ML20086U101
| ML20086U101 | |
| Person / Time | |
|---|---|
| Site: | Point Beach  |
| Issue date: | 10/31/1974 |
| From: | Katanics G, Eric Kim, Pfeifer B BECHTEL POWER CORP. |
| To: | |
| Shared Package | |
| ML20086U063 | List: |
| References | |
| NUDOCS 9201070207 | |
| Download: ML20086U101 (26) | |
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- WISCO!JSIll ELECTRIC POWER
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.h j WISCOtlSIN MICilIGAN POWER COMPANY POIllT BEACH NUCLEAR POWEP PLANT UNIT NO. 2 i
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v h CONTAINMENT BUILDING POST-TENSIONING SYSTEM TilREE-YJAR SURVEILLANCE
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By M k.
m E. Y. Kim
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Reviewed By I c- .u.'. pi b~ =
d b W. I ifer i Decht.el Power Corporation San Francisco, California N' m4 l Approved By _VG. Katanica 8 October 1974
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g.s TABLE OF CONTENTS !
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Section Paqc l 1.n INTRODUCTION 1-1 I j
- i 2.0
SUMMARY
AND CONCLUSIONS 1-1 i f 2.1 Summary 1-1 I 2.2 Conclusions 2-1 3 l t
f 1. 0 GENERAL 3-1 1
i 4.0 TENDON FILLER AND END AC110 RAGE ASSEMDLY 4-1 4.1 Sheathing Piller 4-1 4
4.2 End Achorage Assembly 4-1 5.0 DETENSIONING AND WIRE REMOVAL 5-1 5.1 Lift-Off Forces 5-1 5.2 Wire Inspection 5-2 a.) Discontinuous Wires 5-2 6.0 o WIRE TESTING 6-1
'/; 6.1 Specimen Selection and Preparation 6-1 '
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6.2 Test Equipment 6-1 '
6.3 Test Equipment Calibration 6-2
- 6.g Wire Test Procedure - Long Samples 6-2 g 6.5 Test Results 6-3 g 6.5.1 Percent Elongation at Ultimate Strength 6-3 3 6.5.2 Yield Strength 6-3 6.5.3 Ultimate Strength 6-3 6.5.4 Comparison With Original Acceptance Test Data 6-3 6.5.5 Fracture Characteristics 6-4 6.5.6 Specimens with Surface Defects 6-4 7.0 RI
- TENSIONING AND FILLER INSTALLATION 7-1 t
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LIST Ol' l'IGUltES O
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Tit 1e l 2
i 1- 1 Location and Identification of
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Surveillance Tendone
's - 1 Averago Normalized Wire Force vs.
Time - 1toop Tendons i
.-2 N(>rmalized Wiro Force v3 Titre -
- Vertical Tendons 6- 1 Average Nortaalized Wire Force vs.
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- j. Time - Dorte Tendons
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>- 61 Wire Test Machine Assembly
- f D-1 theu D-9 Wire Inspection Data Sheetr.
,, 1:- l t br u 1:-9 Tendon End Anchorage Sketches 8g9.
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- N LIST OF TABLES Table Title l 4-1 Sheathing Filler and Anchorage Assembly Surveillance Data
, 's - 1 Detensioning and Wire Removal Data l "-2 1
Normallred Lift-Off Forces for Three-Year r,urveillance 1
} 6-1 Test Results - 100-Inch Gage Length
, Wire Specimens 6-2 Acceptance Test Data on Wire Used in Fabricating Tendons
- 7-1 Retensioning and Sheathing riller
{ Installation Data
- c-1 Laboratory Analysis of Sheathing riller W: ,,
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1 1.0 I NTlqET IM 1he Teotion Surveillance Program is a systematic means of cs-
=ensing th 'ontinued quality of the post-tensioning system.
The nutvet nee consists of periodic inspection of a mini- 1 .
rum of nine pre-selected surveillance tendons (three hoop, three vertical and three dome) for physical condition. This provides a measure of confidence in the condition and func- j j
t lonal capability of the system and an opportunity for timely I corrective measures should adversu conditions (such as severe l'
tendon wire corrosion, where the reduction in the cross-sec- t tional area due to corrosion is so substantial, that the citi- f mate tendon wire strength falls below the required minimum '
ultimate strength) be detected.
This report covers the three-year tendon surveillance fer Point Beach Nuclear Power Plant Unit No. 2 as specified by Plant rsAR, section 15, paragraph VII, Tendon Stress surveil-lance. This report was prepared under the continued Technical j Service Agreement designated under Purchase Order No. 10447.
SUMMARY
AND CONCLUSIONS
) 2.0
{Il 2.1 Summary 1
d i Lift-off forces in all tendonc exceeded the minimum effective design puestrers force, which considers -
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- j. losses due to ent. crete creep and shrinkage and steel relaxation. f '
( f:nd anchorage assembliet were found to be in accept-I able condition with r.o sign of development of adverse conditions surh as progressive cortosion. Some mill-scale and a minor amount of corrosion were present on <
p shima and bearing plates this is presumed to have
- - been present at the tipo of installation.
The tendon wires were found to contain minor scratches, g
die marks, heat treating discolcration and some minor
'ocalized corrosion sparsely distributed along the length of the wire. This was also observed during the one-year surveillance and is presumed to have been present at the time of installation. All tendon wires inspected woru continuous.
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' Mechanical tests of specimens, with and without sur- l t
faen irnperfections, indicated the physical properties (yield strength, ultimate strength and percent alonga- l t ion) of the wire exceed initial neceptance require- l ments.
No abnormal discoloration was observed in sheathing
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Iiller sampics. Laboratory analysis of samples from I f each tendon sheath showed the amount of deleterious constituents to be well within established acceptanco l11 levels. >
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2.2 conclusions
' 11ased on the tests and investigation described herein, and on comparison of data contained in this report with data contained in the one-year tendon surveil-lance report, it is concluded that the post-tensioning
- system in the Containment Duilding for Point Beach Nu- *%
clear Power Plant, Unit 11o. 2 shows no evidence of 4
l progressive adverse 'ilslerioration.
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The three-year surveillance of point Deach Unit No. 2 Contain-tunt Du11 ding Post-Tensioning System began in July, 1974 ap-prcximately three years after completion of the containment >
ntructural integrity test performed in March, 1971. !
t This surveillance was conducted in accordance with " Surveil- {
lance Procedure for Containment Building Post-Tensioning Sys- !
tem", Revision 4, and modifications thereto, now incorporated into itevision 5, included in Appendix A.
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The identification and location of surveillance tendons are shown in rigure 3-1.
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9[TQ hl P2GURE 3-1 LOCATIO!! AND IDENTIFICATION OF SURVLILLANCE TENDONS M
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4.0 TtNDON TILLER AND ANCHORAGE ASSEMBLY l
The results of field inspection of the tendon sheathing filler
! I and the end anchorage assembly are shown in Table 4-1 and Appendix E, t
4.1 Sheathing Filler I b
sampics of filler were removed from each end of the tendon sheaths and visually examined. All samples were dark brown, f' I indicating no discoloration caused by excessive amounts of foreign ma*ter such as water.
Laboratory examination (see Appendix C) revealed that de-loterious product content of all samples tested was within established acceptance limits.
The sheathing filler coverage of the anchorheads, bush-ings and shims of the tendon end anchorage inspected was found acceptable.
4.2 End Anchorage Assembly ;
1 The end-anchorage assemblies were found to be in acceptabic condition. Two very small buttonhead splits were found at ;
, the field-end of dome tendon D3-225 which were n"t recorded d during the one-year surveillance. The difference in off- l
, size buttonheads recorded during the ors-year and three-year 1 4 (~
surveillance is not appreciable and results most likely f rom !
the use of dif ferent, c6:ibrated "Go, No-Go" gages. j
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5.0 DETENSIONING AND WIRE REMOVAL h s
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The data and observations obtainod during dotcasioning and wire removal are shown in Table 5-1.
5.1 Lift-off Forces Tendon lift-off forces obtained during the one-yor..
t and three-year surveillances are listed in Table 5-1 ;
(columns 3 and 5). To provide a common basis for com- l parison, tendon lift-off force is converted to lift-i 1
i off force per wire and normalized to account for the following effects:
a) Structural deformations (a function of the post-tensioning sequence).
- b) Initial lift-off force deviation from seven-tenths of minimum ultimate tendon wire stedngth, j c) changes in lift-off force resulting from doten-i sioning and retensioning of the tendon during the wurveillance.
d) Removal of wires during the surveillance.
s jg Normalized lift-off force in obtained by multiplying ga 4 measured lif t-off force by the normalizing f actor (see 74 formulae in Appendix D). These factors are listed in 0 Table 5-2 along with the normalized lift-off force per G wire for each tendon.
- t; ror double-end-stressed hoop and deme 6endons, an av-3 erage of the lift-off force at each end is used. The normalized lift-off forces are plotted on the Force vs.
s Time charts (Figure 5-1 through 5-3) which provide a direct comparison of measured versus predicted loss trends.
The predicted loss trend is based on a stress loss of l g
27.3 Asi over a period of 40 years (for hoop, dome and '
s vertical tendons - from plant FSAR, Fection 5), assum-
/ ing lossen diminish expot.entially with time and 70%
i, of the losses occur in the first year.
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" With an average stress icve? at installation of 0.7 fpu
! (8.25 k/ wire), the predicted average forces after one year and at the end of 40 years are 7.31, and 6.91 kips
,* per wire respectively. (See expected loss curve - Figures T 5-1 through 5-3.)
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\ The trend of prestress losses, based on average values O f or each tendon group for the or.3-year and three-year l wrveillances, indicate that the actual prostress loss- 1 g[ , < es correlate closely with the predicted prestress loss- l
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ky , The normalized lift-off forces for all nine tendons a f ", exceeded minimum effective design prestress.
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Wire Inspection, 3 The results of inspection of each tendon wire removed a for surveillance are shown in Appendix D.
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I soma minor surface imperfections (abrasions, die marks, and discoloration) were found on all wires removed.
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' corrosion level for all wires wac classified in cate-l' gory 3 or less (pitting less than 3 mille in depth). 4
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F The results of a microscopic examination of pitted Jy/, wire are shown in Appendix F. Examination of the pit-l/ ted wire showed no evidence of strees corrosion. hydro-
'5 gen embrittlement or cracking.* Since the reduction in wire cross-sectional area was not significant and no J cracking or embrittlement was observed, no significant
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), 5.3 Discontinous Wires No discontinous wires wer6 found during this surveil-f>
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') \ O' TAliLE 5-2 NORMALIEED LIFT -OFF FORCES FOR TilIZE-YEAR SUP.VEILLANCE t4 .
je k I 'd Tendon Shop or Normalizing Nppalt red Litt-Of f Force Per WlEd
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l No. Field End Factor Each End (KIPS) Average (KIPS) _ k 11K- 12 S 0.958 7.20 7.28 F 0.961 7.35
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,- D3 225 S 0.966 7.07 6.98 (y l F 0.961 6.89 D,,
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TIME AFTER INITI'l. TENSIONING (YEARS) FIGURE 5-3 NOK!iALIZED LIFT - OFT FORCE *... ilyI Fes ? M IENDONS t s
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1 I 6.0 WIRE TESTING to
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j 6.1 specimen selection and Prepatation I Appendix D identifies the specimens selected for testing. A typical section of wire (approximately 10'-0" long) was cut from each end and from the middle portion of cach wire. The specimens were trimmed to a length of i 101 inches, fitted with stressing washers and button-headed to provide a gage length of approximately 100
, inches (clear distance between buttonhchds) . As j specimens were removed from the wire, they were tagged l
with the following information: 0 (1) Tendon identification number. I (2) Sample number indicating location of r.peciinen.
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- These tags remained with the specimens through compic-tion of testing.
6,2 Test Equipment 6{ , The test assembly used for testing nominal 100 inch
$ gage length wires is shown in Figure 6-1. ,k: <[-
t Q A tensile force was applied to the wire through the
'k stressing washers inserted in the pulling adaptors, t l- one adaptor was screwed onto a threaded 1-1/8" diam-4 P eter rod anchored to the end of the reaction frame.
The other pulling adaptor was screwed onto the threao l 4f j ed portion of tne ram plunger. The 10"-stroke two-o way ram was bolted to the pulling end of the reaction
] iO frame. Tension was applied to the wire by pressuris-i t'i ing the " pull" side of the two-way ram with a hydrau-PV lic pump. The force applied to the wire was obtained from calibrated pressure gage readings.
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N e . . . . . _ . . i i l 4 4 Displacement to one percent elongation was measured uti- } ( liring one dial extensometer (having a two-inch travel
- and lowest diviuion of 0.001 inches) mounted as shown in rigure 6-1. The dial mounting bar was anchored rigidly to the reaction frame at its midpoint. The extensometer was positioned on the mounting bar to 1
; measure the displacement of the index rod attached to I the pulling adaptor. This, after proloading to s'est i
, buttonheads into pulling washers, enabled measurement of wire elongation. The elongation under load at failure (ultimate strength) was obtained utilizing a rulo attached to the gage mounting bar at the ram-end to measure the relative displacement between the index rod and the dial mount- - ing bar. Measurements were read to the nearest 1/64 , i inch. h.3 Test Equipment Calibration g The pulling assembly (gage and ram) was calibrated in a testing macnine accurate to +0.55% and -0.11% of load reading prior to tho testing of specimens. f 6.4 Wire Test Procedure - Long Samples Q The test procedure used rurallels that of ASTM Speci-fication A 421-65 with the exception of gage length.
! A nominal 100 inch gage length (instead of 10") was ! chosen to obtain a longer sample more representative of the actual in-place strength of the wire. The 100 ;
inch gage length specimens may indicate a lower ulti-mato strength and less ductility (elongation) than 10 ' inch specimens, since failure will occur at the weak-est point in the wire (equivalent to the lowest value ! that would be obtained from ten 10 inch specimens). Elongation ander load at failure will also tend to be less due to distribution of elongation at the neck-down area over a length of wire ten times that of the nomi-nal 10 inch gage length specimen. D i b r , I ($/ , 6-2
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\ 6.5 Test Results i
/~1 The resulta of tests on 100-inch gage length samples are shown in Table 6-1.
6.5.1 Percent Elongation at Ultimate Strength 1 Due to the effecta discussed in paragtaph 6.4, wire t tested using 100-inch gage length specimens is ex-pected to exhibit less elongation at failure than { 1 l identical wire tested using 10-inch gage length speci-I mens. Based on other test data (1), a wire exhibit- , ing a 4% ultimate elongation by 10-inch gage length ! tests is expected to exhib't a 3% ultimate elongation l by 100-inch gege length tests. All wires from the ntne tendons exhibited elongation > i exceeding 4.0 percent. {
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sg G.5.2 Yield Strength \{ The yield strength of all wire specitiens tested ex-g
! ceeded the specified minimum yield strength of 192 ksi j ,
at it elongation.
;p 6.5.3 Ultimate Strength
>d The ultimate strength of all wire specimens tested *
? exceeded the specified minimum ultimate strength of I; 240 kei.
E y 6.5.4 comparison With Original Acceptance Test Date i, The range of ultimate strength of the samples toeted i compares well with that obtained in acceptance testa j p (see Table 6-2). i u
) (1) The test results comparing elongation at failure of 10-inch and 100-inch specimens are reported g
in Consumers power Company, containment Building F post-Tensioning System One-Year Surveillance,
- Falisades plant unit 1, Docket No. 50-255.
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-- 6.5.5 Fracture Characteristics !
All breaks indicated a necked down cup-and cone " % fracture area. The ultimate stress of all tested j wire samples with breaks at the buttonheads -xceeded f:
" tne minimum specified ultimate strength of 240 hsi. ;
Approximately 50% of all breaks occurred at tho !
,i buttonheads and the majority of these breaks revealed 4 typical fracture characteristics resulting from com-p(? bined ficxural and axial stresses. The flexural ; -' I stresses are resulting from a night eccentricity of the buttonhead,
(!{ p 6.5.6 Specimenn With Surf ace Defects p< E A comparison of wire test results for 100-inch spe-cimens with and without surface defects indicates that there is no detectable decrease in strength and physical properties of wire specimens with % surface defects. f k '.
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i g , i O TADLC 6-1 TEST RESULTS FOR 100" GAGE LI:NGTil WIRE SPECIMENS I h ' l':y 1 Q tenden Sample 17. Yield Stres dlUmate Stress Percent Location oI , No. flo.(1) (KST) {KSI) Elongation Pailure (2), ' f ur-22 1 201 253 5.3 M ! ! a 2 205 255 5.8 M 3- 3 212 255 J 5.9 M My-39 1 199 247 4.3 n11 N. 2 203 251 5.7 M ,/ 3 210 252 5.4 M hNt-b 1 205 253 4.9 M ' [
+
2 208 251 4.0 Bil 3 208 253 4.8 Bit g
/, v-226 204 1 250 4.2 Bit 2 203 248 5.6 M
[u - 3 201 248 5.5 H v-278 1 208 255 5.5 M
- h 2 204 251 5.7 M 11 3 210 253 6.3 g,, O V-339 M
1 205 251 5.1 Bli 2 203 249 4.4 j 3 203 251 4.6 Bil Bil
'A D1-223 207 1 250 4.6 Bil 4
2 208 253 5.1 Bil
, 3 203 2:0 5.0 B}l t
- D2-227 1 205 264 4.0 M 2 218 263 4.6 Bil 3 218 263 4.3 M a-D3-225 1 208 254 5.5 M
[/,' 2 201 200 251 5.4 M 3 253 4.6 Bil jd [ NOTI:S p p( (1) See Appendix D for sample location on wire. 11, (2) 0 11 - Failure within 1" of buttonhead.
- J M - Failure within r. , adle portion of wire.
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6 _,. . . _ _ _ . , _ _ _ _ i t : i - . , N 4 i l I l TADLE 6-2 ACCEPTANCE TEST DATA ON WIRE USED IN FABRICATING TENDONS , l O I TJ Elon Ultimate St::ength (ksi) Yield i hark coil No. Heat No. sample A sample D Strength (KSI), n HK22 281 40320 255 256 215 ; 1 291 40320 254 263 215 E, 755 28459 251 248 214 , i
. y MK39 176 16858 253 258 219 '
'1 187 16858 249 251 219 3 731 40319 251 254 210 MuS4 362 40066 255 247 222 370 40066 254 249 222 470 40066 252 252 222 v-226 468 15493 247 251 213 t 469 15493 240 249 213 8 470 19493 242 252 213 V-278 250 15493 247 254 212
, 257 15493 244 251 212 i i
.e V339 704 27503 248 252 2 f7 '
709 27533 240 255 217
+ { 722 27583 246 251 217 '
737 27583 251 y 249 217 {t i D1-223 696 15492 247' ' 245 211 713 15492 249- 251 211 720 15492 247 . i251 211 D2-227 761 15492- =247M h 6248 211 763 15492 257 4 i p ~fv 261 21' 872 34158 253~ 247 23' D3-225 46 34155 251 253 215 j 150 15401 252 253 215 165 15401 251 255 215 i
.j NOTES:
! w D
] 1) The minimum ultimate strength is 240 kai.
.? 2) The minimum yield strength is 192 kai at in clongation.
- 3) Samples A&B are the results of the two tests to deterr.8 ne ultimate O- strength of each coil d.uring tendon fabrication.
1 1 l 3 4) The yield strength is determined for each heat during wire s manufacture, h, 4 g .___ .. _ __ _. N =Y' '$E fN'
e n n - m c;y: m : n = n _ . -. . . - . I {' r O 3 7 0 h i [ - h 7 Dial Gage j
,r E Mounting Bar Indicator Needle ,
'- s Rule Anchor End g/ Threaded Rod
- Stressing Washer
>st Frame 2-way Ram
- f p' Index Tab Pulling Adaptor l
4 t Index* Rod Test Specimen
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Pulling Adaptor f y Stressing Washer
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g , Adjustable Eypass Valve Hydraulic Electric Pump
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FIGURE 6-1 Wire Test etachine Assembly
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1 i g i 5 7.0 RETENSIONING AND FILI.ER INSTALLATION 5, O.
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The data obtained during retensioning and filler install-I ation are shown in Table 7-1. i i 1 e The tendons were retensioned to approxit*;.ly the same stress level indicated by lift-off1 force data ottsined during this surveillance. Additional elongation stas mcarured as indicated by data. ' { The volume of shecthing filler removed and replaced was recorded. l The retensioning information provides input data for use in the next scheduled surveillance. k 4 .O b w N
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