ML19319D221

Final Deficiency Rept Re Failure of Containment Dome Concrete Pour to Meet 28-day Design Strength Specs Accepts Concrete as Poured,Based on Extensive Evaluation of Concrete Strength.Deficiency Cause Unknown

ML19319D221
Person / Time
Site:	Crystal River
Issue date:	07/11/1974
From:	Rodgers J FLORIDA POWER CORP.
To:
References
NUDOCS 8003130837
Download: ML19319D221 (10)

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1974 3" 7 Pw c a.o....,er.

.o Donald F. Knuth, Director The Directorate of Regulatory Operations U. S. Atomic Energy Ccumission Washington, D.- C.

20545

Subject:

Crystal River Plant - Unit 13 Docket No. 50-302

Dear Mr. Knuth:

In accordance with Federal Regulation 10CFR50.55(e), we wish to. subnit the final report regarding the nonconformance reported on 4/24/74 by Florida Power Corporation.

The_ final evaluation and reco==endations have been cade regarding this nonconfor ance.

As a result of an extensive evaluation of the strength of the in-place concrete, it has beca decided that the concrete be accepted as is.

To assist you in evaluating our decision, we wish to offer the following:

On April 4, 1974, concrete pour L-9 of the reactor building do=e was placed.

This pour is a ec plete circular ring mid-way up the dose of the building, consisting of 129 cubic yards. This concrete had an intended design strength of 5000 psi at 23 days.

Seven day test cylinder breaks indicated that the concrete wculd not achieve the design strength level. The 28 day _ cylinder test results averaged 4570 psi. Gilbert.\\ssociates, Inc. was requested to perfor= a review of the reactor. building doce design to determine a minitua acceptable concrete strength for this particular area of the structure. The results of their review indicated that 4500 psi was an acceptable minimum design strength.

In' evaluating the field' cylinder test results, Cilhert Associates, Inc. has utilized provisions of the 1971 ACI-318 cede to evaluate the structure. Strict interpretation of the 1963 code which was used in the original design calculations, would indicate that the 4500 psi

- require ent is not satisfied, since 10" of the tests. lie below the -

4500 psi. The applicability of the 1963 code to this li=ited number of sa=ples is questionable.

Since the 1971 code provided a clear

-basis of strength evaluation, it is being used in this case.

The Crystal River Unit #3'FSAR is being so acended.

8003130 [ 3 7 3

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Donald F..Knuth U,.S. AEC-('

July 11, 1974

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We have determined that this nonconformance was caused by the failure of the cement to meet specifications.

The exact cause of the failure is not completely clear, since test results for this particular batch of cement su.bmitted-to Florida Power Corporation prior to its use indicated the cement was acceptable.

Test results of sa=ples taken from the silo at the site however, indicate that the cement was, in fact, unacceptable.

In order to preclude a reoccurrence of this

. problem, Florida Power Corporation initiated the following corrective action:

Cement inspection during both the grinding of the cement at the manu-facturer and after its delivery to the site have been markedly increased.

This includes full time inspection at the manufacturer and during the.

grinding of cement for Florida Power Corporation.

In crder to provide you with the necessary data to evaluate our actions-regarding this nonconfor=ance, we are enclosing copies of the following data:

1.

Gilbert Associates, Inc. letter, FPC #10373, dated 1/13/74.

2.

Chronological Log of sequence of events regarding the subject nonconfor=ance.

3.

Florida Power Corporation letter to G. 3. 3rovn, Pittsburg Testing Laboratories, dated 5/14/74, ragarding cement correcti.e action.

4.

Pittsburg Testing Laboratories letter, dated 5/15/74 to Paul Weigelt of the Tampa Office of PTL, regarding ce=ent corrective action.

5.

Gilbert Associates, Inc. letter, FPC #10517, dated 5/22/74, including attachments.

A complete. file of these and other supporting documents is available at the Crystal River Plant site for review by your inspectors at their conven-ience. We hope that this information provides you with all the necessary data to close this item.

Please advise us if you require any further information.

Very truly yours, Lol Idh J.

'. Rodger -

Enclosures Assistant Vice President cc: Norman C. Moseley

. Director, Reg on II i

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,P.O. SOY.1199 / RtADING. PA.19503 May 2, 1974 Mr. W. A. 5:eliscovski, Director FPC - (10373 Gencration ' Ea;;incering Deparr._ccr Florida Power Corporation

- P. 'O. So:< 14042 St. ?ctersburg, Florida 33733 Re:

Concrete in Done Pour L-9 Reacter Building DTstal River - Tnle fG

.Flarida Pwer Corpor.aricn

Dear Mr. Szelistenski:

With ref erence to Telecepy Ns. 6028 fro:: Mr. J. Duren dated May 2,1974 giving the results of the cencrete 23 day test cylinders for pc,ur L-9 of the Dore our findings are as fo11cvs:

We have evaluated the design at location L-9 of the Donc cnd find that the =inic:= concre:7 ctrength required to ccet the locd case givin, the na+m stress is f = 600 pei.

e 1.

The prcrisions cf ACI-313-63 are difficult to apply in the evaluatien of concrete strecath for an inlividual pour with the nu:ber of cylinder teste availchle in this case, however, ACI-315-71 provides a sore definitive

=cthoi of evaluatten.

2.

Interpreting the rest ist.v];s lo accordcace with ACI-313-71 Sectica 4.3.3 the test results overall 2verage o't UTO psi is greater than the 4500 psi required, and no one set of results is less than 500 psi belev 4500. psi, ca this basis the concrete strength is acceptabic.

In ecuclusion, we can accept" the concrete strength in accordance with ACI-318-71, hevever, a devistion fron the FSAR will have to be docunented and presented to the AEC.

Very truly yours, 4

S. N. Dobref f Project Stnict. ural JEL/SND/kf' cc:

W. A. S elistevski (2) g U

C. E. Jacksca J. R. Duren*(Telecopy to St. Petersburg)

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CIIRGit0 LOGICAL LOG 4/1G/74-Low 7 day cylinder breaks for. pour L-9' (poured 4/4/74) reported to W. Buck 4/15/74 no data was available from construction.

4/17/74 WAS requested we expedite resolution of 1cw concrete

- 7trength question - teleccpied request for informaticn tu CEJ.

4/18/74

- At C.R. gathered data on low strength conc. tests.

Requested 5.:!. Dobreff to look at design and report by Monday a minimum acceptable 28 day cylinder strength.

Average o.f 7 day breaks is ;!030 psi. Concrete cores (12)_ are-being removed frca pour. The following data was collected:

a.

7 day and 5 day cylinder breaks b.

design mix curves

. c.

7_ day cement tests d.

pour inspection slips.

4/19/74 Received 6-14 day ccre (dry) breaks frca B. Brcwn Sample fio. i 3740 psi 13 - 3260 psi 5 - 2750 psi 7 - 3040 psi 9 - 2700 psi 11 - 3610 psi Avg. 3185 psi

. Normal expected 7 day strengths have been 73% of 28 day or 3650 psi min.

-4/20/74.

Received the following data from J. Artuso via telephone:

a.

Het core test results (15 dry) 4120 psi 4140 psi 3440 psi-g 2840 psi U

-2820 psi b

'_4010 psi Avg. 3560 p gee.m>M -

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28 day cennnt tests - Silo fl9 (psi):

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5320 5160 5200 5310 5100 5200 5320 5230~

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Grab sample of' cement taken from C.R. #3 site showed less than 20 min set time.

.d.

Mr. 'Artuso's evaluation thus far is that the concrete will evaluate at 4000 psi 23 day cylinder strength.

To justify this, addi tional

-cores may be necessary and the 853 strength factor (from ACI) applied. He estimates reaching 4300-psi at 90 days again based upon a core break analysis.

-4/22/74:

Mr. Dobreff's preliminary analysis of the dome design indicates a minimum acceptable 28 day cylinder strength is 4250 ps.i.

He is proceeding ~ to further refine this design investigation.

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- Met:with JTR,.WAS R$B - briefed them on the above

',lill wait for 28 day evaluation.

Advised C.P. also.

. Message from J. Artuso - results of grab sample of cement - 3 day break 1590 psi, sample failed false set require >2nt ( ASTM).

4/2.6/74 Mr. Dobreff said' their prelininary analysis thus far indicates if we partially prestress the dome and complete the prestrass

.3 months later 4200 - 4300 would be acceptable. Work by GAI is continuing.

4/29/74 Advised JTR and CEJ of'information in paragraph iintediately

.above'- AM.

5/1/74 Mr. Dobreff and tir. Cronberger advised by phone that a minimum acceptabic fc is 4500 psi.

5/2/74-Advised JTR of-above'. He requested a letter frcm-GAI in con fi rmation. Advised by B. Black of 28 day cylinder breaks -;4570 avg.

-5/3/74' Received GAI cunfirming 1ctter;gave to WA5 for approvals.

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Re:

Cement Corrective Action Benne tt,

As per your recccm n.J., Lions, the follacring currective actier.s tre authori:>.il.to be put into ef fect as of this date for closer control.fo cet2nt used ca this. project:

1. ~ PTL to rmovide full tiraa ins'. ction at Cene al Portlend cad d.n ing the grinding of cencut for Florida Pewer Corp.

2.

PTl to provida at;.-Txim:tcly 50% cocara - dering the tr.:nsfer of cc:aat front the production silo to tlin storag: silo.

3.

PTL to seal both top t.nd botta of stcr cce silo after transfer is complete.

4.

PTL in breah bottcm sesis prior to first ship-ment to l'cii Level.

Y' 5.

PTI. during rec ci the s,ilo io periodically verify s

that tcp sca!s are intact.

G.

PTl.Lo perform routino setting tine on the cet::ynt d? livered to Reil trycl.

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Hay 1% G71:

To:

l'aul 1: ' r.elt Tampa

.From:

G. B. Brounc Crystal River

Subject:

Cc. cat incp ctica El.crida Feucr Corp.

Florida Fot:cr has requested uc increase our cc: tent inspection per p

the attached lo!4cr. Itc=s 1 thrcuch.G u;11 have to be. performed by the Tanpa errice. Item 6.uill-he dene here. If you are unabic to: covcr these intpoetiens centact me F.c cocn as possible.

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Cryst:1 PJ.ver - Unit #3 Finridc Pc;c; Cer; ore. tion

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As requested by your ?!r. J.

P.. Duren encicced i., a copy of the etructursi

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ensiacerin; input for the propo:cd report to AEC in :: card to Dc== Peur L-9.

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I'lecan revici cad c:=cnt.

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Project Structural T.cgineer S;*D/hr Inc.

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F.S. A.It. Sect ient 5.2.2.1 recordn that t.be strent.th of the cuncrete rielected for the 1:enetor r,u11 dine. prentressed concrete in 5000 pnl at 23 dnyn and in 5.2.3'.1 Line buildine, denir.n In to be in necoidance with ACI-310-(.3.

The follcning test renuit evaluat ton of the actual concrete strens,th relative to the iaaninora tit re::s icvel:. expect ed in pour I.- ') of f he lh>ue conc ludes.

that the~ concrete strength is 1cus than 5000 psi, houcver, the concrete UL thlH does meet the required strene.t h. f 4500 for the erlLical *:trc83 location including the safety f actors dencoded by ACI-310 63.

1: valuation of Concreto Stron:th Test P.esul t s_

The coneecte cylinders representing the subject concreto consisted of 3

.The average 28 day strength of each set was 4890 psi, 4530 psi and sets.

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4280 psi.

ACI-31S-63 states that the running Everage of all results b'c.cqual to,cr greater chan,f ' and that not note than 10% oE the results r.hould fall c

below,f s aquircant can be usefully appmd for stangth control c

-throughout ccc.struction but is not applicabic for evaluating the concrete strength in a localir.cd pour area such as the one in question.

Ilcsed on ACI-318-71 paragraph 4.3 "F.valuationnad Acceptance of Concrete"

1. or the concrete reprencated by these cylinders would nect a requirenent l ni t.trength at 23 days.

i 4570

' The ACI-318-71 method of cynluation in directly applicabic to the ein

tnin'en enethut ered ist the ::sihjes:1-pour and tht' l en t' re:;u l l e. av. *lable.

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Tennile'."nd Shent Stressen To resist bendine, tensile stresses in the concrete during pouring, rein-forcement is provided, and t.hc co:npresnive and ahear stresses In the con-f cret.c are insignificant.

For all test, operating and accident loading conditions the shears and : onents approach zero in locat.ica L-9 of t.hc Dome, see fi;;ures 5-6 to 5-8 in the F.S. A.R.

No contribution from the tensile capacity of the concrete was relied upon when the required max-iraun prestress force was determined.

It is concluded that since the tensile end shear stresses in the location of peur L-9 are leu. their evaluation is not critical for entablishing the ninimun concrete strength requtred.

Cenpressive Mr,ressen ACI-318-63 Section 2005 divides the allowable corapressive stress levels into i

tuo requi roments: a)

The allevable compressive strens ima?diately follcuing transfer before prestress losses due to creep and shrinkar,c is limited to

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. b) ' The allowabic co::ipressive stress af ter all prestress locsca c

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.On this baaln the erit.ical leati condition (respi trint; tiie maal'::iim f ' value) e van found' to b6 durin;; operation at whicli the.naxinaim strean una 2020 pal ui t.h in.. the ' area of pou r I.- 9. ' Miguat.ini; t he, ac tudd u t ret.. of 2028 pni t.o t he e

0.45 f requirement deternined that the ninh.n.a concrete strent:.h f om e

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