ML19289A564
| ML19289A564 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 11/20/1979 |
| From: | SARGENT & LUNDY, INC. |
| To: | |
| References | |
| SL-3753, SL-3753-V1, NUDOCS 8004090212 | |
| Download: ML19289A564 (95) | |
Text
{{#Wiki_filter:P I N UCLE A R S AFETY-- REL ATED EVALUATION OF IN-PLACE CONCREFE hlARBLE HILL NUCLEAR GENERATING STATION UNTFS 1 AND 2 E 'b REPORT PRE PARED FOR PUBLIC SERVICE COh1PANY OF INDIANA, INC. VOLUME l (fbk b\\ 3 RE PORT SL-3753 NOVEMBER 20,1979
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! SARGENT&LUNDY L= = - -- e~o,~cene 800.4090212
K ENNETH T. MOS TA L m-a... m, November 20,1079 Mr. S. W. Shields Vice President of Electrical Systems Public Service Indiana 1000 East Main Street Plainfield, Indiana 46168
Dear Mr. Shields:
Enclosed are thirteen copies of the following report: Report SL-3753 Evaluation of in-Place Concrete Marble Hill Nuclear Generating Station Units 1 and 2 Dated November 20,1979 This report contains our evaluation of the test results of the in-place concrete at Marble 11i11 and our conclusion that the quality of concrete is acceptable. The report is divided into two volumes: Volume I contains the main.'eport and Exhibits 1, 2, and 4 through 7. Volume 11 contains Exhibit 3 which is the Portland Cement Association
- report, if you have any qt.cstions or comments, we will be glad to discuss them with you.
Your v ry tru y, K. T. Kostal Assistant Manager Structural Department KTK:rg Enclosures _,,,,,ms-n.xn==im=m=s=*>=== ' " " " " " " " " " " " " ~ " ' ' ' ' ' v I
e 4 l ~ NUCLEAR SAFETY-RELATED l 2 1 EVALUATION OF IN-PLACE CONCRETE MARBLE HILL NUCLEAR GENERATING STATION L UNilb 1 A~ND 2 =, I i J REPORT PREPARED FOR ^ _j PUBLIC SERVICE COMPANY OF INDIANA, INC. 7 ) VOLUME I L m i 1_ =_ a ) REPORT SL-37S3 NOVEMBER 20,1979 t _J ~ ~ SARGENT&LUNDY J ENGINEERS l
- ~ ~ - . -. ~, 11-20-79 PAGE' I INTRODUCBON 1 I A. Statement of Problem and Solution Methodology 1 B. Summary of Test Results 1 C. Conclusions 2 II DISCUSSION 2' A.
Background
2 B. Concrete Discontinuities 3 l C. Concrete Under Examination 4 D. Sample Selection 4 III STATISTICAL BASIS FOR TESTING PROGRAM 4 A. Methodology 4 B. Overall Concrete Quality 6-C. Selection of Test Locations 7 D. Acceptance Criteria from a Statistical Standpoint 7 Table 111-1 Sampling Program for Overall Concrete Quality 8 IV TESTING PROGRAM 9 A. Description of Pulse-Echo Technique 9 B. Qualification of Test Equipment 9 C. Location of Test Areas 10 D. Pulse-Echo Test Results 10 E. Coring of Questionable Areas 11 'l' il SL-3753 N
11-20-79 PAGE V DlbCUSSION OF RESULTS 12 A. Acceptance Criteria 12 B. Evaluation of Test Results 12 VI ?)lSCUSSION OF PATCilED AREAS 13 A. Surface Defects 13 B. Repair of Patched Areas 14 VII DISCUSSION OF Tile VOID IN THE AUXILIARY BUILDING SLAB 14 A.
Background
14 B. Repair of The Vold 15 - ill _. SL-3753
11-20-79 1 - NRC Letter Addressing the Marble Hill Concrete 2 - Drawings Defining Test Areas 3 - Portland Cement Association Iteport i 4 - List of Test Areas 5 - Photographs of Core Samples 6 - Newberg Procedures 7 - Location of Vold in Auxiliary Building Slab w i c-iv SL-3753
i 11-20-79 a EVALUATION OF IN-PLACE CONCRETE I MARBLE HILL NUCLEAR GENERATING STATION - UNITS 1 AND 2 -i PUBLIC SERVICE COMPANY OF INDIANA, INC. j 1 'l i INTRODUCTION i -I A. Statement of Problem and Solution Methodoloot 3 ~ %e Nuclear Regulatory Commission has expressed concern that the repairing of ] honeycombed areas in the concrete of Marble Hill Category I structures has not J been donc properly and that, in general, the concrete may not be of a high quality. The Portland Cement Association (PCA) was retained.to perform nondestructive examination of in-place concrete. Sargent & Lundy (S&L) was 7 L retained to independently specify the ',est areas, to review the testing program, and its results, and to assess the quality of the concrete work. -= A nondestructive examination of in-place concrete has been performed on a statistical basis as required by the NRC in its letter of June 27, 1979 (Exhibit 1). A total of 60 areas representing congested and noncongested locations in the structures have been examined using the pulse-echo and a through-transmission testing methods. These methods are capable of loeding j the following discontinuities in concrete: lack of bond between concrete and robar; separation of layers of concrete (lamination); excessive entrapped air; j honeycombing or voids. Some discontinuities are inevitable in concretc [ construction. If they are localized and limited in size, they will not affect the strength, durability, or leak-tightness of the concrete. The primary objective of l this examination is to provide assurance that there are no excessive discontinu-itles that would impair the structural integrity or the shielding capability of concrete structures. l B. Summarv of Test Results The nondestructive examination indicated that 24 of the 60 areas examined had some form of discontinuity. A thorough investigation of these areas by the PCA, using design drawings, shop drawings, and a review of the construetion PROJECT 4808-00 i _. _ SL-3753 ?
m i -1 11-20-79 J sequence and embedded field-routed piping with the field personnel, provided explanations for the pulse-echo readings indicating possible discontinuities in 16 of the 24 areas. The suspected discontinuities were localized and were attrib'ated to reinforcing steel congestion, embedded pipes, and structural or r - reinforcing steel supports for structural items embedded in concrete. Such localized discontinuities are not detrimental to the quality of the concrete and i" are common in concrete construction. U In the remaining eight areas, core samples were taken to determine the nature of the discontinuities. The core samples confirmed that all discontinuities were toe to excessive entrapped air. De cores were tested for compressive strength, and the test results ranged between 5,950 psi and 7,800 psi for the concrete placed in areas requiring a 3,500 psi design strength and tetween 6,750 e psi and 8,550 psi for the concrete placed in areas requiring a 5,500 psi design
- wj strength. The average unit weight measured 148 pef and ranged between 145 w
[ pef and 152 pef. This meets the shielding density requirements, since it is 1 greater than the expected average unit weight of 145 pef. %erefore, the PC A has concluded that no defective areas were observed in the field examination of the 60 areas. On a statistical basis, these tests assure with a high degree of confidence that the concrete placement at Marble Hill meets both the structural integrity and biological shielding requirements. C. Conclusions i Based on the review of the investigation carried out on the in-place concrete, [ S&L has concluded that the quality of the concrete in the structures at Marble ] Ilill Station is acceptable. Berefore, no further destructive or nondestructive [ testing is required. L 11 DISCUSSION A.
Background
The concern that proper concrete placement procedures may not have been used in the concrete structures of the Marble Ilill Station arose when allegations of ~ ?
l> 3 11-70 TE j improper and unacceptable repairs of surface defee a were made by Mr. Cutshall, a former employee of Gust K. Newberg, Subsequent inspection of the repaired honeycomb areas confirmed the improper procedure charges. In addition, a large cavity was discovered below a portion of the auxiliary building base slab. While local honeycombing and other surface defects are not i uncommon in construction and do not jeopardize the strength, durability, or radiological shielding capacity of the concrete, excessive internal volds in the y concrete are not acceptable. Recognizing this, Public Service Company of =! Indiana ordered a 6etailed examination to assess the condition of the in-place concrete. PCA performed nondestructive and destructive testing on the j concrete structures at locations specified by S&L. I 9 j This report describes the statistical basis for the testing program (Section III), the nondestructive testing program (Section IV), and the results of the destructive and nondestructive testing (Section V). Repairs of the patches are discussed in Section VI. The large cavity found below the auxiliary building base slab will be repaired using the proper procedures described in Section VII of this report. B. Concrete Discontinuities The term " discontinuity" in this report means a locus of certain abrupt property j change. Basic forms of discontinuities are defined below. F' Lack of Bond - A reduction in shear transfer capacity between the rebar I and the concrete. L i[ Separation or Lamination - An interface between two pours of concrete L with limited capabilities of load transfer. lionevcombinz - An cecurrence of mortar not completely filling the space between the coarse aggregate particles. Entrapped Air - Air in the form of small bubbles dispersed throughout the concrete matrix during placement. _ SL-3753 m '. i
m W 11-20-79 C. Concrete Under Emmination ] Due to the large void found below the auxiliary building base slab and the sur-face honeycombing observed in the concrete work, the quality of construction j has come under question. Lack of consolidation in concrete, resulting in honeycombing or voids, is more likely to occur in areas congested with rein- ] force ment. It is for this reason that half of the areas selected by S&L for l~ testing are areas of congested reinforcement. i 3 D. Sample Selection Concrete structures were examined by selecting a representative sample of 60 locations from congested and noncongested areas. The statistical basis for this i__ sample, the test locations, and the results of the examination are described in subsequent sections. til STATISTICAL BASIS FOR TESTING PROGRAM n A. Methodolocv i j The pulse-echo test indicates either the presence or the absence of concrete _I discontinuities (e.g., voids). If a discontinuity is present, the acceptability of that concrete depends on the size of the discontinuity. The testing procedure
- j for examining for discontinuities is of a " pass /no pass" type, depending on the
{ acceptability of the discontinuity, l_f the discontinuity is unacceptable for j structural or shielding reasons, the sample is termed " defective." The quality of the entire population is determined by testing a random number of samples. The statistical program for this type of testing is known as " sampling by at tributes." The appropriate number (n) of samples to be tested depends on the size of the a population (N), the confidence level (C), and the acceptable maximum fraction _j of defectives (p) in the population. By testing a number of random samples [ (n out of population N), we can establish with~ confidence C that the maximum I i' 1 E [ - SL-3753
l 11-20-79 ] fraction defective is p if the observed number of defectives is r, using the !j following equation:' (Np\\ j Nq p [ C=1-t x) n-x x=0 N I n (1) In the above equation, q = 1-p and the permutation symbol means n n! (N )! L in this testing program, the values of p, C, and N are given and the equation is solved for n. I i If n is small relative to N, equation (1) can be approximated by iL i [ C=1-[ p*qn-x x=0 (2) 9 The following statistical testing program is developed to establish with 95% i reliability and 95% confidence level, as required by the Nuclear Regulatory Commission (Exhibit 1), that the concrete quality meets the design require-m ents. Using equation (2) and the above parameter values, the number of ~ samples, n, required te establish the quality of concrete has been calculated. As an example, with C = 0.95 and p = 0.05, n is calculated as 59 for r = 0. e ) As a first step, a sample of 59 areas is to be tested. In order to establish with a [ confidence level of 95% that no more than 5% of the population is defective y (i.e., reliability of 95%), none of the samples should fail the test. The sampling j program is sequential in that if a defective area is encountered in the first 59 samples, the sample size is increased to a total of 93, in this larger sample, _f there should be no more than one defective samole. Table III-1 gives the ~ sampling program. 1j
- A. li-S, Ang, and W.II. Tang, Probability Conecots in Engineering Planning and Design, Volume I, "Dasic Principles," John Wiley & Sons, Inc., New York, New York.
1975, p. 361. = SI,-3753
_= 11-20-79 j B. Overall Concrete Quality ~~ q t es in c nerete. Concrete cons et o i such that there are su 1 y s al discontinulties in the form of entrapped air and laminations around rebar, rebar ' splices and embedments. The collective experience of the engineering ] profession is that such discontinuities do not edversely influence the structural = integrity, durability, and leak-tightness of the concrete. Therefore, the objective of the testing program is to ensure with a high confidence level that = no excessive discontinuities are present in the concrete placed at the Marble Hill Station. This is achieved by the statistical testing program described here. r-( The pulse-echo test is performed over an area ranging in size from 10 to 100 i square feet. The concrete of this area is examined for discontinuities. This [ volume of concrete is denoted as a unit of concrete. Here are a large number ] of such units in the concrete placed at the Marble Hill Station so that the use of equation (2) is appropriate for calculating the number of units to be examined. -] Furthermore, if the area exhibits unexplainable discontinuities at the boundaries .J of the test grid, further readings are taken to define th; extent of the discontinuities. The sample size for establishing with 95% confidence that no y more than 5% of the population is defective is given in Table 111-1. De testing procedure is as follows: j_ e Identify and test at least 59 locations (units). j e If there is no defective unit observed, stop further testing. -f elf one defective unit is observed, increase the sample size to 93 units. 1 J eIf no further defective units are observed in this increased sample, stop further testing. J l 91f more defective units are observed, further testing of random samples must be done according to the sizes shown in Table III-1. I i 1 -6. _ _ __.SL-3753 "i
i
- a 11-20-79
,C. Selection of Test Locations ~ ~- ~ M he sketches in Exhibit 2 show the locations of areas where the pulse-echo test has been performed. The test areas havn been selected to include both congested (by rebar and embedment arrangement) and noncongested locations. Fifty-four areas were chosen for testing in Category I strbetures and six areas in Category 11 structures. The inclusion of test areas from the Category II [' structures in the statistical sample increases the conservatism of the test 9 approach since the QA/QC requirements on Category 11 concrete are not as e stringent as those for Category I concrete. The test areas cover the contain ' ment, fuel handling building, auxiliary building, and turbine room, at different elevations. Various structural elements (i.e., base mat, wall, beam, column, and floor slab) are included in the sample, herefore, the test locations selected are representative of the concrete construction at the Marble H;11 Station.' j Though this selection is not random in the strict statistical sense, a j conservative bias is introduced by using congested areas for half of the sample,' since a greater potential for discontinuities exists in these areas. 'Ihere fore, 1 the conclusions from the examination of this sample will be conservative. ? f D. Acceptance Criteria from a Statistical Standpoint The Nuclear Regulatory Commission, in its letter of June 27,1979 (Exhibit 1), y k requ! red volumetric examination of in-place concrete to ensure with 9B% reliability and 95% confidence that the concrete quality meets requirements. [ The statistical testing program adopted for this examination is aimed at ] providing this assurance through the testing of at least 59 units. If no defective unit is encountered in this sample, the concrete placement at the Marble Hill Station is judged to be acceptable. s 1 -i / 3 I l' i. _ _... SL-3753 s
11-20-79 TABLE Ill-1 - - ~ ~ ~ ~ - - ' - SAMPLING PROGRAM FOR OVERALL } CONCRETE QU ALITY a 1 Maximum i Number of a i Defectives Sample Size t_ 0 59 r L 1 93 j 2 124 i 'a 3 153 n i !.~ m i h L J 1 'a l / -i f 2 i) a For a 95 percent reliability with 95 percent confidence (see Exhibit 1).---- - _._..SL-3753
~ M i I 11-20-79 6 IV TESTING PROGRAM ~ ~ l A nondestrnetive examination of in-place concrete using the pulse-echo technique was performed by R. Muenow and Associates, consultants to PCA. The results of the examination have been correlated with the details shown in the design and shop 5 drawings and with the core samples takra in specified locations. j 1 A. Description of the Pulse-Echo Technique
- The pulse-echo method of nondestructive examination is a technique for micro-seismic evaluation of in-place concrete. Microscismic test data are interpreted 1
using the laws of reflection. A mechanical wave producer and an electro /me- { chanical transducer are placed side by side on a concrete surface. The mechanical wave imparted into the concrete is displayed on a cathode ray tube [ (CRT). If the concrete is homoger.ous and contains no discontinuities, the initial signal and the signal reflected off the rear surface of the cocerete element will be displayed on the CRT, Any discontinuity. (e.g., a laminMion or a void) i provides a reflecting surface that will result in a signal being displayed on the CRT somewhere between the front and rear surface signals. 'Ise relative location of the incermediate signal displayed on the CRT will correspond to the location of the discontinuity in the concrete section being examined. A polarold picture is made of at least one out of every 15 readings taken at a particular test location. in addition, a polaroid picture is made of every reading where a { discon%nuity is indicated on the CRT. display. The complete test procedure usbg the pulse-echo method for detecting internal discontinuities in concrete is [ described in the PC A report (Exhibit 3). i l B. Qualification of Test Equinment 1 The pulse-echo technique is used to detect, locate, and photographically recor i physical and mechanical discontinuities within solids. It has been used success-fully in a. number of nuclear and non-nuclear projcets for qualifying the d adequacy of in-place concrete. PCA has provided the qualification documenta ( for the testing equipment in its report (Exhibit'3). l (
- The through-transmission testing method used on areas 37,49, and 50 is described i$
Exhibit 2. ,_o l l - -. SL-3753 7
11-20-79 _ - = Demonstration of this technique on five prepared concrete specimens with j known and observable inhomogeneities (honeycomb, reinforcing steel, and air volds) was witnessed by the NRC inspector. his testing disclosed all of the known and observable conditions (cracking, honeycomb, and embedments) with complete accuracy as to depth, extent, and description. Subsequently, 7 microscismic examination of six of the existing concrete patches (all of which are to be repaired later, see S3ction VI) again demonstrated that the test system and R. Muenow's interpretation are highly reliable (NRC Report No. 50-y 546/79-07; 50-547/79-07, September 18, 1979). y j in the process of this investigation, data for 15 additional locations became available for establishing the reliability of prediction by the pulse-echo tech-nique. In each of these locations, the pulse-echo test readings have been taken and have been verified by examining the core samples or by removing the con-crete. We excellent correlation observed between the nondestructive examina-tion readings and the core findings testifies to the predictability of the pulse-echo test equipment. l H C. Location of Test Areas -d The examination of in-place concrete at the Marble Hill Station has been per-d_. formed on 60 locations. Chapter Ill established that at least 59 areas have to be k examined. The locations have been selected to include both congested and i noncongested areas in the structures. Sketches SKCT-1 through SKCT-33 (Exhibit 2) give the details of these locations. Exhibit 4 lists the locations, it can be observed that the selected areas include various structural elements such ] as base mat, floor slab, shear wall, shield wall, beam, and column. In each location, the pulse-echo test is performed at several points on a grid system. The grid size is defined in the PC A report (Exhibit 3). J i b D. Pulse-Echo Test Results The nondestructive examination indicated that no discontinuities exist at 36 lo-L cations. %cse are called " solid" areas in the PCA report (Exhibit 3). The l design drawings and shop drawings have been reviewed by PCA to detect the [" causes for the discontinuities in the remaining areas.__ The construction u i _ __ SL-37 53 L
i 11-20-79 a ] sequence and the field-routed embedded piping were also reviewed for this purpose. Sketches showing the details of rebar splices, cold joints, and cmbedments have been prepared to correlate the pulse-ccho '.est readings and are included in PC A's report (Exhibit 3). This detailed review has provided an explanation of the discontinuities in 16 of the remaining 24 arets tested. Thesc are termed " explainable areas." The remaining cight areas rre denoted as [ " questionable areas," and require additional testing. Exhibit 4 identifies the l solid, explainable, and questionable areas. E. Coring of Questionable Areas The discontinuities recorded by the pulse-echo testing equ:pment in eight ques-i, tionable areas could not be attributed to the presence of congested reinforcing j' steel, embedded pipes, rebar supports, or cold joints. Therefore a 3-inch nominal diameter core was taken in each of these locations. A visual examination of these cored samples indicated no major discontinuitics such as volds, laminations, or internal honeycombing. The discontinultics observed in ~ l the pulse-echo testing are attributed to excessive entrapped air. The core r samples were photographed to document the absence of major discontinuities before they were tested for compressive strength and unit weight. The photographs are shown in Exhibit 5. g i_ The PC A has conducted tests on the core samples for compressive strength unit weight and absorption and has performed petrographic analysis. The test results are described in the PC A report (Exhibit 3). The corc samples have indicated compressive strengths between 5,950 psi and 7,800 psi for the 3,500 psi concrete j and between 0,750 psi and 8,550 psi for the 5,500 psi concrete. The unit weight ranged between 145 pef and 152 pef. In addition, petrographic analysis of the i cores was performed to assess the overall quality of concrete, as discussed in M the PCA report; it has indicated that the in-place concrete is of acceptable
- quality, w
E =_ M 11-SL-3753 y s mm.im.-m--.---.-i-. i.,
11-20-79 V ' DISCUSSION OF RESULTS ~' ~~ ~~ ~ In the following, the results of the pulse-echo testing and the subsequent testing of core samples are discussed. The acceptance criteria for evaluating these test results are 'stabibbed. A. Acceptance Criteria i The objective of the nondestructive examination has been to detect the presence, if any, of unacceptable discontinuities and to assess the quality of the in-place concrete. The localized discontinuities observed by the pulse-echo test in some locations could be explained by the presence of rebar splices, pipe embedments, cold joints, and steel supports. Where the discontinuities could not be explained, core samples have been taken. The core samples have been examined for strength and radiation shielding requirements according to the following criteria:
- Visual Examit..tlon: The surface of the core shall be examined for the presence of excessive volds and laminations.
e Strength: The cores shall be tested to determine the ultimate compressive strength. This strength shall not be less than the specified cornpressive strength of the concrete, i eUnit Weight: The unit weight of in-place concrete shall not be less than 137 pef for acceptable radiation shielding. e Porosity: A petrographic examination shall be conducted on the core ! samples to assess the overallquality of the concrete. i B. Evaluation of Test Results The core samples from areas 17,23, 30,35,36,51, 53, and 60 have been visually examined; no excessive voids or laminations were observed. The ultimate compressive strength recorded from these core samples has a minimum value of 5,950 psi for the 3,500 psi concrete and a minimum value of 6,750 psi for the 5,500 psi concrete. Since the ultimate compressive strength of core' samples 12- . SL-3753 :
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11-20-79 exceeded the specified compressive strength, these areas are acceptable by the j structural strength criterion. The average measured unit weight of concrete is 148 pcf, which is greater than the minimum acceptable of 137 pef from the j consideration of radiation shielding. The results of the petrographic analysis discussed in Exhibit 3 have. confirmed the quality of the in-place concrete as 7 acceptable. 9 i ] Based on the results of the visual examination and testing of the core samples, f no defective sample has been found in the questionable areas. Therefore, all 60 L areas examined in the concrete structures of the Marble Hill Station have passed the nondestructive and destructive examinations. This assures with a t high level of confidence that there are no unacceptable discontinuities in the in-place concrete. i c Moreover, additional cores were taken from the " explainable" and " solid" regions in the following test areas: 9, 22, 23, 25, 26, 27, and 28. These, too, showed no unacceptable discontinuities, in addition, the strength test results of M concrete work have been monitored and evaluated periodically over the entire construction period using the procedures of ACI-214-77. The allowable design l strength of the in-place concrete computed from the entire set of stre%th tests = to date is 5,023 psi for concrete placed in areas requiring c minimum specified s 126 ps or co e ete p ed n r s r qu ng a u spe if ed ren th i of 5,500 psi. VI DISCUSSION OF PATCHED AREAS A. Surface Defects j A detailed examination was performed of the repaired honeycomb areas in the ly concrete structures. A limited number of surface defects such as honeycombing = _j and entrapped air at the surface are inherent in concrete construction. The l._ American Concrete Institute recognizes the existence of surface defects in H concrete in its published literature. ACI 301, " Specifications-for Structural [ Concrete for Buildings," addresses this subject in Chapter 9, " Repair of Surfacb i Defec ts." Surface defects, when properly repaired, will n'oA~ affect the ~~ ! __.SL-3753 : = 4 s
.a 11-20-79 j structural integrity and the radiation shielding capability of concrete struc-tures. 'l B. Repair of Patched Areas J A field inspection of the areas of honeycombing,.or patched areas, repaired by Gust K. Newberg quality control personnel has revealed that 170 out of 513 H patched areas in Category I structures are not acceptable. The Public Service l, Company of Indiana has instructed that all patches be removed and repaired properly. Gust K. Newberg has developed a procedure (Exhibit 6) for repairing L honeycombed areas. Vil DISCUSSION OF THE VotD IN THE AUXILIARY BUILDING SLAB l i j ~ A. ~ Background A large void was discovered along the formed surface at the bottom of the ] 36-inch-thick concrete slab in the auxiliary building. The top of the slab is at elevation 373 feet 6 inches. The void was at the west edge of the slab along column row N (Exhibit 7). It extended vertically from the bottom layer of the slab reinforcing steel to the mud mat below, a distance of approximately 10 inches, it was 4 feet 6 inches wide in the east-wcst direction. s L The reinforcing steel in the area of the void is congested because of the j presence of wall dowe_s in addition to the slab reinforcing.* S&L recommended an investigation in the form of nondestructive examination in othe: areas of this ] 39 foot by 75 foot stata having a similar reinforcing pattern, where no voids were visible on the surface. On May 7-8, 1979, the PC A performed a nondestructive ] examination using the pulse-echo method. The nondestructive examination i readings were taken at 1-foot intervals along the north, west, and south sides of h the slab, as well as on top of the slab, to determine whether or not any unknown y volds or arcas of honeycombing existed. No evidence of any additional volds or i unsound concrete was found. 1 I
- The congestion was primarily due to the bars from the sump in the diesel fuel oil 1-storage tank area. Since sump areas are typically congested, other sump areas in the auxiliary building were included in the concrete testing program.
SL-3753
+ 11-20-79 B. Repair of the VoM A repair of the void along the west side at column N-30 was implemented by first excavat!ng enough material under the slab to allow access for workmen and tools. All unsound concrete was removed. The intended configuration of q the bottom of the slab was then restored with shoterete. The shoterete repair J was tested using the same pulse-echo testing method and was found to be acceptable. An approved procedure written by Gust K. Newberg (see Exhibit 6) will be ] utilized for filling in the remainder of the void and for backfilling the excavated material under the slab. I SARGENT & LUNDY Prepared by; M. K. Ravindra, F . Supervisor i .Probabilistic Anal sis Section 'j i A A. M. Weiss, Concrete Technologist i R. Hooks, Supervising Design Engineer = N' 4 G ,A Reviewed by: o 7k 4./ q. N o. A. Walser, 17410 P1 9 .IND!ANA Structural Department i Engineering Assistant to i' 'r R SIDENT Manager Sl0 \\ Approved by: 'L b k) h 1 R. ~T. Kostal, Assistant Manager j~ Structural Department 1..._.. SL-3 7 5 3 '
l l EX HIBITS I I I
EXHIBIT 1 SL-3753 11-20-79 m.. i a NRC LETTER ADDRESSING THE MARBLE HILL CONCRETE i ( j i 1 l 6 .._..1.of 3 ;'
' EXHIBIT 1 SL-3753 11-20--79 a /' a g'e UNITED STAtts NUCLEAR RECULATORY COMMIS$10N c ([ *, R$clON lli s N 8 190 BOCStvtLT #Cao k abEN 86 LYN. ILb4N0ll 60137 s, ' y * *. June 27, 1979 -4 = 4 Decke: Nes. 50-546 50-547 Pablic 5e: riee e! Indlar_s Attentiet: F.. S. V. Shields Vice Pr e sid e:: Ele:::1 Sys:c: 1000 E. F_ai S::ce: g Plainfield. IS 46168 Gen:1e=en: This refers to the discussien be:see: ycu and I and others of cur respective staffs c:.7ute 26, 1979, regardics the quali:y of :::::e:e constructie a::ivities a: the Marble 3111 C:1:s 1 and : ple:: si:e. We understand based on these discussie:s tha: Pablic Service of IndLana vill: /
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EXHIBli 4 _ SL-3753 11-20-79 LIST OF TEST AREAS The following table gives the location and type (congested location or uncongested location) of test areas and the type and details of nondestructive examinations per-formed. w 1 of 7 k
M M STATUS CATEGORY Dws. METHOD OF DATE C/U REMARKS t.ocation 9) OF CONC. NO. TESTING TESTED A U AREA I r itwr S l ate 36" Grid A 7g,ggg.,g. 1
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I S-1402 Pulse Echo 6-27-79 C SKC~-28 river Slab 2 o,x.- II S-514 Pu1== Echo 6-27-79 C 9" Grid El. 36 8*-4* T STCT-1 g g, 372. l a?- riour S A 3 0.K. I S-670 Pulse Echo 6-29-79 C 36" Grid .g= SFCT-6 ritwyr Slat-4 r I S-674 Pul=e Echo 7-17-79 C 36" Grid El. 345' A SFCT-9 Wall 5 E I S-674 Pulse Echo 7-17-79 C 20" Grid A t. 346 SECT-9 Wall 6 0.K. I S-67) Pulse Echo 6-28-79 C 20" Grid Rechecked 7-07-79 El. 346' A FFCT-R Wall 7 0.K. I S-673 Pulse Echo 6-22-79 C 20* Grid Partial Fechecked 7'27-79 El. 346' A Finished 7-17-79 g ,, gg f D ui pmen t i g r I S-932 Pulse Echo 6-28-79 C 36* Grid Hatch SEC'-27 Wall 9 g I S-779 Pulse Echo 6-29-79 C 20" Grid El. 364* A SECT-21 I 19 0.K. I S-688 Pulse Echo 6-29-79 17 13* Grid A 373*-6' SECT-18 Ext. Hall 11 O.K. I S-952 Pulse Echo 7-06-79 C 30' Grid Wall under C Em. Air .,.g_ y 7 ful: 97 C CONGESTED LOC A T ION C CONTA8NVENT As AUXILIARY BLOG. l g g r = Explainabler O = ouestionable. o.C. - Acceotab1' Us UNCONGESTED LOCATION T* TURBINE ROOM [MM yIX j Core e g$5 Ct,*, P.S 1. 3* y SARGENT% LUNDY l
- os.e M AR BLE *MLL LIST OF TEST ARLAS w
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M gXI aa u gI[gw M , ~1Tg U M G C C C c C C C C C C A D L O l' h b b b t %I i cg m,,, 'l M. a t a a a a S e a n Y o l 'S 7 Ii 1 lS7 1 J* S3 - tS '7 1lS7 eS7 '2 ll* I S,, R 3 e es 8 8 7 7 7 7 7 1 la4 l y i5 ip* i .r3 . r . r3 . r3 . r3 . r, 3
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no-nc. n,, l CSC Cg CE 'tgl ig U e r l m.. m, m. ng - x to ol l ul ol1 olI oil oy l F E CF CFE CFE CrE CrE e h1 r g tl og E Fg m A 'a C A 4 M 5 O 4 T O N I P E R S K RA MN E R 4 A 5 I N h4 AI M hr TB E e NR R o OU tC CT r C' T a wn t o S S g A t d d d d d d d d d d rnd E i i i i i i i i i l eii A". r r r r r r r r r r por G C G G G G G G G C PG e T "0 "0 re" S 0 0 0 0 6 6 6 6 on3 E 2 2 2 7 2 2 3 3 3 3 CO1 N T IO F NT O OA T TI C S A O I C L L NA O U e U U C y C C C C U L C D E DT ES D T E EE 9 9 9 9 9 9 9 9 9 9 9 SG TT 7 7 7 7 7 7 7 7 7 7 7 EN aS C C DE 0 6 6 6 6 6 6 6 6 0 7 NC 2 0 0 0 0 0 0 0 0 2 1 T ON 7 7 7 7 7 7 7 7 7 7 7 CU = CU F O s o o o o o o o o o o g G h' h h_ h h h h h h h h N c c c c c c c c c c D I E E F E E E E E E E E OT HS e e e e e e e e e e e b TE s s s s s s s s s s s a l l l l l l l l l l l t ET u u u u u u u u u u u r M P P P P P P P P P P P eccA = L 5 5 6 6 s, 9 0 1 1 1 2 0 G. 4 4 5 ~ 5 s 7 7 2 2 2 2 y y 2 2 3 3 g L 3 7 8 4 O 0 0 0 0 0 p I m w T T T 4 4 4 4 7 T T T T K. H 9 9
- p g
N 9 9 9 9 1 1 1 1 6 C C C C D F C C C C C O Y Y F 7 F K F F K S s S S s s s S S s S E S S S S g 3 S S S S S L r e B e g l ] Y. b . R o a S A R R C n P. M d O N o G O i E C t ,s s t T I I I I I I I I I I I e c Ar u a e CO 9 =, ot s, t r 0 l# = C P S Y U e: D T@ N l b D A K K K K a t y r. y K T ), E 0 o E O o O O O 0 n S r i k a T l ii px E A E G E e R P = A 2 3 4 5 6 7 g 9 0 1 2 A 1 1 1 1 3 1 I 1 2 2 r S - R-
qrf a e. fI cw ) i ( . [ mig G OO G A A 3 A A A 3 A A A L O B L a B b b* b b "6 e m a a9 a a Y 3 l* l - l l '6 '6 '6 R S6 S* 6 S6 S 3 3 i. t. 4 5 4 t 4 8 8 1 a r3 r4 3 r3 r3 3 r 3 9 i L i w o. e3 l o. e. 1 l o l l 13 I o o. l o l o. l l 1 X l t il fal l l t ag ll a} iI al U c FE rr E f, FE t e PE Wy WE J. e i. A +,w s C A 6 7 7 M 5 5 5 O 4 4 4 TN O E R I I I S B PA TA F9 K 4 P6 F7 F7 M 5 5 NE R 5 5 .4 I N 4 4 4 A AI h h h M Ce ce ca ce T B r NR E r 1ar er R o o i o o OU t f a C C C C CT "( t t t 'g r{ r{ C T' a M " n "n w w d en en o E' i o t o t e r g S S S G t t t t nd d "ii fnd r nd rnd e d d d d S i
- ii
+ii eii l i t d i i r A Ior Dor or or b r pG G t p i r r r, r G G I pG pG pG a G t Y" e e e i G A
- e "3 r **
C n "0 on0 re r o a "0 "3 n 6 a 0 o 0 0 N T 3 O1 CO2 CO2 CO2 v 2 1 N 2 2 O S I E NT T OA F MC O O L T, U/d O I U C U U U U U U C C U L L C D E ES T D E E E 9 9 9 9 9 9 9 9 9 9 9 mG TT 7 7 7 7 7 7 7 7 7 7 7 N A5 C 7 7 7 7 7 7 9 9 7 7 6 D r. 0 0 0 0 0 0 C mU 1 1 0 0 0 N T 7 7 7 7 7 7 7 7 7 7 7 = 4 CU FO o e m o o o o o o o o d G 5 h h h h h h h h h t c c c c c c c c c c c M D0TI E E E E E E E E E E E a
- S e
e e e a e e e e e e b s s s s s s s s s s s a TE l l l l l l l l l l l t ET u u u u u u u u u u u p V P P P P P P P P P P P eccA L 1 1 9 0 0 3 2 3 6 0 6 1 1 1 1 1 1 2 1 2 2 1 L G. A-6 I 3 1 5 5 9 0 O 9 9 0 O. 7 T 7 3 1 T 7 3 3 ? 7 T T T K H 2 3 3 9 T T wN N 6 C 5 C 7 6 7 C 6 C C C C 6 7 7 C C C 9 7 7 D F F F 4 T F v F Y K R K S S S S S S S S 5 S S S S S E S S S S S S S S L / e B e M R c I Y. a S A n R C n o P. V 4 O *J i G C t E C s e Y-I I I I I I I I I m w TAF w r CO 0 o o t c m n 0 'i J: Y-S D U e i T@ W l r b A K K. K. K a S nw C O K. T 0 O E O Q E O E n k i a i lp N x E A E G E E A D 3 4 6 7 g 0 1 2 3 A 2 2 2 ~ 2 2 2 3 1 3 3 c S [ . o~ a-
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ymfg G.Dg G. L A A A A A a A C C A A B D L B 6 7 3 g b r mW e i-t a4 . d g 2 A a k o .l a-n g l' no. 1 Y eSl a 4' E "0 N l t* S '9 R t o 3 g B S1 all 4 t t7 i 8 g A 0 2 TFE W9 Sl l a7 2 A ,1 t s r4 9 3 t e l. wf 1 r3 I e 4 v m 5.2 a l 8 4 g o. m u%l l b. t o L r snig nu. o. t m c, a o aB l I e a2 nt. X al e8 $9 ll 7 oxl aua9 uol aA ll S3 CEE ETM3 TFE FE U te + t Wg Ca6 FE BS F A e C a A T N S E N M v N A I 4 A M 0 T E 1 N R 1 2 O x 1 1 C H l l 2 o o C 5 C c SA E I d d d d d d d d d A i i i d d i i i i i i r r r i i r r r r r r T G G G r r G G G G G G S G G E "2 "0 o 0 "0 "0 T 0 0 0 6 1 2 2 N 9 2 2 2 2 2 3 fO N T O S I I TA L U C /& O U U U C U C C C U C U L C D E D T EE 9 9 9 9 9 9 9 9 9 9 5 S TT 7 7 7 7 7 7 7 7 7 7 7 E AS C 7 6 6 1 8 8 9 0 9 9 7 DE N 0 0 0 2 1 1 1 2 1 1 0 O T 7 7 7 7 7 7 7 7 7 7 7 C C n F o O o o_ o i o o o o o o o g G h h h s h h b h h h b N c c c s c c c c e c c DI E E E i E E E E F E E OT a e e e e e e e n HS e a e s l s s s un s s s s s s s b TE a l l l ra l l l l l l l ET u u u hr u u u u u u u t V P P P TT P P P P P F P p eccA 2 6 6 7 7 8 4 3 3 5 t =. l 3 3 1 1 1 1 1 1 2 2 1 6 G. 5 - 6 6 - 6 6 0 8 5 5 9 - 0 i O 9 T 9 T 9 T 9 T 9 T 0 T 8 T 9 T 9 T 8 T 7 T K. H 2 W N 6 C 6 C 6 C 6 C 6 C 7, C 6 C g C 8 9 6 C 6 C O C. D - R K - F F F E K F F - E - K 4 S S S S SS S S S s. S S S S s S S S S S S S E e L / l I B 8 b R 0 f. a S A 8 n RC o P. M 4 O N i G O t E C s o s e I 1 1 I I I I I I I I e N T u c CO tw i i AF Q o o r = c P P O Y S e D U N l T@ b T K. K K K K a U A K n L S 0 0 E 0 O O E O O E i E a T lp N x E E G A A R = [1 4 5 6 7 9 9 0 1 2 3 4 C 3 3 3 3 3 3 4 4 4 4 4
- ,a
BLDG. STA7US CATEGO9Y DwG. VETHOD OF DATE C/U REWARKS tm ation OF CONO. NO. TESTING TESTED A g F 1'M r SIab EI-329*- 8' 36* Grid 3 45 E I S-671 Pulse Echo 7-07 79 U SFCT-7 Will 46 0.K. ~ S-675 Tulse Echo 7-07-79 U 3b 6fid EI* 34S'4-A SFCT-3 Floor S I sti 47 0.K. I S-673 Pulsa Ec5o 7-07-79 U 16" Grid Grid moved, NTt has loc ^ A SFCT-9 3eam 4p C I S-67* Pulse Echo 7-1g.79 C 13" Grid Check from 346 1 A R29 LToat A SFCT-12 Co l um Thru 49 0.K. I S-679 Transmissten 7 79 C No Grid Check frem 346 83AB 2,3, A 34 & 37 SFCT-12 Col um Th rt, f3AB 4, 9, A 50 0.K. I S-C79 Tr an w15 s ion 7-21-79 C No Grid Chack frem 346 6 28 SECT-12 seam 51 O I S-690 Pulse Echo 7-07-79 C 13" Grid Check 8rtm 346 1AB56 P to A SFCT-13
- 1 Steam runnel C
52 0.K. I S-996 Pulse Echo 7-18-79 C 20* Grid SKC*-33 t1 Steam 53 0 I S-9*2 Pulse Echo 7 79 C 20" Grid Ttmnet C Floor Slal g '- El. 362*6*
- 1 Steam 54 0.K.
I S-992 rulse Echo 7-18-79 C 20* Grid Tunnal C South idall E l. 36 2 * -(, Sr 'T-31 SI Steam Tmmal C 55 O.K. I s g92 P sise Echo 7-19'79 U 20* Grid rier Slat-grCT-33 FI- "?*' C. CONCESTED LOC ATION C = CONTAINVENT As AU X tLI ARY BLDG. . c. Explainable; o = Ouast ionable 0.K.* Acceptable A WM Ut UNCCNGESTED LOCATION T* TURBlNE ROOM mg FX Co'e No l "C C**=* P.S I. g k'** ~ yUU SfSGEHira tDNDY l %-" 9LE H LL LIST Oi TEST AREAS ~, S Q m-e* o., - =, %, % 4ses / 4o23 to h A =
M M M BLOG. STATUS CATEGORY DW G. WETHOD OF DATE C/U E Oc-CONC. NO. TESTING TESTED 'N.. T 56 0.K. II s-514 ruise Echo 7-19-79 u 36-crid g sFcT-1 [3"'8 7 37 It s-515 ruise Echo 7-19-79 U 36 crid 3 33 srct-2 ricor stab 36" crid $g g II S-526 Pulse Echo 7-19-79 U El. 387*-6 srcT-3 [3]'g T 59 o,g, zr S-587 ru1=e Ecbo 7-19-79 U 10~ crid SRcT-5 Unit #1 re '. 60 g II s-565 rulse Echo 7-20-79 C 36" Grid End Journa y sum ort rt.as1*In" SFCT-4 A' AUXILIA5tY BLOG. C2 CONGESTED LOCATION C
- CONTAINWENT E = Exclainabler O = Questimable: 0.!;.*Acceptabla g g
O' UNCONGESTED LOCATION ,T e TURBINE ROOta Ce'c No Cs w P.S 1. loe+ - SARGENT&LUNDY
- >+c' "A"BLE
"'t t LIST OF TEST.Y B S a.. sv : to. 4809 / 4923 N* 6
- 6 e
D - (A M y I~ X 1 I m w-h 2 0 gwH s. y
EXHIBIT 5 SL-3753 11-20-79 PHOTOGRAPHS OF CORE SAMPLES The following photographs show the details of entrapped air in the in-place concrete. Core samples from the test areas (9,17, 22, 23, 25, 26, 27, 28, 30, 35, 36, 51, 53, and
- 60) are displayed here. There are three photographs for each core sample, taken at a 120* angle, and depleting the entire surface of the sample.
T 1 of 16
_r ' - w.g,,. m,,,%.. yp., ,..x ~- s U ~*$. EXHIBIT 5 -6 SL-3753 r -( 11-20-79 a r 3, ~,k. F 4 -,3 ... r. .s m ). g, s. \\ = v.s,... ~,. s, ~ . u!.
- ;f)
,_ ;~} y ,e, - i 'r ry ~ : n . __z . p ~6- = 4 2:A e s_ a s ;sa -.e~:y m p m u s m ? Y s. }w s * { 4 y 'r 7 ,I -: m' u 3 5 3. 3 uxw >m. .y s W." CORE SAMPLE 1,.'?? 3 .i.. ' 1.; '.; c .o FROM TEST g ~ e 5. = AREA NO. 9 h 4 i h (., _.,.[
- e,'.
u 9 C.c... 8 (s ' q.. 7 i A I ..A y 3 '? a -s-.*w L'-. U 'd ~ )-r L'a lw in , m. x -6.r. I i FPMNI' M ~ -i 3 - i T rfw ;- r nn7,, , 7,%. -. ,y 79, ]f4 i- .a 4.. j & x^) 1
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n. EXHlBIT 5 SL-3753 11-20-79
- p. a
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.m_ J;,... = s i 40 m) _ w.m e . --vpwr+*= . - - = a v i eag k. s = ~ I t l - eg'$ +. eW 99e* 4 $ t w"> .$' h .uea: 1. g p. 4_, a 1 {( n g 4 4 @ e ~ ,4,.' n / %,, + 14 - .. s+ e
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-r n_ ~ 7* -i -.ar'T t CORE SAMPLE FROM y up, - J... -l 7"d TEST AREA NO,17 4, h / M 4, n^ c - ~~ . n, -x m . -,.. ~, g Ik M y u,m _ &..._ e m e & <. r-4 1 p -m. -e . gprgasq q-. g. gege,g-q mgrtog p,*/p pW q ,?t s E 7- ...._~.,.q t . g 9-Pte'&. 4 g 49 = 1 5
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g- .-reed en.secut ta g e 44 N. g sw .d ~. 4 e. 4..-..ew., asmag -un ~ m n.~a -~ .nn ..i i i
= EXHlulT 5 SL-3753 ~~d 11-20-79
- -3......
- * * ^ 94-5 4 s%%.,, 1!' .t- ~ _ ) (. .. i i 4 g- !,s.. . * (*. 1 {
- ..(
3 j a.. m /
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....c. 4 ',,',.. t QQ. . ~ ~ n n.. Qa a ~. e -.1 = 1.. -.~,.. i m g d e m, &e i.... ;;d ~~ .%% m f,,,mm ge - r.a p =. a i . _._ -~ ~ ~ ~. _, =. - ~m a ag a >/ 3
- ~.u -.'
.h CORE SAMPLE 3'/.,.. .,) / j j FROM TEST = i- .,y,..>./ '.,. AREA NO. 22 ,r.. ; 1 -- t 1 i20 ,A, as 4 - a - -.s.2 g. . w. ,. *, y,,, ' * - m um- ' ' "., w s . -; 1 __ c ? .a i 1 l i Sg N s. y .u... m an.m wvm ~ AKt.A a 2 l, e y, ] . t'f, f. j'h' ~ { ;'y l ~ /. 9. / .a ~ 'i y 1 q0l - : ay ;:. + s m '. J, 4 of 16 8, ' 4= ... -'. ' #8.J. L, b [/l s - <1 .9.p A. i
.w m_= E X HILil T 5 SL-3753 -, e 11-20-79 L 1 } -..n w. H ,\\ a _i ~ -... i1 1i g. 9 .,,, e.g, m _ 3 , s-h a wtMeamm h amenes.am sand.. - M M id.'2* 4aihlD ens b sd anfen. M ^ ' ' ~ -""'"q .-... ~.. _,. --= 1 i" .q i, A Wd .._o _s _. _ CORE SAMPLE ? ~4 e - t-FROM TEST . i AREA NO. 23 i B2 s ...++ 1ed ii 4 c. i %eM -> gm W w p gd t. u i _j ~_w,... y I 1 .r _~
- l i
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'7 g,* j 6.: i z e
== me s . '] I, 9 - m 1.g a I .m. i ~ h w 3s 5 of 16 5 16&O decentbedst NadmeM4A.> M - M M4dtafetAS'M4Meer em tea me th6M esdagedew k g .-.-....n ....i a
1 J 4 EXHIBIT 5 7 SL-3753 _7 11-20-79 1 =. .t 't t ^ 1 ~, t. ? t -a s a 9,, ,f 1. I ~- ...,m... . _ e.,. i, i .......a u i. i . _. y._. 3, 7,,,,, _ Ia ,. c... mm - a, s. - _ g. v: u -- g. -s-r--. 1 U d" E1 e J I e .i .y i s j. CORE SAMPLE .y 4 .. i i, FROM TEST J ~ 1 AREA NO. 23 .., i -g . P e 4 e - I. B3 . e -n 64 4g(g g k +- a; n. e .,--*a se S M* W .,f Stet Ng L' A .lS. m -e S g N m f. g ak ~m. ~ 3 m i 1, 3~' ] i 6 l 1 1 a I ',* f; -'. z, a, j A a ( 3. + d i 11 11 I ,,~ 6 of 16 -s l Mwak,.pm.$la m.samM'*3GPe.a.eeds eMem -4er4teurmsheedN'4 seasMM M 1- -
- g. - -
,y. -. y~ g.. EXHIBIT 5 SL-3753 s- '.S 11-20-79 .w
- 4
, 9 ' t__ ja g,, tar'pt. w = = A _m m 'l ~~ . + 4 , e, s' ,T .l i j q ,.T j u,, n <.. ;; i '
- -1 s.
= -- s. 4 r J-4 5 ' ',, ~i [ ".fd 3 ,g;, ...a< s ~ .a****- / Q U,p$. .,%. a s. - 2 d ?- m m.M 5 - c~t v (Q.e wo. - - u. IN m i 7 'l l %,- ) ,*,v. " 'i ) '"1'0'.f i i .,e 5 J 4 5 6 ... c.....,,- I i ~ ..s .4 s cegwg a,..;.. ' v >a : c - '.u.,t L ' a dj,;;.,;..,,s,, w m.u- . m. -- m n. - m 7 77-7 4 w e ,tf Me ~++et.. c. 9 7 L, m '.,u. x/ m t,. m,,.c )
- -C
,= o. t / i .-e .p't v'i j Q.,,...< '., ;,. FRoM TEST y (. '- ',r / CORE SAMPLE i .s c_ o
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L = . mm.: _. ' n.g .a' AREA NO. 25 <4 d s =. v vl.. .7 f 4 4I 6 ... 'g 9 Q. ,.....e ,.-.m..~_. 4 4 l 1 U 2T~ T*.T D *.7' ' ~ ,... ; M.. ~_ -..,,.,e __s .y y ;1.-.n 1;_a.,s.Tx '*,*-5 h ^Y 7 - .i .,.3... z._,,_. ,n.3 y __ <] f L-i V.9 l h ,h-t-- 1 i jI Q \\\\ n t. _._..___. ~ a .{~~ ~ ~ A {% [5,/% d t) d i. i M a 7456 A-3 g; a d 7 ,3 .'*d f ,t,,
- P 4
\\ s-fl ,,.. s 1 ,h N( 3 4 ,, pp, 4 ' ~A .M r . s.. g. g*.' i.d - .w, w k.~' 69 3 'I,. J'l' a e g 7 g =*
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E'F %D'M4 4e gg wgy,. pg.ep q qq g g pg T
- M 7-7 of 16 m
' *%4 # %f.- ? %.*Th s .*7. r p .g %swma 8 .= - -g m ms.., t.. z.. p.,. t-r. c.m.,,,,4m _, t _m.. h i t-. m-- - =-
a ~ ~ ' ~" EXHIBIT 5 J SL-3753 1 11-20--79 i 9 a .s,.- 1 j 1 2 .s. .a \\ .< h. L... 6.1 p. -,,R n i t. 1 J ,- '(... 1 4 a-ahw.. u sa a -- 4 ( A 2e i i 1 ....c ..--..=-a.-. I i CORE SAMPLE
- )
FROM TEST 3 AREA NO. 26 m i 1 m 't I j ...~~.-.4 i e 5 =. _j %.........,c -m ..a ....._.,,s.-.. i i y a i 1 .-_..a..~ b .., - C = < % & e> \\ ( = f,, - - .,n, ./,.,,- p .,i3 . a n i .t s' j M a n 7-- ...v.. !k" ~1 8 of 16 M J I O -S & } x -u_y.i. 2 g,sa - _s- ^ w s
= EXHIBIT 5 SL-3753 y ^ 11-20-79 .1 3.-,_. .q 3 1 .g a
- t., '
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- w 1
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- 1 s
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-l j 1 ~ -a- + - -. ~.. / -1 f. t.. ' s i s 1 -..i j CORE SAMPLE j i,. i } i j FROM TEST c k .1 JJ AREA NO. 27 f w; .**",,,,\\ w d \\ ....q
- -'84.,
a l L m n ..C--.+n hw. and. sese.- - l- ..y-,.._-___ ._, _ m .s 4 4 5 b .' J ^ a O W S 4 4-- O q o ./,
- l. 6 k. *,e- * * *,
/ 4 a nl t s = a I .k --.r*t b (4 9 r -, k (. c .1 -i \\ i J J i + .<l e I q J .-l, 9 of 16 5 1 E L e.A.=r.4. w b.ueJ.n..s 46 a,. 6s.a, i ' a %w g.,,, u;g _h- -=
~ - - - - ,c .a EXHIBIT 5 SL-3753 a 11-20-79 R l e q y,s l .g m s a -_= / l_ r .-a.. -....... u....~.w Wu s.gsm,L. 3 g la 13 D 46 '1 ~ _.,. _m. ) =-- mm. e, ~. b m...n.s am. .. xc w - 'i n t ' s *a ' ' - ~ = _ -.. ~. - - c= i M 5 -. z..., ~ CORE SAMPLE ij g_ FROM TEST { ,~ AREA NO. 28 n u. ..,.s ...._..........~..z...aaw-. ~. .t a u ..n l-c.. s .s, n _.~ m, / >.w > 1 '# m i g _ 2 a i a ,1 N .w- ..... _._._ 2 I. 2 8 A-3 I i 1 .g . a,m.e _ .A n a n .n Q 10 of 16 ,J t ^
y. -- w.. w =,ew es.,. o..w._,,, ,,,.e .w = EXHIBIT 5 SL-3753 m -w -,. -......,. _..m m,. 11-20-79 ,= s t 1 r- .,) i ~..._,., 4 [1 __ y. a4 a 1. i 7 J I~ G f n,.-,,,, ..s -.aw 8 +- =-
- -- : A CORE SAMPLE i
FROM TEST 'I AREA NO. 30 ? - y .y t m g t A .m ___u a a I i^ I .,,,,....,,y.y. I ..;z... u ;;=- - - - \\ B O A-1 ) h ..~s-....,. k -Y . ~. - - 2 +.-,- 2* 1 11 of 16 4 -g ,_4 a t i -i-a.----...ii i in
+' O V'~ w ,.w m,_- m - -.,,,, ,s*bp) EXHIBIT 5 SL-3753 . --.y. i 11-20-79 w 4 j .s. i l J +,'s { t/7 ~ I ~ @\\ ) m. l t W _',c,,,,,, -... b I II ..1,,.'... n*n,O f eseas*.,> 3 y } I,
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_j EXHIBIT 6 SL-3753 11-20-79 si 4e -) I [~ NEh'EEEG PROCEDURES ~ --i-i y Two quality assurance procedures developed by Gust K. Newberg are included here: i h'PN-25 Major Void Concrete Repair h'PN-36 Concrete Core Drilling u l 5_n' a-L, ? ( l Jj 85 ]
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= EXHIBIT 6 SL-3753 11-20-79 ~., _. - 9 [W d MARBLE HILL GENERATING STATION 0 R m on QUALITY ASSURANCE MANUAL p. ' T; -- - " ~ ~ ~ >i p,g, og_ O SIlN N /
Title:
WPN-25 MAJOR VOID CONCRETc. REPAIR L A I TABLE OF CONTENTS 3ECTION TITLE PAGE 1.0 Purpose 3 [O 2.0 Aoplicabiliiy 3 3.0 Definitions and Abbreviations 3 4.0 Procedure 3 4.1 Void Preparation 3 4.2 Forming 3 l.__ 4.3 Fill Material 3 4.4 Consolidation 4 4 4.5 Curing 4 l 4.6 Clean-up 4 m i 5.0 References 4 N ATTACllMENT A Weld-Crete Bo'nding Agent 5-7
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I EXHIBIT 6 SL-- 3753 1}-20-79 ~. _ 07-25-78 l Date 8 N' MARBLE HILL GENERATING STATION O )h hl' !)-lf f e OUALITY ASSURANCE MANUAL 1Page of q jdMNh d ;llitv!
Title:
WPN-25 MAJOR VOID CONCRETE REPAIR ~ s L-a 1.0 PU RPOSE To describe the methuds for repairing major concrete defects. 2.0 APPLIC AB I LITY This procedure shall apply to all concrete defects that are clasci-fled as major in accordance with QAPN-10, " Inspection and Test Control", that require forming. 3.0 DEFJNITIONS AND ABBREVI ATIONS Refer to Appendix A of the Newberg-Marble Hill Quality Assurance Manual. 4.0 PROCEDURE 4.1 Void Preparation Remove all unsoun d material using automatic chipping hammers or by hand. Extreme care will be taken to avoid nicking re-I inforcing steel. Crods sections of individual bars shall not be reduced more than 51 of the nominal area within a length of 3 bar diameters. Larger notches shall be reported i to tbn Consulting Engineers for evaluation. Bottom and sides of /cid shall be cut sharply at least 900 with face of con-crete surface. The top edge of void should Le cut to a fairly horizontal line or if the configuration makes it advisable the top cut ma; be stepped dovn and continued on the horizontal line. The top edge 'll also be cut on an upward slope from the back of void Los rd the face of finish surface to prevent air entrapment. All interior corners shall be rounded to a mini num radius of 1". Inside void surfaces will be treated with the Weld-Crete Bonding Agent ( Attachnent A), and the crea inspected as pec QAPN-10, " Inspection and Test Control". 4.2 Forming I Void area will be formed to the design surf ace. Forms shall oc mortar tight. A " chimney" will be incorporated in the form top to allow for insertion of grout or concrete into void area. If conditions warrant, forms may be placed in sections so th.TL concrete raay be placed '.n lifts of 12" deep. Small diameter holes (<(") will be c-11ed at 12" intervals to act as vent and inspection points. 4.3 Fill Mater ial I Grout the samc compressive strength as the structural member will be used in voids that have t high rebar density that could prevent proper consolidation. Otner voids will,be filled with concrete of the same compressive strength as the structural member. 3 of 12
-iw EXHIBIT 6 SL-3753 3 11-20-79 07 25-78 h1 MARBLE HILL GENERATING STATION Rmion 0 I / h l'l l OUALITY ASSURANCE MANUAL ] ,,,.]
Title:
WPN-25 MAJOR VOID CONCRETE REPAIR Page of J b _M p a 4.4 Consolidation Consolidation will be accomplished by use of pencil vibrators for voids equal or larger than 4" deep, or tapping face of form by use of hammers for voids less than 4" deep. Above = methods will be used during placement until grout weeps thru the inspection holes. ] 4.5 Curing If forms are removed prior to completion of the seven-day 3 ] cure period, the surface will be sprayed with an approved j curing compound immediately after the forms are removed. A second application of curing compound will be made at seven days. i 4.6 Clean-Up I i Concrete or grout protrusions will be chipped of f and area i ground to match adjacent area. Protrusiens shall be removed l by working up from the bottom to avoid concrete breaking ~ out of the repair. ~
5.0 REFERENCES
5.1 " Concrete Manual", Water Resources Technical Publication, Eight Edition. M] 5.2 QAPN-10, " Inspection and Test Control", n I =. f i T ic = A E 4 of 12 =- i
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Title:
WPN-25 MAJOR VOID CONCRETC REPAIR j M_-~~ ? ATTACIIMCMT A-Weld-Crete Bonding Agent = r-i iJ If Cs cata sutLatin ko. 4 30 t oJLtt o. co.c a s tj 5,f as v g i two f.a..vt.s has 6e== =eed to eats *** felly ...elece a retafereed ee eeste one.e..ti 6..ded to.. e.i.it : 7-eeese aheer..iti lit pairAnatost vess.-s.ef.ee. t. .eest.e -a see eid-ce tee nest s: w stattivaatti servo ..a cLian, fece fee. e..ters.1, d.et, est, see..e,... so.se p.s.t. .ite.. e.et, setie.ce, effte-se..,.forets...teesei. e ee ee J void. crete
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levet steel retafeetlos and forevert, then, env. stee up to 10 d.ya efter aspiteetion of the boedteg 4seet, piece ? %= the new conceste well se specified. In the laterval netween the epplitettee of the bendtes agent and pistement of eenctete, the held Cretee ftle should to protected f ree ditt, dust and sobels es well .s the eleoente. Frter to p asement of roottete, to 4-sort.ces to. stove that a sontinvous blue ftie of beld-Ctetespect m toeste the bead ores, "l._ c.er.gg.-6eid-ceesee e,ver..,,,....:.., 200. o0.. ft, pet settoa. depe. dias upon tvee of santece enc aethed of spriteattoa. s i b E ie L M E i N 7-- = 5 of 12
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Title:
WPN-25 MAJOR VOID CONCRETC REPAIR w .] ATTACilMLNT A s Weld-Crete W nding Agent i t.e couct..:
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1-EXHIB1T 6 SL-3753 11-20-79 _. -....... ~ - om* 07-25-7J C..~~-~~'~~ 'N MARBLE HILL GENERATING STATION 0 .l ) h. [j l l l f ', OUALITY ASSURANCE MANUAL N* 1 h ei k{.- 1 1 Page of -L J'\\hi- / U L4 Y ]
Title:
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n ....m EXHIBIT 6 ~ SL-3753 ..11.20-79 l Date 10-29-79 6 g Ni MARBLE HILL GENERATIMG STATION fl) l lh'h ' Rw Non U OUALITY ASSURANCE MA% VAL g h i
Title:
CONCRETE CORE DRILLING WPN-36 l E r _J 1.0 PURPOSE i To describe the methods for drilling of cylindrical holes in con-crete floors and walls and/or concrete block walls to allow penetration of member for other work. 2.0 APPLICABILITY " I This procedure applies to concrete core drilling as indicated above, performed by Newberg-Marble Hill as approved by the Owner. 3.0 DEFINITIONS AND ABBREVIATIONS Refer to Appendix A of the Newberg-Marble Hill Quality Assurance j Manual. 4.0 PROCEDURE ~ j 4.1 General Written notification t; hall be given to the Owner on a case-by-E case basis listing location, eleva tion, building and appropri-ate S&L reference drawings prior to commencement of the work. Written acknowledgement and approval shall be received before I the actual drilling takes place. This information and approval shall be supplied on the core Drilling Record Log (Attachment A). Also, an investigation of the A-E drawings end/or the reinforcing steel placement drawings will be made to lor.a te ' reinforcing and any other embedded items, and documented on the Drilling Release Form (Attachment B). 4.2 Equipment e The drill'ng machine shall be of a type that is specifically ^ designed for concrete core drilling that can be properly secured to the surface to prevent movement during the drilling operation. Dits shall be of a size and type to adequately permit the efficient and proper drilling of the surface and to provide the opening size required. Bits shall be maintained a in good working condition and sball be checked periodically for excessive wear. 4.3 Metal Detection 4.3.1 If required by Owner on the Core Drilling Record Log, a deep magnetic detector shall be used in conjunction g: with the S&L drawings and/or the rebar placement drawings to locate reinforcement and any other embedded metal in the area to be drilled. If metal detection indicates the presence of metal, it will be reported in accordanc with QAPN-12, Design Changes", using the Contractor Change Request. 9 of 12 -mme m mimum u mmi umm-
EXHIBIT 6 SL--3753 1 11-20-79 Date 10-29-79 .s 7 43 ; MARBLE HILL GENERATING STATION f t -ll) ((h QUALITY ASSURANCE MANUAL g ErnTEG flIfD Page of m., i Y CONCRETE CORE' DRILLING WPN-36 L m v-ar _ _ 2 4.3.2 The deep magnetic detector used for the above shall be as approved for installation of concrete expansion anchors (See WPN-28, " Expansion Anchors"), and shall be i calibrated per QAPN-ll, " Control of Measuring / Test Equipment". = 4.4 Drilling 4.4.1 l Wherever possible, the core drilling machines shall be anchored by the vacuum method. Where vacuum is not possible or practicle, anchoring shall be done with concrete expansion anchors. Where the method of anchor- [ ing shall require the drilling or chipping of any I concrete, written approval f rom the Owner shall be ob-tained prior to anchoring. 4.4.2 Bit Selection and Core Removal After properly securing the drilling equipment to the wall or floor surface, the selection of the proper size and type of bit, drilling is to commence to the depth of the particular si o drill bit. After achiev-ing this depth, the drill bit is to be extracted from the surface for removal of the concrete core. The concrete core is to be removed using electric or pneumatic chipping hammers. With removal of each suc-cessive concrete core, the drill bit is inserted into the hole to its next succeeding bit depth. This process is continued depending on the thickness of the core and/ or wall or floor. 4.4.3 Embedments Encountered If reinforcing or other embedded metal, which was not anticipated or discovered by use of the magnetic de-tector, is encountered and/or damaged, the drilling operation will be suspended and the damage will be reported in accordance with QAPN-12, " Design Changes", E using the Contractor Change Reques t. 4.5 Personnel 4.5.1 Drill Crew Shall consist of a driller and helper who are exper-ienced in this type of operation. The driller shall be responsible for the maintenance and operation of the drilling equipment. This shall include but not be limited to utilization of proper bits and drilling pres-The drillers ' qualifications and training shcIl sures. be documented 'n accordance with QAPN-3, " Training and j Oualifications of Personnel". The drill crew shall be ^ 10 of 12 i.ms.smi e em .is .ii.-. iii8
l EXHIDIT 6 SL-3753 11-20-79 ]
- M-Ii NII1'I*F
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~ '- Q ~. ^ CONCRETE CORE DRILLIt1C WPN-36 e i under the direct supervision of the Drilling Superin-tendent whose qualifications will also be made a matter of record in accordance with QAPN-3. 4.6 Documentation Documents' will be maintained in accordance with QAPN-18, "Q.A. Document Control", and QAPN-17, " Data Packages". 5.0 RE FE REtJC ES f WPN-28, " Expansion Anchors" QAPN-3, " Training and Qualifications of Personnel" QAPN-ll, " Control of Measuring / Test Equipment" { QAPti-12, " Design Changes" d QAPN-17, " Data Packages" i Q APti-18, "Q. A. Document Control" m 7 I? = !t 1" i 1& 4 a O g i 6 .= E a L, 11 of 12 i?
i EXHIBIT 6 SL-3753 =, i 11-20-79 %_.-=. Date 10-29-79 i e[ _. _M, '%. MARBLE M.L GENERATING STATION D m jA k [.l..l ', I f ' R mion i OUALITY ASSURANCE MANUAL ...A 6 7 --m -. d li e. /' Page of i i xsIMd: 1:bi: Title-l CONCRETE CORE DRILLING ' WPN-36 ATTACilMENT A CORE DRILLING RECORD LOG N w ... =... m g ./.I.,. ....'J4s . 1 l %.lll.4.lal.l.i l
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= J -I -..-._._....e.,._-_~~._-.___._-.__,..._,_ EXHIBIT 7 SL-3753 11-20-79 ^ (.
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