ML19210B543
| ML19210B543 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 05/23/1973 |
| From: | Avers B GENERAL PUBLIC UTILITIES CORP., UNITED ENGINEERS & CONSTRUCTORS, INC. |
| To: | |
| Shared Package | |
| ML19210B541 | List: |
| References | |
| QC-1, NUDOCS 7911090506 | |
| Download: ML19210B543 (34) | |
Text
,.
3 UNITED E: CINEERS & CONSTRUCTGRS I"C.
QUALITY CONTROL PROCEDURE QC-1, REV. 9 FOR GENERAL CONSTRUCTIO:{ AND STRUCTURAL CONCRETE May 10, 1973 TilREE MILE ISLAND - PROJECT NO. I METROPOLITAN EDISON CO GAhT M
U Approved by: /
B. G. Avers, Manager of Quality Assurance Rev. 9: Insert Revision, Page 14 General Pu'olic Utilities 1566 138 506 7911000 M
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UNITED ENGINEE KS & CONSTRUCTORS INC.
QC-1 Rev. 8 QUALITY CONTROL PROCEDURE QC-1 6/12/72 FOR Page 1 CENERAL CONSTRUCTION AND STRUCTURAL CONCRETE I.
SCOPE This procedure shall be applicable to controls tor the production of concrete, concrete placement operations, reinforcing steel, and structural fill work parfcrmed on all Class I Structures, components, and systems identified as being within the Quality Assurance Boundaries of responsibilities by the Engineer (GAI), including conventional concrete identified Class II.
II.
GENERAL A.
Purpose The ourpose of this procedure is to outline the controls and inspection that will be applied by the Field Quality Control Group at the construction site during the storage of materials and performance of craft activities in erection of reinforcing steel, mixing concrete, delivery, and concrete placement operations.
B.
Reference Documents
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The requirements of the following reierence documents and all approved UE&C Quality Control Procedures shall apply to all items and material covered within the scope of this document.
1.
ASTM = American Society for Testing and Futerials 2.
ACI = American Concrete Institute 3.
CCP-1 For Erecting Tendon Conduit System in the Reactor Containment Wal 4.
CC P-2 Grouting Nuclear Components - UE&C 5.
CCP-3 Ram Pack Grouting of Nuclear Components - UE&C 6.
CCP-4 Erection of Reactor Building Polar Crane Support Structures - UE6 7.
CCP-5 Coating of Interior Concrete of Reactor Building, Auxiliary and Fuc1 Handling Buildings - UE&C 8.
CCP-6 Pump Placement of Concrete - UE&C 9.
CCP-7 Grouting of Holes - UE&C 10.
CCP-8 Erection and Inspection of Structural Steel in Class I Structures - UESC 11.
TP-1 Procedure for Tests for Mixer Performance - Stationary Batch Plant Mixer - UE&C 12.
SP-5550 Quality Acceptance Standards - GAI 13.
SP-5406 Construction Specifications - GAI 1566 139
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QC-1 Rev. 8 6/12/72 Page 2 s.
III.
RESPONSIBILITY A.
The UE&C Field Quality Control Group are responsible for implementing,
the requirements specified herein and references to Quality Control Inspectors in this procedure include UE&C Quality Control Inspectors and the Independent Testing Agency Inspectors.
B.
Independent Testing Acency 1.
United Engineers & Constructors will retain the services of an independent testing agency (T.L.) to perform the necessary inspections and tests required within the scope of these procedures.
2.
The activities of the T.L. will be under the direction of the UE&C Field Supervisor - Quality Control relative to their scope and duties at the project site.
3.
The T.L. shall have sufficient personnel and equipment available at the project site in order to carry out the duties assigned or directed by the Field Supervisor - Quality Control.
(NOTE: Any work performed by the T.L. off site for UESC will be
-s as authorized by the Field Supervisor - Quality Control.)
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4.
Reports and records generated by the T.L. will be' submitted to the Field Supervisor - Quality Control and will become a part of the quality control file as required.
Copies of the reports will be distributed to the Engineer and the Owner as required.
IV.
BATCH PLANT INSPECTION A.
Batch Plant Oncration The Quality Control Inspector at the Batch Plant shall inspect the operation for compliance with the following requirements:
1.
When concrete is produced from a site located central mix or transit mix operation:
a.
Inspect the concrete batch plant, including aggregate storage areas, weighing and measuring systems, stationary mixers, and mixer trucks to conform to ASTM C94-65.
b.
Prior to start of operation of the stationary mixer, mixer performance tests as required by ACI 301, Section 701 will bc performed by the Quality Control Inspector in accordance with UE&C Test Procedure No. TP-1.
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IV.
BATCH PL\\NT INSPECTION (Continued) c.
Check to assure that aggregate and cement used in batching concrete for the scheduled pour are approved and comply with requirements noted in Appendix A.
d.
Prior to the first batch, sample and test the fine and coarse aggregate for gradation ani moisture content in accordance with ASTM C566. Fine and coarse aggregate will be checked for moisture content at least every two(2) hours during production and corresponding water adjustments made as needed gN,/
4 thenwrmy L"5ft'(d y e.
De scales shall be calibrated prior to use.# S tandard weights
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will be availabic for periodic checking of scale calibration, however, calibration shall be scheduled in accordance with QC-13.
2.
Water measurement and admix dispensing will be checked by measuring the amount of liquid delivered from a dial setting. Water measurement will be checked weekly and admix dispensing will be checked continuously by the use of site gauges (or clear containers) through which the liquids flow.
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3.
The autonatic moisture probe will be checked prior to daily operation of the plant against known sand moisture content and corrections to water settings made in accordance with Paragraph IV.B.lb.(1) as applicable.
4.
Check batch card to see that proper approved mix is being, batched and that card is punched correctly.
5.
Check the mixing cycle setting and actual time of each cycle during central mix operations to assure it does not exceed the tolerance range from a minimum of 75 seconds to e' maximum of 135 seconds.
We mix timing device shall be checked for calibration as required by the manufacturer and the Batch Plant Inspector will periodically check the time cycle with a stop watch.
6.
Check that each truck drum is free of excess water before mix ingredients are introduced into it.
This shall be the responsibility of the batch plant supervisor and subject to audit by the batch plant inspector.
7.
Make daily checks of Batch Plant conveyors to assure that mix ingredients arc introduced into the stationary mixer or transit mixer simultaneously.
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IV.
BATCH PLANT INSPECTION (Continued) 8.
The Batch Plant Inspector shall check the batch cord to assure that proper mix is being batched, that the card is correctly punched, and:
a.
Prepare batch tickets that will show:
date, time loaded, truck number, load number, initial number of revolutions on counter, concrete design strength, amount of concrete loaded, amount of each ingredient, including ice added, percent surface moisture of fine aggregate and coarse aggregate. total water content per yard (including surface moisture of aggregates),
amount of water allowable to be added at the pour site, portion of the structure where used, mixing time (cycle) and signature of the batch plant inspector.
b.
Check recording tapes for confirmation of actual batch weights and attach copy to the batch ticket (any notations made on the recording tape shall be initialed by the Batch Plant Inspector).
c.
The Quality Control Inspector at the pour site shall complete the Batch Ticket in accordance with the requirements for g
concrete placement.
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9.
During Central Mix Operations check the slump, air content, and the temperature of the first two(2) truckloads of concrete batched each day to verify that concrete meets the specified tolerances.
If slump, air content, or temperature is out of tolerance the load shall be rejected.
Subsequent truckloads shall be checked until test results of two(2) consecutive truckloads meet specified tolerances.
The Batch Plant Inspector shall note on the Batch Ticket the reason for rejection and where the rejected concrete will be used.
10.
Concrete produced by Transit Mix operations shall be checked at the pour site during field tests of concrete placement.
B.
Water Adiustment (Batch Plant) 1.
The Quality Control Batch Plant Inspector shall be solely responsible for making adjustments in water content of the mix at the batch plant. Recommendations for adjustments of water content shall be made by the Quality Control Field Inspector (s), UE&C Quality Control personnel, UELC Construction Supervision, or Da ch Plant Operators.
However, only the Quality Control Batch Plant Inspector shall be authorized to adjust water content when specified herein.
a.
Adjustment to the water content shall not exceed the water-cement ratio for the approved design min as noted in Appendix A.
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Page 5 IV.
BATCll PLANT INSPECTION (Continued) b.
When applicable, water adjustments shall be made as follows:
(1) Adjust the automatic water setting to account for surface moisture of fine aggregate to assure the correct addition of water as called for in the mix design.
The "over-under" moisture gauge will be monitored and if the indications are that the fine aggregate is running wetter or drier than the determined setting, the surface moisture will be rechecked and the water setting adjusted accordingly.
(2) Enough water will be added at the batch plant to produce an estimated 3" slump.
In addition, water may be added at the pour site if necessary, under the direction of the Quality Control Inspector and.in accordance with the provisions of these procedures and those of SP-5406.
The Batch Plant Inspector shall show on the batch ticket how c.
much water can be added to the load without execeding the allowabic maximum water-ccment ratio.
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V.
FIELD INSPECTION (PREPLACEMENT)
A.
Found a tion 1.
Vapor barriers shall be used under slabs poured on earth subgrade in the areas indicated on the Engineer's drawings.
2.
No concrete may be placed on frozen subgrade material.
3.
On top of rock, and as directed by GAI, a concrete scal mat (3" minimum) shall be placed below the bottom of structural concrete.
Elevation shall be mapped and/or approved by CAI and verified by UE&C Quality Control.
4.
Rock subgrs, shall be cicaned, washed, and airblown prior to placing structural concrete.
Old concrete surfaces shall be cleaned by water jet, brushing or air-blowing prior to placement of a new pour.
B.
Structural Fill 1.
Prior to placing structural concretc on compacted fill, the fill will have been checked by the Quality Control Inspector to determine thac percentage compactien or relative density has been achieved.
Till dens ity may be determined by the Sand Cane Me thod (AST'i D-155e),
nalloon Method (AS'I?! D-2167) or AAS110 - Field ' Determination o f Ikusi ty In-Place (T 147-54) and shall be compacted to a minimum of 70:: relative dennity.
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V.
FTELD IMSPECTION /PREpLACE32ST) (Continued) 2.
Subgrade will be free from debris and organic material and shall be thoroughly wetted unicss a vapor barrier is installed.
3.
Fill material from bcrrow areas previously selected by the Engineers shall be sampled by the Quality Control Inspector for determination of moisture-density relationships.
Selected non-plastic fill material shall conf orm to compaction a.
standard ASTM D2049 and acceptance standard shall be 707.
minimum relative density, b.
Selected plastic fill shall comply with compaction standard AASHO modified method and acceptance standard shall be 95% of maximum density, minimum and t 2% of optimum moisture at time of co=paction.
Prior to beginning placing fill on any day, the surf ace of the c.
existing material will be scarified to a depth of at least 6 inches and moisture conditioned to within 2% of optimum moisture.
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d.
Fill caterial placed below and adjacent to concrete foundations
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will be ce=pacted in 8" layers.
Fill materials placed in trenches for items such as pipe lines, conduit, and ducts uill be compacted in 12" layers.
C.
Forms and Reinforcing Steel 1.
Prior to a pour, construction will check that f orms are clean, oiled, secure, and reasonably tight with e=bcdments located per drawing.
2.
Size, placement, splicing, or cadwelding of reinforcing steal will be checked as required by the specifications and applicable drawings.
3.
It shall be the responsibility of construction to assure that only approved reinforcing steel (subject to audit by the Quality Control Group) is used and that Cadueld operators are qualified to comply with Appendix B.
Completed'cadweld splices shall be inspected by Quality Centrol and sampics shall be sc1ceted to be tested in accordance with the acceptance criteria in Appendix B.
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QC-1 Rev. 8 6/12/72 Page 7 V.
FIELD INSPECTION (PPIPIACEMENT) (Continued) 4.
Checking of forms, embedments, and reinforcing steel including Cadwelds, as noted above, shall be documented on the Concrete Placement Checkout Sheet (Reference Attachment A).
The Quality Control Inspector shall verify the condition of pour base; fo rms ;
and location, size and quantity of rebar; tying and splicing of reinforcing steel and concur t:ith other quality Control Engineers; i.e., Electrical, Mechanical, Welding, etc., prior to placing concrete and indicate his acceptance on the Inspectors Concrete Checkout Sheet and Concrete Status Report (Refence Attachment B & C).
5.
Results of all inspections shall be documented and reported to the UE&C Field Supervisor - Quality Control.
VI.
CONCPITE PLACE >ENT INSPECTION A.
Delivered Concrete 1.
Concrete shall not be ordered for placement until the Concrete Placement Check-Out Sheet is completed by construction and signed-off by Quality Control after completion of final preplacement f-inspcerinn.
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2.
The UE&C Concrete Supervisor and Quality Control Personnel shall have the authority to reject truckloads of concrete.
Disposition and intended use of rejected concrete shall be documented on the Batch Plant Ticket by the Quality Control Inspector.
3.
The Quality Control Inspector shall make the following checks on concrete delivered for placement.
a.
Obtain Batch ticket from the driver and note the initial revolution counter reading and prepare for sample from the middle 80*/. of the load.
(1) Upon arrival, check each truck drum revolution counter and record on the Batch Ticket the number of revolutions at agitating speed or mixing speed and the final revolution count at completion of dischargc.
(2) Central Mix loads that have had more than 300 total revolutions or that have not been placed 1 1/2 hours alter mixing shall be rejected.
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CONCRETE PLACEIT!T INSPECTION (Continued)
(3) Transit (Truck) Mix loads that have had more than 100 revolutions at mixing speed, more than 300 total revolutions, or that have not been placed 1 1/2 hours after mixing shall be rejected.
b.
When visual observation indicates that the slump exceeds tolerance limits, further discharge of concrete shall be stopped and a slump test will be made immediately.
Concrete that is determined out of tolerance shall be rejected.
However, if the test determines that the concrete slump is within tolerance, the concretc will be discharged and tested as requi;nd.
c.
De terstre.the temperature of the concrete in each truck before it is placed and record the temperature on the Eatch Ticket.
Temperature of concrete shall comply with the following requirements:
(Fhan Daily Temp.
Type Load Min. Temo.
40 F or Less)
Concrete Max. Te nn.
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Mass Pour 50 F 70 F i.
Others 50 F 90 F d.
When concrete is produced by the Transit Mix Operation (dry-batch - truck mix), at least the first two loads produced each day thell be checked prior to being discharged.
They will be checked for air content, sluno, and temperature.
If the air content, slump, or temperature in out of tolerance the load will be rejected and the batch plant notified so that the necessary batching adjustments may be made.
e.
Check the concrete in each truck for slump in accordance with ASTM C43-66 and record the results on the batch ticket.
The slump f or 1500 and 3000 poi concrete shall not exceed a range of 1 inch to 4 inches.
The slump for 5000 pei concrete and all concrete produced for the Reactor Building shall not exceed a range of 1 inch to 3 1/2 inches.
f.
If the sluup is found to exceed the maximum limit, the truck may be allowed to meve aside and turn at agitating speed for not more than 10 minutes providing time and total revolution limits are not exceeded.
At the end of this t ime, the slump will be rechecked and if it is within tolerance limits all additional tests shall be satisf actorily completed prior to acceptance of the load.
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6/12/72 VI.
CONCRETE PT. ACE"ENT IMSPECTION (Continued) g.
Check air content in accordance with ASTM C231 or C173 for every 50 cu. yds. of concrete placed (or whenever test cylinders are made) by cither the pressure method or the volumetric method and record results on the Batch Ticket.
Compare test data with permissible air content tolcrances in Appendix A.
B.
Water Ad iuntment (Fieldi 1.
Prior to any addition of water at the pour site, the Quality Control Inspector shall check the batch ticket to determine how much water may be added without c::ceeding the total water requirement.
2.
No water shall be added at the pour site if the temperature and elapsed time after the start of mixing exceeds the following requirements:
Max. Elapsed Time Prior to Ambient Temnerarure Addition of Water at Pour Site Over 90 F 30 minutes 75 to 900F 45 minutes 0
Less than 75 F 1 Hour
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3.
In no case shall the following truck revolutions be exceeded prior to the addition of water at the pour site.
Transit Mix - 90 Revolutions at Mix Speed Central Mix - 100 Revolutions at Agitation Speed 4.
The truck drum shall be turned a minimum of 30 revolutions at mix speed after the addition of water at the pour site.
5.
The number of drum revolutions for Transit Mix operations shall not execed 100 revolutions at mixing speed or 300 total revolutions for either Transit BEx or Central Mix operations.
6.
Water may be added only once to a truck provided the above requirements are complied with, 7.
Temperature of concrete will also be checked in addition to slump, air, etc., af ter addition of water at the pour site.
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CONCRETE PTACE"ENT INSPECTION (Continued) 2.
An additional set of 2 cylinders shall be made for concrete to be used in the exterior shell of the Containment Building.
3.
Concrete cylinder molds shall conform to the requirements of ASTM C470-65T and certificates of compliance to this specification will be available and part of the permanent quality control file.
4.
When concrete is being conveyed or placed by pump, supplementary test sampics shall be taken from the discharge pipe end to determine slump, air content, and temperature.
(Reference CCP-6.)
5.
From each load of concrete sampled for the make-up of concrete cylinders record results of a slump test, temperature check and an air content test per ASTM C231-62.
6.
Return field-cured test cylinders from previous pour to field laboratory for curing.
F.
Evaluation of Concrete Comnrossion Tests 1.
Results of concrete cylinder compression tests shall be evaluated in accordance with ACI 301, Chapter 17, Paragraph 1703 for 5000' psi concrete and Paragraph 1702 for all other structural concrete.
2.
Standard deviations, coefficients of variation, and with-in-test coefficients of variation may be calculated in accordance with ACI 214-65. Calculations of these values is not a specification requirement; however, such data will be periodically accumulated to provide a further means of verifying concrete operation and testing efficiencies.
3.
When concrete test results indicate a design mix is out of control and does not meet requirements specified herein, the GAI structural engineer shall be immediately informed and corrective actions as he may direct shall be undertaken.
G.
_Curine of Placed Concrete 1.
Quality Control shall perform daily inspection to assure compliance with specifications for curing and document inspections of concrete curing activities on the Daily Concrete Curing Record (Attachment E).
2.
Concrete curing relative to form removal, curing compounds, wetting, temperature centrol, etc., shall be as specified in SP-5406, Section 1:15 and SP-5550, paragraph 2.6.
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C0" CRETE PIACCMENT I"SPECTTON (Continued) 8.
Limits as shown in the approved design mix relative to maximum slump, water, and water-ccment ratio shall not be exceeded.
Mixing / agitating time and temperature shall not be violated due to addition of water at the pour site. Such violations are cause for rejection of concrete.
C.
Pumned Concrete 1.
When concrete is conveyed or placed by pump the pumped concrete activitics shall comply with requirements of reference document CCP-6.
The concrete shall be sampled and tested at the pump hopper in accordance with requirements specified herein and air content of delivered concrete should be 0.57, higher than the specified minimum.
In addition, supplementary samples for air, slump, temperature and test cylinders shall be taken at the discharge pipe end.
Supplementary test samples shall be collected for every 500 cu. yds. placed or once a ueek for each class of concrete at lesser quantities.
D.
Concrete Placement 1.
Check concrete placing operations for homoge6 city of mass, assure that the free fall is a maximum of threc(3) feet on finished concretc and five(5) feet on unfinished areas.
Houover. if in this particular case segregation starts occuring, the amount of free fall shall be decreased. Also check that concrete is properly vibrated, consolidated, and finished as specified on drauings using appropriate equipment.
When applicable, provisions for adverse weather conditions shall be made as specified in SP-5406 paragraph 1:13.3 (Reference ACI 306-66 and ACI 605-59) except that accelerators such as Calcium Chloride and Anti-Freeze compounds shall not be used.
The Field Supervisor -
Quality Control shall be notified immediately of all discrepant conditions and concrete placement shall be halted until all discrepant conditions have been corrected.
2.
Quality Control shall inspect all concrete place =ent activities and document inspections on Report of Concrete Placement form.
(Reference Attachment D. )
E.
Test Cvlinders 1.
Make and cure one set of concrete test cylinders (6"x12") per ASTM C31-66 daily for each 50 cubic yards of concrete or portion thereof placed per class. The batch ticket shall indicate the total yardage of that class batched to that time of the day so that field inspectors will know when sylinders are to be made. When cylinders are made the field inspector will notify the batch plant inspector so that a cross check is a~vailable that the proper number of cylinders sets have been made. A set of cylinders shall consist of 6 cylinders for 3000 psi concrete or for 5000 psi concrete, taken frem the middle 801 of one truck load of concrete. Test cylinders shall be stored in an insulated box the pour site for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> for field curing and cured initially in at accordance with ASIM C31-66, Section 9(a).
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VII.
PERIODIC SAMPLING AMD PRODUCTION TESTING s.
A.
Cement 1.
The Quality Control Inspector will sample cement from each manufacturer when a new silo is used.
These samples will be tested for physical and chemical properties in accordance with ASTM C150-66.
Cement not conforming to the acceptance standards of ASE1 C150-66 and Appendix A shall not be accepted and the Non-conformance shall be documented.
2.
Tests may also be conducted at the cement manufacturing plant.
B.
Concrete Ac9recates 1.
' Aggregates delivered to the site will be sampled by Quality Control at least once for every 250 tons received.
The sample will be tested for gradation and determination of fineness modulus, specific gravity, and absorption.
2.
These tests shall be conducted in the field laboratory per test methods and acceptance standards as noted in Appendix A.
3.
Records will be maintained indicating date of receipt, amount
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received, gradation test results, and disposition of rejected loads of material.
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4.
The mixing water (including ice) shall be checked weekly to assure it is potable and that it does not contain more than 100 ppm each of chlorides, sulfides, and nitrates and that its turbidity does not exceed 2000 ppm.
C.
Concreto Cylinders 1.
After sufficient field-curing (usually 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />) the cylinders made by the Quality Control Field Inspector will be transported to the field labor'atory for stripping and curing and capping in accordance with ASIM C192-66.
2.
Two cylinders from each set will be tested at age 7 days, 2 at age 28 days, and 2 at age 90 days.
3.
Two additional cylinders for concrete placed in the exterior of the Containment Building will be tested at age 56 days. Compression tests of cylinders will be evaluated in accordance with Chapter 17 of ACI 301-66.
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VII.
PERIODIC SMtPLTNG M D PRODUCTION TESTING (Continued)
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D.
Cadweld Solices 1.
Cadweld Splices will be tested in tension in accordance with procedures outlined and referenced in ASTM A615 (minimum ultimate strength for specimens of Grade 40 - 70,000 psi and Grade 60 -
90,000 psi) and shall comply with acceptance criteria noted in App.
B.
VIII.
REPORTS AND RT. CORDS A.
Quality Control Inspection Reports 1.
The following records and reports shall be completed and signed following preparations and inspection of concrete operations:
a.
Concrete Placement Checkout Sheet (Attachment A)
This form is initiated by Construction activities and signed-of f by Quality Control on checkout item #10 following acceptable pre placement inspection.
Concrete shall not be ordered prior to acceptance and sign-off
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of this form by Quality Control.
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b.
Inspectors Concrete Checkout Sheet (Attachment B) and Concrete Status Report (Attachment C).
Quality Control will use Attachment B & C to document pre-placement ins pect ion.
Items not completed or requiring correction will be noted on Attachment C in the remarks column.
Upon satisfactory completion, items will be check-cf f in Attachment B and annotated in Attachment C.
c.
Report of Concrete Placement (Attachment D).
Quality Control will use Attachment D to document inspection of concrete placement.
d.
Daily Concrete Curing Record (Attachment E).
Quality Control will use Attachment E to document daily inspection of concrete curing activities.
2.
Reports of all cetivities of Quality Control shall be submittcd to the UESC Field r zirvisor - Quality Control f or inclusien in the Quality Control
'e and distribution to the owner and Engineer, as required.
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R W 63.'3D RF"C_M (Continued)
A copy of the continuous roll of recorder tapes for cach days 3.
production shall be on file at the batch plant.
11and written copics of inspection reports for concretc activitics 4,
and tcres chall be presented to the Field Supervisor - Quality Contrci no later than the morning of the work day follouing execution of the ucrk. These will be replaced with the typed copy as ti:ay are prepared.
B.
De ficienc !s s Results of all tests or inspections that do"not meet specification 1.
requirements shall be immediately reported to the Field Supervisor -
Quality Control who shall inform the UEEC General Superintendent for appropriate corrective action taken.
Eatch tickets shall be annotated to reflect the cause for a.
rejection and the intended use for the rejected concrete.
Nan ~mformancer relati..e to concretc $tcrials,'plac;d ecneratc, h,
rebar and caducids (per Appendix B, Paragraph 4C) shall be documented on a Nonconformance Recore and crocessed in acenraar. n r
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with QC-17.
Deficiencies relative to practices and procedures shall be c.
reported to the Field Supervisor - Quality Control for appropriate corrective action and concrete placement shall be halted until all discrepant conditions have been corrected.
In the event of a disagreement between the Field Supervisor -
2.
Quality Centrol and the General Superintendent as to remedial actions or =casures required to bring productica within standard Quality Control cnd the limits of the engineering specifications, it is then the duty of the Field Supervisor - Quality Control to inform the Construction Manager and request cc=pliance.
In the event corrective action is not implemented, the Field Supervisor 3.
Quality Control shall inform the UE&C Lead Quality Assurance Engincer and_G2v50 Quality Assurance Manager for a decision on the corrective A Quality Assurance decision shall then be nade action to he tal,ca.
f or the disposition and corrective action to be taken.
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QC-1 Rev. 8 6/12/72 Page 15 VIII.
REPORTS AND RECORDS (Continued)
C.
Final Accentance Inspection 1.
The Quality Control Inspector shall inspect embedded items and pipe prior to the release of concrete as required herein and verify:
That all items within the secpe of QC-16 were inspected and a.
documentation records were checked and found to be complete and adequate per requirements of Phase I and/or Phase II Final Acceptance Inspection.
b.
That all other items were inspected by the cognizant Craft Supervisor and indicated his acceptance by signing the Concrete Placement Checkout Sheet (Reference Attachment A).
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Thin e ha1. to Tourt Da te & Ti-e c
Mod..,kr.s,:c~
- r.,.., m' Cra f t Su v'r.
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C112C. 0L A I...,
Minor ite:. to cernlete orter to
. (curnare..,.,o). a a.r daea alace.?nt (if nene,,rint ona)
- 1.. ur f.cc Preparetic1
- 2. l'orr inr!:
- 3. #" ' # CIM Steel s
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"
- n.; e e c.n.-- d l
- l
>c' ou t 5
- 5. Irc1 IJ.
d'.D C!)O Y l'o10%
7* Pipin:
E:-b c d d- -.t s 8* Electric.a.1 c--beddenn t:
- 9. Idne anti crin!c I f
.,.1.1 c 2 - -
..n.-
. ro n - : 3.
-. r.: n r.--.s r.. t ':. c. r -.,.. t t e -.
- .:.t.-- =:
- 10. Qualit. Control e
(surn,"e)
(re m r'..s)
Iten la nuit 'ic stanc.1 L co-tes iton to cencrete pl::cenent suacrvi.:or end job En:incer,rior to 1:cuiu int:.ict cr.!c to b::tch car. crete.
71nt r ibu t ica :
"roi.
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(5) 1566 154 un'r' r. (2)
Cone. 'i,ca. c Test 1.ah (I. )
Other:: (1.l it in 10 ') Dnr1 Affice)
.i n '. Enn.i ice r -
'as't..105
..a
.teJ.
AT P..Ci:' ". -l-"
A
_ _ _, ~.
9 Rev. 1: 2/11/72 UNITED ENGI!!EERS a CLtlSTRUCTOR
'C.
i A Q; D
' 3' Y g g
Unit No'.
1
'66 wi
. q]
. a(
II:SPECTOR'S CCNCRETE C1{ECY. CUT SilEET Unit Uo. 2 q
A. CC:! CRETE SCI:EDULES, POUR S!!EETS, Pl.APS:
G. E!! BEDDED ITD!S (CO::TINUED) 1'
- l. Completeness
- b. Proper location 2.
Craft cert. of readiness
- c. All threads wrapped 3.
Updated 6 avail. of designed plans d.
Secured for concrete placement B~~4.
- 2. t!isec11ancous secci:
SUnCRADE:
- a. Proper location
- 1. Compaction
- b. Secured or properly supported
- 2. Vapor barriers installed
- c. Check drawings for type & num5cr 3.
Perin eter insulation 4.
Condition of materials used it. REINFORCIUC STEEL.:
- 1. Proper spacing C.
COS'STRUCTIC:' JOIt'TS:
2.
Nurber & size of bars
- 1. 1.aitance renoved 3.' Length of laps
- 2. Proper location
- 4. l.cngth of dowels 6 alignment
- 3. Expansien joint materials
- 5. Cadwelds
- 4. Cont raction joints & filler
- 6. Tics
- 5. Spalling
- 7. Form clearance
- 8. Supports D.
FOR!:S:
- 1. Form surface
- 1. FINAL CLEAN-UP:
- 2. Panel joints
- 1. Check all forms & fixturcs for dis-
- 3. Bracing placement
- 4. Tic spacing
- 2. Clcanliness of surf aces, ledges, fores,
- 5. trake-up of ties rebars, embedmonts, blockcuts jcint s,
- 6. Valcr spacing & size subgrades, water stops,chutcs, etc.
___7. Spreaders
- 3. Proper scaffolding
- 8. Croat l e a t.s
- 4. Concrete chute arrangements g
- 9. Form coat ing
___5. Proper type & length of trcmier
__10. Chamfer where necessary
__11.
Crade strip properly installed J. HISCELLAMEOUS:
- 12. Plumb bob lines installcd 1.
~~
- 13. Horizontal f e nn liner installed
~714. Horizontal & vertical alignment of 2.
forns
__15. Installation of keyways on previous 3.
concretc
__16. ifetai lath bulkheads have
'a clear-4.
d ance fren form surface K. ADDITICSAL RD1 ARKS:
E. Ill.CCKOUTS:
- 1. Proper size
- 2. Proper Iccation
- 3. Internal bracing & shoring
- 4. Vibrators holcs tcp & bottem
- 5. Crou: tight L. (REACTOR PCURS : '!.Y) :
1.
Have tendon. I cen tested and appt eved?
F. "JATER STOPS:
- 1. Proper Iccation Pour Area:
- 2. Joint ucids
___3. Supported f or concrete placement Loc ation:
._4. *.'a t e r s t o p.icdged into key'tays
_5. C leanl ines s b.
Il!.%DDt.D ITi"5 :
M PEC r0R DAld 1.
,'.a e l a r '-! r s. i n e.c - e s. afon cicoece.
P f ' c oNa it s, flashin<s, etc.
P
_ _.a. rr,,p.,r pre;cc: ion mACsxEaT a 1566 155
'Rev. 1: 2/11/72
]UNITEDEUCINEERS& CONSTRUCT, fNC.
4 Unit No. 1 CONCRCT:: STATU3 R;rORT Unit No. 2 g-Pour Area:
Location:
It SPECTION ITEMS RE!fARKS Concrete Schedules, Pour Sheets, Plans Subgr de Construction Joints Forms Blockcute
!(
Water Stops Embedded Items
~
Reinforcing Steel Final Cleanup Miscellancous Additional Corrr.ents READY FOR PLACEMENT
~.
Quality Control Inspector Date 1566 156 ATTACHMENT C m
7
)
Fev. 1: 2/11/72 UNITED ENCINEERS & CCNSTRUCTORS INC.
<~
,I REPORT OF
\\
CONCRETE PLACEMENT Project Identification: Metropolitan Edison Nuclear Plant - Three Mile Island Unic No.,_
Pour Area:
Date Location:
FO IMS ACCEPTED RETNFORCE!ENTS ACCEPTED Properly Coated Proper Clearance Free From Holes Proper Support Seams Tight Clean Cican Tie Rods Type:
Proper Shoring &
Spacing:
Support EQUIPMENT:
No. & Size of Vibrators Placceent Equipment l'
(
Tremic Pipes - Number Size Location PLACEMENT:
Consolidation Grouted Time Concrete - Lif t Depth Direction of Pour REMARKS:
1566 157 Quality Control Inspector Date ATTACIPENT D
~ ]fMTTED EIT.TNEERS & CONSTRUCT: 9NC.
DAILY CONCRETE CURING RECORD PROJ ECT:
Three Mile Island Unit No.
Pour No.
s..
Date of Pour:
Location:
Inspect Concrete Curing for Compliance with : Winter Curing Method Summer Curing Method Prepared By Date dummer t uring Metiloo
[
]Coveredwithwetburlap
[
] Scaled with curing compound (not in Reactor Building)
Data Date l
concrete Temp. ( F)
Mint =um Temp.
50 50 50 50 50 50 50 Rec'. 4_rement (UF3
,e -
i Winter Curina Method Protection
[ ] Insulated Forms
[ ] Polyethelene, straw & tarps
[ ] Plywood Forms
[ ]HeatedandVented Data Date Concrete Temp. (OF)
.. u..... u... w..ip.
ncquirement ( F) 50 50 50 32 32 32 32 REMARKS:
1566 158
%s '
Quality Control Inspeccor Date ATTAC1 TENT E
-m
9 9
y~
QC-1 App. A Rev. 1 APPENDIX A Concrete Material
(
and i
List of Approved Concrete Mixes February 11, 1972 Revision 1 1566 159
--w.-
... - ~
QC-1 App. A
/*
Rev. 1 2/11/72 1.
CONCRETE MATERIALS Page 1 a.
Preliminary Tests 1.
Concrete Accrogates - The T.L. shall visit suggested sources for fine and coarse aggregates and obtain sampics of each proposed aggregate size for preliminary testing and approval.
Testing methods and acceptance standards shall be as follows:
Acceptance Test Method Standard Sampling ASTM C75-59 Gradation - Sand ASTM C136-63 PDH, Form 408 Gradation - Stone ASTM C136-63 PDH, Form 408 Mortar Strength - Sand ASTM C87-63T PDH, Form 408 Sodium Sulfate Soundness ASTM C88-63 PDH, Form 408 Los Angeles Abrasion - Stone ASTM C131-66 PDH, Form 408 Material Finer Than No. 200 Sieve ASTM C117-66 PDH, Form 408 Organic Impurities - Sand ASTM C40-66 PDH, Form 408 In addition, the following tests may also be performed to give
/
necessary informantion concerning tha proposed aggregate, how-s ever, the basis for selecting aggregate shall not be limited to the results of these tests.
Test Method Petrographic Examination ASTM C295-65 "ineness Modulus ASTM C125-66 Unit Weight ASTM C29-60 Specific Gravity and Absorption ASTM C127-59 and C128-59 2.
Cement - The T.L. shall obtain sr.mples of the cement proposed for use in the project.
Chemical and physical analyses of the samples shall be performed to determine compliance with the following test methods specified in ASTM C150-66 for Type II cements:
Test ASTM Method Sampling C183 Chemical Analysis C114 Fineness by Air Permeability C204 Autoclave Expansion C151 Time of Setting C266 Air Content of Mortar C185 Compressive Strength C109 Tensile Strength C190 x,,
1566 160
63 53 QC-1 g
GN 1
p i
App. A b
J Jl\\
Rev. 1 t) m 2/11/72 2.
MIX DESICNS page 2
~
All materials used shall be tested as specified above and a.
shall meet the specification requirements and be approved in writing by the Engineer.
b.
Proportions for the concrete mixes shall be determined by Method 2 of Section 308 of ACI 301-66 to comply with the project design strengths and maximum water-ccment ratios specified in SP 5406.
(1) In addition to the above requirements, the maximum water-ccment ratio and maximum total water content of any mix shall be as shown on the approved design mix.
Approved mixes to date have the following water-coment ratios and water contents.
Class 3000 psi - 6.0 gal /sk (max. water, gal /cu. yd. varies with brand of cement.
See Table-1 for approved mi,xes.)
Class 5000 psi - 5.0 gal /sk f
(max. water, gal /cu. yd. varies with
(,j cement content and brand of cement.
See Table-1 for approved mixes.)
(2) Approved mix design proportions are shown in Table-1 herein.
Slump for structural concrete shall not exceed four inches or be less than one inch.
Structural concrete with slump not within these limits shall be rejected.
(3) Structural concrete shall be air-entrained with chemical admix conforming to ASTM C260-66T.
Entrained air content shall be limited per aggregate sizes as follows:
Nom. Max. Size Air Content Coarse Accrecate
% by Volume J/d" 6-10 1/2" 5-9 3/4" 4-8 1-1/2" 3-6 (4) A retarding, water-reducing densifier conforming to ASTM C494-65T, Type D or Type A (as approved by the Engineer), and containing no calcium chloride shall be used with all 3000 psi, and 5000 psi structural concrete.
(5) Results of the design mixes with recommended final mix proportions shall be presented to the Engincer CAI for approval.
.1566 161
h 4
QC-1 App. A Rev. 1 2/11/72 f'
TABLE-1 KEY CEMENT BRAND - as listed Stone
- Type - Crushed Limestone Source - Pennsy Supply, Hummelstown Size - 2B = PDH #2B (l"), 2 = PDit #2 (3 /4 ")
SAND
- Type Natural Source - Pennsy Supply, Yorkhaven WRA
. Water Reducing Admixture P = Plastiment by Sika Chemical Co.
(,
100 = Pozzolith 100xr by Masterbuilders k
200 = Pozzolith 200N by Masterbuilders AEA
. Air Entraining Admixture D = Darex by Dewey & Almy M = r.BVR by Masterbuilders Corp.
1566 162 9
7
e - ?.E-1
/Ns GIT "I APPROVED COCRETC MIXES f
Design Cement
- Cement Stone Sand Water WRA AEA**
Strennth Brand Type (Ibs)
(1bs)
(Ibs)
(Gal.)
(02)
(02)
Lab. Report No.
Approval 1.
1500 Keystone II 376 1,905(2B) 1,385 33.0 8.0 1.6W UST 20311-M1-A D.A. Godfrey 6-19-68 W) 1.6(D) UST 20311-il2-A D.A. Codfrey 6-19-68 2.
1500 fiational 11
.376 1,905(2B) 1,395 32.5 8.0 3.
1500 fiazareth 11 376 1,905(23) 1,395 32.5 8.0 1.6 UST 20311-M3-A D.A. Godfrey 6-19 8 4
1500 Allentown II 376 1,905(23) 1,358 34.0 8.0 1.6 ?) UST P-4734-A D.A. Godfrey 5-4 E'
I 5.
1500 Keystone II 376 1,850(2) 1,430 34.5 8.0(P) 1.6 UST 20311-M1-A D.A. Godfrey 6-19-68 6.
1500 National II 376
,1,850(2) 1,450 35.5 8.0(P) 1.6(D) UST 20311-!!2-A D.A. Godfrey 6-19-68 7.
1500 tiazareth II
-376 1,850(2) 1,430 34.5 8.0 1.6 UST 20311-M3-A D.A. Godfrey 6-19-68 2)
E.
1500 Allentown II 376 1,740 1,444 35.1 8.0(P) 1.6 UST P-4734-A D.A. Godfrey 5-4-68 2B )
9.
3000 Keystone II 517 1,905 1,280 33.0 11.0 2.2 UST 20311-M1-A D.A. Godfrey 6-19-68 2B) 10.
3000 flational II 509 1,905 1,300 32.5 10.8 2.2 UST 20311-M2-A D.A. Godfrey 6-19-68 11.
3000 Nazareth II 509 1,905 1,300 32.5 10.8 2.2 UST 20311-M3-A D.A. Godfrey 6-19-68 12 3000 Allentown II 543 1,905 1,210 34.6 11.6 2.3 UST P-4734-A D.A. Godfrey 5-4 13.
3000 Keystone II 556 1,850(2) 1,275 35.5 11.8(P)
(D)
UST 20311-M1-A D.A. Godfrey 6-19-68 2) 14.
3000 Nc.. i ona l II 571 1,850 1,250 36.5 12.0 2.4 UST 20311-M2-A D.A. Godfrey 6-19-6S
-15.
3000 Nazareth II 549 1,850 1,300 35.0 11.6 2.4 UST 20311-M3-A D.A. Godfrey 6-19-68 O l 6.
3000 Allentown II 554 1,740 1,285 35.4 11.8 2.4( '
UST P-4734-A D.A. Godfrey 5-4-68 m
17.
3000 Keystone II 470 1,700 1,440 31.9 10.0 5.5 PTL 687057 D.A. Godfrey 6-19-68
( 23 )
18 3000 11edusa II 494 1,925 1,300 31.5 10.5(P)
(D) 5.0 UST P-4707-3 D. A. Godf rey 2-23-68 u
19.
3000 itedusa V
517 1.900 1,262 32.5 11.0 5.0 Penns y-Ma r ley
,a
Ihl; LIM e.-
t'
-1 s
APPRorED ETE MIXES De s t,;n Cement
- Cement Stone Sand Uater URA AEA **
S t rere -h Brand Type (lbs)
(Ibs)
(lbs)
' Cal.)
(02)
(OZ)
Lab. Renort No.
Approval 20.
3509 hedusa 11 658 1,950(2B) 1,130 33.6 14.0(P) 5.3(D) UST 20311-l!8-A J.N. David
" 2 6' 21.
3500 Keystone 1
564 1,900(2B) 1,212 33.0 12.0(P) 3.0(D) Pennsy-flarley 22.
4000 Medusa V
635 1,900(2B) 1,163 35.0 13.5(P) 3.5(D) Pennsy-Marley K.E. Nodland 10-24-f 23.
4000 Keystone I
611 1,900(2B) 1,151 34.0 13.0 3.25(D) Pennsy-Marley E) 2'.
5000 National II 775 1,850(2) 1,095 38.3 24.75(P) 7.0(D) PTL 691237 K.E. Nodland 7-10-61 25.
5000 Keystone II 775 1,850(2) 1,095 38.2 24.75 I 7.5(D) PTL 693619 K.E. Nodland 7-os
- s 26, 5000 Nazareth II 775 1,850(2) 1,095 38.0 24.75 I.5 PTL 693618 K.E. Nodland 7-10-65 27.
5000 Medusa II
- 705, 1,850(2) 1,050 37.0 15.0 7.0 UST P-4707-B D.A. Godfrey 2-23-68
)
EI 28 5000 Allentown II 775 1,850(2) 1,095 35.5 16.5 3.3 UST P-4736-C D.A. Godfrey 6-19-68 E) 0)
29.
5000 Allentown II 775 1,905(2B) 1,030 34.8 16.5(P) 3,3 UST P-4734-C D.A. Godfrey 6-19-68 0) 30 5000 Allentown II 1,450 2,050 47-52 30.6(P) 7,3 D.A. Godfrey 2-27-69 W)
(Grout) 31.
50C0 Allentown II 1.450 2,050 64 30.6 7.3 K.E. Nodland 9-18-69 E)
EI (Grout) 32.
5000 Medusa II 658 1,670 1,365 35 19.7{200)7.0INI Master Builders K.E.'Nodland ER70-6 33.
5000 Allentown II 658 1,670 1,365 35 19.7(200)7.0IM)
Master Builders K.E. Nodland ER70-17 34.
5000 Allentown II 705 1,850 1,130 34.7 21.4(100)10IM)
PTL 704832 g K.E. Nodland
(!;ote 1) 35.
5000 Allentown II 705 1,850 1,130 35.1 21.4(200)8.5(M) PTL 704833 K.E. Nodland (Note 1) 36, 5000 Allentown II 752 1,850 1,090 36.7 22.6(100)9.5IN)
PTL 705726 K.E. Nodland
~
(Note 2)
Ln
- - Only Allentown Type II cement permitted in concrete in Reactor Building.
- - Amount shown is amount used to prepare laboratory batches. Amount to be used in field is that necessary to achieve required air content.
m Note 1 - These mixes permitted for all 5000 psi concrete except Reactor Building shell.
- -Ch Note 2 - ibis uix to be used in Reactor !!uilding shell.
Notes 1a 2-these uixes supersedu 5000 psi uixc4 numbered 32 n 33 above.
p n
QC-1 App. E Rev. 1 2/11/72 s,
APPEtmIX B Reinforcing Steel and I
Cadwelding
\\
February 11, 1972 Revision 1 1566 165 t
+ - -
a
QC-1 App. B D *
- fD
- 3 M'V Rev. 1 2/11/72 l
1.
REI!:FORCTMG STEEL
, yy g gJ s
Page 1
(
a.
Mill Test Renorts 1.
Mill test reports of chemical and physical analyses shall be furnished on delivery for all reinforcing steel received on the site, and shall be reviewed f or conformance to the following specification requirements:
Sizes up to #11 bars - ASTM A15, Grade 4.1 and Grade 60 Size 14S and 18s bars - ASTM A615, Grade 40 and Grade 60 b.
Storace 1.
Reinforcing steel, when received is bundled and metal-tagged by heat and size.
2.
Bars shall remain bundled and tagged until User Tests are complete and results found acceptable.
3.
A storage yard log is maintained shouing material received, sampled, tested, and accepted for use.
The log is kept up to date by the Field Supervisor - Quality Control and is oudited by the Quality Control Group.
(
4.
Any steel which does not pass inspection or test requirements will be immediately removed from the site.
s 5.
Reinforcing steci indicative of " tests still unresolved" will not be released for construction.
6.
When user tests are complete and found acceptabic, material is released for construction.
c.
User Tests 1.
UESC Quality Contr'o1 personnel shall select from each heat and size of rebar received at the site, two spriimens per sampic lot for testing to determine the yield point, u.timate streur,th and percent elongation.
These rebar tests will be termed "Uccr Tests" and calculations shall employ the actual measured cross sectional area of the specimen and not the nominal area. ( A sampic lot is defined as material of one heat weighing 25 tons or less).
2.
Whan a f ailure is noted in the User Tests, resampling will be conducted on twice tha number of samplas as originally celected and tested.
tihen all of the resampics pass, the lot represented by the sample shall be cc taidered acceptable.
Only two recamplings of a lot will be permitted.
Failure of the second resampics shall be cause for rejection of the represented lot.
1566 166
'~
3
q Q
QC-1 App. B
.^
Rev. 1
/
2/11/72
(
Page 2 2.
WELDED WIRF. FAP2IC a.
A letter of compliance will be required on welded wire fabric verifying conformance to ASTM A185-64.
3.
CAD'JELD SPLICES a.
Sizes Reinforcing steel bars larger than #11 shall be spliced with the "Cadweld" process, b.
Mill Test Renorts Mill test reports for splicing sleeves will be required and reviewed for compliance with Specification requirements.
Rejected material will be returned to the Vendor or otherwisc removed f rom the s ite.
c.
Qualifientions of Ccdweld Operators pg #%' '[.1 1.
Prior to production work, the operator designated to perf orm
- C "Cadweld" splicing will be qualified by preparing
- test joint for each bar size and position he will be required to splice.
i These test joints will be tested in cension af ter visual examination.
If the test splice develops the minimum specified ultimate strength of the bar (A615 - Gr. 40, 70 ksi and A614 - Gr. 60, 90 ksi) the operator shall be considered qualified to produce that size and position of splice.
2.
Using previously qualified operators, approximately fif ty splices will be prepared under production conditions.
From these splices, at least sixteen will be randomly scicceed and tested to doctruction.
Results of these tests will be turned over to the Engineer for evaluation and determination of the initial sampling rate for production splices.
3.
In qualification of both pre production and production splices, each completed splice shall meet the following acceptance standards:
(1)
Sound filler metal shall be visibic at both ends of the splice s1 cove and at the top hole in the center of the sleeve.
(A singic shrinkage bubbic present below the riser is not detrimental and should be distinquished from general porosity.)
(2) There shall be evidence of filler metal between the sleeve and bar for the full 360, however, splice sleeves which are not exactly concentric or axially aligned with the bars are acceptabic.
Filler metal void limits shall be as shown in Figure 1.
1566 167
QC-1 App. B Rev. 1
/
2/11/72
(
Page 3 3.
CADt? ELD SPLTCES (Continued)
(3) The bar ends shall be clean and free from rust, mill scale, slag, grease, paint, moisture, etc.
(4) Bars shall be longitudinally centered in the sleeves as shown by previously affi::ed center punch marks or similar identifiable location marks on the bar.
(5) Bars shall not be scarfed and the portion of the bar in the sleeve shall have uniform deformations along its length consistent with the rolled mill pattern.
d.
Cadweld Inreeetion Cadwelding in the containment structure shall be inspected by Quality Control for the following requirements:
1.
"When the relative humidity is over 807., molds and bar ende shall be heated above 212 F but not more than 300 F and the bar ends then uire brushed to remove all loose mill scale, corrosion, concrete, and other foreign materials.
The bar ends shall then C
be reheated to 212 F - 300 F.
Any bar not fired within 5 ninutes f
of 2nd heating shall bc reheated to 212 F - 300 F."
(
2.
Sleeves and crucibics shall be checked for cleanliness, rust, etc.
3.
tbids to be preheated when necessary (new mold or change of shif t).
4.
Bar ends shall be free from loose mill scale, rust, moisture, slag, grease, and paint.
5.
Bars shall not be scarfed.
6.
Bars shall be marked by center punching or othe r suitable means, so that assurance ai centering ends within the sleeve may be made.
7.
Completed splices shall be visually inspected in accordance with the following procedure.
Any splice which, in the judgment of the inspector does not pass visu'al inspection, shall be cut out and replaced.
(1)
Properly made splices will have filler metal visible at both ends of the sleeve and at the top hole in the center of the sleeve.
1566 168
QC-1 App. B Rev. 1 2/11/72 Page 4 3.
CADRET,D SPLICES (Continued)
(2) Filler metal need not flow to the very edge of the sleeve due to the gasket action of the asbestos wicking used to seal in the molten filler metal.
(3)
As a result of the Cadweld process, a shrinkage bubbic may ba visibic at the top hole, where the molten metal is introduced and shrinkage fissures and pinholes may be visible at the top of a vertical splice.
These casting flows do not adversely affect the physical performance of the splice and therefore do not consitute cause for rejection.
(4) Filler metal void limits shall be as shown in Figure 1.
4.
CADRELD TESTS a.
Sampling 1.
Random sampics of visually acceptable splices at a rate to be specified by the Engineer shall be selected, cut f rom t he structure and tested in tension to destruction.
b.
Test Recore
(
1.
For each Cadweld splice,. data shall be recorded on rebar data sheets showing:
(1)
Splice number (This number shall also be applied to the splicing sleeve using a heat and weather resistant marking pencil).
(2) Location (3)
Size and orientation of the splice.
(4)
Operator number (crew number)
(5)
Date, weather conditions, and time the splice was made.
(6)
Inspectors initials (7)
Sample number and test result, if applicabic.
1566 169 P"
g Nb
_$'F
- W"*
- O N
yM Y
QC-1 App. B Rev. 1 I
2/11/72 Page 5 4.
CAD'JT.LD TESTS (Continued)
Cadweld Failure c.
fail to meet tension test results less than Cadweld splices that 1.
70,000 psi or 90,000 poi as applicable will be cause for additional sampling.
The next previous or subteiuent splice made by the source operator shall be cut from the structure and tested in tension to destruction.
If this test exceeds the minimum value If this splice also the process will be considered in control.
fails, the operator / crew responsible shall discontinue cadwelding and an engineering evaluation will be made.
1566 170 r
f e
a I
rigure-1
}
V O T D !!.l M I T G si,!ia n s.hal: not bc rcjected where voids of filler metal do not excccd the arca listed hclow, whcn
/
measured n shown in figure bclo T]
i mo m
~ ~ ~ '~~ ~ ~
.;fowabic Void Arca-Square lcchts
' ]
~ "k Car o
3I"'
Sptice Cat. Mo.
Vc~r tiliitTdlT~'-~
6C D
Star dard Splices'DQ Circumference Low 3
/6 RUT 6101(.H) 1.C5
/ 6/7 RS16 7101(.H) 1.05/1.03
%/Ms NO1 ES-
/7 R BT.7101( H-1.03 -
'e s
@ Allowahti. void par cr/' i:.
/ 7/n RBT7 S101(.H) 1.03/1.02 b/%
shown, not the total of bc:b
..... ROT 891( H). _ _ _ -
1.02_..-
ends. For exampic, a spli. e
- 8 t
/ S/9 RB10 9101(.H)
.l.02/1.02
%/%
of //1S bar in RCTd En1
_ _ _..f9 R DC.9 7C(.H)
.60
'Is, woult! be accep:ih!c.,S.,
RBT 9101(.H) 1.02 1 %" wide,1 %
- dcop L' '.
f 9/10 R UC9 107G(.H)
.60/.61
%/M6 both ends (Void crua
.M R UT910101( H) 1.02/1.03
%/ b x (1 % _. E) e 1.D t, n;. : <.
fl0 RCO 107t(.H)
.61
%s R Dl.1091(.H) 1.03 b
inchN j10/11 RCC10117C(.H)
.61/1.03 b/b RB110 ll101( !!)
1.03/1.53 h/b
@ This column f'w :,1 cam dard sp!!ces; ver:ical, han-fil RUC ll76(.H) 1.03 Mc RU1 11101(-H) 1.53 b
zon tal. horizon::.I sid': fili.
/11/14 R D0 l l.147C( H) 1.03fl.24 b/%
angicd spliecs and,, scric; o
RBTl 1 1410!( H) 1.53/1.52 b/%
Structur ; Sp!iccs.
/11/18 R UC l l.187C(.H) 1.53/1.70 b/b R u r l l.18101( _H) l.._.1.53/1.99 b/%
@ This tab'c to be used for
(
J14... _..
RBC-1.:G1/ H) 1.24 b
VeitiCUI "ili:C i O n >' W :,"!'-
(
RUC-147C H) 1.52 fil!er metal croond en: ira cir-RUT 147C(.H) 2.15 cumicience. For sp a: vo'd.
RUT.14101( H) 2.15 (14/18 Rr014187C(.H) 1.52/1.70
%/
use tabic for star;dard piic n.
R DT 14 10101(.H) 2.15/1.99
%/%
.18 RUC 10Gl(-H) 1.99 RUC IS7E( H) 2.64 b
RHT 187C(.H) 2.64 RBI.1891(.H) 3.00 R U T.18 : 01(.H) 3.00 3*'
I~a(Normal void due to sbestos packing.)
NOTE: Void dimensions can Le established b,5 se cf a u
rin. i i-m....,,,
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probe of tic wirc--
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VO:D LIM!YG-C 'iG SEnlES' SU M M ARY C O r/,'.'.> :.::,.Ti C C ' O t J O P.' LY
" * ' ' g " '
The intpection cf a Ct.D'.*!ED rebar sr,0 ic,.. !
- c.,,
Occasion:! cnce,. ira n' :- - -.: m.:r. 1.~p ri..a
( on u r. <,i, n n..'., s r. ;;c.- sf a!! not be tekctr:f vehcre ir O crew.to make rur' that they an fop-e.ing t'..
m"1_
II v n tf.n.,r OP CI"O Id d"'c'. r;il ", ec t:i re m tcr c. 'h.: jt..,
'. in cv. A : c..i u pht e s!~ce tap s
btNe
.us; ? vf dgl5 afC rhi di ep Ibafl I iDCh, cilher iis i'
OM h-OM
'd
'h Ul
- H.. t v.mi os full < in n ofi s. nn. ! f ace h!!
- h00!'I I s C ""'G h C I h ;
'H f' D" I ;"
QLTSTION 17:
" List locations where concrete tests were made referred to in Question 16."
RESPONSE
Slump tests, air entrainment tests and temperature tests were per-formed for each 50 cubic yards of concrete poured in the containnent.
Test cylinders used for compressive strength tests were taken daily from each 50 cubic yards of concrete or portion thereof placed per class.
(See attached UELC Quality Control Procedure No. 1, Rev. 8).
1566 172
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QUEST 10:! 18:
" Describe in detail the flood protective measures and the enount of time required to institute these measures if another "Agnes" type flood occurred."
RESPO:SE:
The enclosed copy of Emergency Procedure #1202-32, entitled " Flood Control", describes in detail flood protective measures for TMI station.
In the development of this procedure, the time required to institute all censures necessary to ensure the continued safe operation or timely shut.down of the station as a function of the rate of increased river flov was taken into consideration.
The river flow at TMI as a result of the June 1972 "Agnes" flood was approximately 900,000 CFS.
Should another flood of this magnitude occur a flood Alert uould be initiated by the Station Superintendent when river flow reached 640,000 CFS.
This flood Alert would not require a shutdown of the plant.
1566 173
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