ML19256F546

Miscellaneous Paper C-74-12,Pullout Resistance of Reinforcing Bars Embedded in Hardened Concrete, Prepared by Engineer Waterways Experiment Station

ML19256F546
Person / Time
Site:	Trojan File:Portland General Electric icon.png
Issue date:	06/30/1974
From:	Stowe R ARMY, DEPT. OF
To:
Shared Package
ML19256F545	List: ML19256F544 ML19256F546
References
TAC-07551, TAC-11299, TAC-7551, NUDOCS 7912190390
Download: ML19256F546 (68)

Text

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J. p. ATTACHFENT 5-3 Page 2 of 21 ( FOREWORD This investigation was authorized by first indorsement from the Office, Chief of Engineers, U. S. Army, dated 28 May 1969, to a U. S. Army Engineer Waterways Experiment Station (WES) letter dated 19 May 1969, Pullout subject, " Project Plan for Epoxy Resins and Other Adhesives: Resistance of Reinforcing Ears in Drilled Holes in Hardened Concrete Grouted with Epoxy Resins (ES Item 628.11)." It was completed as a part of Work Unit 31140 of the Civil Works Research Program, 'Tnvestigation of New Materials, Testing Methods, and Apparatus, approved 25 Jbne 1973 The work was conducted during fiscal years 1972 and 1973 The investigation was conducted in the WES Concrete Laboratory under the supervision of Messrs. Bryant Mather, Chief of the Concrete Labcratory, J. M. Polatty, Chief of the Engineering Mechanics Division, Mem-and,W. O. Tynes, Chief of the Concrete and Rock Properties Branch. bers of the Concrete Laboratory staff actively concerned with the work included Messrs. Mather, Polatty, Tynes, W. F. McCleese, and R. L. Stowe. Messrs. McCleese and Stowe served independently as project leaders; Mr. Stowe conducted the data analyses and prepared this report. Directors of WES during this investigation and the preparation of thir report were COL L. A. Brown, CE, and BG E. D. Peixotto, CE. Technical CF; G. H. Hilt, CE, was Director at the time of publication. Lirector was Mr. F. R. Brown. s = iii

L ATTACHMENT 5-3 Page 3 of 21 COIITC;TS Page .. iii FORE'JORI'. COI;VERSIOII FACTORS, U. S. CUSTOMARY TO IETRIC (SI) UI;ITS OF vii IEASURF2EI!T P ix SUL,,,M i 1 PART I: ETROUJCTICI! k 1 l Background. 2 I Objective 2 Scope L r 3 PART II: MATERIALS, EQUIRIEIiT, TEST ELOCKS, ISD PROCEIUF2S 3 ? ! Materia 10 5 h e Test Blocks 'h 9 d p Equipment and Testing Procedure j 11 j FAFT III: Id;ALYSl*J /d;D DISCUSSI0I!................ a 1 11 i Cement Grout Mixtures 13 t Epoxy-Recin Syste::s 15 l Displacemento ,t 17

I FART IV : COI;CLUSIOI:S /d!D REC 0!/'EIIDATICI:S e

I L 17 t I Conclusions 18 Recommendationc t 20 'ITEFATURE CIED......................... TABLES 1-6 i ( FIATEC 1-5 t. I i o [6Id3.117.ll 1; uW $w:,.,., m,,..,.~"am.n' *..u, n.'s.,y h%.c,;:.;w .c.wm.D..,.>)n&, m,,,,..:3:.c.m*m{ <...;, ma. f=1;. 5;iLam. n. m, rm .m.., ch y. r .-,.4g, , m u m.m.n e m': psn .,,.,. q. e - y.,.- .w ., s.. s - - . p:.

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f ATTACHMENT 5-3 Page 4 of 21 t J ') i )b 'l b p (t h Il 1 SUICKRY i Holes for embedding reinforcing bars were diamond-drilled into i [ The holes were 1 in. (25.4 mm) in diameter mass cencrcte test blocks. j and deep (nough to embed No. 4 and No. 6 deformed reinforcing bars to U Portland-ccment depths of 5, 8,10, and PO nominal bar diameters. l [ grouts and commercially available epoxy-resin systems were used to an-s The bonding agents were allowed to chor the bars in the drilled holes. j { cure, and the reinforcing bars were axially loaded to determine which - J In all instances, ) bonding agent offered the most pullout resistance. the epoxy-anchored reinforcing bars exhibited more resistance to pull-if The bonding out than did the bars anchored with the cement grouts. agents evaluated in this investigation are recommended for anchoring y - reinforcing bars in drilled holes in hardened mass concrete; however, 1E certain limitations are specified for their use. ap-g..4 a;t i&. d @ i, 1 1 J(5 r ,I t, 4.. ),' V I 11-r 1 c l i I : I I i t 1 f F. 3, k n n m 1 ',. h 1620 308 j i- -l ?' .s. f -[. 'h- ~

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yS:M&Z%5"5~.Tsm-~ f f ATTACHMENT 5-3 Page 5 of 21 1 5 Incufficient data are available to provide adequate guidance 1 i for field usage of bonding agents. This investigation was initiated to e obtain cuch data. g 4 i Objective 6. The objective of this invectigation was to determine which of k ceveral bonding agents vould best anchor deformed reinforcing bars in g j holes drilled in hardened concrete. Tnree co=nercially available epoxy-resin systems and two portland-ccment grouts were evaluated. 1 [ Secte j 7 Existing 5-by lo-by 20-ft+ (1.524-by 3 048-by 6.096-m) mass concrete blocks, which vere cast during a cement-replacement program, were used as test blocks. All test blocks contained 6-in. (152.4-mm) maximum-sice aggregate. Five 6-by 12-in. (152.4-by 3ch.8-mm) corce were drilled from each tect block and tested for compressive strength. Hole for embedding reinforcing bars vere drilled into the test block: I using a thin-wall diamond bit. The holes were 1 in. (25 4 mm) in dian-eter and deep enough to embed I!o. 4 and I;o. 6 bars to depths of 5, 8,10, i 1 and 20 nominal bar dianeters. Two portland-ccment grouts and three ) two-component epoxy-recin cyctems were used to anchor the bars in the sj drill holes. The bonding agente vere allowed to cure for 14 days, at 5 which time the barc were pulled using a reaction frame and a hydraulic jack. Initially,12 tests per adhecive were to be conducted; however, the number of test was reduced depending upon the yielding of the bars .s i (i.e., if either the I!o. h or I!o. 6 har yielded at, say, the second em-( g bedment depth, then the test at the third embedment depth was omitted } from the test schedule). Dial indicators vere used to monitor relative j displacement between the reinforcing bar and the concrete test block, e d n ? i 3 A table of factors for converting U. C. customry units of measure-3{ ment to m tric (gI) units in presented on page vii. .k ..s..

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QXfk. = s =- ATTACHMENT 5-3 Page 6 of 21 while specimens from batch B3 expanded considerably. Epoxy-recin cyctemc_ The three commercially available epcxy-recin cyctens used 10. Each cf the during this study were decignated systens A, B, and C. i da epoxy-recin systens consisted of two eccponente, an epoxy rec n an Systen A vas a filled systen, while systems B and C curing agent. The systems were uced as received from the were unfilled cyctens. manufacturers. No generally accepted tecting criteria vere found for eval-11. tion uating epoxy-resin systenc that are proposed for general construc Concidering the scope of this investigation, the following tests were deened appropriate: (a) cel time, (b) bond strength, (c) tensile use. The gel time (d) elongation, and (c) nodulus of elasticity.

strength, test was conducted in accordance with American Society for Testing and 24'/1-71.5 Tne bond strength tests were Faterialc (ASU4) Designation D by the conducted in accordance with a procedure that hac been proposed U. S. Army Engineer Waterway [ Experiment Station (WES) as an ASZ4 This pro-nethod for accertaining the strength of epoxy-resin syctenc.

6 cedure is deceribed in Appendix A of Husbands, Derrington, and Pepper. The tensile strength, elongation, and nodulus of clasticity tects were 7 The recults conducted in accordance with ASTM Decignation D 638-71a. of these tects are presented in table 2. A large difference in gel tinec existed between sycten A and 10. the measured gel tirec of cystens B and C were h and cystenn B and C : A 4.25 times greater than the cel time of systen A, which van 20 min. 20-nin working time uac found to be adequate for the cnall number of this reinforcing barn that were bonded in place at any one time during With ideal working conditions, it took 2 min to paar the epoxy into a 1-in.-diam (25.h-mm) by 5-in.-deep (127.0-mm) drilled hole, vork study. the reinforcing bar to the bottem of the hole, plumb the bar, and se-i d cure the bar within a centering frame., Given that 3 min were requ re d to mix the two-component epoxy cyctem, only 8.5 bars could be embedde Certainly, with more than one person working, during the remaining tine. With all conditions being equal, additienal bars could be embedded. 1620.310 A~ ' m . e;.g w y.~ m m w ~.,,,, s.3, g -m ,. n g.,my n.ewrx.,,w a;am.m.gw. n., .~ ~ ~.; %~ >...mw.n,ssm a.u ~a.,.py,.. - s w

p n ; - ~. ~, -, -,-- ATTACHMENT 5-3 Page 7 of 21 6 m) The blocks mencured 5 by 10 by 20 ft (1.52h by 3.Oh8 by 6.09 WE3. 'lhe and contained 6-in. (152.4-mm) maximum-cize limestone aggregate. concrete used to cact the five blocks used in thic invectigation had a The replace-nominal cement factor of 2-1/h bagc/ cu yd (see table 3). nent materialc, which were different for each of the five blocks, were pumicite, blast furnace clag, natural cement, calcined chale, and un-The replacement materials were combined with type calcined diatamite. Table 3 pre-II cement in various percentages ranging from 12 to 50. cents the percentagec of replacement material used and the 90-day com-preceive strengths of 10-in.-diam (254.0-m=) cores obtained in 1954 Thece ctrengths, which were not concic-fram the tops of the blocks. tent, ranged from 1360 to 2390 psi (9 38 to 16.48 Fra). It vac believed that the various replacement materialc would 17. not appreciably influence the adhecive interaction between the bonding agente and the concrete macc, and thus not infl1cnce the pullout resist-For example, given one bonding ngent and a weak and a strong con-ance. crete with similar quantities and qualities of cement and aG6re6 ate, the adhesive interaction between the bonding agent and the concretes should However, a large strength difference between con-be nearly the same. Therefore, the chear and cretec might influence the pullout resistance. tensile strengths of the two concretes ch7ald control, to a large ex-tent, the pu.llout recistance of the reinforcing barc.

18. Five 6-in.-diam (152.h-mm) cores were drilled from each test block at locations at the came elevation ac that used for the pull-out tects (top portion of the bloch). Tnen, 6-by 12-in. (152.4-by 305 8-mm) specimens vere prepared fram the cores and tested for compres-Tnece tests were conducted to see if the five test cive strength.

The blocks still had inconcictent strengths af ter approximately 17 yr. i 17-yr strength resultc are presented in table 4 along with the 90-day t Over the 17-yr period, all five of the concrete blocks l strcnCthc. l The 17-yr average strengths ranged from 2280 chowed a strength gain. t to 3720 poi (15 74 to 25.65 Mpa); thuc, the blocks were still chowing Hou large of a strength difference would have inconsistent strengthc. 1hD311 6 A. m ,.n . m e r-m w m m,= m,z. %p M %;r'r4M:.Nw...a.mx.na ?.@ D,ywr,u'dqum,5.tv 9 :y _ ; A.ai J.} y, %$ @ inJS ':.i w L cp.;. w.vi. - e, v.~ n. =t

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ATTACHMENT 5-3 Page 9 of 21 that the beam supports would not influence a potential concrete failure Cone.

24. A7/16-in. (ll.1-mm) prestressing chuck was used to hold the exposed end of the I:o. 4 bars (see fig. 2). The chuck perfomed ade-quately as was evident by the fact that no bar yielding was observed in this region of the bar. Be I!o. 6 bars were threaded, and the jack force was transmitted to the bar through a specially desif;ned nut. No bar yielding could be observed near the threaded region on any of the No. 6 bars that did yield. The No. 6 bars were threaded with 16 threads per inch, and the cross-sectional area was reduced from a nominal O.h4 sq in. (283 9 sq mm) to 0 372 sq in. (240.0 sq mm). This fact is mentioned in ca::e the reader wishes to check bar yield r',resses.

Tne nominal crocc-sectional area of a No. 4 bar is 0.20 sq..n. (129 0 sq mm). 25 The relative displacement of a bar with reepect to a concrete block was measured by the use of two dial indicators. Tne indicators were mounted on a cross am that was attached to each bar before it was pulled. The indicators were secured to the cross arm so that movement close to the bars could be monit,ored. Displacement readings were taken at regular increments of jacking pressure.

26. After the bonding agents had cured for lh days, they were tested for pullout resistance. A particular test was terminated 1/nen the concrete cracked or when no additional load could be added to the reinforcing bars.

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Types of failures N.-f. %.a.$r-9 @n Nr / Tables 5 and 6 present I.1#g& atfMZfT ,*%/Q% n 29 -- A the pullout loads and the modes of . I fi failure observed for the No. 4 and MgNN-$'bbd4,7 ** %.g., ( @b b k v' dt .A No. 6 bars, respectively. Two modes .. k ~ of failure were observed for the bars anchored with grout. These L- .- ~ - -- - s-

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• ~'F' in other instances. One mode of failure was the grout-bar failure Fig. 3 Typical example of shallow-where the bar was pulled completely depth concrete cone and grout-bar failure (combination failure) away from the grout. The predomi-nant mode, the combination failure, was characterized by a shallow-depth concrete cone and a grout-bar failure occurring together (fig. 3).

Nor-mally, the concrete cone remained on the bar as the bar was pulled out of In these instances, the bond between the grout and the sur-the grout. The nominal concrete cone depth for rounding concrete remained intact. the No. h bars when L/D = 5 and 10 was 0.78 in. (19 8 en). The nominal (76.2 mm). cone diameter (measured at the base of the cone) was 3 in. En.bedment depth appeared to have no effect on the depth of the concrete cone pulled from the test block. The nominal concrete cone depth on the No. 6 bars was 30. (851 rr.), while the nominal cone diameter was 16 in. 3 35 in. The concrete cone failures were shallower than the theo-(h06.4 mm). h retical h5-deg angle, i.e., less than 25 deg for an average cone dept A possible contributing factor to the width of of 3 35 in. (85.1 ra). the concrete cone is the large aggregate used in the mass concrete test In several cases, pieces of accregate larger than 3 in. blocks. (76.2 mm) were found within e concrete cone that had been pulled from The failure surface occurred along the bottom of these a test block. l have shown that preload cracking l Slate end Olsefski large aggregates. in concrete in much more proninent at the bottom of the aggregate as This fact is basically due to segregation during settlement of placed. am-nnenwem3.y.. g--. g. _ ~ g w w.h. s s.c m a.n.u.v q. g,7:.t p ~,;,,; 4,y a y g ;; g g,, g,u ;,._., y.a, mn . ~.,. ~. ~ ~.. ~. - .W

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Typical examples of failures shouing full-depth concretc cone and epoxy-concrete failure with partial cone 0 5 to 2.5 in. (12.'7 to 63 5 mm) D for both the No. 4 and no. 6 bars. n /- The nominal cone diameters were sinilar to those measured on the r T'% ~ groated bars. Fig. 5 illustrates ,,.S.. .9 - ..A ' ' '.'\\> ; a t T cal exanple of the cones i [> w 'i?[,.....k,.k>b, ~.x _. s / IS' for the epoxied bars. As was / ~ ' q M A':*/ L - -,. 9.?:m., the case with the grouted-in-4. G.4 7 M place bars, the shallow-depth cones predominated. The angle of the failure surface averaged about 30 deg as opposed to the '~ g theoretical 45-deg angle. The pig, 5 Typical example of wide-red for the vide-bnsed, shallcw-depth concrete cones XP for bars epoxied in place based, shallow-depth failure ggy o D 14 huwnnmc...._, -u mew *'FT&""U5" '?DENU_"# 5 =~

%l7fd$$N3Ni s ATTACHMENT 5-3 Page 12 of 21 anchored with mixture A exhibited the greater amount of displacement. The maximum average movement, 0.0453 in. (1.15 rm), vac recorded for the bars anchored with mixture B at L/D = 10. 40. Plate'3 shows the displacement results for the No. 6 rein-forcing bars anchored with the two mixtures. AtL/D=5,thebars anchored with mixture B displaced about twice as much as the bars held with mixture A. However, at L/D = 10, the bars anchored with mixture A displaced nearly 4 times as much as those held with mixture B. The dis-placement data indicate that, for the L/D and the test setup used, both mixtures A and B allowed similar displacements of the stressed reinfore-ing bars. However, mixture B allowed slightly more movemen; than did mixture A.

41. Tne No. 4 barc anchored with system A displaced approxi-mately twice as much as did the bars anchored with systems B and C for L/D = 5 and 10 (plate 4). The No. 4 bars held with systems B and C underwent cimilar average Sicplacements, 0.013 in. (0 33 mm). The large displacement coupled d th the relatively low pullout recistance makes cyctem A the least der trable epoxy-recin bonding agent evaltytted during this study.

42. The no. 6 barc anchored with system C had an average di.,- placement greater than that of the barc anchored with the other epoxies. System A had the next largest displacement, while system B showed. the least movement (plate 5). The average displacements of the thice sys-tenc were 0.0275, 0.0225, and 0.01 in. (0.699, 0 572, and 0.254 mm) for cystems C, A, and B, recpectively. Generally, for all of the bonding agents, the bars embedded the deepest showed less displacement than the bars at the shallower embedment depths; this recult was as anticipated. 43 In comparing the grouted and epoxied bars of equal size, it appears that for the No. 4 bars, both types of bonding agents re-strained bar movement approximately the same. Houever, the epoxied No. 6 bars displaced about twice as much as the. grouted No. 6 bars. 6 1620.315 - - ~ _

[ @ F d! % % il N [3$5 A M 9, W M d: d y.y g g g ; n g.,p p yy g g g s, 4 k p p g, s ATTACHMENT 5-3 Page 13 of 21 when systens A, B, and C are used as bonding agents. However, adequate data were collected for epoxied rein-forcing bars at L/D = 10, and this L/D is considered to define a sufficient minimum embedment depth. Recommendations 45 As an outgrowth of this investigation, the following recom-mendations are made for field guidance; these recor=endations are applicable to grade 40 deformed reinforcing bars: This study concerned itself with testing reinforcing bars a. with relatively small diameters. Therefore, it appears reasonable that the results of this study could be exten-ded to bars having a 1-in. (25.4-mm) diameter. Larger bars should be evaluated for pullcut resistance. Although not a varlable parameter in this study, the diameter of the drilled hole would have some effect on the type of failure. Therefore, it is reco= ended that a minimum drilled hole /bar diameter ratio of 2 should be used. b. The three epoxy systems evaluated are reco= ended for anchoring No. 4 through No. 8 reinforcing bars in drilled holes in hardened mass concrete. However, the following ite.s must be complied with: (1) A minimum embedment depth defined by L/D = 10 should be used when epoxy systems A, B, and C are used. (2) The epoxies should only be used within the tempera-ture range recommended by the manufacturer. (3) The drilled holes must be free of debris and well dried. (4) The epoxies must be cured at least 14 days before being stressed. (5) Where possible, the drill holes for embedding reinfore-ing bars should be placed at least 20 bar diameters from a free surface. Although the ninimum embednent depth was not determined c. during this investigation for grouted-in-place bars, the following guidance is suggested; this guidance is based on reasonable extrapolation oS the data presented in this report. If cement grouts similar to those used during this investigation are used to anchor No. 4 through No. 8 rein-forcing bars in nass concrete, a minimua embedment depth defined by L/D = 15 is recontnended. 5620 M6' 13 A.,,. ~ -. ~.. _ _

a -- -~.m y g gr2 m +51mf*Z h. w ATTACHMENT 5-3 Page 14 of 21 LITERATURE CITED U. S. Army Engineer Waterways Experiment Station, CE, " Handbook for 1. Concrete and Cement," Aug 1949 (with quarterly supplements), Vicksburg, Miss. Lutz, L. A. and Gergely, P., " Mechanics of Bond and Slip of Deformed Bars in Concrete," American Concrete Institute Proceedings, Vol 64, 2. No. 11, Nov 1967, pp 711-721. Caverson, B. and Parker, J., " Roof Bolts Hold i.est with Resin," 3 Society of Mining Engineering, Vol 23, No. 5, May 1971, pp 54-57 Nordlin, E. F., " Evaluation of Concrete Anchor Bolts," Research 4. Report No. MLR 36390, Jun 1968, State of California, Materials and Research Department, Division of Highways, Sacramento, Calif. American Society for Testing and Materials, " Standard Method of 5 Test for Gel Time and Peak Exothermic Temp trature of Reacting Tnermosetting Plastic Compositions," 1972 Annual Book of ASTM Standards, Designation: D 2471-71, Part 26, Jul 1972, Philadelphia, Pa. Husbands, T. B., Derrington, C. F., and Pepper, L., " Effects of 6. Water on Epoxy-Besla Systems," Technical Report C-71-2, Sep 1971, U. S. Army Engineer Waterways Experiment Station, CE, Vicksburg, Miss. American Society for Testing and Materials, " Standard Method of Test 7 for Tensile Properties of Plastics," 1972 Annual Book of ASTM Stan- ~ Pa. dards, Designation : D 638-71a, Part 27, Jul 1972, Philadelphia, Willetts, C. H., " Investigation of Cement-Replacement Materials; 8. Performance of Various Materials in Mass Concrete, Field Study (Phase D)," Miscellaneous Paper No. 6-123, Report 6, May 1957, U. S. Engineer Waterways Experiment Station, CE, Vicksburg, Miss. Arg/ Slate, F. O. and Olsefski, S., "X-Rays for Study of Internal Struc-9 ture and Microcracking of Concrete," American Concrete Institute Proceedings, Vol 60, May 1963, pp 575-588. t e 20 1620 317 ~ M*tiy* ' - .mmtv.r-r,m~wn,n.m,. r.

-glhpr.2q? -;Aj: w f5,4,.

31.';, vFF.fr. ,.a ..-:,m m. g a. m #A g g,[vJA e34Q'i',1rw;,4 v 'pr.m.. TMJ '.qU,4Qy.aAS;Q ..w,_

• '?

i

_7:U$4.T+$d!2dhdMTi2MiidWmh%hblJi#84M!ctia 2:hW'MEie: WJ % % v. y ATTACHMENT 5-3 Page 15 of 21 Table 2 Su. mary of Test Results of Enexy-Resin Systems Gel Bond Tencile Tangent Modulus of Epog - Time Strtndh Strength Ibrcent Elasticity. tillicnc Eccin System min psi FPa psi VFa Floncation esi 17a A 20 2490 17.17 5720 39 44 1 91 0:580 0.00399296 2430 16.75 5360 36.96 2.27 o.357 0.00246143 2670 18.41 4960 34.20 2.08 o.382 o.oc263350 5270 36.34 2.o9 o.485 0.00334396 5150 35 51 1.73 o.474 o.00326811 Average 2530 17.44 5290 36.49 2.02 o.456 c.00314125 Standard deviation

• 280 1 93 o.20 0.089 0.o0061363 B

So 4560 31.44 7170 49.44 3 94 o.337 o.00232353 4610 31.78 7340 50.61 4.27 0.281 o.00193743 4610 31.78 6840 47.16 3 93 0.299 o.00206153 6920 47.71 3.64 0 321 0.00221322 6Sio 47 23 4.03 0 341 0.00235111 Averace 4590 31.67 7000 48.43 3 97 o.316 0.00217736 Star 3ard deviation 220 1 52 o.35 0.026 c.oco17926 C d5 4h00 30.47 4730 32.61 1.15 o.459 o.00316469 4630 31 92 4390 30.27 1.03 o.471 o.00324743 4560 31 5S 4520 31.16 1.13 o.467 o.00321955 4990 34.40 1.02 0.48S o.00336464 4490 30 96 1.06 o.483 0.03336464 Average 454o 31 32 4620 31.83 1.12 0.475 0.00327225 Etsadard dcriation Oko 1.65 0.o9 o.013 0.00005963 .s ~ { }

n < 30.

The standard deviation was calculated usin6: s= -* *T --- - m ?, m ' F M " * " ~ .m -w n - _,y

--w fqy w a A '4Wu-duus2 a n msw wa- ~ vn ~n '---p i ATTACHMENT 5-3 Page 16 of 21 Table 4 Summary of 90-day and 17-yr Comtrescive Strencths of Corec Average Avere{c Compreccive Comprescive Compreccive Compreccive Strength, pci Strength Strength, MPa Strength Block Average psi Average MPa Ilo. 90 d ayc

• 17 yr 17 yr 90 dayc*

17 yr 17 yr 6 1360 2250 9 38 15 51 6 2270 15.65 6 2330 2280 16.06 15 74 7 2010 2200 13.86 15 17 7 2800 19 31 7 3770 2920 25 99 20.16 8 1770 4600 12.20 31.72 16 55 8 2400 8 4160 3720 28.68 25.65 9 1830 2560 12.62 17.65 9 3170 21.86 9 3110 2950 21.44 20 32 10 2390 3150 16.48 21.72 lo 2220 15 31 lo 3850 3070 26.54 21.19 1 I 6 M20' 3M Average of two tectc. -memff'% MGJAE.Af R%_.92W.FWN#W"COhW "NN'N" " "' ^ 7' "' '~

Viitad1&lZt3' 2r:Mdin y ATTACHMENT 5-3 e Page 17 of 21 we 6 6 Peinfercir.e. Static A.xial it.ai Test Pesults frr *. Tar Crouted aa ! T c r.la l f r. Pl aae s Ccncrete

c. cf taflure Averge e

Grut-LICXy. lar a palloat Lcad _ Pall

• g.'

Mr_ ce r c rc te_ YieldieE Blo:P poridir4 Ihtei-4nt g; y17 o r a e..,. 4;.c-t - Ic:th, in. 3.L,, L /D 3 75 "5 3 - -- 6 Mixture A 5 3 75 7.0 31.1 6 Mi.xture A 5 3 75 8.1 36.03 3 00 76.2 X 6 Mixtu.re A 5 3 75 11 9 5'e 93 9*o LC.c3 3 75 9,s.,. 3,gg 7c,; y 7 Mhture B 5 3 75 96 '3*59 c 10.0 1.'. 4S 99 1.,.0L 3.e5 gc x 9 75 ~ 1 ~~ 7 l'.1xture P s 2 50 63.*> 10 cystem A 5 3 75 12.C 53 35 10 Eycten A 5 3',') 11 5 51.15 11.6 Sc,7 ^ ~ y 1,ge p 5. f. X ~ 9 syster E 5 3 75 lh'5 b, ','0 X l p 3 75

11. 5 64.50 1L.5 6L.50 < 03 5r X

9 Systen -n s g,53 1p,7 ..e* c. C 5 3 75 11.5 51 15 o e, 8 p" 1'$r 3 1 X L Eystet C 5 3 75 1L.3 63 61 12 9 a y g.. sten C 2 60 25'0 X p[ ^ 60 PL.C 108.93 E L 8" 11C'10 ~~ r sten C C X 6 Mixture A 10 75 17.C 75 02 y 6 Muture. A 10 75 17*5 77'Fh C Mixtare A 1,- 7,c,

1,0 93 1.1 18.*

D E3 " X 7 Mtyturc r 10 7.5 15 5 68.95 X y 7 MSture e 10 7 *5 l's.5 50'95 15 5 '=~95 1C Eyrten A 10 7 *5 15*5 e=*95 X ~ 5 6"*95 15. ':- 5 " X r sten D 10 I*5 17*0 75't X I 1C S.'stm A 10 ~, X o ~.5 II.3 81 'O 17 7 7'*51 p 1e-3.-- t er C 10 M 15 C %...h X 4, ry:ter. - ste C 10 '/ 5 17 0 75*6r 1.c 71.17 y I I. l I l

• Tth cf ecne r'ullM frm test t 1. th

-G e Pvat-rarh ]L frr *9Tlrmiliin of high inlue. h %MNTaM3Wm.~+ A5MQ@Rt3!Q'$F&ysy q, - ~

W ?k{&EKkb?l$02%.s%WMTMf 4%Wuz ? %,s-snw u_,_, j , = _.. i y ATTACHMENT 5-3 Page 18 of 21 e 1 - 88 96 20 I es 72 (S 2x e s" 2 S 0 /^ i to (0.0 4 S 3 IN.,0.S) Z v s t s 21.24 S ~ - A B 003 002 00t 0 dis PLaEE u[NT, IN l I I l 1 0.762 O SOS 0254 C DISPL AC[ut NT, uu LEGEND A L/Os S O L/Dsto D L/Ds20 NOTE: E ACH CURVE REPkt$ENT$ AN AVE R AGE OF T WO TE S TS. A AND S ARE WINTURE DE58GNaTeoNs PULLOUT AND BAR YlELD LOADS VS DISPLACEMENTS i l FOR NO.4 BARS ANCHORED WITH MIXTURES A AND8 } PLATE 2 1620 321 ~ 1 A) -, wg.gc.,_,_ m,a ys w _ w mn w M ~v:;,nduin wnR 7?.,3 5 g; .a- ~

W#WN1NTSRS5EIWL'U$???* Ads !'$.:E76%NMc:r.W2l+LSsEdd?:cf2'Sd' f L-a ATTACHMENT 5-3 Page 19 of 21 20 66 72 SS e O S S e A Y at E E A 10 44.48 n 5 e c "g p ens E = y 8 1 T 4 b 22.24 A 0 O DI 002 003 dis *L ACE MENT, IN. 0

0. 2 S 4 0.5C8 0.762 D158L ACE ME NT, WW LEGEND A

L/Da S O L/Drto NOTE: E ACH CURVE NE PRE SENTS AN Avt R AGE OF T wo TESTS. A,B, AND C ARE SYST EM LE5iGN ATIONS. PULLOUT AND BAR YlELD LOADS VS DISPLACEMENTS FOR NO.4 BARS ANCHORED WITH SYSTEMS A, B, AND C 0.. IN PLATE 4 1 ~_.. ..,,.n_..-_=_a__

-k~)$E Nadv'ik.MZIMWN %$ M.GR# Air /~M24fMcwe. 2%. 1 ATTACHMENT 5-3 Page 20 of 21 t 4 U nlaentf*ici so u.u. c i.. v,... - DOCUMENT CONTROL DAT A. R & D n.,.,,s....,,,....,,,,,.6....,.....,,.,,,,,,,....,.......,,.,...,.....,...m......,,,.,~,e.,i...m<, ........,.co..,.c6.....c.,,o. i...........c,..., ,c.,,,,,,,.. .y Ur.classifici U. C. fac Engineer '<3tm:ny: Eyreri.:ent Ctation Vicksburg,liissic:1ppi j IULLO*7T EE31CTANCE OF PEII.TORCIL 1 ATC E"! EDI ED IN HARDENED CONOPIE o.. e...,.. o... c re r..... e o.a u.... a...> Final rcrort .-....,,,.,.............,.4....., Eichcri L. Sto,:e I i -o o,..... ..... o..... June 197 36 9 ...o.,o... ..o.....,o.......,=ww.s.... .. co,..c,c.e..~,.o i Miscellaneou: Paper C-74-12 f .. e.as. e, a E ....,.....,,,.,......... ~,........,,., ..,.,....,9 a. y s. pe..... s, s o =.,.,. as., Iqproved for public release; dictritution unlinited. .c.. r. 6.,.., .c,...,, ,, Office, Chief of Eni;ineers, U. S. Artc-i. .w. 6.- ~....... Washir.cton, D. C. . cre dircond-drille d into inss: concrete test ......2c, Holc; for er. beldin; reinforcic; bar:rr.) in 'ilsr.eter and deep encui;h to enbcd Co. h Tne hole: t ere 1 in. (T 5.': 6 deforried reinforcinr, t,:.rs tc depths of S. 6.10. and 20 r.cninal btr dian-blocks. cr.d ;b. eters. h.rtland-cenu.t grout.s enJ cennerejally availatit-e;, oxy-resin rystcns were irille nole.i. 10.dir.c synts were elloved to cure, used to e.nenor the tars in tne. ar.d tr.* reit.forcir.c bars vere axially leaded to deternir.e which bandit.g a6cnt effered In all ins, tar.ces, tl.e c;cxy-anchored reir.forcir.g bars the r.ar'. } ullout resistcr.ce. exhibi,ei rare rccictance to allout tinn did t'.c bars enrhored with the cc:c. cat cvaluate.1 in this inventliption are recomended for fruuts. Tae bonjing t;ent: rechorirr reinforcing barc in c1rille.1 ' ole in hsrdeaed nas: concrete; howcVer, r cert:In lir.it:'tlom arc steifle l for a 2ir usc. D* 0

• D'T b6 c

J n .....c . os,...... ,s.,......e.,, Unelassifies! DD,rona....] 4 / o..at. .....u... 5.cwenty CI...ifec.ts.n 1620 $23 - g T pa p, n g_,, g.,r/ufWIf*,'M@%QTT*\\: %E6.. %_MM_ C%4W v4W7..F. C._'7.s?,F.-- ~ 7 f m e

• '- = '-

1

d M v; y; nae w.7.d,. %qc.g.. f**. Xb. i l.hdt- : 1. ; ?- s. !lf t%.z.,'v.p, *

• h q,. ~,.. y..,,r : Q ; a.,';..

a,c i-: c: ;.* .c w'M;& M &im h.,f.r.. e . t1w _ u 2 p M. yt-0. % h 4, a y il 9,i n.. ud r M L. 1 r "c n. 7:, ' ~,.e < n M,,,, ~ c, ?;AOL..~ arm. g: fi p!. ? ATTACHMENT 5-3 1. Page 21 of 21 44 a [4 h 7 In accordance with ER 70-2-3, paragraph 6c(1)(b), dated 15 February 1973, a faccic:lle catalog card in Library of Corgress format is reproduced below. i-t '? i r, Stove, Richard I, Pullout resistance of reinforcira bars embedded in han$eced concrete, by R. L. Stove. Vicksburt;, U. S. Aq E;;ineer k'aternys Fxperiment Station, ISr/k. t 1 v. (various pagincs) illus. 27 cm. (U. S. Water-Miccellar.cous raper C-7k-12) ways Dperieent Station. 5 Sponsored by Office, Chief of Engineers, U. S. Arqy. Includes bibliography. '.g ' j

1. Anchorirc.

2. Bonding c. Cents.

3. Pass concrete.

4. Pullout resictance.

S. Reinforcing bars. I. U. S. Arry. Corps of Ereineers. (Series: U. S. Waterways j Experirent Station, Vicksburg, Miss. Miscellaneous yaper C-74-12) TA7.W3 m no.C-7 k-12 k ~ l 4 e i 1620 Y 4

ATT Page & of 6 t n,. e ]dKest Penn Testmg La<3 ora:ones, Inc. e An independens inspeccion Bureau and Tessing Latrorasary West Hornestead, Pennsylvania 1S120 I 482 West Eighth Avenue P.O. Box 324 + Area Code 412 462 3717 File No. WP-2002 March 14, 1978 Page 1 Report of REINFORCING BAR SHEAR BOND TESTING Susquchanna Steam Electric Station PROJECT: Pennsylvania Pcwer & Light OWNER: Research-Cottrell CONTRACTOR: March 10, 1978 DATE OF INSPECTION:. Scope To determine if the shear bond strength of grout uscd to anchor reinforcing bars could withstand loading as great or greater than the tensile strer.gth of the steel. Descrigt_i,cn of RpinforcingAnchorin:; i The The reinforcing to be tested were grade 60 deformed bars. ~ "Mo bars were anchored into prc-drilled holes of varying diaceters. One agent was different product s were used to achieve toe bcnd. The other agent 5-Star Grout, prcdvacd by U. S. Grout Corporation. was Sika Hi-Mod produced by Siha Chemical. Test Set-u2 All single Ears were testod using a calibrated 20 ton Holl-e ram Centerhole Jack (RCH 202 014) connected to a hydraulic pump throu;,h line prcosure. ItJo 8 inc$'e 10,000 lb. Test Gauge used to measurechanncis with t a Duragau The yohe was placed over the bar. wclded together to form a yohe. bearing on steci shircs cet at a distance of 10 inches on either The test jack was placel over the bar and set on side of the bar. A cadueld was placed on the bar over the jack to provice . the yoke. a rueans of applying the load to the bar. librated 50 t.on Enerpac Jack (RC 506 AHS)p was tested using a caconnected to The doubic tar set u A re-the Duragnuge Test Gauge used to reensure line pressure.inforced The beam had bearing on steel shims placed 10 inchet, of the bars. from the centerline, The test iack was centered on the beam. Tha yoke previously describcd was piaccd over the bars and cente on the jack. load transfer. e e 4

ATTACHMENT 5-4 Page 2 of 6 ?lest Penn Testing Laiora"ories, Inc. a e An independent inspection Bureau and Testing Laboratory 482 West Eighth Avenue West Homestead, Pennsylvania 15.120 P.O. Box 324 4 Area Code 412 462 3717 File No. UP-2002 Ibrch 14,1978 Page 2 REINFORCING BAE SHEAR B0!D TESTING Susquehanna Stcou: E1cetric Station Pennsylvania Power & Light Research-Cottrell thrch 10, 1978 Test Procedura In all tests a surcharge of 1000 lbs. uso applied to the com-plcted test apparatus for the purpose of scatinS all cozocnents. 1aad was relsased and all bearing dictances were recnecked. fne 'Ihc test load uns applied at a ccnstant rate until a load of 1257, of the bar design uas obtained, or until failure. In applicabic cases the maxin.ttu load uas held for 5 minutes then gradually re-leased to zero load. TEST RESULTS: 5-Star Grout Series Placcrl March 6, 1978 Test No. Bar Size Hole Size C_ogent 1

1. 7 2.75"x10d No failure at futi load of 45 060 lbs.

3 2

1. 7 2.75"x10" No failure at full load 3
2. 7 2.75"x10" No failure at full load 4
3. 6 2.75"n10" Double bar set up No failure at full' load of 61,120 lbs.

Toad iner ased to 69,000 lbs. D** ~ D'q-causing cracking in of A. concrete oo 5

1. 6 2.75"x10" No failure at fu'.1 lead of 30.560 6
2. 6 2.75"x10" No failure at full load 7
3. 6 2.75"x10" No failure at full locd

( g

= ATTACHMENT 5-4 Dage 3 of 6 West Penn Testing Laioratories, Inc. ,,. m An independens inspection Bureau and Tening Lab.~~*e*? 482 West Eighth Avenue West Homestead, Penn3y{gnitr/5g2 P.O. Box 324 4 Area Code 412 462 371;7circh 14,1978 Page 3 REINFORCII;G BAR SHE.\\R BOND TESTI!!G Susquchanna Steam Electric Section Pennsylvania Pcuer & Light Research-Cottrell March 10, 1978 TEST RESULTS: Siha Hi-Med _ Series Placed March 6,1978 Tcst No. Ba,r,Sice Hole Size Comment-No failure at full load 8

1. 7 2.75"v10" of 45,060 lbs.

Cracks evident en Siha product surface 9

1. 7 2.75"x10" No failure at full load No cracks 10
2. 7 1.25"x10" Failure et 37,500 lbs. loz 11
3. 6 1.00"n10" Failuro at 21,000 lbs. le:

The tests were perfor=cd by Ifr. D. Steiner of ticst Penn Testir.g Laboratorin, Inc.. Those in attendance at the tire of testing were Dr. P. Herren, Mr.11. Follen, Mr. A. CribSc, Mr. T. Patel represer. ting Research-Cottrell; !!r. R. Miller, Mr. m Griffin 3 Mr. J. Carulla and Mr. C. Fazendin representing Dechtel Corporation; Mr. F. D2cccrdi and Mr. J. D'Ambr2 representing G & H Stcul Service. Respectfully subrd.tted, 6c-mm .m N. D. Q cpbell ~w* o => IJEST PENN TESTING IABORATORIES, TUC. Cc: 3-Roscarch-Cottroll Mr. Coorge Gay Encl. ~ r620 327 0

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11RC Ouestions (9/14/79) O. 7 Page 1 of 5 Propose an inservice inspection program for the bolts to be used to provide for shear transfer between the new and existing structural elements. Provide and justify the bases on which it can be concluded that the proposed inspection program will provide assurance that the relied-upon bolt tensions will be maintained in all bolts throughout the life of the plant. Answer: An inservice inspection program for bolt tension will be con-ducted on new bolts included in the Control Building modifica-tion for which bolt tension is relied upon to develop the frictional force for shear transfer between new and existing structural elements. Although potential pretension losses in the bolts have been conservatively considered in the design (design based on an assumed loss of 25% of final construction pretension), the following inservice inspection program to verify bolt tension with time will be implemented: Control Building Modification Connection Bolts The structural adequacy of the bolts used to reinforce the Control Building shall be demonstrated at the end of 6 months and one, three and five years after initial ten-sioning and at five year intervals thereaf ter. Structural 1620.331

11RC Ouestions (9/14/79) O. 7 Page 2 of 5 adequacy shall be demonstrated by: a. Demonstrating that each bolt in a random and repre-sentative sample of not less than 25% of the total number of bolts has a tension of equal 1o or greater than 80% of the initial bolt tension. If the tension in any bolt is below 80% of the initial bolt tension, the tension in two adjacent bolts shall be measured. If either of these bolts is found to have less than 80% of the initial bolt tension, then all bolts shall be tested. All bolts found to have less than 80% of the initial bolt tension shall be retensioned to the original installation tension value. b. Demons tra ting the acceptability of the test sample by showing that E-20 is greater than 0.8xo, where ~x is the mean sample tension, o is the standard deviation and x is the mean initial bolt tension. If g this criterion is not met, then all bolts shall be tested to the criteria in (a) above. c. Determining that there is no evidence of degradation or abnormal conditions by visual inspection of the condition of all bolts in the sample, their end anchor-ages and concrete or masonry in the vicinity of the anchorage. d. If the bolts inspected during the first four inspec-tions meet the acceptance criteria of (a), (b) and (c), i620 33U?

!!RC Ouestions (9/14/79) O. 7 Page 3 of 5 then the sample for the subsequent inspections may be reduced to not less than 10% of the total number of bolts. This proposed inservice inspection program will provide an appro-priate evaluation of 1) the tension in the bolts at the time of the test, 2) the relationship of possible bolt pretension losses with time, and 3) the conditions of the concrete or masonry at the bolt anchorages. The acceptance criteria are based on assuring that the bolt design preload is maintained and that allowances for total time dependent losses are not exceeded. It is not considered necessary to establish limits for variations in the rate of pretension losces as long as the bolt tension at any point in time is equal to or greater than the design value. A random and representative sar.pling of 25% of all bolts will provide a suitable sample size from which a meaningful standard deviation can be determined, particularly since all bolts are of identical configuration ( s tra igh t through-wall, loaded in direct tension only with constant design preload values, all of the same material and diameter, and all of similar length). Also, the service environment for the bolts is essentially the same throughout. The acceptance criterion for an individual bolt test tension of equal to or greater than 80% of the initial pretension value f urnishes a margin against the 75% of initial pretension value that was used in design, in addition to the factor of safety 162nB 333

NRC Ouestions (9/14/79) O. 7 Page 4 of 5 of 2 provided in the bolt tension-shear transfer relationship. The bolt tension will be measured using calibrated test equip-ment that has an accuracy of at least 2%. The acceptance criterion for the entire sample requires that the sample mean ~ 2o ) be equal minus twice the sample standard deviation ( to or greater than 80% of the mean value of the initial bolt pretension (xo). This provides reasonable assurance that, as a minimum, 97.5% of all the bolts will have pretension values not less than 80% of the initial pretension value, still with a factor of safety of at least 2. The condition of exposed portions of the test sample bolts, end anchorages, and concrete or masonry surfaces adjacent to the end anchorages will be visually inspected during each test. The portion of the bolt within the wall will be wrapped with a tape, such as teflon tape on asphaltic base tape, to produce a bond breaker between the bolt and the grout. This tape will have no deleterious effects on the bolt or the grout and will serve to protect the bolt from corrosion. The time dependent behavicr of the bolts is expected to be an exponential function of time where most losses that will occur should occur relatively soon after the initial installation. The reduced sampling rate of 10% of the total number of bolts is predicated on the condition that the first four inspections (i.e., inspections at 6 months, and one, three and five years after initial tensioning) meet the acceptance criteria and thus show that the pretension losses in the bolts have stabilized as expected. The 10% sampling rate for subsequent inspections

NRC Ouestions (9/14/79) Q. 7 Page 5 of 5 is, therefore, suitable for confirmatory demonstration that bolt pretension loads have reached essentially constant values equal to or greater than the desian values. We believe that the proposed inservice inspection program will provide assurance that the bolt tension, in all bolts, which is relied upon to develop the frictional force for shear trans-fer between new and existing structural elements will be main-tained throughout the life of the Plant. 1620 35

NRC Ouestions (9/14/79) Q. 10 Page 1 of 3 Verify that the. computer program WECAN was used only for linear elastic analyses. Additionally, verify that the com-puter program verifications for the CYLNOZ, SPHNOZ and DESREV meet the requ'.rements of Standard Review Plan Section 3.9.1. II. Answer: In the reevaluation of equipment with response spectra based on the modified Complex, the computcr program WECAN was used only for linear elastic analysis. The equipment so analyzed was auxiliary mechanical equipment such as tanks, heat exchang-ers, and demineralizers. 1 The computer programs CYLNOZ and SPHNOZ were used only to calculate local stresses caused by external loadings in cylin-drical and spherical shell elements of auxiliary mechanical equipment. CYLNOZ and SPHNOZ were developed by the Franklin Institute, Philadelphia, Pa. and are based on the curves pre-sented in Welding Research Council Bulletin 107. The CYLNOZ and SPHNOZ programs have been verified by Westingbouse. Ve r i-fication was accomplished by comparing the stresses calculated by the programs to stresses determined directly from the curves presented in Bulletin 107. Good correlation was obtained be-tween the numbers calculated by the programs and those obtained from the curves. This method of computer program verifica-tion is consistent with the acceptance criteria for verifica-tion in Standard Review Plan Section 3.9.1. II. 2.c. 1620356

NRC Ouestions (9/14/79) Q. 10 Page 2 of 3 The DESREV computer program, which was used only in the reeval-uation of the CVCS holdup tank recirculation pump, performs static analyses of Gould's end-suction, foot-mounted pump as-semblies (which consist of pump, motor, coupling and base-plate). In addition to nozzle and seismic loads, loads created by pump operation are considered in the analysis of the functional capability and structural integrity of the pump, bedplate, shaft and hold-down bolts. These loads are also cons ide red in the analysis of the pressure retaining portions of the pump. The DESREV program solutions to a series of test problems are substantially identical to hand calculations, and program verification has been performed by Gould's Pump Company in accordance with the criteria of Standard Review Plan Section 3.9.1.II.2.c. In addition to the WECAN, CYLNOZ and DESREV codes, the post-processor routines ALLOW and COMPARE were used by Westinghouse in the re-evaluation of the spent fuel pool bridge crane. ALLOW is a routine which computes allowable stresses for linear supports, with input member section properties and geometry, in accordance with ASME Section III, Appendix 17 equations. COMPARE is a routine which combines the static, and three-direc-tional earthquake response results from WECAN and prints direct, bending, shear, and torsional loads and stresses, and the ratios of calculated stresses to allowable stresses. f620'N7'

NRC Questions (9/14/79) 12/15/79 12:30 PM DRAFT Q. 10 Page 3 of 3 Both ALLOW and COMPARE were developed by Westinghouse and verified by Westinghouse by comparison of results calculated by these routines with hand calculated results. This method of verification is in accordance with the criteria of Standard Review Plan Section 3.9.1. II. 2.c. I'620338-e

NRC Ouestions (9/20/79) O. 3 With regard to your September 5, 1979 response to question 22, provide the details of your determinatins of E (sub) shu and C (sub) u and justify all assumptions in detail. Answe r: (ultimate shrinkage strain coefficient) The quantities Eshu and C (ultimate creep coefficient) appear respectively in u the expressions for determination of the shrinkage strain (Esh) and the ratio (Ct) f creep strain to initial elastic strain for the new Complex walls. E and C are dependent shu u upon the characteristics of the aggregate used in the concrete. and C used in the September 5, 1979 re-The values of Eshu u sponse to NRC Question No. 22 were selected as repres'entative of the low strink and creep aggregate which will be used for the new concrete walls. However, as explained in response to NRC Question No. 2 of this set of questions, a significant degree of conservatism exists in the assessment of shrinkage and creep strains in the new walls. Therefore, any reasonably and C expected deviation from the specified values of Eshu u would not alter the design. 1620c339 \\

NRC Ouestions (9/28/79) O. 3. Page-1 of 2 Confirm that the required control room differential pressure requirements (Technical Specification 4. 7. 6.1.d. 3 ) can be continuously maintained with open drilled holes in the control room wall. Provide the basis for your conclusion. Also, con-f irm that these requirements can be met during installation of Plate 8. Answer: The referenced Technical Specification requires periodic verification that the Control Room emergency ventilation system, CB-1, is capable of maintaining a positive pressure in the Control Room relative to the outside atmosphere during certain specified events. As each hole is drilled through a Control Room wall it will be immediately closed with a temporary fireproof silicone foam tapered plug

• which has been pre-fabricated to eliminate set-up time.

This will provide an air-tight seal and will be done on removal of the drill bit. Thus, there will be no more than one 3" hole open into the Control Room at any one time, and that hole will be open for only so long as it takes to clear the hole and insert the plug. Therefore, the capability of the Control Room emergency ventilation system to maintain the required positive pressure in the Control

• These plugs will be formed using Dow Corning No. 3-6548 silicone fo am.

This material is fireproof, it is the same material used in sealing NCLPIA-rated barriers in penetra-tions at Trojan. 1620340

NRC Ouestions (9/28/79) O. 3 Page 2 of 2 Room relative to the outside atmosphere will not be effectively reduced. The silicone foam plugs will remain in place until installa-tion of Plate 8. When Plate 8 is installed, the plugs will be removed one at a time, and a through bolt will be installed before the next plug is removed. The plate washer will be placed in position and, in order that grout can be placed behind it, will be shimmed one inch from the wall. A metal form for the grout will then be put into position around the plate washer. Prior to placing the grout between the plate washer and the wall, the seal will be maintained by installing an "O" ring type seal, made of the same material as the plugs, above the bolt to seal the existing gap between the steel washer, the steel form for the grout, and the wall. This "O" ring will be removed immediately before placing grout behind the washer. P.7 ant operators will be instructed with respect to the instal-12 tion of the plugs and "O" rings should such become neces-sary. Spare plugs and "O" rings will be provided for such purposes. ) E

FRC Ouestions (9/28/79) O. 7. Page 1 of 10 In reference to your September 5, 1979 Structural Branch response number 4, it appears that a considerable amount of concrete is to be removed from the electrical auxiliaries room floor along column line N' in order to properly attach the added wall in the Control Building railroad bay to the existing structure. With the aid of drawings, fully describe and discuss the following: (a) The equipment that will be employed to remove the exist-ing concrete shown in Figure 4-1. (b) The equipment to be employed in drilling the 1-inch holes in the existing 12-inch thick precast floor slabs. (c) The specific equipment that will be employed to preclude the spreading of dus t, grit and debris generated during the above work, e.g., water sprays, evacuation fans, periodic clean ups and/or isolation of the work area by temporary barriers. (d) Indicate the location and describe the safety-related functions of all electrical auxiliaries room equipment located within the area of influence of construction-generated vibratory motion, water, dust, crit and debris. (e) The reason why you conclude that the construction acti-vities being carried out in this room will not impair the operability of the permanent plant equipment located in the electrical auxiliaries room. 1620 342

NRC Ouestions (9/28/79) O. 7. Page 2 of 10 Answer: In addition to the removal of floor slab concrete along column N' at el. 65', this answer addresses removal of the concrete encasement from Column 41R between el. 65' and el. 77', as well as cutting of rebar and Cadwelding necessary to tie in rebar at that location. These two activities will not be conducted concurrently. The answer describes the work to be done and the protective measures to be employed by Licensee to assure that such work will not affect safety-related cables or equipment in the Electrical Auxiliaries Room. Des ign details for the modification work are now being completed. It is possible that, as these details are finalized, work of a nature similar to that described for column 41R will be required at columns 46R, 46N and 41N at various elevations. If this is the case, the techniques described in this answer will be em-ployed to provide the same protective measures at these other locations. In order to properly tie the new N' wall to the existing struc-ture, certain preparation is necessary at el. 65' along Column line N'. Figures 7-1 and 7-2 show the area where this work vill be done. The floor slab will be prepared to insert rebar U-bends to provide dowel action between this slab and the top of the N' wall below. A diamondtipped concrete saw will be used to cut grooves 2" deep by approximately 24" long into the concrete floor topping where each hoop will be be placed.*

• This reflects a change from previous response (dated Sept-ember 5, 1979 to NRC Staff Question No. 4,) which indicated a trench would be dug.

1620 343

NRC Ouestions (9/28/79) Q. 7. Page 3 of 10 The grooves will be cleared by using a hand-held chipping hammer. A diamond tipped core drill will be used to drill through the topping and precast floor panels at each end of the grooves. The tendons in the precast floor panels are spaced at regular intervals within each panel. The two panels af fected by this work will be surveyed prior to drilling to ensure that no tendons will be cut during the drilling operation. Upon completion of rebar installation, the concrete topping over the rebar will be restored with concrete or non-shrink grout. The location of the safety-related equipment and the equip-ment's orientation to the construction work along Control Building column line N' is shown on Figures 7-1 and 7-2. A description of the functions of the safety-related equipment located along column line N' are listed below: 1. 125 Volt DC Control Center - D20X/D40X D20X/D40X is a 125 volt DC control centet that consists of two main circuit breakers. This equipment provides an alternate means of serving the 125V DC distribution busses D20 and D40 if the main power source to the 125V DC distribution busses is removed from operation for maintenance. 2. Battery Chargers - D22 and D24 D22 and D24 are battery chargers for the train B 125 Volt battery. l620'344

NRC Ouestions (9/28/79) O. 7. Page 4 of l0 3. 125 Volt DC Distribution Panels - D20 and D40 D20 and D40 are 125V DC distribution panels that provide power to various train B safety-related equipment throughout the Plant. 4. 120 Volt Preferred Instrument AC Panels - Y22 and Y24 Y22 and Y24 are the train B 120V AC power source for the safety-related instruments and electrical circuits through-out the plant. 5. Static Inverters - Y26 and Y28 The equipment Y26 and Y28 are the train B plant inverters that supply the associated preferrred ac buses Y22 and Y24 with power. 6. Solatron Line Voltage Regulators - 036 and 038 036 and 038 are line voltage regulators that are used to regulate the voltage serving the train B Nuclear Instrumentation System equipment. 7. 480 Volt AC Motor Control Center - B26 B26 is a motor control center that supplies power to various train B loads associated with the Service Water System, Component Cooling Water System, Safety Injection System, Containment Spray System, and the RHR System. 8. Electric Unit Heater - VW188 VW188 is an electric heater that serves the train B battery room. 4 1620 345

NRC Ouestions (9/28/79) O. 7. Page 5 of l0 9. Train B Battery The train B 125 Volt DC battery provides back-up power for control of safety-related equipment in the Plant. The other equipment identified on the sketch that is not in the above list is nonsafety-related equipment. This nonsafety-related equipment consists of the plant computer inverter (Y30) and 120 Volt AC instrument busses (Y02 and Y03). Dust, dirt, grit, and debris generated in the floor slab pre-paration will be controlled such that it will not affect any of the listed equipment or any other safety-related equipment in the Electrical Auxiliaries Room. During the drilling opera-tions, water spray will be used to lubricate and cool the diamond-tipped drill. This water will eliminate any dust generation. Water will be mopped up as the drilling is done. Any dust generated during the very limited chipping on the floor slab concrete will be controlled by water sprinkling the area being worked on and/or use of a shop vacuum as the work is being performed. During the work, concrete debris will be con;.nuously cleaned up and removed from the area using brooms and dust pans. The small chipping hammer to be used will not generate vibratory motion sufficient to affect any safety-relt 'ed equipment in the vicinity of this work. In o': der to tie the R line wall into the existing structure, it sill be necessary to completely remove the concrete and 1670.3k6-

NRC Ouestions (9/28/79) Q. 7. Page 6 of 10 block encasement from Column 41R, cut away some of the existing rebar near the Column, and join the new rebar with existing re-bar by Cadwelding. The area where this work is to be done is shown on Figures 7-1 and 7-3. A concrete saw will be used to cut a vertical groove approxi-mately 1/2" deep along the boundary of the section of the wall to be removed. A pavement breaker will be used to remove the majority of the concrete encasement. Licensee now plans to use a 60 pound pavement breaker to do this; consistent with Licensee 's response, dated November 21, 1979, to NRC staff question No. 5, dated September 28, 1979. A chipping hammer will be used to remove the smaller pieces. A hand or electri-cally operated wire brush will be used to clean the steel, concrete and masonry surfaces. After the concrete encasement has been removed, a cutting torch will be used to cut some of the existing rebar near the column. The new rebar to tie the wall to the existing structure will be joined to the existing rebar by Cadwelding. (See Figure 3-2 of Licensee's response dated June 29, 1979 to NRC Staff question No. 3, dated May 18, 1979.) The removal of the encasement will begin and be mainly per-formed outside of the Control Building. Only that portion of the work that cannot be effectively reached from the exterior will be done from inside the building and enclosure. l k7

NRC Ouestions (9/28/79) O. 7. Page 7 of l0 The removal of the concrete encasement from Column 41R will cause an opening in the R line wall between the Turbine Build-ing and the Electrical Auxiliaries Room. This opening will be approximately 1 foot wide and extend from el. 65' to el. 77'. Removal of the concrete encasement will generate some dust, and the cutting and Cadwelding operations could generate smoke which could af fect the smoke detectors and safety-related equipment in the Electrical Auxiliaries Room. To protect the safety-related equipment from the dust and smoke generated by the work, Column 41R will be isolated from the Electrical Auxiliaries Room by a, dust-tight flameretardant enclosure. The location of the enclosure is shown on Figure 7-3. The enclosure will extend from the 65' floor slab up to the under side of the 77' floor slab to enclose an approximate 5' by 5' area within the Electrical Auxiliaries Room. It will be constructed with a man-door for access to the 41R column from the Electrical Auxiliaries Room. The enclosure will be so erected that it will be a sufficient distance from the work face to allow access for performing the work. This enclosure will be built of light lumber and fire-retard-and plastic. The lumber for the enclosure framework will be treated with the "Flamort-WC" fire retardant. The plastic material to be used is "Griffolyn 75", which has been approved by the Plan t's insurers, American Nuclear Insurers. 0 g t e % 9

NRC Ouestions (9/28/79) O. 7. Page 8 of 10 It will be anchored to the walls, floor and ceiling to pre-clude the possibility that it might fall and damage the safety-related equipment in its vicinity. A fan will be located on the Turbine Building side of R wall and directed toward Column 41R so that the dust and smoke will not enter the Turbine Building. These measures will assure that dust and smoke generated by work on column 41R will not enter the Electrical Auxiliary Room, or the Turbine Building and will be forced to the outdoors. A desc-iption of the safety-related and nonsafety-related equipment located in the crea of contruction work at column 41R is listed below: 1. 120 Volt Preferred Instrument AC Panels - Yll and Y13 Yll and Y13 are the 120V AC power sources for train A safety-related instruments and circuits throughout the Plant. 2. Plant Static Inverters - Y15 and Y17 Y15 and Y17 are plant inverters that supply the train a preferred ac busses Yll and Y13 with power. 3. Solatron Line Voltage Regulator -035 and 037 035 and 037 are line voltage regulators that are used to regulate the voltage to the train A Nuclear Instrumentation System equipment. 1620 349

NRC Ouestions (9/28/79) O. 7. Page 9 of 10 4. Battery Charger-D21 Battery charger D21 is utilized with the train A 125 Vblt DC batte ry. 5. Cable tray - ABA288 ABA288 is a train A safety-related electrical cable tray. The function of the train A cables contained in this cable tray have been described in the response to the NRC's question no. 4 dated July 20, 1979. 6. Transformer - X56 Transformer X56 is not safety-related. It provides the primary power to the rod control system. 7. Voltage Regulator - 039 Voltage regulator 039 regulates the voltage to the rod control system and is nonsafety-related. 8. Enclosure - NTB109 The enclosure NTB109 is nonsafety-related and contains a device that eliminates high voltage increases to the rod control system. 9. Cable tray - NBA346 and NBA360 MBA346 and NBA360 are nonsafety-related cable trays. The function of these nonsafety-related cables contained in these cable trays consists of power supplies to nonsafety-related instrumentation, control room alarms associated with the turbine generator, and 1620L350'

NRC Ouestions (9/28/79) O. 7. Page 10 of 10 control of the normal Control Room HVAC system. In view of the precautions being taken, neither cutting nor Cadwelding of rebar poses any risk to safety-related equipment in the Electrical Auxiliary Room. The cutting of the rebar will be done by either electric arc or oxyacetylene torch. The Cadwelding operation creates a large amount of heat in a local area but there is little, if any, fire potential since the heat is confined to the Cadwelding sleeve. Sparks are generally not released outside the Cadwelding sleeve and those few that may escape will f all straight down. Fireproof blankets (of the same types previously indicated for protec-tion against other cutting and welding) will be utilized in the area of the cutting and Cadwelding of rebar to provide additional protection to the enclosure and any equipment in the vicinity. Prior to any cutting or Cadwelding on the 41R Column, a " Welding and Cutting Permit," as described in Licensee's Response to NRC Staf f Systems Branch question 12, July 20, 1979, must be obtained. Among other things mentioned therein, this permit requires that a fire watch be stationed in the immediate vicinity of the work. This fire watch will remain at his station for at least 30 minutes after completion of the welding or cutting operation. In addition, as explained in response to NRC staf f question No. 4, dated September 28, 1979, a fire watch patrol will inspect the area of the en-closure on an hourly basis as long as the enclosure is erected. 8 G i620351

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NRC Ouestions (10/2/79) Q. 1 Page 7 of 7 The reduction in area due to the drilling of bolt holes e. at any period of time will not be more than that described in Licensee's response dated June 29, 1979 to NRC Ouestion No. 30. The above condition will be assured by stoppir.g the drilling whenever the area reduction percentages reach the limits set in the above referenced response. 1621'do)

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NRC Ouestions (10/2/79) O. 8 Your July 6 response to question 45 indicates that the stiff-nesses incorporated in the STARDYNE analysis were derived from the test results for specimens L1 and L2 which implicitly had incorporated into them the ef fects of the embedded frame. These were referred to as upper bound stiffnesses. Your July 10 res-ponse to question 46 illustrates that the frame was considered as additional reinforcing steel. Justify this seeming double consideration of the steel framing. Answer: In response to NRC Question No. 45, dated July 6, 1979, it was stated that although the bond between the embedded structural steel columns and the surrounding concrete was ignored for the capacity evaluation of the Complex Walls', the contrib'ution of the steel framing was considered in the stiffness determination to provide an upper bound stiffness of the Complex. The stiff-ness reduction curves given in Appendix B of PGE-1020 include the stif fnesses obtained from test specimens L1 and L2 by trans-fo rming the effect of the steel columns and their anchors to ad-ditional vertical reinforcing steel. This trans formation pro-cedure is explained in response to NRC Ouestion No. 46(b), dated July 10, 1979. The responses to the two dif ferent questions, therefore, are complementary to each other. Thus, the contri-bution of the steel framing has not been inappropriately con-s id e red. 162t 003

NRC Questions (10/2/79) Q. 11 Page 1 of 2 Provide the properties of the grout which will be used for pur-poses other than the grouting of additional rebar. Justify the adequacy of the grout to perform its intended function. Answer: The same grout (Five Star) used for anchoring additional rebars will be used in all instances where grouting is required for the modification program. Licensee's response dated December 17, 1979, to NRC Staff Question No. 1 dated October 2, 1979 addresses the adequacy of this grout for restoring abandoned drill holes. Licensee's response dated December 17, 1979 to NRC Staff Question No. 7 dated September 14, 1979 discusses the lack of deleterious effects of the grout on the through-bolts for the steel plate. As discussed in Licensee's response dated July 6, 1979, to NRC Question No. 6(C), bolt losses due to creep in the grout are conservatively taken as 2.0 times the elastic deformation. Shrinkage losses need not be considered since testing to CRD-C588-78 shows that Five Star Grout does not exhibit significant shrinkage after hardening. Th(cefore, the use of this grout is adequate for placement around the through-bolts. Grout will also be placed between the steel plate and the block wall on line R, behind the bearing plates, and also at the top of the new walls where they connect with a slab above (walls R and N at el. 65' and 77', and wall N' at el. 65'). In e.ll of these applications, the grout is used only as a medium for force transfer. It is merely the extension of the concrete b62100k'

NRC Ouestions (10/2/79) Q. 11 Page 2 of 2 or block with which it forms an integral part, and after hardening it has the properties of normal concrete. Tests performed in accordance with ASTM C109 have established that Five Star Grout has a compressive strength of at least 8000 psi at 28 days, which is well above the compressive strength of the block or concrete. 1~621 00$

NRC Ouestions (10/2/79) Q. 19 (a) Your September 15 response to question 29 is not adequate. a) State the codes used in the design of the anchorages for the bumping posts and the allowable stress limits. Answer: The codes used in the design of the anchorage for the bumping post are: Reinforced concrete - ACI 318-77 Structural steel'- AISC Manual of Steel Construction, Seventh Edition, including all supplements issued to date. Stress limits used in the design of the bumping post anchor-age were taken as the applicable basic allowable stress limits. Increases in allowable stress limits, where permit-ted by the codes for impact conditions, were not utilized. 1621 pf)6

NRC Questions (10/2/79) Q. 19 (b) Page 1 of 2 b) At each of the assumed ductilities, summarize the stresses in the compression members of the post and the correspond-ing allowable stresses, along with the basis for the allow-able stresses. Answer: As described in the September 15 responsc to Question 29, in order to respond to the request for a parametric representa-tion of the energy absorption characteristic of the bumping post, ductility ratios were selected to provide the basis for calculation of contact velocities of unloaded and loaded flat-cars hypothesized to impact the bumping post. The force in each of the compression diagonals (W8X40), corresponding to the load on the bumping post which produces yield in the ten-sion diagonals, is 352 kips and the compressive stress is 29.8 KSI. The elastic buckling load capacity fcr the com-pression diagonal was obtained by multiplying AISC Code equation 1.5 - 1 by the factor of safety (about 5/3) and the compression crosssectional area. For this calculation, the effective length coefficient, K, was conservatively taken as 1.5 to represent an upper bound value (since the compression diagonal ends are restrained in all directions at the location where the load is applied, a K value of 1.0 would probably be more representative). The elastic buckling capacity of the compression diagonal, calculated as described, is 393 kips and the corresponding compressive stress is 33.3 KSI. 4 e 161f1 007

MRC Ouestions (10/2/79) Q. 19 (b) Page 2 of 2 At the location where the flatcar draf t gear would engage the bumping post the horizontal load which produces yielding of the tension diagonal is less than that which would cause elastic buckling in the compression diagonals and ductile behavior of the bumping post is available. Within the range of displacements corresponding to the ducti-lity ratios considered and once yielding in the tension diagonals occurs, the load on the bumping post and in each compression diagonal remains essentially constant. At the load level which produces yield in the tension diagonals, the horizontal displacement of the bumping post at the locat-ion of impact is approximately 0.12 inches. For the maximum ductility ratio considered, p = 10, the corresponding horizontal displacement would be only 1.2 inches. The ef fects on bumping pocc force distributions associated with changes in geometry for displacements of this magnitude are insignificant. For all practical purposes, the loads and stresses in the compression diagonals at all ductility ratios can be considered to be equal to those occurring at the bumpi ng-'pos t load level which causes tension diagonal yielding, as described above. f621y08

NRC Questions (10/2/79) Q. 19 (c) c) Provide the bases for your determination that all connec-tions are adequate to develop the stated ductilities. Answer: As described in the response to Question 19 part (b), the loads in the bumping post in the inelastic range, for the range of ductility ratio considered, are essentially independent of the ductility ratio and the stresses in the bumping post and connections are, for all practical purposes, bounded by the magnitude of stress induced by the load on the bumping post which causes yielding in the tension diagonals. External connections for the bumping post were designed to code basic allowable stress limits without using the permitted increases in these stress limits for impact conditions. The bumping post design does not utilize internal connections to transmit impact loads (see the illustrations attached to the response to Question 19, 7/20/79). Tensile loads are developed by the one-piece yoke which is fitted to the impact head assembly. Loads are transmitted between the tension yoke and head assembly by direct compression. Reinforcing plates are added at the location of the attachment bolt to assur e that the tension yoke cross-sectional area is maintained at the bolt hole. The bumping post compression diagonals are boxed in by steel plates and connected directly to the impact head such that pr imary load transfer is developed through direct compression between the compression diagonals and impact head. Thus, the capability of the bumping post to develop ductile performance is not limited by connection capacity. 6 Di)9 ~

NRC Questions (10/2/79) Q. 19 (d) d) Describe how the actual strength of the steel (vs. Code allowables) and strain hardening and strain rate effects are factored into your evaluation and design. Answer: Evaluations of the bumping post capacity and the design of anchorage were based on either the applicable Code recommended ica ter ial strength parameters or values which were conservative relative to the Code allowables. In general, it is not neces-sary to consider second order ef fects, such as material strengths which could be greater than those specified, strain hardening or strain rate ef fects, because their influence.on results is generally small and self-compensating. In the case of the bumping post, the load resisting system is simple, i.e., basically tension and compression truss action. Since these secondary ef fects are essentially linear in terms of both tension and compression capacity, the conclusions regarding structural performance would not change. Strain hardening and strain rate effects were not considered in the anchorage design for the bumping post because the anchorage capacities would be increased in essentially the if those same proportion as the load on the bumping post effects were considered. The increase in the capacity of the connections due to impact loads, as permittted by the codes, was not used in the design. .}}