establishing the equivalence of materials fro m the different lots or different portions of the same lot in accordance with Article 4.4 of ASTM C494.
Storage of admixtures was as specified in Se ction 2.5.5 of ACI 301.
B/B-UFSAR B.1-6a REVISION 7 - DECEMBER 1998 The following admixtures were used in the concrete mix for restoration of the con tainment opening follo wing steam generator replacement:
- a. Air-entraining admixture conforming to ASTM C260 with chloride ions not exceeding 1% (by weight).
- b. Water-reducing admixture conforming to ASTM C494, Type A, with chloride io ns not exceeding 1% (by weight). c. High-range, wate r-reducing admixture conforming to ASTM C494, Type F, with chloride ion s not exceeding 1% (by weight).
B/B-UFSAR B.1-7 B.1.2.6 Water and Ice Mixing water and ice were cl ean and the maxi mum content of chloride ion in mixi ng water did not exceed 500 ppm.
Qualification tests prel iminary to mix design were p erformed to ensure compliance with the requi rements specified.
Control testing was pe rformed using the foll owing ASTM tests:
- b. ASTM C109, "Compress ive Strength of Hydraulic Cement Mortars," C191 and C151 - every 3 months.
B.1.2.6.1 Water and Ic e, Chloride Ion Content ANSI N45.2.5 has no re quirement for the chlori de ion content in water and ice. ASME Boiler and Pressure Vessel Code,Section III, Division 2, subparagraph CC
-2223.1 limits the chloride ion content in water to 250 ppm.
Subsection B.1.2.6 sta tes that the maximum ion content did not exceed 500 ppm.
At Byron Station, t he maximum chloride ion content in the mixin g water does not e xceed 250 ppm. At Braidwood Station, the maximum chloride ion content in the mixing water did not exceed 347 ppm with an average content of
300 ppm.
A chloride ion c ontent of 500 ppm is a conservative limit when compared with the limits allowed in ACI 201.2R-77 and in the proposed revision to ACI 301-72.
Limiting the chloride content in water is an indirect and easy method to limit the total soluble chloride content in the concrete. In ACI 201.2R-77, it is stated that some fo rms of chloride are readily soluble and hence, are likely to induce corrosion in the reinforcement.
Other chlorides are not likely to induce cor rosion. However, the test for soluble chloride is time co nsuming and difficult to control. ACI 201 committee recommends testing for total chlorides and, when le ss than recommended ma ximum, states that the test for soluble c hlorides is not required.
In Section 4.5.4 of ACI 201.2R-77 the ma ximum chlori de content in concrete is limited in terms of cement content, concrete exposure and type of construct ion. The average total chloride content per cubic yard of concre te at Braidwood Station exceeds Byron Station. The to tal chloride in water, cement and admixtures at Braidwood Station equals 0.025
% of the weight of cement. Of this, ap proximately 59% is provi ded by the water, 28% by the cemen t, and 12% by the admixture.
B/B-UFSAR B.1-8 When the limits for soluble chlo ride in ACI 201 and the proposed revision to ACI 301 are compared with 0.025%, it shows that this content is 2.4 t imes less than that allowed for prestressed concrete, four times less th an that allowed for reinforced concrete in a moist envi ronment exposed to c hloride, and six times less than that allowed for reinforced concrete in a moist environment but not exposed to chloride, respectively.
At the Byron/Bra idwood Stations, whatever water is in contact with both prestressed and rein forced concrete is neither sea water nor the brackish water present on bridge decks and highways due to winter deicing salt.
Therefore, the chloride induced corrosion of e mbedded metals in this concrete is highly unlikely.
Additionally, the ASME Boiler and Pressure Vessel Code Summer 1980 Addenda,Section III, Division 2, subpa ragraphs CC-2224.1 and CC-2231.2 were rev iewed for conformance.
Both Byron and Braidwood Stations conform to these requirements for chloride content in concrete and admixture. For Brai dwood Station, the chloride content of the cement paste (cement , admixtures, and water) portion of the concrete is 170 ppm by weight. The chloride content at Byron Station is less.
B.1.3 Concrete Properties and Mix Design
Concrete mix design conformed to ACI 211.1, "Recommended Practice for Selecting Proportions f or Normal Weight Concrete," and to ACI 304 Title No. 68-33, "Placing Con crete by Pumping Methods," including Ch apter 9 of ACI 304.
Mix properties:
- a. Slump - Concrete was proportio ned to have a slump of 3 inches
+/-1 inch at 70
°F as determined by ASTM C143, "Slump of Portland Cement Concrete." b. Air content - Air content conf ormed to the following requirements as dete rmined by ASTM C231, "Air Content of Freshly Mixed Concrete by the Pressure Mixture":
Nominal maximum size Total air content, of aggregate, in.
%, by volume 3/4 6 +/- 1 1 5 +/- 1 B/B-UFSAR B.1-9 REVISION 9 - DECEMBER 2002
- c. Specified compressive st rength: Struc tural concrete strengths and one fill concrete strength were furnished as follows:
- 1. 5500 psi at 91 days, 2. 3500 psi at 91 days, and
- 3. 2000 psi at 28 d ays (fill concrete).
Fly ash content when u sed equaled 20% of the weight of cement.
Concrete for restoration of the SGRP containment opening was proportioned to have the following properties:
- a. Compressive strength:
5500 psi at 7 days, b. Slump: 5 inches to 8 inches, and
- c. Air content: 6.5
+/- 1.5 percent.
B.1.3.1 Trial Mixtures
Trial mixtures having pr oportions and consiste ncies suitable for the work were made using at least three different water-cement ratios which pro duced a range of strengt hs encompassing those required for the work. All mate rials including the water were those used at the project site.
For each water-cement ratio, at least th ree compression test cylinders for each t est age were made and cured in accordance with "Method of Maki ng and Curing Conc rete Compression and Flexure Test Specimens in the Laboratory" (ASTM C192). They were tested for streng th at 7, 28, and 91 days, in accordance with "Method of Test for Compressive S trength of Cylindrical Concrete Specimens" (ASTM C39). From the results of these tests, curves were plotted showing t he relationship between water-cement ratios and compressive strength.
Mix design qualificati on of the concrete for restoration of the SGRP containment opening was p erformed using t he trial batch method described in ACI 301. The mix was designed for a required average strength of 6900 psi (5500 psi plus 1400 psi) at 7 days based on t he requirements of ACI 3
- 01. A minimum of two water/cementitious m aterial ratios were te sted to produce a range of strengths encompass ing the required value.
B.1.3.2 Design Mixtures
Until the standard deviation was calculated for each of the mixtures used, the req uired average strength was determined by adding 1200 psi to t he required compress ive strengths of 5500 psi and 3500 psi at 91 days.
B/B-UFSAR B.1-9a REVISION 7 - DECEMBER 1998 This required average strength was entered into water-cement ratio strength c urves to determine the maximum water-cement ratio.
This water-cement ra tio was used with the water requirement reported from trial mixtures for the aggregate s ize to calculate the minimum cement content.
Adjustments in absolute volume to maintain y ield were made by adjusting aggregate amounts wh ile maintaining the sand percentage of the original trial mixture.
B.1.3.3 Adjustment of Design Mixtures
After the accumulation of no less than 30 te sts at 91 days of a mix design, these test results were evaluated by statistical methods in accordance with ACI 214 and t he standard deviation
B/B-UFSAR B.1-10 was calculated. A new r equired average strength, fave req. was computed, using the higher of the values computed below:
+=343.1f.req f'c ave +=326.2 500f.req f'c ave where: 'c f = specified comp ressive strength = standard deviation.
With this new requir ed average strength, the design mixtures procedure was repeated to obtain revised mix proportions using the curve for the water-cement r atio and compressive strength.
If, during the course of construction, statist ical surveillance revealed that the required ave rage strength was not achieved, an investigation was p erformed by Sargent &
Lundy to investigate the cause and determine what corrective acti on was necessary.
The equations presented above for the ad justment of design mixes are the same as those in ACI 318-77 Commentary Section 4.3.1.
These equations are obta ined when the pr oper values of the statistical parameter t , corresponding to the probable frequencies in ACI 318-77 Section 4.7, are used in Equations 4-1a and 4-1c of ACI 214-77 or in Equation 7 of ACI 214-65.
The values given in ACI 318-77 S ection 4.3.1 for the required strength, are the results obtain ed from Equations 4-1a and 4-1c of ACI 214-77 when t he higher of the sta ndard deviation values are used.
B.1.3.4 Grout
Grout of proportions similar to the mortar in concrete was determined as follows:
- a. A trial mix was calculated. Qua ntities of fly ash, fine aggregate and admix tures were com puted in the same ratio to cement as in the concrete.
- b. The trial mixture was performed, and the quantity of water and air entrain ing admixture required was determined. If wate r required caused the water-cement ratio of the concrete to be exceeded, cement
B/B-UFSAR B.1-11 REVISION 7 - DECEMBER 1998 was added until the original water-cement ratio was restored. Compressive s trength of the grout was tested in accordance with ASTM C109.
B.1.3.5 Additional C oncrete Testing for Concrete Used in Containment
After the approval of the concre te mixtures, the following tests were performed:
- a. Compressive strength at 7, 28, and 91 days (ASTM C39).
- b. Static modulus of elasticity at 91 days (ASTM C469, "Static Modulus of E lasticity and Pois son's Ratio of Concrete in Compression").
- c. Poisson's ratio at 91 days (ASTM C469).
- d. Specific gravity at 91 d ays (ASTM C642, "Specific Gravity, Absorption, and Voids in Hardened Concrete").
- e. Coefficient of thermal conductivity at 91 days (CRD-C44, "Calculation of Thermal Conductivity of Cement").
- f. Coefficient of thermal e xpansion at 91 days (CRD-39, "Coefficient of Linear Thermal Expansion of Concrete").
- g. Specific heat at 91 days (ASTM C351).
- h. Shrinkage strains up to at least 180 days after 7 and 28 days of continuous moist curing, and then drying at 70
+/- 2°F and 50% relati ve humidity (ASTM C157). i. Creep strain of concrete in compress ion loaded after 28 and 91 days of contin uous moist curing, to a sustained stress of approxim ately 2500 psi on test specimens drying at 70
+/- 2°F and 50% relative humidity and on sealed t est specimens (ASTM C512).
The following tests were performed after the concrete mix was approved for the restoration of the containment opening following steam gene rator replacement:
- a. Compressive strength at 1, 7, and 28 days in accordance with ASTM C39.
Static modulus of elasticity and Poiss on's ratio at 7 and 28 days in accordance with ASTM C469.
B/B-UFSAR B.1-11a REVISION 7 - DECEMBER 1998
- b. Creep and shrinkage strain measurements for specimens maintained at 73
+/- 3°F and 110
+/- 3°F and loaded at the ages of 7 days and 28 days in accordance with ASTM C512.
However, the specific gravity (ASTM C 642), the coefficient of thermal expansion (C RD-C39), the coeff icient of thermal conductivity (CRD-C44), and the specific hea t (ASTM C351) were not tested to determ ine these parameters for the following reasons:
These parameters do not vary significant ly for concrete mix designs. To demonstrate this, the value of specific heat, thermal conductivity, and coefficient of thermal expansion for the original mix designs are summarized below.
Parameter BraidwoodBraidwoodByron Byron 28 days 1 year 28 days 1 year Specific Heat (Btu/lb°F) 0.234 0.256 0.237 0.242 Thermal Conductivity (Btu/ft 2/hr°F/in) 14.7 15.1 14.6 14.2 Coefficient of Thermal Expansion 5.82 5.88 5.59 5.92
Based on the small surface area of the contain ment opening (approximately 600 ft
- 2) and the small volume of the replaced concrete (approx imately 2100 ft
- 3) in comparison with the total surface area and vol ume of the contain ment, the effects of variation (if any) in the va lue of these parameters are insignificant.
The containment analys is used 150 lb/ft 3 for concrete density and 5.5E-06 for the coeffici ent of thermal expansion.
These values are consistent with the origin al design and are industry standards.
B.1.3.6 Heavyweight Concrete
Heavyweight concrete mix conform ed to Appendix 4 of ACI 211.1, "Recommended Practice for Se lecting Proportions for Normal Weight Concrete."
B.1.4 Formwork
All formwork conformed to Chapter 4 of ACI 301 and as hereinafter specified.
B/B-UFSAR B.1-12 Forms for all expose d surfaces conformed to Section 10.2.2, "Smooth Form Finish," of ACI 301.
"Exposed surfaces" as used, meant all formed c oncrete surfaces exposed to view on completion of work.
All exposed projecting corners of concrete work such as piers, columns, equipment foundations, switchyard f oundations, and turbine foundations were beveled.
For exposed surfaces and exposed ver tical corners of structures in contact with the ground, the smooth f orm finish and the vertical bevels were e xtended 1 foot 0 inch below finish grade.
B.1.5 Joints and Embedded Items
Joints and embedded items conformed to Chapter 6 of ACI 301 including the following:
- a. For bonding methods in S ections 6.1.4.1 and 6.1.4.2 of ACI 301, specific app roval by the purchaser or its representative was required.
- b. Horizontal con struction joints in containment walls are cleaned by cutting the concrete surface layer and exposing the aggregate without undercutting.
Construction joints in Category I st ructures were grouted immediately before placement of concrete in accordance with provisions of Section 8.5.3, ACI 301, except that no grout is required on vertical surfaces of walls. Where keys were used, grouting of horizontal joints were not required.
- c. Unformed construction joints were protected against loss of water requir ed for curing by application, immediately after completion of construc tion by one of the following methods:
- 1. Application of damp sa nd or moistened fabrics kept continuously mo ist until placement of concrete was recommended.
Prior to resumption of placement, the cu ring materials were completely removed from the concrete surface, in accordance with provisio ns of Section 8.1 of ACI 301. 2. Application of curin g compound containing nonfugitive pigments. P rior to resumption of
placement, this surface was completely cleaned by sand blasting, chip ping, or jack hammering until no trace of pi gment remained.
B/B-UFSAR B.1-13 REVISION 1 - DECEMBER 1989 B.1.6 Bar Placement Bar placement conformed to the design dr awings and to the applicable requirements of Section 7.2 and 7.3 of ACI 318, to Chapter 8, "Placing Re inforcement Bars" of CRSI "Manual of Standard Practice," to Subarticl es CC-4340, CC-4350, and CC-4360 in Section I II, Division 2 of the ASME Boiler and Pressure Vessel Code, and to the following:
In lieu of Section 7
.3.2.1 of ACI 318 and Paragraph 7, Chapter 8 of the CRSI Manual of Standard Practice, t he following applied:
- a. Clear distance to formed surfa ces: For No. 3 through No. 11 bars:
+/- 1/4 inch for straight bars, +/- 1/2 inch for bent bars.
- b. For No. 14 and No. 18 bars:
+/- 1/2 inch for straight bars, +/- 1 inch for bent bars.
- c. The cover was not reduced by more than one-third of the specified cover, nor to less than 1-1/2 inch for No. 14 and No. 18 ba rs at interior surfaces.
- d. Spacing tolerances between parallel bars: For No.
3 through No. 18 bars;
+/- 2 inches.
B.1.7 Bending or Straightening of Bars Partially Embedded in Set Concrete
Bending or straighte ning of bars partial ly embedded in set concrete was not permitted exc ept in isolated cases where corrective action or a field change was requ ired and specifically approved by Sargent & Lundy.
The bend diameter conformed to t he requirements listed below.
The beginning of the bend wa s not closer to the existing concrete surface than the mi nimum diameter of bend.
Bars No. 3 through No. 5 were co ld bent once.
Preheating was required for subsequent straightening or bendi ng. Bars No. 6 and larger were preheated for any bending.
MINIMUM DIAMETER OF BEND Bar Size Minimum Diameter of Bend
No. 3 through No. 8 6 bar diameters
No. 9, No. 10, No.
11 8 bar diameters
No. 14, No. 18 10 bar diameters
B/B-UFSAR B.1-14 When required, preheating prior to bending or straightening was performed in accordance with the following:
- a. Preheating was a pplied by methods which do not harm the bar material or cause damage to the concrete.
- b. The preheat was applied to a length of bar at least equal to five bar diamet ers in each direction from the center of the portion to be bent or straightened, except that preheat was not ex tended below the surface of concrete. To avoid s plitting the concrete, the temperature of the bar at the concrete i nterface did not exceed 500
°F. c. The preheat te mperature was 1100
°F to 1200°F. d. The preheat temperature was maintained until bending or straighte ning was completed.
- e. The preheat temperature was measured by temperature measurement crayons or contact pyrometer.
- f. Precautions were taken to avoid rapid cooling of preheated bars. Water w as never allowed to be used for cooling.
All bent and straightened bars were visually examined for cracks. Visual exam ination of preheated bars was performed after the bars reached ambient temperature.
Bars straightened after a first bend were checked for cracking using liquid penetra nt method with the following sequence:
- a. The first three straightened bars.
- b. One out of the next and each sub sequent unit of ten straightened bars.
- c. All bars with subsequent straightening or bending and all bars that fail ed visual examination were
checked using liquid penetrant method.
- d. Concrete surface was v isually examin ed for any damage due to the pr eheating, bending or straightening operations.
Bars exhibiting transv erse cracks were properly replaced.
B.1.8 Batching, Mixing, Delivery, and Placement Batching, mixing, and delivery equipment, including their operation, conformed to the requirements of ASTM C94, Articles 7, 8, and 9. To the extent ap plicable the pla cement complied
B/B-UFSAR B.1-15 REVISION 7 - DECEMBER 1998 with the requirements of the criteria for concrete placement in
Category I Structures.
B.1.9 Witness and Inspections Prior to production, the testing agency inspected batch plant, stationary and truck mixers to verify conformance with B.1.8 above. After the concre te batch plant and m ixers were placed in production, the testing agency inspected the production facilities to verify that conc rete was produced in accordance with Section 7.2 of ACI 301.
B.1.10 Concrete Placement
Air Content
- The allowable limits of air content was as indicated in Table B.1-1, exce pt as noted in Subsection B.1.3 for the restoration of the containment o pening following steam generator replacement.
Slump: Concrete slump was within the allowable limits as indicated in Table B.1-2, exce pt as noted in Subsection B.1.3 for the restoration of the containment o pening following steam generator replacement.
Concrete Placing Temperature
- Concrete plac ing temperature conformed to the criteria given in Table B.1-3.
Concrete placement conformed to the applicable requirements of Sections 8.1, 8.2, and 8
.3 of ACI 301 and Ch apter 6 of ACI 304 and the following:
- a. All concrete was pla ced in a continuous and uninterrupted operation in such manner as to form a monolithic structure, the co mponent parts of which were integrally bond ed together. No concrete was deposited which had been segre gated, contaminated by foreign materials, or considered nonplastic.
- b. Concrete was considered plastic if either of the following requirements were met:
- 1. If immediately befor e recommencing concrete placement a vibrator s pud suspended vertically was applied to the con crete surface and it penetrated at least 6 in ches into the concrete during 15 seconds of a pplication, the concrete was considered plastic, if not, the concrete was considered nonplastic.
- 2. If the tempera ture of the conc rete in place and the time interval between placement of successive batches was within the following temperature and time limits:
B/B-UFSAR B.1-16 Concrete Temperature Time Limit 80°F 35 minutes 70°F 40 minutes 60°F 55 minutes 50°F 65 minutes
- c. If concrete was found to be no nplastic, concrete was placed in accordance with requirements of Section 8.5.3 of ACI 301, except that no dampening was required before the application of grout.
- d. All concrete was depos ited in the forms after introduction of mixing water to cement and aggregates, within the following time limits:
Concrete Temperature Time Limit Below 60°F 2-1/2 hours 61°F to 70°F 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> Above 70°F 1-1/2 hours The above limitations were w aived if the concrete was within the allowable lim its for slump, provided it could be transported and placed without addition of water to the batch. Othe rwise the concrete was
rejected.
Concrete that was beyond the allowable limits for slump and air content but wi thin the extreme limits as placed in the forms, was placed within a 1-1/2 hour time limit. Otherw ise the concrete was rejected.
- e. Hot weather concreting c onformed to Section 12.3.2 of "Recommended Practice for Hot Weather Concreting," Section 12.3.2 of AC I 301, except as modified below:
- 1. Adequate provisions we re made against plastic shrinkage cracking, as specified in Chapter 2 of ACI 305, "Recommend ed Practice for Hot Weather Concrete." ANSI N45.2.5 Section 4
.5.2 requires adherence to specified requirements for hot weather concreting practice as given in ACI 305.
ACI 305-72 Section 2.2.1 states that:
"For the more massive type of heavy construction, i.e., those whose di mensions are such that significant heat is generated thro ugh hydration of cement,
B/B-UFSAR B.1-17 a temperature of 60
°F (16°C) or even lower would be desirable." Table B.1-3 allows minimum concr ete temperatures up to 70°F when air tempera ture is above 45
°F and up to 75°F when air tempera ture is below 45
°F. The recommendation in ACI 305-72 applies to more massive structures than those found at Byron and Braidwood Stations. The containment mat foundation is the most massive concrete element and it is much less massive than concrete placements for dams. In addition, midwest hot we ather concreting conditions are mild when compared with hot weather conditions in southern regions for whic h the recommendations in ACI 305 w ere intended.
ACI 305-77 Section 2.2.2 doe s not contain specific concrete temperature lim its, but states that:
"It is impractical to recommend a ma ximum limiting temperature because circumst ances vary widely.
Accordingly, the committee can only point out the
effects of higher temper atures in concrete and advise that at some temperat ure, probably between 75°F and 100°F there is a limit that will be found to be most favorable f or best results in each hot weather operation, and s uch a limit should be determined for the work."
The limits in Table B.1-3 are determined to be conservative for the construction of nuclear power plants. f. Cold Weather Concretin g: Cold weath er concreting conformed to the fol lowing provisions:
- 1. Concrete was placed at a temperature within the allowable limits indicat ed in Table B.1-3 and in accordance with the minimum tempe rature for the time indicated in Ta ble 1.4.2 of ACI 306, "Recommended Practice for Cold Weather Concreting," and upon removal of heat, the maximum temperature drop conformed to Table 1.4.1, Line 17 of ACI 306.
- g. Where early strength was critical, as indicated by Sargent & Lundy, concrete was maintained at the minimum allowable temper atures indicated in Table B.1-3 for the period of time indicated in Table 5.1.7 of ACI 306.
- h. If construction temper ature records indicated the possibility of a portion of the concrete in place
B/B-UFSAR B.1-18 REVISION 7 - DECEMBER 1998 being exposed to freezing temperatures prior to elapse of curing times indic ated in Table 1.4.2 of ACI 306, or during place ment, an inves tigation with concrete test hammer, drille d cores, or soniscope was conducted.
Concrete placement for the c ontainment openi ng restoration following steam generator re placement confor med to the applicable requirements of ACI 301 and 304R.
B.1.11 Concrete Control Tests
Concrete testing and sampling fr equencies conf ormed to Tables B.1-4 and B.1-5. Allowable limi ts conformed to Tables B.1-1, B.1-2, and B.1-3.
Concrete samples were obtained at truck chutes, except samples from pumped concrete w hich were obtained at point of discharge from the pump. Samples were obtained in accordance with ASTM C172, except that wh en a sample was secu red by diverting truck chute or pipe discharge into wheelbarrow, no compositing was required; and when central mix ed concrete was delivered, the sample was taken from any portion of the truck discharge.
Each time sampling commenced, requirements for normal sampling as defined in Table B.1-4 were followed.
All normal samples w ere randomly selected.
When a concrete sample was taken from a truck as concrete was being discharged, discharge from the truck w as immediately resumed while concrete was being tested.
If results from test s for slump, tempera ture, or air content were beyond the allowa ble limits, placem ent continued for the next five loads providing te st results were not beyond the extreme limits and t ightened sampling was instituted.
For tightened sampling, samples were tak en from the next available truck whether or not its disch arge had begun.
Discharge from this truck was resumed immediat ely after the sample was taken. If test results were beyond the allowable limits, discharge from this truck was discon tinued and a sample was taken from the n ext available truck.
This may have continued until five consecutive loads outsi de the allowable limits had been tested at which time concrete placement was discontinued until cor rections were made.
If two consecutive samples were tested wi thin the allowable lim its, normal sampling was resumed.
The required test specimens from each sample were molded and cured in accordance with ASTM C31.
B/B-UFSAR B.1-18a REVISION 7 - DECEMBER 1998 B.1.11.1 Fresh Co ncrete Testing Table B of N45.2.5 req uires that the first b atch produced every day be tested for slump, air content, and temperature.
Table B.1-5 requires that the first batch of concrete used in the containment is tested fo r slump, air content, and temperature. For ot her safety-related struc tures, first batch testing is not required.
Testing the first batch is i ntended to control overnight variations in the moisture con tent of aggregate, variations in the concrete materials and errors in the concrete mix proportions. Since the batch plant bins and silos are usually kept full during concrete prod uction, the mate rials used in the next day first batch a re the materials alrea dy in the plant from the preceding day of production. Segreg ation, contamination, and degradation in pro perties of the aggrega te used in the first batch of the next day are not di fferent from tho se during the previous day. Therefore, testing of the first b atch of concrete will not be of any sig nificance in controlli ng the quality of concrete.
Experience has shown that some variations in slump, air content, and temperature may occur several batches after production is started. These variat ions are related to material transition from the materials l eft in the batch p lant bins and silos overnight to those materials l oaded after overni ght materials are used in concrete production.
B/B-UFSAR B.1-19 REVISION 9 - DECEMBER 2002 Concrete testing, sampling, and allowable limits for the restoration of the con tainment opening follo wing steam generator replacement were as follows:
Concrete was sampled and tested in accordance wi th ASTM C94.
Samples were taken at the point of placement.
If the slump, air content, or temperature fell outside the lim its specified, an additional test was ma de immediately on anot her portion of the sample. In the event of a second failur e, the concrete was rejected. Tests were performed at the beginning, middle, and the end of the placement.
Allowable limits:
Slump: Working Limit 5 inches to 7 inches; rejection limit 8 inches, Air content:
5% (+/- 1.5%), and Temperature:
between 45
°F and 90°F. Tests: Slump: ASTM C143, Air content: ASTM C173 or ASTM C231, and Temperature: ASTM C1064.
B.1.12 Evaluation a nd Acceptance of Fresh Concrete
Test results on fres h concrete were in a ccordance with the requirements in Tables B
.1-1, B.1-2, and B.1-3.
Concrete which had s et was not retempe red but discarded.
Concrete was rejected for remixing or wasting if any or all the following conditions existed:
- a. Time limitations after introduction of water to cement were exceeded.
- b. Five consecutive trucks or batches remained on tightened inspection in Subsection B.1.11.
- c. Temperature, s lump, or air conte nt was beyond the extreme limits, as l isted in Tables B.1-1, B.1-2, and B.1-3.
B.1.13 Evaluation and A cceptance of Concret e Compression Results
The strength level of concrete was consi dered satisfactory if the following two crit eria were satisfied when using the standard deviation from at least 30 cons ecutive strength tests representing similar c oncrete, and condition s of concrete being evaluated:
B/B-UFSAR B.1-20 REVISION 1 - DECEMBER 1989
- a. A probability of not m ore than 1 in 100 that an average of three consecu tive strengt h tests was below specified strength.
- b. A probability of not m ore than 1 in 100 that an individual strength test was more than 500 psi below the spec ified strength.
Methods in ACI 214 w ere used in concrete evaluation along with the above criteria.
The above criteria was considered sa tisfied if either:
- a. The average of all sets of three consecutive strength test results at 91 days equaled or
exceeded the spe cified compressive strength of the concrete and no individu al strength test result fell below the specified compressive strength by more than 500 psi, or
- b. The average comp ressive strength, fave req., conformed to the follo wing two expressions:
+343.1f.req f'c ave +326.2 500f.req f'c ave where: 'c f = specified comp ressive strength = standard deviation.
B.1.13.1 In-Process Con crete Compressive Testing
ANSI N45.2.5 Table B requires that two cylinde rs for 28-day strength tests be ta ken every 100 yd 3 for each class of concrete. UFSAR Table B.1-4 requires six standard cylinders for compressive testing be prepared from concr ete samples taken every 150 yd 3 of concrete placed in Cate gory I structu res other than the containment.
Two cylinders e ach are tested for compressive strength at 7, 28, and 91 days.
Concrete acceptance is based on the 91-d ay result, however, the 7- and 28-day results were used to monitor the compressive strength development during concrete producti on. Concrete testin g frequency for the containment conforms to the ANSI Standard.
ACI 349-76, "Code Requirements f or Safety-Related Concrete Structures," establishes a com pressive strength test frequency of one for every 150 yd 3 of concrete pla ced for safety-related structures other than the co ntainment. Sect ion 4.3.1 of ACI
B/B-UFSAR B.1-21 REVISION 7 - DECEMBER 1998 349 allows an increase in the number of cubic yards representative of a si ngle test by 50 yd 3 for each 100 psi lower than a standard deviation of 600 psi. Table CC-5200-1 of the Summer 1981 Addenda of t he ASME Boiler and P ressure Vessel Code,Section III, Division 2, allows a testing fr equency of every 200 yd 3 if the average strength of at le ast the latest 30 consecutive compressive strength tests exceed the specified strength 'c f by an amou nt expressed as:
)69.8/f(419.1f f'c'c cr+=
At Byron/Braidwood S tations, the average compressive strength consistently exceeded this f cr for all the co ncrete placed.
Concrete compressive strength te sting and samp ling for the restoration of the con tainment opening follo wing steam generator replacement was as follows:
One set of cylinders was made at the beg inning, middle, and end of the concrete pour. Two cyl inders each we re tested at 1, 7, and 28 days.
B.1.14 Consolidation of Concrete
Consolidation of concrete conformed to requirements in Section 8.3.4 of ACI 301, and the following:
- a. All concrete was con solidated by sufficient vibration so that conc rete was w orked around reinforcement, around em bedded items, and into corners of forms, eliminating air or stone pockets.
- b. When a layer of concrete was being consolidated, the vibrator spud penetrated at le ast 6 inches into the previously con solidated layer.
- c. Spacing of v ibrator insertions and withdrawals caused overlapping " spheres of influen ce," generally at about 18 inch spacing.
- d. Vibrators were not used to eff ect horizontal movement of concrete.
- e. If in the opinion of the inspector, segregation was occurring prior to a dequate consolidation, adjustment of mixture or pattern of vibration was considered.
- f. Internal vibrators used in the work had a minimum frequency of 8000 vibrations per minute.
B/B-UFSAR B.1-21a REVISION 7 - DECEMBER 1998 B.1.15 Concrete Finishes Concrete finishes for all unfo rmed surfaces co nformed to the finishes indicated on the drawin gs and to Sect ions 11.7, 11.8 and 11.9 of ACI 301 and to the f ollowing addition to ACI 301:
- a. Section 11.7.1:
Brooming exposed some of the aggregate and scored the surface to provide mechanical bond for the separate finish.
B/B-UFSAR B.1-22 b. Section 11.8.1:
A scratch finish was used for the top of turbine and e quipment foundations and top of concrete duct runs.
- c. Section 11.7.2:
Spreading of cement or a cement-sand mixture directly on top of c oncrete was not permitted.
The finish surface was not marked off in areas or scored in any manner.
- d. Section 11.8.2:
A float finish was used for the top of concrete walls, f loors of tunnels, crib houses, manholes, sump pits, ele vator pits, valve pits and misce llaneous pits.
- e. Section 11.8.3:
A troweled fini sh was used for floors, stair treads and for the top surface of curb, piers, pads, pedes tals, switchyard foundations and other outdoor equipm ent foundations where top surfaces were exposed after completion of the work.
- f. Section 11.7.4:
Strokes were sq uare across the surface and made so as to pr oduce regular scoring without tearing the surface or exposing aggregate.
Scoring ran transverse to th e direction of traffic.
- g. Section 11.8.4:
This finish was used for driveways.
This finish was used for other surfaces only if specifically indicated.
For floor surfaces c overed with chemical-resistant floor the finish surface was d ropped 1/4 inch so that the chemical-resistant finish was flush with adjacent floor areas.
B.1.16 Curing a nd Protection
Curing and prote ction conformed to the require ments of Chapter 12 in ACI 301 and the following:
- a. Subsections 12.2.1.1 thr ough 12.2.1.6 and 12.2.2 of ACI 301 did not apply.
- b. Where forms were strip ped before completion of specified curing perio d, curing compound was applied immediately after co mpletion of specified surface treatment.
- c. Prior to initial use of specified compounds, the manufacturer's technical rep resentative visited the jobsite and personally g ave instructions on the correct use of materials.
B/B-UFSAR B.1-23 REVISION 7 - DECEMBER 1998
- d. To control membrane thickness, compounds were applied at the rate of approximately 300 ft 2/gal, unless otherwise instr ucted by manufacturer.
- e. Curing was conti nued for not less than the minimum periods specified in Sec tion 12.2.3 of ACI 301 before applying any other surfacing or before opening to traffic.
Regulatory Guide 1.94 references Regulatory Guide 1.55 "Concrete
Placement in Category I Structur es" which endors es the use of ACI 301.
Items (a) and (b) ab ove take exception to the portion of ACI 301-72 Section 12.2.
2 requirement that reads "Moisture loss from surfaces placed against wooden forms or metal forms exposed to heating by the sun s hall be minimized by kee ping the forms wet until they can be safely removed."
The practice of wetting the forms is pri marily intended for hot and dry weather condit ions typical of arid regions and especially for thin me mbers where wooden forms can easily desiccate. The plastic impregnated plywood fo rms used in the Byron and Braidwood St ations reduce the mois ture loss to minimum regardless of being ex posed to heating by th e sun. Also, the midwest summers are humid and sun radiation is not as intense as in arid regions for which the provisions in ACI 301 were intended. Furthermore, thin concrete sectio ns exposed to a hot and dry environment do not exist in conc rete structures for nuclear power stations.
The concrete for the restora tion of the containment opening following steam generator replac ement was cured and protected in accordance with ACI 30 5R, 306R, and 308.
B.1.17 Preplaced Aggregate Concrete Preplaced aggregate concrete con formed to provis ions of Chapter 7, "Preplaced Aggreg ate Concrete" of ACI Standard 304, "Recommended Practice for Measur ing, Mixing, T ransporting, and Placing Concrete," and to the following:
- a. Time of efflux for the premixed grout was in the range of 20 to 24 seconds when measured immediately after mixing in accordance with CRD-C79, "Flow of Grout Mixtures (Flow-Cone Method)," and
- b. The preplaced aggregate concrete test sp ecimens made in accordance with CRD 84 attained a strength of 5500 psi in 91 days.
B.1.18 Evaluation and A cceptance of Concrete
The evaluation and acc eptance of concrete wa s accomplished in conformity to Chapters 17 and 18 of ACI 301.
B/B-UFSAR B.1-24 TABLE B.1-1 AIR CONTENT
ALLOWABLE LIMITS COARSE AGGREGATE TOTAL AIR CONTENT (VOL.) % NOMINAL MAXIMUM SIZE IN COARSE FREE ZING AND THAWING FREEZING AND THAWING ASTM C 33 AGGREGATE (in.) RESISTAN CE REQUIRED RESIST ANCE NOT REQUIRED Allowable Extreme Allowable Extreme Limits Limits Limits Limits 8 3/8 7 to 9 6 to 10 3 to 9 3 to 10 67 3/4 5 to 7 4 to 18 2 to 7 2 to 8 57 1 4 to 6 3 to 7 1.5 to 6 1.5 to 7
B/B-UFSAR B.1-25 TABLE B.1-2 LIMITS FOR SLUMP
CONCRETE TEMPERATURE ALLOWABLE LIMITS EXTREME LIMITS AS PLACED (°F) (in.) (in.) Minimum Maximum Minimum Maximum Below 55 2 5 1 6.0 Between 55 and 64 2 4.5 1 5.5 Between 65 and 74 2 4 1 5.0 Between 75 and 85 1.5 3.5 1 4.0
B/B-UFSAR B.1-26 REVISION 3 - DECEMBER 1991 TABLE B.1-3 PLACING TEMPERATURE
ALLOWED LIMITS FOR CONCRETE EXTREME VALUES FOR CONCRETE TEMPERATURE AS PLACED (°F) TEMPERATURE AS PLACED (°F) Exposed concrete face(s) normal Moderately Moderately to the thickness Thin Massive Thin Massive of the pour Section Section MassiveSectionSection Massive One face exposed 12 12 to 48 >48 12 12 to 48 >48 Two opposite faces exposed 18 18 to 72 >72 18 18 to 72 >72 Between Max. Max. Max. Max. Max. Max.
90 and 81 80 75 70 85 80 75
TEMPERATURE Between Max. Max. Max. Max. Max. Max.
OF AIR 80 and 46 90 80 70 90 85 75 SURROUNDING CONCRETE (°F) Between Max. Max. Max. Max. Max. Max. 45 and 26 90 80 75 90 85 80 Min. Min. Min. Min. Min. Min.
55 50 45 50 45 40
Between Max. Max. Max. Max. Max. Max. 25 and 0 90 80 75 90 85 80 Min. Min. Min. Min. Min. Min.
60 55 50 55 50 45
B/B-UFSAR B.1-27 TABLE B.1-3 (Cont'd)
____________________
Notes:
- 1. No concrete was poured when surrounding air in contact with the concrete was below 0
°F.
- 2. In all cases s ubsequent freezing of co ncrete was prevented by providing the pro tection recommended in Table 1.4.2 of ACI 306.
- 3. Since metal deck and noninsulated formwork do not prevent heat dissipation significant ly, concrete surfaces in contact with them we re considered as h aving exposed faces.
- 4. When concrete was placed at a temperature exceeding 70
°F, cement was added and mix adjus ted if water-cement ratio exceeded that of the mix design.
In computi ng water-cement ratio, total water a vailable as mixing water in concrete from whatever source was considered.
Adjusted mix proportions, including total water avail able, were shown in the inspector's report and were reported with the strength test results.
B/B-UFSAR B.1-28 TABLE B.1-4 CONCRETE COMPRESSION TESTING
TYPE TEST ASTM CONTAINMENT* CATEGORY I OTHERS Normal Sampling Number of Number of Testing of Number of Number of Testing of for strength Samples Cylinders Cylinders Samples Cylinders Cylinders of concrete for total yards of concrete in each continuous placement 500 yd 3 Compression C 31 One (1) each from Six (6) Tested at One (1) each from Six (6) Tested at Cylinder every 100 cubic required from 7, 28 and every 150 cubic required from 7, 28 and yards or each each Sample 91 days yards or each each Sample 91 days Compressive C 39 day's placement day's placement Strength if less than 100 if less than 150 cubic yards cubic yards 500 yd 3 to Compression C 31 One (1) each from Six (6) Tested at One (1) each from Six (6) Tested at 2000 yd 3 Cylinder every 100 cubic required 7, 28 and every 150 cubic required 7, 28 and yards from every 91 days yards from every 91 days even sample even sample (Example (Example 2,4,6,8, 2,4,6,8, etc. etc.)
Compressive C 39 Two (2) Tested at Two (2) Tested at Strength required from 91 days required 91 days every odd from every sample odd sample (Example (Example 1,3,5,7, 1,3,5,7, etc.) etc.)
B/B-UFSAR B.1-29 TABLE B.1-4 (Cont'd)
TYPE TEST ASTM CONTAINMENT* CATEGORY I OTHERS Number of Number of Testing of Number of Number of Testing of Samples Cylinders Cylinders Samples Cylinders Cylinders
>2000 yd 3 Compression C 31 One (1) each from Six (6) Tested at One (1) each from Six (6) Tested at Cylinder every 100 cubic required 7, 28 and every 150 cubic required 7, 28 and yards from every 91 days yards from every 91 days third Sample third Sample (Example 3, (Example 3, 6,9,12, etc.) 6,9,12, etc.)
Compressive C 39 Two (2) Tested at Two (2) Tested at Strength required 91 days required from 91 days from re- remaining maining Samples (Ex- Samples (Ex- amples 1,2, amples 1,2, 4,5,7,8, etc.)
4,5,7,8, etc.)
etc.)
____________________
- External Concrete: Reactor cavity, tendon tunnel, and containment basemat, shell, and dome.
B/B-UFSAR B.1-30 TABLE B.1-4 (Cont'd)
CATEGORY II Number of Number of Testing of TYPE TEST ASTM Samples Cylinders Cylinders Normal sampling Compression C 31 One (1) each from Six (6) required Tested at for strength Cylinder every 200 cubic from each Sample 7, 28 and of concrete for yards or each 91 days total yards of Compressive C 39 day's placement concrete in Strength if less than 200 each continuous 200 cubic yards placement of 500 yd 3 500 yd 3 to Compression C 31 One (1) each from Six (6) required Tested at 2000 yd 3 Cylinder every 200 cubic from every even 7, 28 and yards Sample (Example 91 days 2,4,6,8, etc.) Compressive C 39 Two (2) required Tested at Strength from every odd 91 days Sample (Example 1,3,5,7, etc.) > 2000 yd 3 Compression C 31 One (1) each from Six (6) required Tested at Cylinder every 200 cubic from every third 7, 28 and yards Sample (Example 91 days 3,6,9,12, etc.)
Compressive C 39 Two (2) required Tested at Strength from remaining 91 days Samples (Example 1,2,4,5,7,8, etc.)
B/B-UFSAR B.1-31 TABLE B.1-5 CONCRETE TESTING
- External Concrete: R eactor cavity, tendon tunnel, and containment basemat, shell, and dome. CATEGORY ICATEGORY IITYPE TEST ASTM CONTAINMENT
- OTHERS Slump C 143 Air Content C 173First batch placed each For each 50 yd 3 of concrete, or C 231day and for each 50 yd 3 for each day's placement, if less Fresh Con- placed. than 50 yd
- 3. crete, Normal Temperature Sampling Unit Weight/C 138Dail y during production Not Required yield Mixer C 94 Initially and every 6 months Not Required Uniformity Slump C 143When tests on normal samples s howed measurement of a concrete property temperatur e, slump, or air content out of allowable l imits but within t he extreme values, an Fresh Concrete Air Content C 173 C 231 Additional Sample was ta ken from chute of the next available truck. If m easurement of this additional Tightened Temperature sample s howed this property to be within allowable limits, Sampling and deviations were not directly attributable to the transport from the truck chu te to the forms, this truck load was placed. If not within allowable limits a second additional sample was then t aken from the next available truck and tested. This procedure was continued until tests on two success ive additional sam ples had indicated that the concrete properties w ere within allowable limits.
Normal sampling was then resumed.
B/B-UFSAR B.1-32 TABLE B.1-6 GRADATION OF HEAVYWEIGHT AGGREGATE
Fine Aggregate
- Spec. Required Sieve Size 3/8 in. 100
- 4 75 - 95
- 8 55 - 85
- 16 30 - 60
- 30 15 - 45
- 50 10 - 30
- 100 5 - 15
Coarse Aggregate
- Spec. Required Sieve Size 1 in. 100
3/4 in. 90 - 100
1/2 in. --
3/8 in. 20 - 55
- 4 2 - 15
- 8 0 - 8
- Fine Aggregate: 10% of the material passing the 3/8-inch sieve was allowed to pass the No. 200 sieve if the material passing the No. 200 sieve was shown to be essentially free of clay or shale.
B/B-UFSAR B.2-1 B.2 REINFORCING STEEL B.2.1 Requirements for Category I Materials
Reinforcing bars for all Category I structures w ere Grade 60 deformed bars tested in accordance with criteria in NRC Regulatory Guide 1.15 for "Tes ting of Reinforced Bars for Category I Concrete Structures." They met the requirements of ASTM A615, "Specific ations for Deformed and Plain Billet-Steel Bars for Concrete Reinforcem ent," with the following modifications. Paragrap hs 4.2, 7.3, 8.3 and all of Sections 9 and 10 as indicated below were u sed in lieu of the same parts as specified in A615.
- a. 4.2 The chemical comp osition thus determined was transmitted to Purchaser or his representative.
- b. 7.3 The percentage of e longation for bars Nos. 3 through 11 was as pr escribed in Table 2.
- c. For bars Nos. 14 and 18, the minimum elongation in 8 inches (full-section specimens) was 12%.
- d. 8.3 Bars of size Nos.
14 and 18 were bend tested as required below in Section 9.3.
- e. 9. Test Specimens 9.1 All tension test specim ens were full-section of the bar as rolled and randomly sampled.
9.1.1 The test procedures were in accordance with ASTM A-370, "Methods and Definitions for Mechanical Testing of Steel Products." 9.1.2 Delete.
9.2 The unit stress d eterminations on full size specimens were based on the nominal bar cross-sectional area as in Table 1.
9.3 The bend test speci men was full-sec tion of the bar as rolled. The pin diameter for the 90 o Bend Test was equal to 10d for Bars Nos. 14 and 18.
- f. 10. Number of Tests.
10.1 At least one speci men from each bar size was tested for each 50 tons or fraction thereof, of the reinforcing bars that were produced from each heat.
10.2 Testing in cluded both tension tests and bend tests.
B/B-UFSAR B.2-2 10.3 If any test specim en developed flaws, it was discarded and another full-s ection specimen of the same size bar from t he same heat substituted.
10.4 If any of the tens ile properties of one out of the total n umber of test spec imens corresponding to a heat was less than that specified in Section 7 as modified herein but was greater than the limits shown below, ret est was allowed:
Grade 60 Tensile strength, psi 83,000 yield stress, psi 55,000 Elongation in 8 inches, percent Bar no. 3, 4, 5, 6 6 7, 8, 9, 10, 11 5 14, 18 9 10.4.1 The retest consi sted of at least two additional full-section tensile tests on samples of the same bar size and heat fraction.
10.4.2 Each one of the addi tional test specimens and the average of all of the test specimens corresponding to the same bar size for this heat, (including the origi nal one) met the requirements of Section 7 of ASTM A 615, as mo dified herein.
10.5 If the original test failed to meet the limits indicated in Para graph 10.4, or if any
tensile or bending prope rty of specimens retested in accordance with Parag raphs 10.4.1 and 10.4.2 did not meet the requirements of Section 7 of ASTM A615, as modified herein, that material was rejected.
10.6 If any tensile property of the tension test specimen was less than that specified in Section 7 of ASTM A615, as modified in Paragraph 10.4, and any part of the fracture was outside the middle third of the gauge length, as indicated by scribe scratches marked on the specimen before testing, a retest was p ermitted.
All reinforcing was tagged or ma rked in a manner to ensure traceability to the Certified Material T est Report (CMTR) during production, f abrication, transpor tation and storage.
B/B-UFSAR B.2-3 REVISION 7 - DECEMBER 1998 Traceability for all reinforcing bars was by the original heat number. Traceability of all re inforcing was complete d up to the placing of the reinforcing, which was considered as the last hold point for the bars.
B.2.2 Reinforcing Bar Fabrication
Fabrication for all reinforcing bars conformed to the requirements in Chap ter 7 of CRSI "Manual of Standard Practice" and to the following:
- a. Bar ends for bars which were spliced using Cadweld procedures were checked for clearance after shearing, using a test sleeve with a standard Cadweld sleeve. B.2.3 Cadweld Splicing
Splices in reinforcing bar sizes No. 11 and smaller were lapped in accordance with A CI 318, "Building Co de Requirements for Reinforced Concrete," or Cadweld spl iced. Bar sizes No. 14 and No. 18 were Cadweld spli ced. The splice was designed to develop the specified minimum ul timate strength of t he reinforcing bar.
B.2.3.1 Qualification of Operators
Prior to production spli cing, each Cadweld o perator prepared two qualification splices for each position used in his work. These were tested and met the join t acceptance standards for workmanship, visual quality, and minimum tensile strength.
B.2.3.2 Procedure Specifications
All joints were made in accordance with the manufacturer's instructions, "Cadweld Rebar Splicing," plus the following additional requirements:
- a. A manufacturer's repre sentative, experienced in Cadweld splicing of reinforc ing bars, was required to be present at the jobsite at the outset of the work to demonstrate the equipment and techniques used for making qual ity splices. He was present for the first 25 production splices to o bserve and verify that the equipment was being used correctly and that quality splices wer e being obtained. For the restoration of the steam gen erator replacement containment opening, the manufacturer's representative was prese nt for a minimum of the first 10 production spli ces. The Cadweld manufacturer furnish ed the Certified Material Test Report for each lot of s plice sleeve material delivered. This report incl uded the physical and chemical properties of the s leeve material. The splice sleeves, exot hermic powder, and graphite molds were stored in a clean dry area B/B-UFSAR B.2-4 with adequate protection from the elements to prevent absorpti on of moisture.
- b. Each splice sl eeve was visually examined immediately prior to use to ensu re the absence of rust and other foreign material on the insi de diameter surface, and to ensure the presence of gr ooves in the ends of the splice sleeve.
- c. The graphite molds w ere preheated with an oxyacetylene or propane torch to dri ve off moisture at the beginning of each shift when the molds were cold or when a n ew mold was used.
- d. Bar ends to be spliced were power-brushed to remove all loose mill scale, lo ose rust, concrete, and other foreign materi al. Prior to power-brushing, all water, grease, a nd paint were remo ved by heating the bar ends with an oxyacetylene or propane torch.
- e. A permanent line was m arked 12 inches back from the end of each bar for a re ference point to confirm that the bar ends were properly centered in the splice sleeve. In those cases where the 12 inch gauge length was not pra ctical, different gauge lengths were use d, provided th ey were properly documented.
- f. Immediately before the splice sleeve was placed into final position, t he previously cleaned bar ends were preheated with an oxyacetylene or propane torch to ensure complete absence of moisture.
- g. Special attention was given to maint aining the alignment of sleeve and pouring basin to ensure a proper fill.
- h. The splice sleeve was externally prehe ated with an oxyacetylene or propane torch after all materials and equipment were in po sition. Pro longed and unnecessary overheating was avoided.
- i. Each splice was examined by the operator prior to forming to ensure compliance with all requirements.
All completed splices and si ster test specimens were stamped with the operator identification mark.
B.2.3.3 Visual Examination
All completed splices (including the sis ter test specimens) were inspected to en sure compliance with the visual examination
B/B-UFSAR B.2-5 acceptance standards.
Splices that failed a ny requirement were rejected and replaced and not used as tensile test samples.
All visual examinations on completed spl ices were performed only after the s plices had cooled to amb ient temperature. The visual examinati on acceptances standards were:
- a. Filler metal was visib le at the end(s) of the splice sleeve and at the tap hole in the center of the sleeve. Except for void s, the filler metal recession was not more than 1/2 inch from the end of the sleeve.
- b. Splices did not contain slag or poro us metal in the tap hole or at the end(s) of the sleeves. When in doubt as to whether filler m etal or slag was in the tap hole, the riser was broken with a punch or file, filler metal shines wh ile slag rem ains dull.
If slag was found, the inspector removed slag at the tap hole and searched fo r filler metal. This requirement was not cause for rejection unless the slag penetrated beyo nd the wall thic kness of the sleeve. c. A single shrinkage bubble present in the tap hole was distinguished from g eneral porosity and it was not cause for rejection.
- d. The total void area at e ach end of the sleeves did not exceed the following lim its (for splicing bars up to Grade 60):
- 1. for No. 18 b ars - 2.65 in 2 2. for No. 14 b ars - 2.00 in 2 3. for No. 11 b ars - 1.5 in 2
- 4. for No. 10 bars and sp lice Catalog Number RBT-10101 (H) - 1.58 in 2 5. for No. 5 bars - 0.53 in 2 e. The distance between the gauge lines f or a type "T" splice was 24-1/4 inches
+/- 1/2 inch for the 12 inch gauge lengths, or (X
+ Y + 1/4)
+/- 1/2 inch when the X and Y gauge lengths are us ed. The c enter of the gauge line connecting the gauge marks fell within the diameter of the tap hole.
- f. The distance between the gauge line and the structural steel for Type "B" splice was 12-1/4 inches +/- 1/4 inches or any o ther documented distance.
B/B-UFSAR B.2-6 REVISION 7 - DECEMBER 1998 B.2.3.4 Sampling and Tensile Testing Splice samples were prod uction splices and s ister splices.
Production splice samples were not cut from the structure when Type "B" splices were used, or when Type "T" splices were used for curved reinforcing bars. Representative straight sister splice samples were used in such cases, using the same frequency as Type "T" splices on straight bars, except that all splice samples are sister spl ices. Separate sa mpling and testing cycles were established for Ca dweld splices in horizontal, vertical, and diagonal bars, for each bar grade and size, and for each splicing op erator as follows:
- a. one production s plice out of the first ten splices, b. one production and three sister splices for the next ninety production splices, and
- c. one splice, either pro duction or sister splices for the next subsequent units of 33 splices. At least 1/4 of the total number of splices tested were production splices.
The splice sample testing for the containment opening restoration following steam generator replac ement was based on sister splices in acco rdance with Section CC-4333.5.2 and CC-4333.5.3 of 1989 ASME Section III , Division 2.
One splice was tested for each unit of 100 production splices.
The tensile testing acce ptance standards were:
- a. The tensile strength of each sample tested was equal or exceeded 125% of the minimum yield strength specified in the ASTM A615 for the grade of reinforcing bar using lo ading rates as stated in
ASTM A370 for the gr ade of rei nforcing bar.
- b. The average tensile strength of each group of 15 consecutive samples was equa l to or exceeded the ultimate tensile strength sp ecified in ASTM A615 for the grade of reinforcing bar.
B/B-UFSAR B.2-7 REVISION 7 - DECEMBER 1998 Procedure for Substandard Tensile Test Results:
- a. If any production splice used for testing failed to meet the strength requir ements in (a) above and failure did not occur in the bar, the adjacent production splices on each side of the failed splice were tested. If any sis ter splice used for testing failed to meet t he strength requ irements in (b) above and failure did not occur in t he bar, two additional sister splices we re tested. If either of these retests failed to meet the strength requirements, splicing was halted. Sp licing was not resumed until the cause of failu res were corrected and resolved to the sati sfaction of Sargent & Lundy.
- b. If the running average tensile stren gth indicated in (b) above failed to meet the tensile requirements stated therein, spli cing was halted. Sargent &
Lundy investigated the cause, determined what corrective action (if an y) was necessary, and notified the Contractor to perform the corrective action (if any).
- c. When mechanical splicing was resumed, the sampling procedure was started anew.
B.2.4 Reinforcing Steel Repair for Steam Generator Replacement Project Containment Opening
Reinforcing steel of the conta inment was damaged during the concrete removal process of the steam generator replacement project. The steel was repa ired by a welding process in accordance with AWS D1.4
-92. The reinforcin g steel has a carbon equivalent in excess of 0.55%, and ASME Sect ion III, Division 2 specifically limits fu sion welding of re inforcing bar to heats with carbon equivalents not greater than this level. AWS D1.4-92 allows welding of reinfor cing steel with ca rbon equivalents in excess of 0.55%, provided that low hydrogen elect rodes of the appropriate strength l evel are used, the electrode storage conditions are contr olled to preserv e their low hydrogen characteristics, and the appropr iate minimum preheat and interpass temperatur es are maintained.
The repair process r epresents a deviation from the Code; however, the NRC approved the re lief request, as documented in a letter from R. A. Capra (Office of Nuclear Reactor Regulation) to I. M. Johnson, dated September 22, 1997, and the NRC's Safety Evaluation Report fo r approval of a requ est for relief related to repair requir ements for damaged reinforcement steel.
B/B-UFSAR B.3-1 REVISION 7 - DECEMBER 1998 B.3 POST-TEN SIONING TENDONS B.3.1 General
A Birkenheimer, Brande stini, Ross, and Vogt (BBRV) post-tensioning system was used. Tendons con sisted of 170 1/4-inch diameter parallel lay wires.
Positive anchorage at ends was provided by buttonheading. The materials, erection and fabrication procedures, and test ing requirements conformed to the technical provisions of Sect ions CC-2400, CC-4400, and CC-5400 of the 1973 AS ME B&PV Code,Section III, Division 2, Proposed Standard Code for C oncrete Reactor Vessels and Containments, issued for interim tri al use and comme nts with the exception of CC-4464.
B.3.2 Materials B.3.2.1 Tendon Material
The 1/4-inch diameter wire conformed to cold-drawn ASTM A421, Type BA, stress-relieved, havi ng a guaranteed minimum ultimate tensile strength, (f pu), of 240,000 psi a nd a minimum yield strength not less than 0.80 f pu , as measured by the 1.0%
extension under load method.
B.3.2.2 Buttonheads
The positive anchorage of tendons to anc hor heads was provided by buttonheading of the wires. All buttonheads were cold-formed after threading wires through wire holes of anchor heads.
Buttonheads were formed symmetri cally about the axis of wires and were free from harmful s eams, fractures, and flaws.
B.3.2.3 Tendon Sheathing Tendon sheathing through the fou ndation consisted of black seamless steel pipe, A STM A53, Grade B a nd the wall sheathing was a black interlocked steel strip conduit, 22 gauge minimum wall thickness, fabric ated to be watertight. The inside diameter of the sheathing was ap proximately 4.75 inches. All splices were sealed to prevent intrusion of ce ment paste. The tendon sheath splice was made using a sn ug fitting coupling approximately 1 foot l ong. The joints betwe en the sheath and the coupling were taped. The minimum radius of curvature used was 30 feet, except in certain cases where a smaller radius of curvature was shown to be acceptable. S ome of the original tendon sheathing was removed during re storation of the containment opening fo llowing steam generato r replacement at Byron Unit 1.
B.3.2.4 Permanent Co rrosion Protection
A corrosion preventi ng grease, Viscono R ust 2090 P-4, Nuclear Grade was used as a te ndon casing filler.
B/B-UFSAR B.3-2 REVISION 11 - DECEMBER 2006 B.3.2.5 Anchor Heads For Byron Station, t he anchor heads conf ormed to ASTM A-322, "Specifications for Hot-Rolled Alloy Steel B ars," AISI 4140/4142 hot rolled, vacuum degassed, and heat treated to Rc 42
+/- 2 per MIL-H-6875D with a guaranteed ma ximum annealed h ardness of 217 Brinell.
For Braidwood Station, the anchor heads confor med to ASTM A-322 "Specifications for Hot-Rolled Alloy Steel B ars," AISI 4140/4142 Hardness Number of 38 to 43 per MIL-H-6875D.
B.3.2.6 Bearing Plat es and Shims Bearing plate and shim materials conformed to hot rolled ASTM A-36 plate to silicone-killed fine-grain practic
- e. For 1/8" shims, material may also conform to either ASTM A607 Grade 50 or hot-rolled open hearth .
4/.5 carbon steel (20%
or 17% ductility).
B.3.3 Quality Control B.3.3.1 Testing
The erection and fabrication pro cedures conformed to Section CC-4400 with the exception t hat the welding procedures and welder qualifications were in accordance with AWS D1.1.
B.3.3.1.1 Tendon Tests Tensile tests were performed on 100-inch long samples taken at a rate of 1% of all tendons incl uding all anchorage hardware. One test was performed on the vertic al group, one test on the dome group and two tests were performed on the horizontal group. The tendons were require d to carry a load co rresponding to 100% of the guaranteed ultimate tensile strength of the tendon without failure. Failure of any anchorage component was unacceptable.
B.3.3.1.2 Tests on Wir es and Buttonheads
Wires were tested in accordance with ASTM A421, "Specifications for Uncoated Stress-Reli eved Wire for Prestres sed Concrete." A bend test and buttonhead test was made on each coil of wire.
The bend test specimen was cold bent back an d forth in one place 90° in each direction ov er pins with a 5/8-inch radi us. Each return to vertical was one complete bend.
The wire must have sustained a minimum of six bends before complete fracture. The buttonhead test was a static test perf ormed to check the buttonhead machine a nd to confirm th e integrity of the buttonhead. The butto nhead was acceptable if failure occurred within the shaft of the wire. The but tonhead machine was routinely checked at the beginni ng of each shift.
Ten percent of the wires in each tendon were checked for buttonhead size and conformance with a "Go, No-Go" gauge. A ll buttonheads were visually examined to ensure th at splits, cracks, and/or slips did not exceed accep tance criteria.
B/B-UFSAR B.3-2a REVISION 8 - DECEMBER 2000 Also, one rupture test of wire was performed in the field similar to that used in the tendon. A 1 2-inch long sample of wire was tested using a portable tensile tes t apparatus prior to initiating the b uttonhead operation on t he respective tendon.
The sample was
B/B-UFSAR B.3-3 REVISION 7 - DECEMBER 1998 prepared using the same equipment and operat ors that performed the buttonheading operation.
B.3.3.1.3 Tests on Corrosi on Preventative Grease The manufacturer of corrosion pr eventative tendon coating materials performed chemical ana lyses to measure the presence of water soluble chlorides, nitrates, and sulph ides and provided certification of compliance with the acceptance criteria given in the ASME Code, Se ction III, Division
- 2. In addition, each shipment of permanent co rrosion preventative grease was retested in the field to verify that the materi al had remained contaminant free.
B.3.3.1.4 Anchorage Hardwa re Tests and Inspections
Anchor heads were tested to 12 0% of the minimum ultimate tensile strength of the prestres sing steel employing a test machine that was chosen to simulate t he actual loading co ndition as close as possible. All welds were gi ven 100% visual examination for completeness, workmanshi p, and slag removal.
B.3.3.2 Fabricat ion Tolerances The differential length of any two wires in the same tendon did not exceed 1/16 inch f or wires up to 100 fee t long and 1/8 inch for wires over and up to 200 f eet long, and an additional 1/8 inch for each 100 fe et increment in length over 200 feet.
Trumpet perpendicularity was measured to ens ure that the angle between the trumpet and the bearing surface of the b earing plate was within a tolerance of
+/- 0.3 degrees. Ec centricity of a buttonhead from the axis of the wire was not permitted to exceed 0.010 inch. Wire holes in anchor heads must have been within 0.010 inch of the specified lo cation on the bu ttonhead bearing surface. Drift was with in 0.035 inch from t he centerline. Wire hole diameter must have fallen within the ra nge of 0.257 inch to 0.264 inch.
B.3.3.3 Field Installa tion Tolerances Tendon bearing plate s were installed with a tolerance of +/- 0.25 inch from the specif ied locations. Crit ical dimensions were established for the placing of tendon sheath ing and the tolerance on these critical dimensions was +/-
0.5 inch. All gauges, instruments and jacks were calib rated against known standards that were traceable to the N ational Bureau of Standards. Elongation measurements commenced at 20% GUTS. The tolerance on lockoff pressure du ring the stressing operation was established by the cri teria that stress in the tendon wires at the anchor point after anchoring must have b een at least equal to, but could not have exceeded, the specifi ed value by more than 5%. The number of broken or defect ive wires or button-heads was limited to a maximum of three per tendon. This limit may be exceeded if an analysis shows that the condition is acceptable. The
B/B-UFSAR B.3-4 REVISION 13 - DECEMBER 2010 total number of brok en or defective wires in any one group of tendons (hoop, vertical, or dome) was not al lowed to exceed 1%
of the total wires in the tendon group.
B.3.3.4 Corrosion Protection Tendons were pro tected from corrosiv e elements during fabrication, shipping, storage, and installa tion by application of a thin film of Visc onorust 1601 Amber, as made by Viscosity Oil Company, immediate ly after fabrication.
Further, tendons were shipped and stored in polyethylene bags. Tendons were not permitted to be expo sed to inclement w eather, condensation, or injurious agents such as solutions containing chlori de. Damaged or corroded tendons were rejected on inspection. Exterior exposed surfaces of bear ing plates and grease retaining caps were protected from corrosi on by application of a prime and a finish coat of paint. The prime coat of paint was required to have a minimum dry film thick ness of two mils.
B/B-UFSAR B.4-1 B.4 STRUCTURAL STEEL B.4.1 Structural Steel Materials
Structural support steel was ASTM A36, ASTM A572, Grade 50 and ASTM A588 high strengt h, low alloy corro sion-resistant steel. Structural steel tubing was ASTM A500, Grade B a nd ASTM A501.
B.4.2 Structural Steel Connect ions and Connection Material B.4.2.1 Bolted Connections
Structural steel bolted connections used AST M A325, Type 1 and ASTM A490, friction-type high strength bolts.
These high strength bolted connections co nformed to "Spec ification for Structural Joints using ASTM A325 or A490 Bolts" issued by the Research Council on Riveted and Bolted J oints of the Engineering Foundation a nd endorsed by the A ISC, and to Framed Beam Connections, Table I or II of the A ISC Manual. ASTM A307 and A325 bolts were used for non-friction type applications in specified connections in the containment building. For non-friction type sliding conn ections, the load nut was torqued to a specified range (50-100 ft-lbs) a nd a jam nut was installed snugtight against the load nut. ASTM A36, "Specifications for St ructural Steel," n uts were used, with ASTM A36 threaded rods and all ASTM A307, "Specifications for Carbon Steel Externa lly and Internally Threaded Standard Fasteners," bolts.
B.4.2.2 Welded Connections
Standard welded beam c onnections conform to Table III or IV of AISC Manual. Shop and field welding procedures were in accordance with AWS Spec ifications listed in Table 3.8-2.
Selection of ele ctrodes and recommended minimum preheat and interpass temperature were in accordance with AWS requirements.
All welders and welding operators were certified by an approved testing laboratory and were qualified under AWS procedure as stated in AWS Specifications.
B.4.3 Quality Control
B.4.3.1 General Quality assurance requ irements applied to th e fabrication and testing of structures and components. C ertified material test reports were furnished stating the actual results of all chemical analyses and mechanical tests required by ASTM specifications. Identif ying heat numbers were furnished on all structural steel to trace the st eel to the specific heat in which the steel was made.
B/B-UFSAR B.4-2 B.4.3.2 Testing and Insp ection of Weldments One hundred percent of all complete penetration groove welds had complete radiographic ex amination, excep t that welds impractical to radiograph were examined by u ltrasonic, magnetic particle, or liq uid penetrant methods.
The above nondestructive test me thods were in compliance with the following ASTM specifications:
- a. E94, "Recommended Practi ce for Radiogr aphic Testing,"
- b. E142, "Controlling Quali ty of Radiographic Testing,"
- c. E164, "Recommended Pract ice for Ultrason ic Contract Examination of Weldments,"
- d. E109, "Dry Powder Magn etic Particle Inspection,"
- e. E138, "Wet Mag netic Particle I nspection," and
- f. E165, "Recommended Pra ctice for Liquid Penetrant Inspection Method."
B.4.3.3 Fabrication
The fabrication of structural steel conformed to AISC specifications.
B/B-UFSAR B.5-1 B.5 CONTAINMENT LINER WITHIN THE CONTAINMENT BACKED BY CONCRETE B.5.1 General
The materials, erection and fabr ication procedur es, and testing requirements conformed to the technical prov isions of Sections CC-2500, CC-4500, and CC-5500 of the 1973 ASME B&PV Code,Section III, Division 2.
B.5.2 Materials The containment liner materials performing only a leaktight function (excluding leak test ch annels), within the containment backed by concrete m et the requirements of the ASME B&PV Code,Section III, Division 2, Paragraph CC-25 00, and complied with the following sp ecifications:
APPLICATION SPECIFICATION Liner Plate SA 5 16 GRADE 60
Containment Liner Anchors A36
B.5.3 Quality Control B.5.3.1 Testing of Welds B.5.3.1.1 General All nondestructive examination procedures were in accordance with Section V of the ASME B&PV Code.
B.5.3.1.2 Liner Plate Seam Welds
B.5.3.1.2.1 Radiogra phic Examinations The first 10 feet of weld for each welder and welding position was 100% radiographed.
Thereafter one spot radiography of not less than 12 inc hes in length was taken for each welder and welding position in each additio nal 50 foot incr ement of weld.
In any case a mi nimum of 2% of liner seam weld was examined by radiography. All ra diographic examinations were performed as soon as possible after the weld was placed.
The spots selected for radiography were r andomly selected. Any two spots chosen for radiographic examination were at least 10 feet apart. If a weld failed to meet the acceptance stand ards specified in NE-5532,Section III of the AS ME B&PV Code, two additional spots were examined at locations not less than 1 foot from the spot of initial examinat ion. If either of t hese two additional spots failed to meet the acceptance standard s then the entire weld test unit was considered unacceptab le. Either the entire unacceptable weld was removed and the joint rewelded, or the
B/B-UFSAR B.5-2 entire weld unit was c ompletely radiographed and the defective welding repaired. T he repaired area s were spot radiographed.
B.5.3.1.2.2 Ultras onic Examinations Ultrasonic examinations were performed on 100% of the jet deflector support embedments.
If a weld failed to meet the acceptance standards s pecified in NE-5330 of Section III of the ASME B&PV Code, the weld was repaired and reexamined.
B.5.3.1.2.3 Magnetic Par ticle Examination
Magnetic particle examination was performed on 100% of liner seam welds for f erritic material. If a weld failed to meet the acceptance standards s pecified in CC-5533 of Section III of the ASME B&PV Code, the weld was r epaired and reex amined according to the above Code using magnetic par ticle examination.
B.5.3.1.2.4 Liquid P enetrant Examination
Liquid penetrant examina tion was performed on 100% of liner seam welds for a ustenitic materials. If a weld failed to meet the acceptance standards specified in CC-5534 of Section III of the ASME B&PV Code, the weld was repaired and reexamined according to the ASME Code using the liquid pene trant method of examination.
B.5.3.1.2.5 Vacuum B ox Soap Bubble Test The vacuum box soap bu bble test was perf ormed on 100% of liner seam welds for l eaktightness. If leakage was detected the test was repeated after t he weld was repaired.
B.5.3.1.3 Leak Test Channels
Wherever leak-chase-system cha nnels were installed over the
liner welds, the channel-and-lin er plate welds w ere tested for leaktightness by pressurizing the channels to the containment design pressure and doing a pneu matic test of 100% of the welds. A 2 psi change in pressure over a 2-hour holding period was allowed because of a possible variation in temperature during the hol ding period.
B.5.3.2 Fabrication and Installation
B.5.3.2.1 General
The fabrication and installati on of the containment steel boundaries backed by concrete were in accordance with the ASME B&PV Code,Section III, Division 2, Para graph CC-4500.
B/B-UFSAR B.5-3 B.5.3.2.2 Welding Qualification The qualifications of we lders and welding procedures were in accordance with Section III, Division 2, Par agraph CC-4500 of the ASME B&PV Code.
Installation Tolerances
All pressure retaining components conformed to the applicable requirements of NE-4220 of ASME Section III.
Cylinder Tolerances:
- a. For each 10 foot elevation of the liner the difference between the maximum diameter and minimum diameter did not exceed 8 inches. This requirement w as satisfied by measuring diameters spaced approximately 30
°. b. The radius of the liner was within
+/- 6 inches of the theoretical radius.
- c. The deviation of the liner from true vertical did not exceed 1 inch in any 10 feet nor 3 inches in the full height of the liner.
- d. The local contour of the shell was controlled by limiting the fol lowing deviations:
- 1. A 1-inch gap between the shell and a 15-foot-long template curved to the required radius when placed against the surface of a shell within a single plate se ction and not closer than 12 inches to a welded seam.
- 2. A 1-1/2-inch gap when the template above was placed across one or more welded seams.
- 3. A 3/8-inch gap when a 15-inc h-long template curved to the required radius was placed against the surface of t he shell within a single plate sec tion and not closer than 12 inches to a welded seam.
- 4. A 3/4-inch deviation from a 10-foot straight edge placed in t he vertical di rection between circumferential seams.
Dome Tolerances:
- a. For each point the height of the dome above the spring line was no g reater than 12 inches above theoretical height b ut in no case was it less than the theoretical height a bove the spring line.
B/B-UFSAR B.5-4 b. Radius measureme nts were taken at the top of each roof course at 30
° intervals, to determine the horizontal distance from the vertical centerline of the containment to the dome roof liner plate.
- c. The local contour of t he dome was controlled by limiting the fol lowing deviations:
- 1. A 1-inch gap between t he shell and a 15-foot-long template curved to t he required radius when placed horizontally aga inst the surface of the shell within a single plate sect ion and not closer than 12 inches to a welded seam.
- 2. A 1-1/2-inch gap when the template above was placed horizontally across one or more welded seams.
- 3. A 3/8-inch gap when a 15-inc h-long template curved to the required radius was placed horizontally against t he surface of the shell within a single plate se ction and not closer than 12 inches to a welded seam.
- 4. A 3/8-inch g ap when a 15-inch-long elliptical template was placed along the meridional of the surface of the s hell within a single plate section and not closer than 12 inches to a welded seam.
- 5. A 1-inch gap between the shell and a 15-foot-long elliptically curv ed template when placed along the meridional sur face of a shell within a single plate section a nd not closer than 12 inches to a welded seam.
- 6. A 1-1/2-inch gap when the elliptical template above was placed across one or more welded seams.
B/B-UFSAR B.6-1 B.6 CONTAINMENT STEEL BOUN DARY NOT BACKED BY CONCRETE The materials, fabricati on, installation and t esting requirements were in accordance w ith the 1971 ASME B&PV Code,Section III, Division 1, Subsection NE, with Addenda through Summer 1973.
B.6.1 Materials
The materials complied with the requirements of the 1971 ASME B&PV Code,Section I II, Division 1, Paragrap h NE-2000, a nd also to the following specifications:
APPLICATION SPECIFICATION Emergency personnel airlock and equipment access hatch with integral personnel airlock SA516 Grade 70 Penetration pipe sleeves (i) up to 24 inch diameter SA-333 Grade 1 or 6 Seamless (ii) over 24 inch diameter SA-516 Grade 60 B.6.2 Quality Control
B.6.2.1 Testing B.6.2.1.1 General
The testing of the c ontainment leaktight boundaries not backed by concrete were in ac cordance with the ASME B&PV Code, Section
III, Division I, Subsection NE-5000.
B.6.2.1.2 Testing of Welds One hundred percent of all welds between penetration and flued fitting, and flued f ittings and pipelines were examined by radiographic examination
- s. One hundred percent of all welds in the equipment hatch, p ersonnel airlock, and penetration sleeves were inspected also by radiographic examination where possible.
Where radiography could not be employed, ult rasonic examination was used. Penetration to insert plate welds and penetration to liner welds were magnetic particle or liquid penetrant examined in lieu of 100%
radiography. Penetration insert plate to liner weld was spot radiographed a nd magnetic part icle or liquid penetrant examined in lieu of 100% radiography.
Penetration insert plate to frame welds for air locks and access openings were magnetic partic le examined or l iquid penetrant examined in lieu of 100% radio graphy. If a weld
B/B-UFSAR B.6-2 failed to meet the a cceptance standards spec ified in NE-5300,Section III of the ASME B&PV Cod e, the entire un acceptable weld was removed and the joint reweld ed. The repaired areas were radiographed.
B.6.2.2 Fabrication and Installation
B.6.2.2.1 General
The fabrication and installati on of the containment steel boundaries not backed by concrete were in ac cordance with the ASME B&PV Code,Section III, Division I, Subsection NE-4000.
B.6.2.2.2 Qualification of Welders
The qualifications of we lders and welding procedures were in accordance with Section III, Division 1, Subsection NE-4300 of the ASME B&PV Code.
B/B-UFSAR B.7-1 B.7 STAINLESS ST EEL POOL LINERS The liner for the spent fuel pool, fuel transfer canal and spent fuel cask pit are not covered by t his section. For further details on t hese liners refer to Subsection 9.1.2.3.
B.7.1 Materials
Stainless steel pool liners were fabricated from A240 Type 304 Material, hot rolled , annealed and pic kled and further processed by cold rolling.
B.7.2 Welding
Welding procedures were in accordance with the ASME B&PV Code,Section III, Division 2, Paragraph CC-4540, and ASME Section IX. All seam welds were complete penetration groove square butt welds.
The liner plate seam welds were examined and tested as follows:
- a. Radiographic examina tion was performed in accordance with the requ irements of ASME Section V, "Nondestructive Exam ination." A minimum of 2% of all liner seam welds were examined.
- b. Ultrasonic examination m ay be performed in lieu of radiography on liner seam welds when joint detail does not permit radiog raphic examination.
- c. Liquid penetrant examina tion was performed on austenitic materials. T he weld surfaces and at least 1/2 inch of the ad jacent base ma terial on each side of the weld were examined. The examination
coverage was 100% of all shop and field seam welds.
- d. Vacuum leak test was per formed for lea ktightness on all liner plate seam welds.
B.7.3 Erection Tolerances
Tolerances for free-standing liner w ork conformed to CC-4522.1.1 of Section III, Divi sion 2 of AS ME with the following additional requireme nts for the refueling water storage tanks:
- a. The radius of the cy lindrical sh ell was within
+/-3 inches of the theoreti cal radius. Radius measurements were made at 10 foot inc rements vertical ly and at 36
° increments cir cumferentially.
- b. The radius of the inner surface of the dome does not deviate from the design value by more than
+/- 3 B/B-UFSAR B.7-2 inches. The height of t he dome above the spring line was not greater than 6 inches above the design height, and in no case was it less than the design height above t he spring line.
B/B-UFSAR B.8-1 B.8 OTHER STAINLESS STEEL ELEMENTS Stainless steel embedded plates and stainless steel checkered floor plates were fabricated f rom A240 Type 304 material, hot rolled, annealed and pickled.
Stainless steel bars a nd rounds were fabrica ted from A276 or A479 Type 304 materi al, hot rolled, anne aled and pickled.
Stainless steel pipes were fabricated from A312 Type 304 or A358 Type 304 or A376 Type 304 materials, hot rolled, annealed and pickled.
Stainless steel gratings were fa bricated from A2 40 Type 302 or Type 304 materials, hot rolled, annealed and pickled prior to fabrication and then electropolished after fabrication.
Stainless steel sump liners were fabricated from A240 Type 304 or Type 316 materials.
Stainless steel bolts were f abricated from A 193 Class 1 material.
Stainless steel nuts were fa bricated from A194 material.
Stainless shapes were fabricated from A276 or A479 Type 304 materials.
For further discussion on austen itic stainless steel, refer to Subsection 5.2.3.4.
B/B-UFSAR B.9-1 B.9 NUCLEAR STEAM SUPPLY SYSTEM (NSSS) COMPO NENT SUPPORT STEEL B.9.1 General
Material and Quality Control P rograms for comp onents support steel conformed to the requirements of S ubsection NF of the 1974 ASME Code, Summ er of 1975 addenda,Section III, Division I. All further refere nces to Subsection NF in this section on NSSS component s upports imply the same edition and addenda.
B.9.2 Steel Materials
Component support steel materials are summarized in Table B.9-1.
B.9.3 Welding Qualifications
All welding procedures were qual ified in accordance with the welding procedure qual ification requirements of NF-4300 of ASME Section III, S ubsection NF.
B.9.4 Quality Control
B.9.4.1 General Certified material t est reports which provid e the results of all chemical analyses and mechanical tests were furnished in accordance with the re quirements of NF-2000.
Test reports included the results of Charpy Impac t Tests which conformed to Subsection NF of the ASME Code.
Identification of material requiring traceability was provided in compl iance with Section III of the ASME Code.
B.9.4.2 Lamina tion Tests
Plates loaded in tension during service in t he through thickness (short-transverse) dir ection, as defined in NF
-3226.5, Subsection NF of ASME,Section III, were examined by th e straight beam ultrasonic method in acc ordance with ASME SA-578.
B.9.4.3 Nondestructive E xamination of Welds
Nondestructive examinati ons were conducted in accordance with the requirements of ASME Section V and NF-5000 of Section III Subsection NF. A cceptance standards for radiography, ultrasonic, magnetic particle, liquid pene trant, and visual examinations, complied with the requirements of NF-5000 of Section III, Subsection NF.
B.9.5 Fabrication and Installation The fabrication and installation of NSSS component supports were accomplished in conformity with NF-4000 of ASME Section III, Subsection NF.
B/B-UFSAR B.9-2 REVISION 1 - DECEMBER 1989 B.9.5.1 Installa tion Tolerances Installation tolerances for (a) NSSS component support embedment location, and (b) ce nterlines and wo rk points with reference to in-place NSSS com ponent supports are specified on the design drawings.
B/B-UFSAR B.9-3 TABLE B.9-1 MATERIAL FOR NSSS COMPONENT SUPPORTS MATERIAL APPLICABLE ASME SPECIFICATION NUMBER PRODUCT FORM CODE PROVISION A618 GRADE III TUBE CODE CASE 1644 A588 GRADE A, B PLATES, BARS CODE CASE 1644 SHAPES SA-540 GR. B24 CLASS 1 BOLTING MATERIAL SECTION III AND CLASS 4 SUBSECTION NA TABLE I-13.3 A490 BOLTING MATERIAL CODE CASE 1644 SA-194 GR 7 NUTS SUBSECTION NA TABLE I-13.3 SA-533 CLASS 2 PLAT E SUBSECTION NA TABLE I-1.1