ML19350D842
| ML19350D842 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 05/11/1981 |
| From: | Alley R, Angstadt C, Whitehead C GILBERT/COMMONWEALTH, INC. (FORMERLY GILBERT ASSOCIAT |
| To: | |
| Shared Package | |
| ML19350D841 | List: |
| References | |
| GAI-2304, NUDOCS 8105190426 | |
| Download: ML19350D842 (59) | |
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t May 11, 1981 GAI Report No. 2304 Lq PF3RY NUCLEAR POWER PLANT: REPORT ON EVALUATION OF HILTI KWIK-BOLT QUALIFICATION TESTS A final report on the conclusions and corrective action taken as a result of on-site anchor qualification tests. C. W. Whitehead C. R. Angstadt R. W. Alley Calbert /*N.A 8105190M W
l l D ! TABLE OF CONTENTS Section Ites Title Pm
1.0 INTRODUCTION
1-1 t 2.0 TABULATION OF TEST RESULTS 2-1 2.1 NOVEMBER 1978 QUALIFICATION TESTS 2.2 JULY 1980 VERIFICATION TEST RESULTS 2.3 SEPTEMBER 1980 VERIFICATION TEST RESULTS 2.4 NOVEMBER 1980 VERIFICATION TEST RESULTS 2.5
SUMMARY
TABULATION OF TEST RESULTS AND SPECIFICATION REQUIREMLNTS 3.0 DATA EVALUATION 3-1 3.1 BASIS OF EVALUATION 3.2 STATISTICAL EVALUATION OF PERRY CONCRETE MIXES
3.3 CONCLUSION
S OF NOVEMBER 1978 TESTS
3.4 CONCLUSION
S OF JULY 1980 TESTS
3.5 CONCLUSION
S OF SEPTEMBER 1980 TESTS
3.6 CONCLUSION
S OF NOVEMi '. 1980 TESTS
4.0 CONCLUSION
S 4-1 4.1 1-1/4 INCH DIAMETER ANCHORS 4.2 1 INCH DIAMETER ANCHORS 4.3 3/4 INCH DIAMETER ANCHORS 4.4 5/8 INCH DIAMETER ANCHORS 4.5 1/2 INCH DIAMETER ANCHORS 4.6 3/8 INCH DIAMETER ANCHORS 4.7 1/4 INCH DIAMETER ANCHORS 4.8 CONCRETE MIXES APPENDICES: A. HILTI INC. LETTER DATED OCTOBER 27, 1980 B. HILTI INC. LETTER DATED FEBRUARY 23, 1981 C. STATISTICAL EVALUATION OF CYLINDER BREAKS l l
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1.0 I_NTRODUCTION On October 10, 1980, the Cleveland Electric Illuminating Company reported a p9ssible 10CFR50.55(e) significant deficiency concerning results of site qualification testing of Hilti Kwik-Bolts. The events leading to this report as well as follow-up evalaations and corrective actions taken are summarized in this report. Concrete expansion anchors were adopted for use on the Perry Nuclear Power Plant (PNPP) in 1978 as a means of attaching miscellaneous structures, systems, and components to Category I structural concrete when embedments had not been provided. The supply and installation specification,_SP-208-4549-00, specified the use of the Hilti Kwik-Bolt as manufactured by Hilt 1 Fastening Systems, Inc. The
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specification also required that on-site qualification tests be performed to establish installation torques and to confirm that manufacturer's published capacities used for design were realistic. These installation qualification tests were to be performed at the site prior to the installation of anchors for structural purposes. In November 1978, Qualification Testing o the Hilti Kwik-Bolt was performed at the PNPP Site. The results of these tests were marginal and were finally determined acceptable on March 14, 1979, following a period of revic> of deviations from the technical requirements. In March 1980, due to a change in responsibility for qualificatica testing, the November 1978 test results were further scrutinized resulting in a recommendation that further tests be performed to substantiate the November 1978 results and conclusions. l l The first attempt at verification was made in July of 1980. The results of these additional tests vers questionable due to significant scatter in data. The tests had been performed in a test slab in a remote area of the plant grounds in concrete of a non-typical nature, as described in Section 2.2. Thus, further tests in actual job placed concrete were recommended, and were performed in
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. \ September 1980 on the roof of a plant structure. The test results were supportive of the original conclusions but still indicated significant scatter in data, questions regarding some of the installation torques, and concern for the eff.ects of concrete strength. Inclement weather conditions during the tests may have had an adverse effect on results. Therefore, further tests were recommended to permit a totally conclusive resolution of the concerns. The final tests were performed in November 1980 in two areas inside the plant in representative structural concrete. The results of these tests generally substantiated the original results with the exception of four items relating to specifi~c bolt diameters. One installation torque and three ultimate capacities required further investigation. Review of all test results is,1cated that although the anchors were generally achieving the required design capacities, they were not demonstrating strict conicrmance to manufacturer's published capacities for the higher than minimum concrete strengths being encountered in the test areas. Concern for this action prompted an investigation of Category I cylinder break results to determine the nature of concrete being used throughout the plant. The manufacturer indicated that anchor performance is dependent on many variables, including the characteristics of the aggregate used for the concrete. Therefore, a direct duplication of published capacities is not always possible. The background and details of the cylinder break evaluation are contained in Appendix C of this report. The results of that evaluation, discussed in Section 3.0, demonstrate that the concrete strengths encountered in the test areas are representative of that to be encountered throughout the plant. This permitted a better evaluation of the test results and determination of the performance of the Hilti anchors to be anticipated in PNPP Category I Concrete. b l-2 e - o p.p.++ y,,--
4 This report provides the details and conclusions of the tests, and the corrective actions taken to assure reliability of these anchors throughout the plant. O L 0 0 Geert/C ._ _. - - _* 1-3
l 2.0 TABULATION OF TEST RESULTS l l The following tabulations represent the applicable results of the ) various tests relating to installation torque and ultimate load capacity and associated test parameters used as the basis for data f evaluation in Section 3.0. In the interest of clarity and brevity, it is not considered necessary to reproduce the entire test report but rather just the final results.
.ue tabulated test results are in pounds which is consistent with the manufacturer's practice with published capacities and in the test reports. Actually, this approach implies greater accuracy than that actually achieved in the tests. Test results are recorded in psi hydraulic pressure and converted to pounds. A small gauge of 1000 psi capacity is used for loads up to approximately 7000 pounds.
Then, a larger gauge of 10,000 psi capacity is used. The first gauge h:2 10 psi increments with a conversion factor of 7.15. Using a reading accuracy of 5 psi i= plies an accuracy on results of 1 35 pounds on loads up to 7000 pounds. The second gauge has 100 psi , increments and a conversion factor of 7.1. Ucing a reading accuracy of 50 psi implies an accuracy on results of t 350 pounds. This should be kept in aind when reviewing the test results. 2.1 November _1978 Qualification Tests Anchor Installatibn Slip Ultimate Diameter Embedment Torque Load Load (Ft.-Lbs.) (Lbs.) (Lbs.) 1/4" 1-1/4" 10 1334 166C 1/4" 1-1/4" S 1167 2001 1/4" 1-1/4" 8 1001 2001
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Anchor Installation Slip Ultimate Diameter Embedment Torque Load Load (Et.-Lbs.) (Lbs.) -(Lbs.) 3/8" 4-1/2" 35 1668 6337 3/8" 4-1/2" 30 2335 5336 3/8" 4-1/2" 25 1668 6337 1/2" 6" 80 4002 7004 1/2" 6" 80 4002 8710 1/2" o" 80 5336 8710 5/8" ' 7-1/2" 120 6670 12000 5/8" 7-1/2" 110 5336 10125 3/4" 9" 240 10125 17100 3/4" 9" 220 3710 17750 3/4" 9" 180 9415 20000 1" 10" 290 9415 19250 1" 10" 290 9415 24125 . 1" 10" 290 9751 19250 1-1/4" 10-1/2" 530 17750 16375 1-1/4'i 10-1/2" 480 13250 20650 1-1/4" 10-1/2" 480 15625 29000 Concrete Data: 28-day Cylinder Breaks (2): 3424 3353 Avg. 3389 psi l l 2" 4 Cores taken @ testing: 1889 g 2138 l Avg. 2014 psi Concrete cores observed to be questionably porous. OJhert /Commommeou 2-2
2.2 July 1980 Verification Test Results Anchor Installation Slip Ultimate Diameter Embedment Torque Load Load (Ft.-Lbs.) (Lbs.) (Lbs.) 1/4" 2" 5 715 2550 1/4" 2" 5 655 2426 1/4" 1 7/8" 5 1054 1926 3/8" 4 1/8" 22 1926 4815 3/8" 4" 22 1319 4815 3/8" 4" 22 1319 5335 1/2" 5 7/8" 75 3788 7388 1/2" 5 4/3" 75 3918 7388 1/2" 5 3/4" 75 3778 - 5/8" 7 3/8" 90 4848 14163 5/8" 7" . 90 5205 10776 5/8" 7 1/2" 90 4815 12808 l 3/4" 8 5/8" 200 7557 19533 3/4" 8 1/2" 200 6710 17551 3/4" 8 3/8" 200 7557 18567 1" (10" min) 270 10098 25751 1" 290 8675 19583 1" 290 8404 20261 1 1 1-1/4" (9 3/4" min) 480 12300 27813
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1-1M" 480 8066 20688 ! 1-1/4" 480 10437 31407 f Concre'et Data: 28-day cylinder breaks averaged 4200 psi. The test l report indicated that drilling did not produce a " fine powder" generally associated with drilling concrete but rather a debris which Geert/C 2-3 l
had the consistency of " wet sand". In addition, failure was by pulling through the wedges with very little deformation of the
. tapered end. This is indicative of a lack of concrete hardness.
2.3 September 1980 Verification Test Results Anchor Installation Slip Ultimate Diameter Embedment Torque Load Load (Ft.-Lbs.) (Lbs.) (Lbs.)
, 1/4" 1-5/8" 5 841 1973 1/4" 1-3/4" 7 938 2297 1/4" 1-3/4" 7 938 2491 1/4" 1-5/8" 7 1100 2653 1/4" 1-5/8" 7 1488 2070 1/4" 1-5/8" 7 1100 2200 3/8" 4-1/4" 30 1747 5823 3/8" 4-1/4" 30 1488 6039-3/8" 4-3/8" 30 1812 5629 1/2" 6" 40 4141 11239 1/2" 6" 50 4141 10736 1/2" 5-7/8" 50 4464 6710 1/2" 6" 70 3753 10736 1/2" 6" .70 4270 8723 1/2" 6" 70 3300 9394 1/2" 5-7/8" 80 4011 11407 1/2" 5-7/8" 80 5241 10233 1/2" 5-7/8" 80 4270 6710 5/8" 7-1/4" 90 4853 12414 5/8" 7-1/4" 110 4982, 15265 5/8" 7-1/4" 110 5305 12749 5/8" 7-1/4" 120 4917 21472 5/8" 7-1/4" 120 5111 14091 5/8" 7-1/4" 120 4203 14091 Geert /Commonwesth 2-4
1 Anchor Installation Sl'.p Ultimate Diameter Embedment Torque Load Load (Ft.-Lbs.) TGs. ) TEi. ) 3/4" 8-3/4" 200 6039 20130 3/4" 8-7/8" 200 4853 24156 3/4" 8-5/8" 200 6276 22143 3/4" 8-1/2" 290 7717 18117 3/4" 8-5/8" 270 9394 23485 3/4" 8-1/2" 25 0 8723 20801 1" 10-1/8" 290 8723 23653 1" 10-1/4" 290 7717 24156 1" - 290 8052 - 1" 10-1/8" 340 9897 25498 1" - 340 9730 - 1" 10" , 330 9562 22479 1-1/4" 9-3/8" 480 8052 42944 1-1/4" 9-5/8" 480 10065 40931 1-1/4" 9-3/4" 480 6710 39589 1-1/4" 9-1/4" 550 10065 40260 1-1/4" 9-3/8" 530 13085 39589 1-1/4" 9-3/8" 520 12749 35563 1-1/4" 9-3/8" 560 12749 43615 Concrete Data: Two Cores (6" Dia.) taken
@ time of testing: 4707 4674 Avg. 4691 psi Age of Conc. @ testing approx.1-1/2 years.
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i 2.4 November 1980 Verification Test Results Anchor Installation Slip Ultimate Diameter . Embedment Torque Load Load (Ft.-Lbs.) (Lbs.) (Lbs.) 1/2" 5-5/8" 25 2832 12780 1/2" 5-1/2" 25 930 6220 1/2" 5-5/8" 25 788 7810 1/2" 5-3/8' 50 )188 9230 1/2" 5-1/2" 50 3146 7100 1/2" 5-5/8" 50 2789 7100 1/2" 5-5/8" 75 4862 12780 1/2" 5-1/2" 75 5577 9230 1/2" 5-1/2" 75 3075 5363 1/2" 5-3/8" 110 7100 9230 1/2" 5-1/2" 110 4505 7100 1/2" 5-3/8" 110 6650 14700 1/2" 5-1/4" 125 7455 13490 1/2" 5-3/8" 125 7810 11360 1/2" 5-1/4" 125 6292 9940 1/2" 5-1/8" 100 5577 10650 1/2" 5-1/2" 100 4862 10650 1/2" 5-1/2" 75 4515 12070 1/2" 5-1/2" 75 4576 9230 1/2" 5-1/2" 50 3074 9940 1/2" 5-1/2" 50 3504 10650 J/8" 6-5/8" 40 3790 19880 5/8" 6-1/2" 40 3831 22780 5/8" 6-1/2" 40 3647 19880 5/8" 6-1/2" 80 6027 19880 5/8" 6-1/2" 80 4862 19880 5/8" 6-1/2" 80 5077 20235 5/8" 6-1/2" 125 6578 19880 5/8" 6-3/8" 125 7810 19170 I uwuc_- . : 2-6
Anchor Installation Slip Ultimate Diameter Embedment Torque Load Load (Ft. -Lbs . ) (Lbs.) (Lbs.) 5/8" 6-3/8" 125 7100 18880 5/8" 6-1/2" 25 2360 21300 5/8" 6-3/8" 25 2217 21300 5/8" 6 1/2" 25 2288 20540 3/4" 8" 125 5220 30530 3/4" 8" 125 4791 24140 3/4" 8" 125 4505 24850 3/4" 7-7/8" 175 7810 24140 3/4" 8" 175 8520 22720 3/4" 8" 175 7100 24140 3/4" 7-7/8" 250 14200 21300 3/4" 7-7/8" 250 11360 21300 3/4" 7-7/8" 250 10650 25500 3/4" 8-1/8" 300 .13490 23430 3/4" 8" - 300 12780 25560
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3/4" 8-1/8" 100 4505 24140 1" 9-1/2" 200 4970 26270 1" 9-5/8" 200 6035 24140 1" 9-3/4" 200 6745 28400 1" 9-1/2" 275 7455 23430 1" 9-3/8" 275 7808 28400 1" 9-3/8" 275 6745 23430 1" 9-1/2" 350 9588 22780 1" 9-3/8" 350 11360 24850 1" 9-5/8" 350 12825 28400 1" 9-1/4" 400 13490 25560 1" 9-1/4" 400 12780 22010 1" 9-1/2" 150 2840 22010 G & t/Ce mon eee 2-7
>+ Anchor Installation Slip Ultimate Diameter Embedment Torque Load Load (Ft.-Lbs.) (Lbs.) (Lbs.) 1-1/4" 9 './2" 325 5325 32660 1-1/4" 9 1/2" 325 5148 48370 1-1/4" 9 1/2" 325 4793 36920 1-1/4" 9-1/4" 425 7100 31950 1-1/4" 9-3/8" 425 8520 47570 1-1/4" 9-1/4" 425 8875 36920 1-1/4" 9" 550 11360 39760 1-1/4" 9" 550 9585 34080 1-1/4" 9" 550 12070 36920 1-1/4" 8-7/8" 650 12780 49700 1-1/4" 9-3/4" 650 15620 46150 1-1/4" 8-7/8" 650 16330 44020 1-1/4" 8-3/4 725 17040 34790 1-1/4" 9" 725 18460 45440 1-1/4" 9-1/8" 725 22720 49700 Concrete Data: The 1-1/4-inch diameter and 1-inch diameter anchors were tested in concrete having an average (of 6 cylinder breaks) 28-day compressive strength of 4460 psi. Two 6-inch cores taken at time of tests averaged 4860 psi. Age at time of te' sting was approximately 2-1/2 years. The 1/2 inch, 5/8 inch, and 3/4 inch tests were in concrete having an average (of 32 cylinders) 28-day compressive strength of 5820 psi with two cores taken at time of testing averaging 6410 psi. Age at time of testing was approximately 3 years. 2.5 Summarv Tabulation of Test Results and Specification Requirements Tables 1.1 through 1.7 provide a summary of the results of the tests for comparison to the specification requirements. The following definitions provide the basis for determination of the tabulated values. cautic { 2-8
I Embedment: The tabulated embedment is the average of the test specimens rounded to the nearest 1/4 inch. Installation Torque: This value represents the value of torque, implied by the test results, as that necessary to preload the anchor to 1.5 times the working load defined in the specification. Working Load: This is the maximum permissible design load for the anchor based on a minimum factor of safety of 4.0 on ultimate load capacity. Slip Load: Slip load is the average test value for the given installation torque at which initial displacement occurred. This is comparable to 1.5 times working load. Ultimate Load: Ultimate load is defined as the maximum pull-out load which the anchor can sustain, independent of displacement. The tabulated value is the average of all tests of the given diameter. Theoretical Ultimate: This value represents the manufacturer's published ultimate capacity for the actual concrete strength and embedment of the test. These values are based on linear interpolation of manufacturers published capacities for 2000, 4000, and 6000 psi concrete strengths. I l s feihert/Commemmeaath 2-9 1
s Table 1.1
SUMMARY
TABULATION FOR 1/4 INCH DIAMETER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 Item Requirement Test Test Test Test l 4691 I Conc. Strength (psi) 3000 min. 2014 4200 - Embedment (inches) 1-1/4 1-1/4 2 1-5/8 - i Installation - Torque (ft.-lbs.) 8 8 5 7 Slip Load (lbs.) 765 1000 808 937 - Ultimate Load (lbs.) 2050 1890 2287 2261 - Theoretical Ultimate 2050 1875 3148 2692 - l Load (lbs) 1 Table 1.2 )
SUMMARY
TABULATION FOR 3/8 INCH DIAMETER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 l Item Requirement Test Test Test Test Conc. Strength (psi) 3000 min. 2014 4200 4691 -
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Embedment (inches) 4-1/2 4-1/2 4 4-1/2 - Installation Torque (ft.-lbs.) 35 35 22 30 - Slip Load (lbs.) 1575 1668 1521 1680 - Ultimate Load (1bs.) 4190 6003 4988 5965 - Theoretical Ulti:nate 4190 3580 4813 4980 - Load (lbs) Table 1.3
SUMMARY
TABULATION FOR 1/2 INCH DIAMETER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 ! Item Requirement Test Test Test Test { Conc. Strength (psi) 3000 min. 2014 4200 4691 5820 l Embedment (inches) 6 6 5-3/4 6 5-1/2 Installation Torque (ft.-lbs.) 80 80 75 80 67 Slip Load (1bs.) 3990 5002 3828 4500 3990 Ultimate Load (lbs.) 10650 8141 7388 10964 9839 Theoretical Ultimate 10650 9000 12480 13200 14871 Load (1bs)
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Table 1.4
SUMMARY
TABULATION 70R 5/8 INCH DIAMETER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 Item Requirement Test Test Test Test Conc. Strength (psi) 3000 min. 2014 4200 4691 5820 Embedment (inches) 7-1/2 7-1/2 7-3/8 7-1/4 6-1/2 Installation Torque (ft.-lbs.) 120 120 90 120 75 4875 5670 4956 5007 4875 Slip Load,(1bs.) Ultimate Load (1bs.) 13000 10513 12582 14396 20388 Theoretical Ultimate 13000 9000 17400 18200 20550 Load (1bs) Table 1.5
SUMMARY
TABULATION FOR 3/4 INCH DIAMETER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 Item Requirement Test Test Test Test Conc. Strength (psi) 3000 min. 2014 4200 4691 5820 Embedment (inches) 9 9 8-1/4 8-5/8 , 8 Installation Torque (ft.-lbs.) 200 200 200 270 170 Slip Load (1bs.) 7402 8710 7275 8560 7402 Ultimate Load (1bs.) 19750 18283 18269 22345 24318 Theoretical Ultimate 19750 16000 23510 23530 23546 Load (lbs) Table 1.6
SUMMARY
TABULATION FOR 1 INCH DIAPITER ANCHORS SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 Item Requirement Test Test Test Test Cone. Strength (psi) 3000 min. 2014 4200 4691 4460 Embedment (inches) 10 10 10 10 9-1/2 Installation Torque (ft.-lbs.) 290 290 290 330 290 Slip Load (lbs.) 8565 9415 8542 9672 8565 I Ultimate Load (lbs.) 22850 20875 21865 24290 24968 Theoretical Ultimate 22850 18200 28250 2975 29225 Load (lbs.) Geert/Commonweep
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Table 1.7 SLWiARY TABULATION FOR 1-1/4 INCH DIAMETER ANCHORS
. SP-208 Nov. 1978 July 1980 Sept. 1980 Nov. 1980 l Ites Requirement Test Test Test Test Conc. Strength (psi) 3000 min. 2014 4200 4691 4460 ;
Embedment (inches) 10-1/2 10-1/2 9-3/4 9-3/8 9-1/2 Installation Torque (ft.-lbs.) 480 480 480 540 560 Slip Load (lbs.) 12690 13250 10634 12806 12690 l Ultimate Load (lbs.) 33850 22008 29636 40115 40754 Theoretical Ultimate 33850 26800 384,60 39780 39318 Load (lbs.) O l m g: - e
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s . 3.0 DATA EVALUATION 3.1 Basis of Evaluation The primary concern with the test results which lead to the filing of the possible significant deficiency was the fact that the anchors were not achieving the manufacturer's published capacity for the actual concrete strength being encountered in the tests. Questionable quality concrete in the test slabs for the November 1978 and July 1980 tests, and inclement weather conditions in the September 1980 tests, contributed to further confusion in interpretation of results. The manufacturer indicates that aggregate used for the concrete can have an effect on anchor performance. The Perry concrete mixes have a relatively high sand content. It is possible that this could have an effect on ultimate capacity. In addition,
. due to the inherent variability of concrete, the relatively small sample size used'to establish published values, and their experience with actual field testing, Hilti indicates that a 10 to 15% variation on the average of test results is to be expected. By definition, when average is used'as the basis for evaluation, half the results will fall below the average.
Lik'ewise, half will be higher than the average. However, when dealing with relatively small sample sizes (such as 3 tests), the effects of variation can become quite marked. Realizing the potential for variation in test results and in the variable nature of the materials involved, the USNRC, in I.E. Bulletin 79-02, established a minimum factor of safety of 4.0 between design load and ultimate anchor capacity for this type anchor. In view of this high factor of safety, the manufacturer's contention that results can vary up to 15% can be accepted. This becomes the first criterion for evaluation. umic . , 3-1
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l The extenuating circumstances associated with the first three sets of tests minimizes the conclusions that can be drawn. l l Although certain sizes performed favorably in one test, there ; was little consistency from one test to the next. The slab for the first test was not a typical Perry six design (i.e., low strength), the slab for the second test was not QA controlled and appeared to be poor quality, and the inclement weather of the third test could hinder performance. Therefore, the weight of the results of these tests should be treated accordingly when reaching a conclusion. This is the second criterion. The third criterion for evaluation involves the two Hilti letters concerning ultimate capacity of the 1/2 inch and 1 inch sizes. The October 27, 1980, letter (Appendix A) indicates that the one-inch bolt capacities published by the manufacturer were to be reduced. Apparently, the hardware was reaching a limiting capacity beyond which increased embedment or increased concrete strength have no effect. The February 23, 1981, letter (Appendix B) implies. a similar problem with the 1/2 inch size. The number of samples in Appendix B, far exceeds those of either of the Perry Tests or for the original published values. The fourth criterion involves the results of a statistical evaluation of the Perry Plant 28-day Category I concrete cylinder break results. Many anchor test results were less than those published by the manufacturer for the actual concrete strength being encountered. The concern was: what performance could be anticipated if the minimum 3000 psi concrete strength, as permitted by the specification, was actually encountered. One approach would be to test anchors in a Perry mix that achieved only the minimum concrete strength at 28-days. Alternatively, if it can be demonstrated that the strengths encountered during testing are typical of the Perry concrete strength's, the test results can be accepted as being typical of performance in PNPP concrete.
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The final criterion regards installation torque. IE Bulletin 79-02 requires assurance that bolt pretension is equal to or greater than working load. The installation spec conservatively requires a minimum pretorque of 1.5 times working load. Anchors installed with a torque which provides a pretension less than 1.5 but greater than 1.0 times working load can be considered acceptable. 3.2 Statistical Evaluation of Perry Concrete Mixes As a result of the concern for the influence of concrete strength on anchor performance, a statistical evaluation of the 28-day Category I cylinder break results was performed. Complete details of this evaluation are included in Appendix C. Th'e basic conclusion of the evaluation was that the actual concrete compressive strengths for concrete are considerably higher than the 3000 pst design minimum. According to the
- riteria of ACI 318-71 for qualification of concrete mixes, the lowest acceptable design strength of any of the PNPP mixes is 3794 psi. In fact, only two out of ten categories of mixes 4
would qualify below 4000 psi. The lowe st cylinder break average was 4488 psi. Half of the mixes averaged in excess of 5000 psi. The concrete strengths encountered in the test areas in September and November 1980, are therefore considered to be representative of that throughout th'e plant. 3.3 Conclusions of November 1978 Tests The November 1978 tests established installation torques according to the requiretents of the specification. This involved trying a value of torque and checking slip load. If slip load was not achieved, the torque was increased until slip load met or exceeded the requirements of the specification. Genert." . the torques established are adequate. ,The prime conci ,ith these tests was the low ultimate capacities. As 3-3
' ~
s , indicated by the Hilti, Inc. Test Report, although the cylinder breaks indicated a strength in excess of 3000 psi, the actual cores taken were considerably lower and appeared " porous", possibly due to high air content. Ultimate capacities were finally accepted on the basis of comparing the test values to the published values of the manufacturer for the 2014 psi concrete strength observed for the cores. 3.4 Conclusions of July 1980 Tests The July tests were run to verify the results of the original qualification tests; therefore, the procedure varied slightly in that the established installation torque was used and slip load was checked. Most anchors failed the slip load test and all but the 3/8-inch failed ultimate capacity for the actual concrete strength. The slip loads were typically less than those of the first test. However, there was no consistency of comparison on ultimate capacity. Some values exceeded those of the first. tests, others were considerably lower;'therefore, the manufacturer's concerns u *.th the " hardness" of the test slab had potential validity. This test cycle should be weighted low in final conclusions. 3.5 Conclusions of September 1980 Tests This third cycle of tests was performed in actual job-related concrete to minimite further concerns on quality of the test slab. The procedure for determinin'g installation torque matched that of the original tests. The resulting torques indicated that the originally determined torques for sizes 1/4 inch through 5/8 inch were adequate. Torques for 3/4 inch,1 inch and 1-1/4 inch did not provide the pretension of 1.5 times working load required by the specification. Ultimate loads as required by the specification were exceeded for all size m p. ..-,, 3-4
. . . _ . . . . . . . . _ , - , , . . ~ ,- ,._ . _- --- - -. ,,......_ .e,.,-...-
anchors. However, the rather high ratio of actual concrete 1 strength to 3000 psi created concern since only the 3/8 inch achieved published capacities for 4600 psi concrete. In view of the statistical evaluation, the results of this test can be considered indicative of anchor performance in PNPP concrete. The manufacturer felt that the adverse weather onditions in the outside environment made it difficult to keep the drilled holes properly cleaned. Rain had caused the drillings to form a paste whi.;h was difficult to remove from the hole. This paste may hasa adv.ersely affected anchor slip loads. 3.6 conclusions of November 1980 Test-This final round of tests was run indoors in actual structural concrete to preclude any further reservations on test conditions. Two adjustments in procedure were authorized with the intent of reaching more conclusive results. These adjustments were to increase the sample size from 3 to 12 and to use several torque values selected above and below the originally specified torque to enable plotting of a torque-pretension load curve for.each diameter. This plot would better define the pretensioning effects of torquing. In order to comply with the specification, a minimum of three samples at any ' selected torque value would be used. In addition, it was felt that prior tests had provided sufficient information on the 1/4 inch anu 3/8 inch diameter anchors, so further testing was unnecessary. These tests identified certain aspects of anchor performance which, although they may have been present in prior tests, they could not be identified due to the limited data or extenuating circumstances. These are: Installation Torque for 1-1/4 inch diameter anchors of a. 480 ft.-lbs. will not guarantee a slip load of 1.5 times working load as required by the specification. Geert/Cannesese l 3-5 l l l -, -. - - - - . _ _ _ . - .__....-.m.--.-._ . . _ _ , _ _ _ _ _ _ . _ - _,..._.-_m-,~_. -_
l
- b. Ultimate capacity of the 1 inch diameter anchor exceeds I
that required by the specification, but has not achieved the original theoretical capacity published by the manufacturer for the concrete strength encountered.
- c. Ultimate capacity of the 1/2 inch diameter anchor is slightly lower than that required by the specification and significantly lower than the theoretical published capacity for concrete strength encountered. l l
i Due to the number of samples in this test, improved consistency of results, and lack of extenuating circumstances, these results should be weighed more heavily than the results of prior tests. l 8 9 e 0 l l i F.wibert/C_-- .- JJ 3-6 l l __ _ . _ . _. . ._- . -- _~ -
4.0 CONCLUSION
S 4.1 1-1/4 inch Diameter Anchors Tests in September and November 1980 indicated a higher installation torque value was required. This was 560 ft-lbs compared to 480 ft-lbs used since 1978. The torque vs. pre-load plot of figure 4.1 is based on results of the November 1980 tests. This test res-Ited in the maximum required installation torqre of all the tests. Using 560 ft-lbs is considered conservative but it guarantees 1.5 times working load as required by the specification. The 480 ft-lbs originally used provides at least a minimum preload of 1.0 timea working load as required by I.E. Bulletin 79-02. Therefore, although the former value is adequate, it does not meet the additional conservatism of the specification. It does however, guarantee the minimum USNRC requirement. CONCLUSION: Incraase torque for future installations. Existing installations are adequate. 4.2 1 inch Diameter Anchors The one inch anchor capacity used for Perry designs is less than the revised hardware capacity recommended by Hilti in their October 27, 1980 letter. Inspection of that data shows that for 10 inch embedment and 4000 psi concrete, the anchor reaches its peak capscity. The September 1980 and November 1980 test results at PNPP are indicative of anchor performance in Perry concrete. These tests show that the 1 inch anchor exceeds the minimum capacity required by SP-208. In view of the conclusions on concrete strength presented in this report, it %can be concluded that the 1 inch anchor will develop its required design capacity. The originally specified installation torque is adequate. Therefore, one inch anchors installed to date sans c _ - I 4-1
- w-v
are acceptable. The recommendation to tse the reduced ultimate capacity for future designs, implemented in November 1980, should continue. CONCLUSION: Reduce Ultimate Capacity for future designs. Existing installations a're acceptable as is. 4.3 1/4 inch Diameter Anchors This anchor has demonstrated reasonably consistent results throughout the tests. Therefore, the originally specified values for torque and ultimate capacity are considered adequate. CONCLUSION: No further action required. 4.4 5/8 inch Di. meter Anchors
. . This anchor has reasonably demonstrated its performance in the November 1980 tests. Therefore, the originally specified values for torque and ultimate capacity are considered adequate.
CONCLUSION: No further action required. 4.5 1/2 inch Diameter Anchors Disposition of the 1/2 inch anchor is somewhat more complex. The February 23, 1981 letter from Hilti indicates a potential problem similar to that which developed with the 1 inch. Tests t in 5000 psi concrete (4000 psi design mix) averaged 11,804 lbs. ultimate. Tests in 6000 psi concrete averaged 11,596 lbs. j Obviously, there was no increase in capacity with additional concrete strength. The problem is that of determining where concrete strength is no longer affecting capacity. The ultimate capacity achieved in the Hilti tests (Feb. 23, 1981 letter) is i the same as that recommended for 4000 psi concrete in the Abbott ; G.ibert/CommonwealtA 4-2
l
. r ,
and Hanks tests. Since this report demonstrates that the Perry concrete typically exceeds 4000 psi compressive strength, it can be assumed that the 1/2 inch anchor is reaching maximum capability. Therefore, it is concluded that the 1/2 inch anchor will achieve peak hardware capacity in typical Perry concrete. In the September 1980 tests, the peak capacity was 10,964 lbs., slightly higher than required by the specification. In the Novembet 1980 tests, the value'was 8% low. It is significant to note that only 4 out of 21 values in the November 1980 test exceeded the 11,800 lbs. achieved by Hilti. This adds further confirmation that the anchor is reaching peak hardware capacity. All tests run at PNPP, totalling 35 samples, averaged 9843 lbs. which is again, 8% below the specification requirement. This variation is within the 10 to 15% variation on the average, indicated by the manufacturer, and is coepensated by the factor of safety established by the USNRC. The original installation ! torque established in the 1978 tests will adequately develop the 1.5 times working load required by SP-208. (Refer to Figure 4.5). In conclusion, the 1/2 inch anchors installed to date are achieving capacity within normal industry standards, and therefore can be accepted. The recommendation to discontinue use of this anchor implemented in November 1980 should be conticasd pending the outcome of any further tests by the manufacturer. CONCLUSION: Avoid further use of this size anchor. Existing installations are adequate. ' 4.6 3/8 inch Diameter Anchors This anchor was not tested in November 1980 due to the results of all prior tests. The three previous tests consistently demonstrated the capacity of this anchor to achieve the anticipated values. G4ert/Cammenween 4-3 , l
7 CONCLUSION: No further action required. 4.7 1/4 inch Diameter Anchors This anchor achieved theoretical capacity in the original test.
- In the September 1980 tests it met the specification requirement in typical concrete and was approximately 85% of manufacturer's published capacity for actual concrete strength. Considering the concrete strengths being achieved on PNPP, this anchor is acceptable. The original torque value was conservative.
CONCLUSION: No further action required. 4.8 Concrete Mixes Since Category I concrete work is nearly complete (except for the Reactor Shield Buildf.ngs) it is unlikely that new mixes will be introduced for use at this time. In the event new mixes are used, the qualification cylinder breaks should be reviewed for compatibility with the strengths achieved by existing mixes or alternatively,. anchors should be qualified in the new mix. Regarding future sampling of cylinder breaks, there is no need t.o continue monitoring cylinder breaks in the context of this report. Breaks should be monitored for compliance to specification requirements only. The evaluation in the Appendix C is based on a sufficient sample size to adequately demonstrate the quality of concrete being achieved. CONCLUSION: No further statistical evaluation is required at this time. If new mix designs are introduced, further consideration is required. GeerttCommon=ese 4-4
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e 4 APPENDICES e l I I t 1 e Geert/Camuneneeman I I w - - - - - - ,--- - , . , , .-,-,,,,-,,..e<n-,
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AWENDIX A WA1 R: port F23U4) [- i.g l [----- . e
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b~ b INC. , PASTENING SYSTEMS ( CORPORATE HEADQUARTERS P.O. SCX 45400. tut.SA. OK 74145.(918) 627-9711 Cetober 27, 1980 , I l I i l 1 l Gentlemen: I The purpose of this letter is to advise you of a change in published values of the average ultimate pull-cut performance of 1" diameter HILTI Kwik-Bolt anchors. In September 1980, HILTI, I3c. conducted in-house tes ing of , 1" diameter Kwik-Bolt mechanical expansion anchors embedded ; 7-1/2" deep in 4,000 psi design strength concrete blocks. The average ultimate tensile lead obtained for the 24 anchors - tested is 23,441 lbs. /~- The previously published independent laboratory test results , 1, provided by EILTI to nuclear power plant design firms, for this specific use', indicates an average ultimate tensile value of 27,500 lbs. Since no explanation for the reduced product performance obtained during the in-house testing has yet been identified,.we have decided to contact nuclear power plant Kwik-Bolt customers and design firm; so as to advise them to revise their on hand HILTI literature.
\
Please replace your existing 1" Kwik-Bolt data with the attached sheet. This new data sheet should be used for your future 1" HILTI Kwik-Bolt applications. j EILTI has statistically evaluated the impact of using the previously published average ultimate value (27,500 lbs.) in design calcula-tions for anchors that might perform according to :.he value obtained during the in-house testing program. Our analysis verifies that if the actual working lead applied to the anchor is obtained by apply-ing a minimum factor of safety of 4 to 1 to the existing published ultimate value, the associated risk factor of anchor failure is not increased over that for the standard use of this product. This is due to the lower coefficient of variation obtained during the in-house testing program (approximately 10% instead of the usual 12-15%). A-1 l l
1 1 P AGE .. . _ _ _ , , l. We are very sorry for any inconvenience this change may cause you, our valued customer, but we firmly believe our prim'ary responsi-bility is to is: mediately advise you of such matters. EILTI has, in accordance with the requirements of 10 CFR, Part 21, also advised the Nuclear Regulatory Commission regarding this variation in product performance. HILTI will conduct additional independent laboratory tests for.the 1" Kwik-Bolt in the immediate future. As soon as we have the addi-tional data completed, we will forward it to you. If you have any questions or require further technical assistance regarding this matter, please contact your local HILTI Field Engineer. Thank you for your understanding. Very truly yours, EILTI, INC. J - e f.. H E N ~n.~:.L , P . E .
't HERBERT Director / Technical Services HE:cib Attachment .
G 0 6 l l l A-2
I i s REVISED i 1" DI7d'.ETER HILTI KWIK-BOLT AVERAGE ULTIMATE TENSILE AND SHEAR LOADS ANCHOR CONCRETE STRENGTH EMBEDMENT DEPTH 2000 PSI 4000 PSI 6000 PSI
"~
(INC5ES) ULTI."X '. ULTO'.A"'I ULTD'.AT: ULTIMATE ULTIMATE ULTIMATE TINSION SEEAR TENSION SEEAR TENSION S~cs.AR 14000 27355 16000 26579' 20500 32112 4-1/2 . 5 15500. 27355 18900 25879 23441 32112
.- 6 17600 27355 . 23441 26879 23441 322:12 (k 7 18200 27355 23441 26879 23441 32112 8 18200 27355 23441 34491 23441 36394 9 18200 27355 23441 34491 23441 36394 10 h.8200 27355 23441 34491 23441 36394
- i NOTE: The maximum working loads should'not exceed 1/4 of the average ultin te values listed. Actual factor of safety to be used depends on the application.
g_3 10/27/30 HLH l
. 1
_ _ _ ._ _ _ . . _ . . _ _._..._ . _ _ _ ___ _ .._ _ . (
APPCIDIX 3 (GAI Report #3306) m._. [ t _l 1 L_ iuc. FASTENING SYSTEMS P.O. box 45400 TULSA, oK 74145,(918) 627 9711 CCAPORATE HEADQUARTERS February 23, 1981 Mr. John C. Herr, P.E. Supervisor-Specialty Structures Power Division Gilbert Associates, Incorporated Post Office Box 1498 Reading, PA 19609
Dear Mr. Herr:
Because of the results of the test of Hilti Kwik-Bolts performed in November at Perry Nuclear Power Plant, Perry, Ohio, Hilti has con-ducted an extensive in-house test program. Attached you will find the results of this testing. As you can see, the performance of the 1/2" Kwik-Bolt in 4000 psi concrete is satisfactory with a relatively large sample size. We feel' that there should be no problem with the use of the Hilti 1/2" Kwik-Solt in concrete with a design strength of 4000 psi. You will note in the attached figure that our cur ent re-sults fall within acceptable variance of our published data. As you can see in the results, we did testin'g in addition to those in-dicated necessary by the results at Perry Nuclear Power Plant. We per-formed several tests in 6000 psi concrete :o determine if there is a reduction in the parformance of the 1/2" Kwik-Bolt in 6000 psi concrete. Even though this should have no impact on your design at Perry Nuclear Power Plant, we feel that this information will be of interest to you. We intend to expand our test pr:: gram next month and at that time pub-lish new results if the reduction in pullout strengths indicated in our test data is confirmed. l l l 1 1 3-1 t
'Jchn C. HOrr, P.E.
February 23, 1981 Page 2
. . . - - . . _ ' '~ ~
... . . . - -We cannot account for the low ultimate pullout values during the test-ing at Perry Nuclear Power Plant. We can only surmise that there was possibly an incomcatibiiity between the 1/2" Kwik-Bolt and the concrete during that testing. - In order to eliminate any doubts in the Kwik-Bolt's performance, we suggest that additional testing be performed in proximity to where the Kwik-Bolts will actually be installed. We at Hilti will be glad to participate in this testing and will await fur-ther comment from you. Very truly yours, HILTI, INC. Dennis A. Lau r, P.E. Service Engineering Manager DAL:til Attachments xc: C. Poparad V. Kedrus H. Henkel J. Kelly W. Snyder R.L. Dixcy y J. Fairman 9 9 3-2
4/11/01' 1/2" KWIK-BOLT TESTING KEY t Samples 22S through 05-3 installed using a 2-1/2 lb. Hilti hammer. All other samples installed with a 14 pound dead weight installation i tool, l
- All samples set to 100ft-lbs unless otherwise noted.
8 All samples failed by pulling out of the hole with the wedge slipping over the end of the mandril. e G l 3-3 ! l
2/11/81 1/2" KWIK-BOLT TESTING SAMPLE BLOWS TO TURNS TO ULTIMATE PULLOUT NUMBER INSTALL 1 TORQUE 2 (LBS.) 3 PNP 49 9 2-1/2 15514 PNP 50 10 2 10644 PNP 51 11 2-1/4 10644 PNP 52 12 2-1/4 10283 PNP $3 10 2-1/2 11004 PNP 54 11 2-1/4 10463 PNP 55 12 2-1/4 13350 PNP 56 , 12 1-1/2 11726 605-28 13 4 10282 605-29 18 1-1/4 14251 605-30 25 1 10643 606-31 25 1-1/4 11545 606-32 22 . 1 11906 620-1 11 2-1/2 11004 620-2 9 3-1/2 10102 620-3 9 2-1/4 9741 621-1 11 2-1/4 11184 622-1 10 1-3/4 9561 605-31 10 2-1/4 11184 605-32 10 2-3/4 12267 605-33 11 2-3/4 11906 606-33 9 2-3/4 10824 606-34 12 3-1/4 13349 620-4 36 3/4 , 11004
- 620-5 28 1 13530 621-2 27 1-1/8 11906 622-2 22 7/8 13710 623-4 29 3/4 11184 AVG. 15 .2 11596 12.5%
Concrete: 6000 psi Design Mix, Limestone Aggregate Concrete Strength During Test: 5970 psi Drill: TE-17 Bit: TE-C-1/2 x 12, 0.515 inch diameter maximum Embedment: 5-1/4 " i 1 3-4 l
2/11/01 l 1/2" KWIK-BOLT TESTING
- oncrete: 4000 psi Design Mix, Limestone Aggregate -
?oncrete S trength During Test s . 5026 psi *
) rill: TE-17 lits TE-C-1/2 x 12, 0.516 inch diameter maximum-Embedment: 5-1/4" BLOWS TO TURNS TO ULTIMATE PULLOUT SAMPLE BLOWS TO TURNS TO ULTIMATE PULLOUT iAMPLE 3 (UMBER INSTALL
^OROUE (LBS.)
3 NUMBER INSTALL TORQUE a (LBS.) , 22S 10 2 12808 605-1 21 1-1/4 11365 23S 11 2-1/2 12808 605-2 22 1-1/2 11545 24S 10 2 11184 605-3 22 1 11906 25 PNP 18 1-1/2 12808 605-4 26 1-1/2 11004 , 26 PNP 16 1-1/2 1244,7 605-5 23 3/4 12988 27 PNP 17 1 9741 605-8 23- 2 0140 ft-Ma l3349 28 PBNW 12 1-3/4 11545 605-10 22 1-1/46125 " 11365 29 PBNW 11 1-3/4 12447 605-11 19 2-1/4 12808 30 PUNW 11 1-1/2 13710 605-12 17 2-1/4 11365 3S-1 9 3 11726 605-14 34 1 11545 i SS-2 10 2-1/2 10282 605-15 27 , 1-1/4 " 12267
)S-3 11 3 9020 605-16 18 2-3/40125 13349 503-1 26 3/4 9380 605-17 26 2-1/40125 12628 508-1 20 1-1/2 11004 605-18 21 1-1/20125 12628
- 513-1 21 1-1/4 10102 605-19 28 1-1/29125 12267
. 518-1 32 1 13710 605-20 27 1-1/2 9125 12447 i 523-1 30 1-1/4 12628 605-21 19 l-1/2 9741 626-1 28 1-1/4 9922 605-22 21 1-1/4 12988 t 603-2 25 1-3/4 lud24 605-23 25 1 17679 508-2 25 1 10102 605-24 25 7/8 15514 28 1/2 12086 605-25 28 1-1/4 10463 l513-2 29 1/4 9922 620-6 10 2-3/8 11184 ~ 618-2 623-3 28 1/2 11365 620-7 10 2-1/2 10102 3/4 14792 620-8 '13 1-1/2 9200 i 618-3 31 9561 613-3 31 3/4 11545 621-3 13 2-1/4 12447 624-2 14 1-1/2 12086 ! 608-3 32 1 26 9741 i 603-3 30 1 11726 620-9 1 603-4 24 1 11545 620-10 43 1-1/4 10463
, 608-4 16 1-1/2 11184 621-4 32 3/4 12628 l 613-4 27 3/4 11906 625-2 35 3/4 15153
)610-4 25 3 12988 624-1 32 1-3/4 9741 AVG. 25 1-1/2 11804113.5% ! 603-5 22 1-1/4 11906 608-5 18 1-1/4 11349 4 613-5 26 1-1/4 12447 (B-5)
- 618-5 26 3/4 10643
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APPENDIX C: STATISTICAL EVALUATION OF CONCRETE CYLINDER BREAKS I' C.1 SAMPLING AND RECORD KEEPING Concrete for the Perry Nuclear Plant is batched in a central batch plant operated by National Mobile Concrete Corp. The batch plant dispenses generally 10 cu. yd. units into mobile concrete mixers (Ready-Mix Trucks) which agitate while in transit to the placement point. In process testing is determined on the basis of cumulative yardage as required by the concrete supply specification and is traceable to a unique truck tag number. A minimum of 3 compression test cylinders are molded at a maximum 100 cu. yd. interval. Each cylinder is given a unique identifying number which is a sequentially increasing count of cylinders being molded for the entire plant. This unique number permits traceability to mix, placement location, in process test results, contractor, truck tag, aco batch. Total control is possible and all functions are Q.A. controlled. Four items were tabulated to permit proper identification and sorting of data. These are:
- 1. Unique Cylinder I.D.
. 2. 28-day Cylinder Break
- 3. Contractor
- 4. Mix Designation (Batch Code)
Exact placement location.was not necessary for this evaluation since the intent is to address the entire plant. If the results ne'cessitate identification of strengths by specific building or area within a building, this data could be included at a later time. U.S. Testing Corp. is responsible for in-process testing and record keeping. They were requested to provide 28-day cylinder break results for all Category I concrete. A total of 7020 records, each consisting of the four items desired, were provided in handwritten form to the GAI Reading office for compilation. In addition, an explanation of the mix code system was provided for identification of differences between mixes. A table c' these mixes is contained in the appendix. Mart /Ca - ~^
Upon receipt of data, the first step was to keypunch the information on computer cards. For convenience and ease of analysis, each contractor was given a unique numerical identifier. A total of eight contractors requested Category I concrete from the batch plant. During this preparation phase, it was discovered that the data contained 252 90-day break results. These were
! eliminated leaving 6768 records for procescing.
C.2 DATA SCAN The GAI computer system contains a library of routines referred to as the " Data Analyzer" which is merel7 a pre-programmed report generator. There are no arithmetic operations performed, i.e. data remains unchanged. The routines permit a scan of a particular data set to sort data, count variables, and print information in a specific order as requested by the user. The data analyzer was utilized several times in order to check and order the data for evaluation. As a result, the mixes used by each contractor were determined as well as extreme values for cylinder breaks. Since the Perry project is composed of several unique contract packages, it is possible to identify specific areas of the plant by contractor. Three contractors were associated only with offshore structures. These structures used minimum 4000 psi concrete and did not utilize any Hilti Kwik-Bolts. In addition, review of the batch codes indicated that values had been provided for lean / concrete fill, 5000 psi mixes used.for precast work, and for a. non-structural heavyweight concrete used for shielding. All of the above were deleted. Therefore in summary, of the 7020 records originally provided, 252 were 90-day break results, 570 were for offshore work, and 894 were for non-structural or precast work. Deletion of these records left 5304 for processing. These records involved 5 contractors and 24 mix codes. Due to a change in mix designation, certain codes refer to the same mix. These are contained in Table II of this appendix. , l Mart /Canmanween l l
C.3 FINAL GROUPS FOR PROCESSING Investigation of the rentining mixes and Tables I and II provides a basis for combining the data for* statistical evaluations. Assuming that a change in any item constitutes a new and unique mix design, it is necessary to group the remaining data by quantity of raw materials, type of cement, and chemical additives. This results in 10 different groups of data as follows:
- 1. Standard 3000 psi Pump Mixes .
Code 040 - 156 Records Code 316 - 27 Records 183 Total
- 2. Yield Adjusted 3000 psi Mixes (Medusa Cement)
Code 041 - 2475 Records
- 3. Yic1d Adjusted 3000 psi Mixes (Bessemer Cement)
Code 141 - 252 Records
- 4. Standard 3000 psi Mix With Flyash (Medusa Cement)
Code 230 - 60 Records
- 5. Standard 3000 psi Mix With Flyash (Bessemer Cement)
Code 330 - 72 Records
- 6. Modified Flyssh Mixes (Bessemer Cement)
Code 312 - 118 Records Code 320 - 58 Records Code 740 - 62 Records 238 Total l Geert/C_. - . _2
, _ ~ . - - - , - - - - - - - _ , - - , . . _ _- , _
- 7. Modified Flyash Mixes (Medusa Cement)
Code 311 - 26 Records Code 640 - 12 Records 38 Total
- 8. 3000 psi Mix With Water Reducer Code 314 - 101 Records
- 9. 4000/5000 psi Mixes (Bessmer Cement) l Code 317 - 491 Records Code 534 - 20 Records Code 541 - 32 Records 543 Total
- 10. 4000/5000 psi Mixes (Medusa Cement)
Code 318 - 1115 Records Code 434 - 38 Records Code 418 - 6 Records C. ode 441 - 173' Records 1342 Total The data was separated into the preceding 10 files for evaluation. Each file was stored on disk for access by a fortran program discussed in Section C.6. At this point it was decided that no further attempts to alter the files were necessary until at least an initial statistical run was made. Gdturt /Commonweep
,. _ . - . _ . - , . _ . - . _ _ . - _ _ _ _ . . _ , . _ . ~ - . . _ _ _
l l C.4 INVESTIGATION OF EXTRDE VALUES As indicated in Section C.2, the data analyzer was used to identify extreme values. Searches were. requested to identify any values less than 3000 psi, any l values in the range 3000 to 3500 psi, and any values greater than 6000 psi. The results were: Breaks Less Than 3000 - 7 Breaks Between 3000 and 3500 - 19 Breaks Greater Than 6000 ~- 941 The 26 breaks less than 3500 psi were matched with their compansion cylinder, which can be accomplished through the sequential numbering system. The intent was to see if the companion cylinder was equally low. In some cases the companion was equally low while in others there was considerable difference. These values were sent back to the field for verification. The response was that all values were correct as originally transmitted. Table III in this Appendix shows low values and companion cylinders. The 941 values greater than 6000 psi were then reviewed. Generally, these were from mixes qualified as 4000 psi or greater therefore the number of values was not surprising. A total of 55 of these values were for 3000 psi qualified mixes. Since ACI 214 establishes the premise that concrete evlinder breaks are normally distributed, these extreme values are not unanticipated. Further investigation of these results would probably provide reason to disregard certain values in accordance with ACI 301-72, paragraph 16.3.4.3 which states:
"If one specimen in a test manifests evidence of improper sampling, melding, or testing, it shall be discarded and the remaining cylinder shall be considered the test result. Should hoth specimens in a test show any of the above defects, the entirs test can be discarded." A check of the two lowest values, which ironiaally occurred in companion cylinders, indicated suspicion of improper 29cipg or sampling. These are questionable results since the third cylinder molded at the time broke higher at 7 days than these two did at 28 days.
Geert /Casunon=ese l l l
Sin'ce there is not a disproportionate number of either low or high values, it is felt that these will not adversely affect the results. The rationale for this approach as well as the justification for not being concerned with the values themselves is contained in ACI 214-77 Section 4.1 which states, ".. . for a given mean strength, if a small percentage of the test results fall below the design strength, a corresponding large percentage of the test results will be greater than the design strength with an equally large probability of being located in a critical area." Therefore, there is'no need to further pursue the investigation of these values and none of the data will be deleted. C.5 JUSTIFICATION OF STATISTICAL APPROACH ACI 318-71, Chapter 4 entitled " Concrete Quality", provides a basis for selection of concrete proportions and acceptance of concrete quality. The intent is to provide adequate insurance that the concrete being produced for a particular application has..."an average compressive strength sufficiently high to minimize the frequency of strength tests below the value of the specified compressive strength of the cancrete..." This section also refers to ACI 214-65
" Recommended Practice for Evaluation of Compression Test Results of Field Concrete." ACI 214 includas a complete discussion of the statistical approach to be used and identifies the fact that cylinder compression tests can be a'ssumed to fall into a normal frequency distribution curve. This fact provides the basis for the statistical work utilizing standard deviation about the mean of cylinder break results. A given concrete mix can be considered acceptable if test results satisfy the following three criteria.
- 1. A probability of 1 in 10 that a random strength test will fall below the specifiedstrengthfg.
- 2. A probability of 1 in 100 that the average of three consecutive strength tests will fall below f'.
. 3. A probability of 1 in 100 that an individual strength test will be more than500psibelowf;. Geert /Commonweena
-. _ --. _.n , ,,, , - . . ,,._,,,,,.,,,_._,,,_,_m,,. ,v.
~
The fact that concrete cylinder strengths are considered 'normally distributed permits the following characterization of valves:
- 1. 68.2 percent of all values will fall in the range of the average plus or minus one standard deviation; i.e. (i - a to i + a).
- 2. 95.4 percent of all values will fall in the range of the average, plus or minus two standard deviations; (i - 2a to i + 2a).
It is this characterization which permits conversion of the three acceptability criteria into numerical requirements. Thus, criteria 1 requires that: f e, = f' + 1.282 a Criteria 2 requires that: f er
= f'e+ 2.326 c = f'e+ 1.342 a and Criteria 3 requires that:
f Cr
= f' C
-500 + 2.326 a where:
f = average strength i to be used for establishing mix er proportions. f' = strength level used for design a = standard deviation of test results. The coefficients of a used in the preceeding equations are known as t-values. These are constants, taken from tables which relate area under the curve between established limits to the total area under the curve. Values vary with the probability desired. G.IbertICammenweeth
- . . _ - _ _, _ _ _ . . _ . _ . _ _ _ _ _ _ _ , . . . _ . ~ . . - _ . .
C.6 FORTRAN PROGRAM In the interests of simplicity, a computer program was written in the Fortran language to read the necessary values from the 10 groups of data and compute the mean and standard deviation. Since data is not printed, it was felt that a heading should be read from the data set and printed out with the results. Also, the program read a number n on the second line of the data set which defined the number of data values to be read. These two items, a heading and the number of data points, where prefixed to each of the disk files in preparation for processing. The program itself utilizes standard statistical methods to calculate mean value, variance, and standard deviation. The equations involved in determining the mean, i, and standard deviations, o are: x= E *i 3 c=!I(x -g x) /(N-1) where: x are the cylinder break results 1 N is the total number of values in the data set x is the average a is the standard deviation l A program listing is conta .2 at the end of this appendix. l I l C . 7. STATISTICAL RESULTS Section C.3 discusses the 10 groups of mixes which were processed. The l following tabulation shows the results of the statistical evaluation. I r4bert/Commoneeso ( l . l l l l
l MIXES NUMBER OF MEAN STANDARD GROUP No. SAMPLES (x) DEVIATION (a) 1 040, 316' . 183 4911 494 2 041 2475 4727 443 252 4860 444 3 141 4 230 60 4676 594 330 72 4488 483 5 6 312, 320, 740 238 5416 475 311, 640 38 5423 493 7 8 314 101 5414 562 9 317, 534, 541 543 5819 392 10 318, 434, 418, 441 1342 5971 755 C.8 APPLICATION OF ACI CRITERIA Using the results of the statistical evaluation listed in section C.7, the three criteria presented by ACI 318 can be applied. Note that the three equations are being used in reverse, that is, setting f cr = , the highest
~
allowable f' can be determined. Although the resu. ting f' may be somewhat impractical and would not be specified as a design value, it does demonstrate the relative ranges of concrete strength which may be encountered. GROUP NO. i o CRITERION #1 CRITERION #2 CRIITRION #3 1 4911 494 4278 4248 4262 2 4727 443 4159 4132 4197 3 4860 444 4291 4264 4327 4 4676 594 3914 3878 3794 5 4488 483 3879 3839 3865 6 5416 475 4807 4778 4811 7 5423 493 4791 4761 4776 8 -5414 562 4694 4659 4607 9 5819 592 5060 5024 4942 5971 755 5003 4957 4715 10 Gbert/Canmenweena
- - . _ _ , _ _ . , _ _ . _ . _ _ , . _ ,___. _ .I
APPENDIX C TABLE I: CATEGORY I APPROVED HIX DESIGNS t t llatch Cement " Material Quantities (lbs.) Design W/C hement Water Fine Agg. Cour. Agg. Strength Ratio Additivies Comments Code Type 014 . Lean Concrete Fill 110 Lean Concrete Fill 532 Lean Concrete Fill i Cheatree Neavyweight Conc. 890 Hedusa II 564 282 1490 1513 3000 0.50 - Std. Pump Hix 316 : . 040 Medusa Il 5b4 282 1490 1513 3000 0.50 - New Designatian for 316 l I 041 Hedusa II 564 282 1490 1555 3000 0.50 - Yield Adjusted 040 Bessemer II 564 282 1490 1555 3000 0.50 - Pump Mix 141 320 Bessemer 11 475 248 1347 1614 3000 0.44 Fly Ash and l Water Reducer j
~
330 liessemer II 478 282 1353 1652 3000 0.50 Fly Ash 230 Medusa II 478 282 1353 1652 3000 0.50 Fly Ash 311 Medusa II 475 248 1411 1691 3000 0.44 Fly Ash and j Water Reducer 248 1411 1691 3000 0.44 Fly Ash and New Designation for 311 640 Nedusa II 475 i Water Reducer < 312 Bessemer Il 475 248 1411 1691 3000 0.44 Fly Ash and ' Water Reducer 248 1411 1691 3000 0.44 Fly Ash and' New Designation for 312 l 7 <40 Bessemer II 475 ' Water Reducer 493.5 248 1404 1629 3000 0.49 Water Reducer 314 Bessemer II 259 1462 1484 3000 0.46 Water Reducer Original 3000 psi Mix 317 Bessemer II 564 259 1462 1484 4000 0.46 Water Reducer New Designation for 317 417 Bessemer 11 564 564 259 1462 1484 4000/5000 0.46 Water Reducer New Designation for 317 534 liessemer 11 1
APPENDIX C TABLE I: CONTINilED Batch Cement Material Quantities (lbs.) Design W/C Code Type Cement Water Fine Agg. Cour. Agg. Strength Ratio Additivies Comments
$41 Bessemer II 564 259 1523 1546 3000 0.46 Water Reducer 318 Hedusa 11 564 259 1462 1484 3000 0.46 Water Reducer Orig. 3000 psi Mix 418 Hedusa II 564 259 1462 1484 4000 0.46 Water Reducer New Designation for 318 434 Hedusa II 564 259 1462 1484 5000/5000 0.46 Water Reducer New Designa, tion for 318 441 Medusa II 564 259 1523 1546 3000/4000 0.46 Water Reducer 413 Hedusa Il 705 338 929 1601 4000 0.48 Water Reducer Tremmie Conc.
443 Hedusa II 705 338 1016 1778 4000 0.48 Water Reducer Yield Adjusted 413 436 Hedusa II 705 338 929 1601 4000 0.48 Water Reducer New Designation for 443 415 Medus. 'I 611 293 1154 1601 4000 0.48 Water Reducer Tunnels & Shafts 437 Medusa 11 611 293 1154 1601 4000 0.48 Water Reducer New Designation for 415 444 Medusa II 611 293 1218 1713 4000 0.48 Water Reducer Tunnels & Shafts 445 Medusa II 611 293 1260 1713 4000 0.48 Water Reducer Yield Adjusted 444 448 Medusa Il 670 295 1419 1419 5000 0.44 Water Reducer .i e l (
APPENDIX C TABLE II: BATCH CODE CROSS REFERENCE OLD BATCH CODE NEW BATCH CODE l 110 532 141 460 311 630 311 640 311A 640 312 430 312 730 312 740 312A 730 314 531 316 431 316 440 316 040 317 534 317 541 317A 541
~
318 434 318 441 318A 441 320 730 321 330 322 230 413 436 413A 443 415 437 415A 444 417 534 418 434 NOTE: New batch codes 'are effective Oct. 3, 1977 with cylinder number 8397. Gibert16
APPENDIX C TABLE III: STRUCTURAT. MIXES WITH CYLINDERS BELOV 3500 psi CYLINDER MIX I.D. NUMBER 28-DAY STRENGTH AVERAGE 5041 31il 1057 5042 318 1132 1095 5960 318 2926 5961 318 2573 2750 21993 041 2803 21994 041 4015 3409 5043 318 3148 5044 318 2873 3011 19753 041 3903 19754 041 2926 3415 12436 041 4847 12437 041 3074 3961 19261 041 4759 19262 041 3172 3966 22409 041 3184 22410 041' 3850 3517 20389 041 3254 20390 041 - 3573 3414 20589 041 3256 20590 041 3691 3474 6818 318 3518 6819 318 3268 3393 20312 041 4706 20313 041 33;3 401'2 25217 041 3366 25218 041 3331 3349 19514 041 4528 19515 041 3343 3936 9479 330 3613 9480 330 3401 3507 23102 041 3408 23103 041 3268 3338 GJbertICommon=ese
g APPENDIX C TABLE III: STRUCTURAL' MIXES WITH CYLINDERS BELOW 3500 psi Page 2 l CYLINDER MIX I.D. NUMBER 28-DAY STRENGTH AVERAGE l 1 25311 041 4023 25312 041 3437 3730 10295 040 5200 10296 040 3449 4325 24561 041 3799 24562 041 3472 3636 27481 041 3479 27482 041 4050 3765
- em
-i Gibert/C - _
I
S) . YO NEM4 150 FOREGROUHD llARDCOPY NNNN W OSil AllE: A594a . S T A T . FOR T C TilIS PROGR All C0tlPUT ES IllE ilE All, VARI ANCE. AHD SI AllDARD DEVI ATI0li 00000010 C 0F A GIVEli ARRAY OF llutlBERS. FOR Tile V ARI AllCE, REFEREllCE FORMUL A' 00000020 48 C 3.14, PAGE 38, OF llUNISBERGER AHD BILLINGSLEY, ELEHENTS OF 00000030 C STATIS1ICAL IHFEREHCE. TilIRD EDITION, ALLYH AHD BAC0H, 805T081, 00000040 C 1973. 00000050 IllPL ICII RE AL N8 (A-H,0-Z) 00000052 M9 DillEllS10ll X(100 0 0 ),IllDR( 20 ) 00000060 IllRT : 0 00000062 , READ (2,5) IllDR 00000064 5 FORilA T ( 20 A4 ) 00000066 READ (2,10) ll,lHRT 00000068
.d3 00000070 READ (2,15) ( X ( I ) , I :1, II )
10 F O Rl' A T ( 15. 2 X , I I ) 00000030 . F ORilA I ( 2 0 X, F 5. 0 ) 00000032 15 00000090 O xil : H 00000100 Sut! : 0.0
- 00000110 50;15Q : 0.0 DO 50 I :1, Il . 00000120 00000130 C) 'Sutt : SUH + X(I) 00000140 5U1150 : SutlSQ + X(I)hM2 00000150 50 C0HilfluE 00000160 XtlEAll : Sutt/XH 00000170
() XVAR : (501150 - (SUHNh2)/XH)/(XH-1.0) -00000130 XDEV : DSQRI(XVAR) 00060182 WRITE (6.90) IllDR 00000184 90 FORilA T ( Illt . 2 0 A4// ) 00000186 () - IF(IWRT.EQ.0) GO TO 99 00000183
!!R I T E ( 6,95 ) H,(X(I),I:1,H)-
FORilAT(lX,'H :',Il0/(IX,F15.5)) 00000139 95 00000190 99 WRIIE(6,100) () 10 X , 'llutlB ER ' ,10X, ' T O T A L ' ,12X ,
- tlE All' ,9X, ' S T . DEV . ' ,10X, 00000200 100 F0EllAl( 00000210 l'VARIAllCE'/) 00000220 l!RI T E( 6.110 ) H ,5Ull, XtlE All, XDEV ,XV AR 110 FORilAI(/llX,15,7X,F10.0,7X,F8.2,9X,F8.2,7X,F13.2) 00000230 -
d) 00000240 STOP 00000250
""C") EllD .
O
@ C"3 ll:0 bCT3 (O
lllillf. to *:" - I"""" APPENDIX C: Fortran IV Program Listing A (5 \
0 e e e e. 4 l l Pt e N W O Q @
# Z N O <
m O O M C 4 O > c S
- e o
>
- w W N A Q N G
- O M S Q
* 'A ee U
Ob e3 Z N Z W
< =
N W D h C 4 4 e O
.J N
=C O b= og C
m o U W M COOOOOOOOg 4 L COOOOOOOOOOOOOO COOOOOOOOW N 00000000000000O O O O O O O O O O c3 ed 400C0000000COOOO C00000000: O NOOOOOOOOOOOOOOO co*M M oe.=M @ cN, coo.=c O e e cO M gmN M 3 o e e e e e e e o e e e e o e e e e a e e e e e og C O 4 N M e e.= c 4 e e ome=e m m a3 O e 4c@ ** MN O M44mM e-o M eo Q @MeQN@co*NemMM N a= @ A
- ; P00RORlCINj; O O O G S 9 ,
9 9 O d O O O O O O C
- - - - - - NNOM-0OMm- .-
.) ;y ^
- 3 TEST PROG DP B2 00000010 ,
9 H= 20 t 18.20000 43.90000 I 23.50000 57.10000 43.00000 , 71.50000 I- 10.90000 . 1.60000 - 12.00000 46.50000
). 91.00000 95.40000 .
37.20000
) 88.00000 4
75.30000
- 75.30000 78.00000 y 42.40000 ,
48.60000 I 89.00000 ST. DEV. VARIANCE HullBER TOTAL NEAN 9 20 1948. 52.42 '29.48 869.36 .
! I .
8 1 i 8
. "9C"F -
c C:3 l
._:::ct 4
i f"Pt
=
-- .w e
r. 1 m-2 3 r"-- APPENDIX C: Sample Probica
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