ML19345C992

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Responds to IE Bulletin 80-11,Item 2b, Masonry Wall Design. Evaluation Indicates That Walls Comply W/Fsar & Tech Spec Requirements
ML19345C992
Person / Time
Site: Crystal River Duke Energy icon.png
Issue date: 11/17/1980
From: Baynard P
FLORIDA POWER CORP.
To: James O'Reilly
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
3-110-10, IEB-80-11, NUDOCS 8012080738
Download: ML19345C992 (32)


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. . . .a Mr. J. P. O'Reilly Director Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Suite 3100 101 Marietta Street Atlanta, GA 30 03

SUBJECT:

Crystal River Unit 3 Docket No. 50-302 Operating License No. DPR-72 IE Bulletin 80-11: MASONRY WALL DESIGN

Dear Mr. O'Reilly:

Enclosed is our response to IE Bulletin 80-11, Item 2b.

Should you have any questions concerning our response, please contact this office.

Very truly yours, -

FLORIDA POWER CORPORATION T

Patsy Y. Baynard Manager Nuclear Support Services Lobo (M05)DN-98-3 Attachment cc: Director Office of Inspection and Enforcement Division of Reactor Operations Inspection U.S. Nuclear Regulatory Commissfr.

Washington, DC 20555 8012080 73T I

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STATE OF FLORIDA COUNTY OF PINELLAS P. Y. Baynarti states that she is the Manager, Nuclear Support Services Department of Florida Power Corporation; that she is authorized on the part of said company to sign and file with the Nuclear Regulatory Com-mission the information attached hereto; and that all such statements made and matters set forth therein are true and correct to the best of her knowledge, information and belief.

~/ (./74.?A na P. f.vBaynard Subscribed-and sworn to before me, a Notary Public in and for the State and County above named, this 17th day of November, 1980.

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Notary Public, State of Florida at Large, My Commission Expires: June 8,1984 Lobo (M05 Notary)DN-98-3

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REPORT ON MASONRY WALL RE-EVALUATION PROGRAM CRYSTAL RIVER UNIT #3 6

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TABLE OF CONTENTS pagg 1.0 IhTRODUCTION 1 1.1 PURPOSE 1 i 1.2 PLANT DESCRIPTION 1 1.3 STRUCTURES 2 2.0 MASONRY WALLS 3 2.1 GENERAL 3 2.2 WALL LOCATIONS AND DESCRIPTIONS 3 2.3 MATERIALS 3 3.0 INSTALLATION AND INSPECTION 5 3.1 GENERAL 5 3.2 INSTALLATION 5 3.3 INSPECTION 6 4.0 RE-EVALUATION 6 4.1 GOVERNING CODES 6 4.2 LOADS AND LOAD COMBINATIONS 7 4.3 ALLOWABLE STRESSES .05g EARTHQUAKE 8 4.4 ALLOWABLE STRESSES .10g EARTHQUAl2 8 4.5 DAMPING 9 4.6 ANALYTICAL PROCEDURE 9 4.7 INPLANE LOADS 10 4.8- BLOCK PULLOUT 10

5.0 CONCLUSION

S 10 Figure 1 General Building Arrangement Figure 2, 3 control Complex (Wall Locations)

Attachment 1 Extract U.4RC Bulletin 80-11 Attachment 2 FPC 60 Day Submittal Attachment 3 Plan & Elevation Drawing of Walls Attachment 4 Response Spectra e,

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1.0 INTRODUCTION

1.1 PURPOSE This report is in response to the requirements of USNRC IE Bulletin No. 80-11 MASONRY WALL DESIGN dated May 8,1980 which requires response to Item 2.b (see attachment 1) within 180 days of the date of the Bulletin. The data re-quested by the Bulletin within 60 days was submitted on July 3,1980 and is included as Attachment 2 of this report.

1.2 PLANT DESCRIPTION 1.2.1 General The Crystal River Plant Unit 3 nuclear steam supply system is a pressurized water reactor type similar to systems operating or under construction. It uses chemical shtm and control rods for reactivity control and generates steam with a small amount of superheat in once-through steam generators.

The nuclear steam supply system is supplied by The Babcock & Wilcox Company.

The nuclear steam supply system is capable of an ultimate output of 2560 MWt, (including 16 MWt contribution from reactor coolant pumps), corresponding to a gross electrical capability of about 885 MWe. However, the power conversion systems are designed only to accommodate core power levels up to 2452 MWt.

Site parameters, principal structures, engineered safeguards, and certain hypothetical accidents are evalusted for the ultimate core output of 2544 MWt.

1.2.2 Site and Ensironment The site is located on the Gulf of Mexico, 70 miles north of Tampa, Florida.

The exclusion area h s a radius of 4,400 feet within a 4,738 acre site wholly owned and controlled by the Florida Power Corporation.

The site region is predominantly agricultural in nature.

The sub-tropical marine climate of the site' region is characterized by diurnal i

wind shif ts from the Gulf of Mexico and frequent nocturnal inversions; how-over, atmospheric' diffusion of waste gases is good. " Extreme mile" winds are not expected to exceed 110 mph once in 100 years. The nuclear generating unit at the site is protected against the wind and tidal effects associated with the Maximum Probable Hurricane.

All potable water supplies within a 20 mile radius of the site are derived from wells or springs fed by the ground water table which slopes to the Gulf.

of Mexico. Surface and subsurface drainage is to the Gulf of Mexico only and therefore cannot affect any potable water supplies, streams, or surface waters in the area.

The structures are founded on underlying limerock which is competent with respect to foundation conditions for the plant. Florida is in a relatively i

aseismic zone; therefore, the plant structures are designed conservatively to a horizontal acceleration of 0.05 gravity.

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. 2.

1.1 STRUCTURES 1.3.1 General The major plant structures are a reactor containment, auxiliary building, control complex, intermediate building, diesel generator building, and turbine building. A general building arrangement is shown on Figure 1.

Structures are classified according to requirements for seismic design as shown in the following tabulation:

Original Present Items Class Class Buildings and Structures Reactor Building including all penetrations, equipment hatch and air locks, concrete shell, liner, and interior structures I NSR Auxiliary Building (excluding the steel roof support structure) I NSR Control Complex I NSR Dnergency Diesel Generator Building I NSR Intermediate Building I NSR NSSW Intake Structure I NSR Turbine Building III NNS Other buildings containing conventional facilities . III NNS The listing includes the designation at the time of construction and the current terminology, i.e., either Seismic Category I, Nuclear Safety Related (NSR), or Non-Seismic Category Cper14 W4 Ndn M.Oedcq Nuclear Safety Gf\I (NNS)MdGlW The foundations for the Reactor Building, Auxiliary Building, Intermediate Building, and Control Complex are connected by shear keys to prevent dif-ferential displacements. The upper portion of the Reactor Building is separated from the other structures by a seismic rattle space.

1.3.2 control complex The Control Complex is a seven level structure with its lowest level at Elev. 95', and others at Elevs. 108', 124', 134', 145', 164', and a roof at Elev.186'-10". The structural system consists of a concrete beam, slab, and column system and a concrete base mat founded on rock, which has been grouted to fill any voids.

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1.3.3 Other Structures The remaining plant structures do not contain masonry walls which require re-evaluation relative to the Bulletin.

2.0 MASONRY WALLS 2.1 GENERAL A field survey was conducted of all walls in the Turbine Building, Auxiliary i

Btilding, and Control Complex to determine if any Safety Related equipment is attached to or located within a distance equal to the wall height of any masonry wall. Several areas of the plant, such as the Containment, the Waste Gas Storage Tank Room, the Spent Resin Storage Tank Room, the Deborating Domineralizer Room, the Cation Domineralizar Room, and the Air Shaft, are currently inaccessible. Although construction drawings indicate chat no Safety Related equipment is jeopardized by masonry walls in these areas, a field survey will be conducted to verify this during the next scheduled plant shutdown. The presence of a Nuclear Safety Related device within a wall height

, of any non-evaluated wall was. assumed to jeopardize that item's NSR system.

It should be noted that more detailed checks of system function might prove that this is too stringent a requirement.

2.2 WALL LOCATIONS AND DESCPIPTIONS Figures 2 and 3 show the location of masonry walle whose collapse might en-danger Safety Related equipment. As can be noted, only five wall segments at two elevations in the Control Complex provide a potential hazard. Attach-met:t 3 contains plan and elevation drawings of these walls. The submittal of July included several other walls as potential problems, but those were eliminated as a result of the field survey.

All the evaluated walls are normal partitions whose function is to separate occupied spaces. The walls do not perform a safety function or act as fire or security barriers. The walls are constructed of hollow concrete blocks.

The nominal thicknesses are shown in Attachment 3.

2.3 MATERIALS .

The project specified that materials used for the performance of the masonry wall work should meet the following requirements:

2.3.1 " Concrete Masonry Units l 1. Hollow load bearing units shall conform to ASTM C 90-66T, Grade A.*

2. Solid concrete block units shall conform to ASTM C 145-66T, Grade A.*
3. Units,which will be exposed shall be of fine texture, of medium grr.in, with' edges and corners clear and sharp.
  • The designation " Grade A" is not used in the 1966 version of ASTM C 90. It refers to a designation in the 1952 version of the specification which is equivalent to the Grade G-ll of the 1966 specification.

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4. Units receiving plaster shall have sufficiently rough surface for good bond.
5. All units shall come from the same plant, be at least 28 days old before
shipping to the job site, and at the time of setting shall not exceed

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40% moisture content of their total absorptive capacity.

6. Unless noted otherwise on the drawings, all openings in concrete block walls shall be fitted with precast concrete lintels. Faces which are exposed to view shall be cast to match closely the surface texture of
the surrounding block. Aggregates used for lintel concrete shall be the same as used for block. Concrete mix shall be 1
2:3 with 3,000 psi .

, strength. Steel bars shall be Grade 40 deformed billet steel conforming to ASIM A 615-68. Lintel bearing shall be 6 in. minimum."

2.3.2 " Block Wall Reinforcing (where called for on drawings)

j. 31ock masonry walls and partitions shall be reinforced horizontally in the

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joint using Dur-O-Wal-Standard Welded Steel No. 9 rod reinf xcing or equal,  :

such as Hohmann and Barnard Standard Truss-Mesh-Lock, or Kofstone Steel and Wire Co. Truss Type Keywall.- Reinforcing shall be laid up in proper widths l for each wall thickness, laid continuous in horizontal joints every 16 in. on

! center vertically. Fernish prefabricated corner and tee sections. Rein-forcing shall be lapped at least 6 in. at all running splices. Reinforcing shall be laid ovec block, and mortar placed over rods to ensure a positive and full bend with rods, and the next course of block shall be bedded in this mortar."

~2.3.3 " Block Wall Scrap Anchors _

Interior masonry walls abutting masonry walls shall be anchored at 2 ft. on

, center vertically with 1 1/4" x 3/16" x 8" galvanized metal anchors with ends i

turned down 2 in. Extensions into walls shall be 4 in. All blocks shall be j filled with mortar where anchors turn into core, and all partitions which j terminate or butt steel columns shall be as detailed on drawings. No rigid l ties between steel and masonry are permitted so as to prevent cracking."

I i 2.3.4 'idortar ,

Mortar for concrete masonry units shall conform to ASIM C 270-64T, Type N. l 1

The following standards shall'ba noted: I

1. Portland Cement: ASTM C 150-68, Type I or II
2. Hydrated Lime: ~ ASTM C 207-69, Type S, or Miracle Lime as made by G. & W. H. Corson, Inc., Plymouth Meeting, Pennsylvania, or equal.
3. Sand:. All sand shall be clean masonry sand (light in color) conforming to ISTM C 144-66T."

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3.0 INSTALLATION AND INSPECTION 3.1 GENERAL Construction of Crystal River Plant Unit 3 was authorized by the United States Atomic Energy Commission by issuance of provisional construction permit CPPR-51 on September 25, 1968 in Docket 50-302.

3.2 INSTALLATION The installation of the brick and block was controlled by the following requirements:

3.2.1 " General

1. The CONTRACTOR shall carefully unload and stack concrete block off the ground, on wood planking, and cover block piles with waterproof sheet material. Delivery in palletized form is permissible, provided units are stored off the ground and covered. Delivery shall be arranged to avoid prolonged site storage.
2. 'lockwork shall meet the Florida Concrete and Products Association Gaide Specification for Concrete Masonry Units CM-1.
3. No masonry shall be laid when the temperature of the outside air is below 40 F,' unless suitable means are provided to heat the masonry ma-terials and protect the WORK from freezing. Protection shall consist of heating the masonry materials to at least 40 F, and maintaining an air temperature above 40 F on both sides of the masonry for a period of at least 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />.
4. Wall tops shall be covered with waterproof canvas or equal material at the and of each daf's work and when WORK is suspended by rain. Covers used shall shed water and shall be anchored securely."

3.2.2 " Laving Block l

1. All block laying sht11 be in 8 in. course height, length 16 in., with all horizontal and vertical joints being 3/8 in. Walls shall be built plumb and true to line with straight joints. Required block cutting j shall be neat and accurate with cut block arranged in balance and symmetry '

at wall openings.

2. All block joints exposed to view shall be neatly tooled to a smooth con-cave surface free of sharp lines and fins. Interior partitions shall be run up to the underside of roof or floor above so as to leave no open-ings for transmission of sound between adjacent rooms or areas. Provide openings for passage of ducts, pipes, etc., as required." l 3.2.3 "Pointinand g Cleaning
1. At the completion of the WORK, all holes or defective mortar joints in exposed masonry. shall be pointed and, where necessary, defective joints shall be cut out and repointed.

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2. Exposed masonry shall be protected against staining from wall coverings or other sources and excess mortar shall be wiped from the surface as the work progresses."

3.3 INSPECTION During construction, FPC provided a group of inspectors and field engineers at the site to assure that contract and specification requirements were met. However, since nuclear quality assurance controls were not applied to the work at that time, no records of the inspection were maintained. The fact that no evidence of records of non-conformance to plans and specifica-tions exist, plus the re-evaluation inspe= tion, indicates that the masonry walls were installed in accordance with the contract plans and specifications.

4.0 RE-EVALUATION 4.1 GOVERNING CODES The following general criteria for design is outlined in Section 1.4 of the FSAR:

"The Crystal River Plant Unit 3 has been designed and constructed taking into consideration the general design criteria for nuclear power plant construction permits as listed in Federal Register 50.34 Appendix A which are applicable to this unit. In the discussion of each criterion, references are made to sections of this report where more detailed information is presented. The principal safety features that meet each criterion are summarized as follows:

1.4.1  ::RITERION 1 - QUALITY STANDARDS (Category A)

Those features of reactor facilities which are essential to the prevention of accidents or to the mitigation of their consequences must be designed, fabricated, and erected to:

a. Quality standards that reflect the importance of the safety function to be performed. It should be recognized, in this respect, that design codes commonly used for non-nuclear applications may not be adequate.-
b. Performance standards that will enable the facility to with-stand, without loss of the capability to protect the public, the additional forces imposed by the most severe earthquakes, flooding conditions, winds, ice, and other natural phenomena anticipated at the proposed site.  !

DISCUSSION 'l Essential Systems and Components The' integrity of systems, structures, and components essential to accident prevention or mitigation of their consequences has been included in the reactor design evaluations and the quality program described in Section 1.7.  ;

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7 1.4.2 CRITERION 2 - PERFORMANCE STANDARDS (Category A)

Those systems and components of Reactor Building facilities which are essential to the prevention of accidents which could affect the public health and safety or to mitigation af their consequences shall be designed, fabricated, and erected to performance standards that will enable the facility to withstand, without loss of the capability to protect the public, the additional forces that might be imposed by natural phenomena such as earthquakes, tornadoes, flooding conditions, winds, ice, and other local site effects. The design bases so estab-lished shall reflect: (a) appropriate consideration of the most severe of these natural phenomena that have been recorded for the site and the surrounding area, and (b) an appropriate margin for with-standing forces greater than those recorded to reflect uncertainties about the historical data and their suitability as a basis for design.

DISCUSSION The systems and components identified in Section 1.7 have laen de- ,

signed to performance standards that will enable the facility to withstand, without loss.of capability to protect the public, the ad-dicional forces or effects which might be imposed by natural phenomena.

The designs are based upon the most severe of the natural phenomena recorded for the site, with an appropriate margin to account for un-certainties in the historical data, or upon the most severe conditions which are susceptible to synthetic analyses."

Section 1.7 describes the Quality Assurance Program for Class 1 (NSR) structures and systems.

The FSAR is silent on specific code requirements for masonry walls but the codes which were applicable to masonry at the time of construction are:

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1. " Concrete Masonry Structures, Design and Construction", Report by ACI Committee 531 (ACI 531).
2. Southern Standard Building Code, Southern Building Code Congress (SSBC).

4.2 LOADS AND LOAD COMBINATIONS 4.2.1 Under paragraph 5.4 the FSAR provides the following loads to be considered in the structural design:

1. The loads due to normal operating conditions are:
a. Dead Load
b. Live Load
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e. Design Earthquake i

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2. Abnormal loads include:
a. Tornado Load
b. Main Steam Turbine Missiles
c. Tornado Missiles
d. Maximum Hypothetical Earthquake 4.2.2 Load combinations given below are utilized; they are in agreement with the load combinations provided in the FSAR page 5-32 (for the Reactor Building) but have been modified to reflect the terminology of SRP 3.8.4 and to eliminate terms which are inapplicable to the masonry wall.

D + 1.25 E D + 1.0 E' Symbols used in the above equations are defined as follows:

D = Dead load of structure (a value of D1.05 shall be used where it produces maximum stress)

E = Seismic load based on .05g ground acceleration E' = Seismic load based on .10g ground acceleration 4.3 ALLOWABLE STRESSES .05g EARTHQUAKE For load combinations including the .05g earthquake, the FSAR (section 5.4.3.2.1) states that for concrete structures, "The stresses in the concrete and reinforcing steel resulting from combinations of those loads listed in section 5.4.1.1 (of the FSAR) have been in accordance with ACI 318-63, ' Working Stress Design'." This requirement would be equiva-lent to the stresses recommended by ACI 531, relative to masonry walls.

This document, plus the SSBC, provides the following safe working stresses:

1. Axial compression (SSBC*) = 70.0 psi
2. Tension normal to bed joint .5 f352 = 13.69 psi
3. Flexural compression .33 f'm = 396 psi
4. Tension parallel to bed joint 1.0 [l52 = 27.39 psi
  • Source of criteria, other criteria from ACI 531.

The numerical values are based on a block compressive strength of 700 psi on the g*ross area and a 28 day strength of mortar of 750 psi.

4.4 ALLOMBLE STRESSES .10g SARTHQUAKE For abnormal loads the FSAR (paragraph 5.4.3) indicates that for concrete structures, ACI 318-63 Ultimate Strength design should be used. To provide l

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A the equivalent of this requirement for masonry walls where stresses for load combinations, including the .10g earthquake, do not exceed 1.67 times the safe working stress, the structure will be assumed to be acceptable. This maintains the stress level at 2/3 the ultimate strength assuming a W.S.

safety factor of at least 2. At this stress level the wall's function will not be impaired as required by FSAR paragraph 5.2.1.2.5.

4.5 DAMPING The damping values to be used in conjunction with the response spectra shown in Attachment 4 which were developed,as described in the FSAR 5.4.5,for the floor elevation of each wall are 2% for the .0Sg earthquake und 5%

for the .10g earthquake.

4.6 ANALYTICAL PROCEDURE 4.6.1 A modified (Gilbert Associates program S087) form of the SApIV computer program has been used to analyze the masonry walls. Individual models of each wall were prepared for analysis.

4.6.2 The wall models utilized a basic two foot by two foot (2' x 2') grid. The elements used were Type 6 - Plate and Shell Element (Quadrilateral) as de-fined in the SAPIV Users Manual with a thickness equivalent to the thickness of the walls. A modulus of elasticity E equal to 1,350 ksi was assumed.

All openings whose areas are larger than or equivalent to the area of four (4) blocks (4 x 8" x 16") were modeled. For convenience of the modeller, some shif ting of the actual opening location was tolerated in order to main-tain grid uniformity.

4.6.3 As provided in FSAR peragraphs 5.2.1.2.9, primary steady state stresses were combined with the seismic stress resulting from the response to a ground acceleration of 0.05g acting horizontally and 0.033g acting vertically and occurring simultaneously. A ground acceleration of 0.10g acting horizontally and 0.067g acting vertically and occurring'simultane-ously was also used.

, 4.6.4 The computed stressas were increased 5% to account for higher modes of vibration.

4.6.5 The computational technique used will consist of several independent com-puter runs for each wall.

1. The first dynamic run accomplishes three tasks, it calculates the natural frequency of the wall, and selects the appropriate acceleration from the floor response curves. It also calculates stresses due to the horizontal component of the earthquake.
2. The second run computes the dead load stresses and the stresses for the load combinations listed in paragraph 4.2.2.

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3. The third, post processing, run is made to add the dynamic and static stresses and compare them to allowable stresses and <. compute and print out the ratio of ACTUAL STRESS .  :

ALLOWABLE STRESS 4.7 1NPLANE LOADS Previous experience indicates that stress levels for inplane loading are less critical than for out of plane loadings.

4.8 BLOCK PULLOUT 8

There are no direct attachments to the walls considered for this re-evaluation. The local pullout of blocks was not evaluated.

5.0 CONCLUSION

S The evaluation indicates that the walls comply with the requirements out-lined in the FSAR and the plant Technical Specification.  ;

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ATTACEEhT 1 Extract USNRC Bulletin 80-11 s

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ATTACHMENT 1

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b. Submit a written report upon completion of the re-evaluation program. The report shall include the following information.

(1) Describe, in detail, the function of the masonry walls, the con- i figurations of these walls, the type and strengths of the materials of which they are constructed (mortar, grout, concrete and steel),

and the reinforcement details (horizontal steel, vertical steel, and masonry ties for multiple wythe construction). A wythe is considered to be (as defined by ACI Standard 531-1979) "each continuous vertical section of a wall, one masonry unit or grouted space in thickness and 2 in. minimum in thickness."

(11) Describe the construction practices employed in the construction of these walls and, in particular, their adequacy in preventing signifi-cant voids or other weaknesses in any mortar, grout, or concrete fill.

(iii) The re-evaluation report should include detailed justification for the criteria used. References to axisting codes or test data may be used

. if applicable for the plant conditions. The re-evaluation should 4

specifically address the following:

f (a) All postulated loads and load combinations should be evaluated

, against the corresponding re-evaluation acceptance criteria. The re-evaluation should consider the loads from safety and non-safety-related attachments, differential floor displacement and thermal effects (or detailed justification that these can be considered self limiting and cannot induce brittle failures), and the effects of any potential cracking under dynamic loads. De-

, scribe in detail the methods used to account for these factors in the re-evaluation and the adequacy of the acceptance criteria for both in-plane and out-of-plane loads.

(b) The mechanism for load transfer into the masonry walls and postulated failure modes should be reviewed. For multiple wythe walls in which composite behavior-is relied upon, describe the methods and acceptance crit 6ria used to assure that these walls will behave as composite walls, especially with regard to shear and tension transfer at the wythe interfaces. With regard to local loadings such as piping and equipment support reactions, ,

the acceptance criteria should assure that the loads are ade-  ;

quatsly transferred into the wall, such that any assumptions  !

regarding the behavior of the walls are appropriate. Include the potential for block pullout and the necessity for tensile stress transfer through bond at the wythe interfaces.

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