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- a Bechtel Associates ProfessionalCorporation Inter-ottice Memoranoum
.Decemberh,1979 Tc-T.E. Johnson Det' - Setje:.. Problem Alert From E. Rumbaugh Large Settlements Due to Incorrectly Placed Backfill Of Engineering
- Ccpies to K.,n.iedner At Ann Arbor J.-Milandin
-It appears _that K. Buchert's TPO Problem Alert will delete a lot of the substance from your draft and may not fully cover us in future backfill operations. I suggest that we de the following: 1. Try to get the TPO Standard Specs. revised to cover future work similar to your draf t problem alert and appropriate new TP0 Specs. issued-(See Section V of your draft). 2. Use the TPO Proble= Alert and your draf t problem alert as' commentary with the TPO Standard Spec. so anyone in this office will have benefit when using the TPO Specs. in the future. SD OLO1 / T ~
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o,1, November 28,1979'.7' To ' E. A. Ruabaugh subjec. Problem Alert - Large Settlements p,,, J. Milandin C '.~=.y#. - Due' to Incorrectly P1 aced Backfill b' J. 3 7-of Quality Assurance m . it-- i Copies to - At Ann Arbo f ~.. T. E. Johnson W. T. Kellermann / i__. u C. A. Tuveson-S. L. Blue /1 ..S. I. Heisler i/_, 'M = i 4J4f. m g -;" i The subject Pmblem Alert was originated by Ted Johnson as MJ of _ a meeting which we held on June 13, 1979. Tne Problem Alert was, in effect, issued to take advanta'ge of the Midland problem by providing - for certain revisions in our specifications and controls to preclude such a situation from recurring on another project. As you recall, I suggested -the Problem Alert. Ted Johnson has been working very closely . with me to insure that QA concerns were included. Ted issued the report to Ken Buchert on October 19 and received a reply, attached, from Xen Buchert,.appamntly incorrectly dated, on August 27,1979. Buchert's reply, in'effect, deleted all the recomended corrective actions by the Ann Arbor Office and effectively stated corrective actions which are essentially the same as the present. program. Without the AA0 mcomendations, the Problem Alert is truly incomplete. It will not-prevent-the' problem from occurring again once this Pmblem Alert has been filed. Tne idea behind the recomended action of the Ann Arbor Office was to.perserve these experiences by revising generic specifications and control procedums which govern the placement of backfill. It is requested lthat you look'into this matter to detemine why'the San Francisco Power Division Civil Structural Chief rejected the corrective . actions proposed by the Ann Arbor Office. Each of those actions, which were preposed, were tied back to pmblems which were identified during the course of the investigation and were carefully developed to preclude the recurrence of such a situation in the future. Tnemfore, as the situation now stands, if.the office follows through on the Buchert August 27 letter, new projects may fall into the same situation as Midland did when memories dim. Please respond by 12/12/79. Please advise whether yo'u consider this a matter to be handled by an MCAR. \\., Cr, . Miiandin JM/le M-79-122 File: AAO-QAR-79-66 SB 033n2 g ry w n p -e w- -e. ,-----y y w--gg e -,-w e-.e y9,i .*,-v.sem awypmyC---et.r, +--e-e -wg e-- w.m-
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or w. Inter-office Memorancum - To J. Milandin Date Neve=be r 16, 1979 4 ~ Subject Problem Alert From. T. E.-Johnson Large Settle =ents Due to Incorrectly Placed Backfill Of Civil / Structural - Copies to Tile: 502 At Ann Arbor Office Attached for your information is a copy of the TPO response to the proposed problem alert on incorrectly placed backfill sube.itted for res-lev by c:y IOM dated October 19, 1979. /', f- ) \\ / f.B(M/~ / G.,Tuveson for T. E. Johnson Tr.7/cT/wh Attachment. i I i.UC!Vtu F A';f t Af:%'. QUA:.1TY MtUTANc5 l w:. l i.e. 5.,,1 1 sw i LCi.R- --._ ~l ldh.i D;J hill.:'- --aJ DtG 1. :C J) SU.bi'_ ' fsM.iis..j!, ! '. -3 _- a .e [ Sg a t
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b6Chiei ro ver wpora,w., Interoffice Memorandum i. Distribution- ,.f ~ 2.0, 2.2 d j '/ so..n Soil Fills, Bechtel o.s. - August 27, 1979 Generic Position r,.. K. P. Buchert SFPD - Civil / Structural oi w. MET /34/B9 in 0552 = t s The following Bechtel. Generic Position on soil fills has been finalized after coordination between Engineering and Construction, l.- See that soil report, PSAR, and. specifications are in agreement on all . proj ects. Test fills will be used on all projects. 2. Assign a Soils Field Engineer in Construction (Bechtel Construction or on a Subcontractor's staff) to oversee fill operations. Testing will normally be done by a testing laboratory. 3. QC will be responsible for surveillance of the work done by the testing. laboratory. This will be done if Bechtel does the work or a subcontractor does the work. This will be in addition to that done in item 2. 4. Construction will prepare an inspection pl'an and it will be reviewed by Project Engineering with consulting by the Civil Chief's staff and by H&CF. Acceptance and rejection limits will be'specified. 5. H&CF soils representative will make periodic visits to the site to make an overall review of entire operation to detennine if performance criteria are met. Please proceed with implementation. w-X. P. Suchert KPB:sih Distribution A.-J. Arnold (GFD) 4 t W ohnson'9 AAU) W. P., Ferris (H&CF) A. L. Cahn R. J. Kosiba (LAPD) R. A. Schnaible (H&CF) s J. A. Dunlap M. J. Mitchell H. B. Friend J. H. Mulay (M00) R. F. Gibson K. Wagstaffe (HAO) D. W. Halligan Civil Supys. SB 03394 ....... v 'i n. i
39 Chiel ASSOOiEiss PTOISSS!O3E;L0rp3rEuc Inter-o!! ice Memorandum To K. P. Eucher: Date Oc cber 19, 1979 Subje:. ? oble= Aler: From T. E. Johnson Large Se::lener. s Due to Incorrectly Place Zackfill of Civil /S uctural Copies to Tile: 502 At Ann Arbor A. J. Arnold P. A. Becntl R. J. Kosiba J. Milandin K. Wagstaff A : ached for your review is a copy of the proble= alert on incorrectly placed backfill which occurred,a: the Midland jobsi:e. I strongly urge .you to issue.this as a TPO problem alert. A copy has been coordinated with P. Secnel of San Francisco Legal, and his con =ents have been incorporated in the attached draf t of the problem alert. ' d 9W I T. E./Johnson TEJ/j s Attachmen: I S 6 6 Sij o 3 a..05 e
~ Bechtel hssociates Professionaj Corpore Inter-office Memorancum -K.P.Ju/ f/)^ . To che.rt Date October 19, Ic79 / subje c. - Preblem. Alert From T. E.' Johnson ' Large' Settlements'Due.to / -' Incorrectly ~ Place Backfill of Civil / Structural / , Y'g ( gep;n to File: 502 ',,'s,, [v At Ann Arbor l A. J. Arnold .. t. \\ P. A. Becnel f
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/ p. w J. Milandin, j f / K. Wagstaff d0 ,s ' [, - /' /. '{ 5 h i >~} il-j ,,/ ~ 0 j Attached for your reviev is a copy of the proble= alert on incorrectly placed backfill which ocedrred at the Midland jobsite. I strongly urge you to issue this as a TPO problem alert. A' copy has been ccordinated with P. Becnel of San Francisco Legal, -and his comments have been incorporated in the attached draf t of the problem alert. g.gy y f ./ j,.g['c;'::t. E::.~.: ::: -?. T. E. Johnson ty.r ..n - - .r-. .s v TEJ/j s j,-[ j 3 t.- Copied for: M au3thntend 3 50 A. J. Arnold _1;. "._ ' _ _...
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i K. Wagstaffe i . - ~ R. J. Kosiba C ~~ P. Becnel i ~~ e R. F. Gibson i A. L. Cahn i J. N. Mulay !$J" 8 E' i r c-- c o =.7EDf Sections I, II, III generally okay. Delete Sections IV, Y, VI, VII. Add my memo. KPB Ed Salinas, please prepare TP0 Problem Alert. KPB 11/9/79 "3Gog
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~ ' EE U$ID I!: DIVC.0?I!;0 APPR0pK1ATI 1:07:FICATIO!;-OR T.ICO.T:C; DATIO :S TO CLII::!S,177 ?RIVILI:;ID OR OTHIRWISI SI::SITIVE I:70??.'.TIO:: SHALL ::DT II Iy. m.CTID',ITHOUT_AIOVI APPROVAL. -4 L* sci [line: Civil Engineerin Origin: Ann Arbor
Subject:
Large Settlements Due to incorrect 1v Placed'Iackfill Discipline Proble=' Alert Nu=ber: I. APPLICA3ILIIT e ' These conditions are applicable to all-proj ects where structures are supported fully. or partially by co=pacted backfill =aterial. . II. PROILD: DISCRIPTION Insufficiently co:pacted plant area backfill under the diesel generator building was discovered because of excessive settle =ent during construction. The settle =ent =enitoring progra=, which. is . designed to detect such conditions, did aler the project to this ,l. proble=. Further investigation by a soils-boring progra= has _g indicated that both granular and cohesive soils were i= properly co=pacted in other areas of plan: fill as well as at the diesel i , generator building. Tnis required extensive reanalysis and/or
- =odifications of the diesel generator building the service water
[ - structure, < the feedvater isolation valve pits, and portions of the .~ auxiliary building. L Iased on a thorough investigation, the =os: probable causes for the resulting re=edial work include the following. 1-A. . All types of co=paction equipment used for plant area backfill-r vere no: prequalified for lif t thiebess and nu=ber of passes. Tnis was particularly true for the s=all hand-operated equip =ent. 1
- Ixcept for the prequalified heavy earth-=cving equipmen: used to construct the plant area dikes, reliance was placed on
' acceptance being established by and result AST/. acceptance tes:s. 4-T 13. A review of test results by the geotechnical soils group has shown that the testing laboratory failed to obtain =eaningful .c and. accurate results af ter perfor=ing the applicable ASD: acceptance tests. Some exa=ples are the following. 1. More than one-half of the tes: results for relative . L._ density and percent co:paction vere cu: side the thecre:ical comparison limit. l. SU H3307 i f:^ e e -,-rc-tM r--w+ w wt--t1 m w, ,-,we.-m-w-.-- e-w+---t-*--e---e&w*ni,a-+ +-e-t-amp-miw+--v-n--r-i+--e'en*---y-w w w-fr~*--w-*,v=---v---v-' 9 Y
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Incorrect soil indentifica: ion end calcula: ion c :c:c ware presant. 9 3. . Clearing of f ailed tes:s was improper.or ine==ple:e. . III. COE?.ICT_VI ACTION T/J'EN WERE pp.CEI.EM OCCUp.EED ' The structures are being =odified to ec:pensate for the in A.: situ soil-ccnditions using the following solutions: 1. Underpinning by the use of caissons or piles fer pertiens of structures partially supported by fill 2. Reduction of ' residual settlement by surcharge loading the strue:ure totally supported by fill 3. ell =ination of the possibility of liquefaction of extensive sand backfill areas during a seismic event by installing a per=anent devatering syste= E. The earthwork specification has been revised to provide more guidance to construction. The specification now requires co=paction methods be established which include the nc=ber of - passes for a given lif t thickness for all approved equipment. C. The quality control (QC) department has rewritten its inspection plans..Instead of essent.ially providing a surveillance _ program for the ad=inistrative aspects of the soils testing progra=, an inprocess, in-depth inspection progra= has been adopted. This program includes the verification of equipment qualifica:Lons for the placement methods adopted. D. A resident-geotechnical soils. engineer.has been assigned to the site to oversee the_ backfill operation. .) E.- The soils testing laboratory has been =ade aware-of all testing discrepancies and has taken actions to prevent recurrence. , I Procedures to control testing activities are now being provided. L .7. I- ' All of the construction 2quipment to be used for cc pacting the various types of soils at the site has been qualified to i a =axi=u= lif t thickness with a specified nu:bar of passes. i i IV. ACTION TO EE T.U*IN ET EECHTIL PROJECTS { ~ A. Each type of co=paction equipment should be qualified at the l jobsite for the respective type of soils to be cc=pacted. [ This qualification includes lift thickness and nu=ber of passes, which adds a method criterion to the perfor=ance l~ criteria for acceptance. However, the final acceptance criteria are still to be. based on testing by_the appropriate ASIM . acceptance standard. l L Sn oJ.J.OS o I. l ,~.. .a..
~ E. A project soil enginac: and a field soil engineer shcu;d be assigned to each =2jer project. The prcject soil engineer is ~ assigned by the geotechnical services deparrnen and reports to the head of the scils group in the engineering of fice. The 7/ field scil engineer is en the project cons:ruction staff and 1 reperts directly to the construction superintendent. Ihe 1 field soil engineer vill be hired by 3echtel c:ns: rue: ion or i r i retained through a subcentract with an outside ergani:a: ion spe:iali:ing in soil engineering. project engineering and the geotechnical services group will reviev.the qualifications of the candidate for field soil engineering and monitor the adequacy of his technical perfer ance. The project specifications should clearly establish the responsibilities of the project and field soil engineers. As a mini===, the proj ect and field soil engineers will have the following duties. 1. The project soil engineer's respcasibili:ies will include, as a =ini- , the coordination of all project soil engineering activities, the continuous review of soil-related construction activities, and the monitoring of the technical perfor=ance of the field soil engineer. 2. The field soil engineer's responsibilities will include, as a minimum, the =onitoring of fill place =ent activities, soil testing laboratory activities, founda:ica excavations and pile or cassion foundation installations. In addition, he vill coordinate all soil-related activities between project engineering /geotechnical services and construction, and forward progress reperts to project engineering. t 3. In the event the soils and fodnda: ion work becones minor, project engineering /geo cchnical services =2y agree that a full-time field soil engineer =ay not be needed. The project soil engineer vill then assu=e the responsibilities of the field soil engineer. C. Quality assurance manuals and vendor procedure canuals for the soils laboratory testing should be reviewed by geotech as well as proj ect engineering. D. A caxi=um 11=1t of the nu=ber.of ti=es a proctor curve =ay be used as representative of the caterial being placed should be established. The procedures =anual should be reviewed by geotechnical services as well as quality en;ineering to ensure that proper controls are outlined. E. To =ini=1ce errors in testing, the soils testing laboratory should include the following practices in its testing pro-cedures manual. i-t E5] (l.*Jo* rq9 e64
) -~ / '1. ' Cohesive Soils - The :isture con:ent associa:cd with a J given-field density cannot fall cu: side the ':cro air voids curve for the respective specific gravity. 2. Cranular soils - The stockpiled =aterial sheuld be tested for relative density by both the ve: cnd dry
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ce: hods as defined in :h,e ASIF. s:andards to ensure tha: the taxi =um relative ~ density attainable vill be used in . placement. F. Zackfill Under Structures
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To ensure that' proper cenpaction is obtained, the frequency of plotting proctor curves or maxi===/cini=u= density tests should be increased. 2. Consideration should also be given to perfor=ing static plate. bearing tests as defined in the ASTM standards. The project or field soil engineer should have the option of requesting this type of test when appropriate. V. ACTION TO 3E TAKIN BY THE TPO CEIIT CITIL/STRUC'NRAL D;GD?IER A. TPO Specifications C-441 Rev 6 and C-442 Rev 0 which are the materials testing services specifications for both nuclear
- pejerTplan:s and fossil fuel power plants are to be revised to eli=inate the soil laboratory testing section.
-B. New I?O soil laboratory testing specifications are to be issued by. Tebruary 1,1980. In addition to the infor=ation presently i= I?O Specifications C-441 and C-442, these specifi-cations should be expanded to include the following ite=s: i 1. Establish a limit on the nu=ber of times a proctor curve may be used as representative of the material being placed. 2. Require a check to ensure that for cohesive soils the moisture content a:sociated with a given field density does not fall outside the zero air voids curve. 3.' Require stockpiled granular soils should alwayt be tested
- or relative density by both the vet and dry methods as defined in the ASTM standards.
4. Require procedures to. control testing methods. _C.. Keevaluate and revise as necessary the soils sections of the folleving T?O Specifications by' February 1, 1980. e '%29 v e y ,-e- -r---v.- w e - rw + --r &-a,--+-v-we,w-------%--*ra-*- e-wr-<.- +-r-r r - --, 3 +v+ -w,,-=*--et++-*-c-s- e i-ee w-t*
C-033 Riv 1 Site C cding s C-052 Rev 0 Pressure Water Piping, Furnishing and Installing
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C-053.2 Rev 1 Turnish and Ins:cIling Yard Fire ?:c:ection Systen 'i. C-054 Rev 0 S:or: Sever, Furnishing and Installing C056.1 Rev 1 'lurnishing and Installing Culvert C-058 Rev 2 Constructing a Sanitary Seve.: C-062.1 Rev 0 Circulating Water Pipe Ins:alla:Lon (S: eel) ~' ,C-062.2 Rev 0 Circula:ing Water Pipe Installation (Cencrete) C-314 Rev 0 Circulating Water Pipe Installation (Fiberglacs) C-234 Rev 2 Structural Encavation and Earthwork Construe: ion VI. FURTEIR INFO??.ATION For further infor=ation contact G. Tuveson, Ann Arbor office, (313) 994-7727. s VII. FURTEIR COORDINATION Reevaluation and modifications of the T?O specificatiens sh uld be coordinated with the geotechnical services departnent of the E&CF division. 10/17/25 SD o3v.11
f ~; 'l* W U J (!4H 8 j 1. Cues tion: tiith available information, provice the best estimate of the type and quantity of fill (i.e., lean concrete, sand, or clay) within the limits of E075 to E430 and 55225 to 55036. Also, provide plan and cross section sketch of such information. Recponse: The engineering protrayal provided in the early cross J section developed by Engineering provides the infor-mation req'uested above to the same level of occuracy which the field would provide if we were to generate a similar drawing. The only exception to the forgoing is the case of Ican concrete where we note (via a review of personal records) that the attached annunts of lean concrete were placed. f t SD l'?S.96 ~ = ,,,--.-,mww wmm--
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~ -. m ol;r-3 4 ~'s io-lW. q W* + s [ MIDIAND SOILS c CHRONOLOGY AND SUFyJaY s ~ Soils placenent on the Midland job is broken down between cooling pond dike
- construction and plant fill. nis write-up will address the soils placacent l history for both' areas, however, greater detail vill be provided for the f plant, fill as thakis the area where significant soils proble=s have been
' encountered. ~ A subcontractor (Cannonia, Inc.) constructed the dikes during the period of 1969-1950 and 1973-77. ne original contract was lac to Cannonie in 1968. The dike design is basically a clay berm with a sand core, ne dike was designed to be constructe'd ~ from on-sita clay materials and imported sand. Shortly after work started, it was discovered that sufficient specified clay materials were not available on site. In response, Project Engineering revised 'the specification to allow greater fines (i.e., delete the requirement that. not more than 60* pass: the No. '200 sieve). York continued and the emergency cooling water. pond i.as essentially completed and some dike work complaced ' prior to subcontract closeout in 1969. - nis subcontract closure was a part cs, of project shutdown due to licensing problems. s The subcontract-vas rebid in -1973 upon project reactivation and was again 4 'N awarded to Cannonie. The previous specification-change on increased fines [ ,was* omitt ed rem the new subcontract specification and had to be added after award. g. N ' Cannonia. contihuously complained about the lack of " good soil" to build ~ w x 1-I \\ SB 17131 x. ' 4e
m. i / it. 2_ 1 haul roads. - Even when veu compacted by heavy earth moving equipment, the roads turned to quagmires when heavy rains feu. Cannonie also experienced continual problems with moisture control in the borrow and fin - areas. In 1975 a contract change was negotiated for over $1,000,000 to compensate Cannonie for changed conditions. Cannonle completed the pond dikes, the plant area dikes and the north plant fill during' the 1973 1974,1975 (part thereof) and 1976 seasons. In 1977 Cannonia returned to the site to complete site fill south of the power block - part of which had been completed by Bechtel. 'The specification for the dike construction required the-use of mechanized. equipment'for fill placement and compaction. It.also required this equipment and the==v1=um lift thicknesses for which the material 'vas to be placed to be qualified.- These qualification tests were run and documented. In process acceptance of fill placement was based on the number of passes of the equipment, the minimum number to achieve compaction being determined in the aforementioned tests. Final acceptance of the clay fin.vas based on in place density and moisture tests taken within specified - frequencies. .Cannonia's Quality Assurance program included an on site quality control engineer to provide a continuous overview and inspection of their work. His duties included verification of proper equipe.ent selection and performance, material lif t thickness, number of roller passes and - maintenance of quality related documentation. The Bechte2 Subcontracts Sg t*/132
+ _3 ' Group -administered the subcontract for Bechtel while the Bechtel Quality Control Department provided a surveillance inspection over Cannonie's Bechtel's Geo-Technical Q-listed work for the period -of 1974 thru 1978. Group ~ provided an overview of Cannonia's work by a series of periodic 1973-1974 These site visits were most frequent in the site visits. Bechtel's Quality Control Department was responsible for ~ vork period. reviewing the in place moisture and density tests for final acceptance of There were Bechtel and Cannonie generated conconformances dika. material. over. the dike work. - These nonconf ormances have been resolved owing in part to borings taken to qualify questionable materials. ' Plant area fill (which is essentially complete) has been placed by both Cannonie's work was limited
- a sithcontractor (Cannonia, Inc.) and Bechtel.
to placement of large, open plant fill areas with mechanical equipment, h id While Bechtel generally placed smaller areas inaccessible to =ec an ze Bechtel has, however, placed some equipment with " hands on" compactors. Placement of plant fill areas of plant-fill with mechanized equipment. has extended from 1974 to present. There are some noteworthy differences between.the dike work and plant fill which should be examined. First, the Project Engineering call out for )lant fill, including that under Q-listed s':ructures on fill, consisted Random fill, by definition, could consist of any. site of random fill. materials which were free of humua, organics, or other deleterious material' that could be compacted to meet specification requirements. Concrete could be and was utilized as a random fill material at the SB 19133
~ ^ . w: 4-discretion of the field engineer. There were no specification directions prohibiting or specifying the use of 'different types of random fill materials -in -a co: anon area. Layering of different random fill materiala was allowed. Secondly, the acceptance of plant fill has been based upon meeting the specification compaction requirements as determined by taking -tests within specified frequencies as opposed to a number of equipment passes., The specification did specify maximum lift thicknesses (12" for . clay and sand) and required that, qualification tests be run to verify . that' the compaction requirements could be met. Qualification tests were run, albeit, as production tests on fill placements. 'The Project Engineering documents for compaction of clay materials used - for plant fill have been contradictory in the past. The Dames and Moore soil report, which was a part of the PSAR, specified a compactive effort to yield 95% of the maxi== density by ASTM 1557 Method D. The " Placement" .section of the projection specification indicated that the material should be placed to meet the aforementioned criteria, bovaver, the " Testing" section of the same specification called for the material to be tested -to 95% of maximum. density by the Bechtel Modified Proctor (BMP) (95 mar 4== density by the BMP is equivalent to approximately 90 maximum - density by ASTM 1557 Method D). The projec't specification for the on site materials testing subcontractor (U. S. Testing, Inc.) also specified-that ithe clay material be tested to 95% of maximum density by the BMP. Field -Engineering questioned' Project Engineering on this contradiction and were advised that 95% of maximum density by the BMP was to be used. Geo-Tech caintains that Project Engineering was in error in their position; SB 19134 -b'-. .,r- -..---,,w-.%,, ..-ww. r,--,,-, y. ,-~,,,--,0 w$,,.-,-...,,m.-y,,.,-y, ..,,-,,..ww.-- ,-.-.,,,,.,-we,y--., yw-m--.-
E' , 9 specifically, 95% of maximum density by ASTM 1557 Method D has always been.and. is still required. Project Engineering did revise the affected specifications recently to require 95% of maximum density:by ASTM 1557 Method D, however, the field. has only been able to qualify a. single piece of hand held compaction equipment (" jumping jack") at a-4 inch lift thickness. All other hand held equipnent has failed at the 4 inch lift thickness. Attempted qualification of a 25,000 pound dynamic forca sheeps foot roller at an 8 inch lift thickness has also failed. It would appear from these qualification tests, that the on site . clay material.is suitable for dike construction using large equipment-but is not suited for use as plant fill in the power block area where the work areas are small and generally inaccessible to mechanized equipment. As stated previously, an overview of dike construction was provided by Geo-Tech (most notably) in the 1973-1974 period. The Dames and Poore r soil report and a Project Engineerfug internal design criteria procedure required that all soils work on the Midland project including testing be performed under the continuous direction of a qualified soils engineer. Neither of these documents defined a qualified soils engineer nor did the project specification require the presence of this individual. (The Lfield found out about this requirement during the NRC investigation of the i " soils problem". Geo-Tech did not provide an overview on past soil placements for plant fill. 'The project specification has, however, been changed L. recently to require an on site Geotechnical Soils Enginese to provide i technical direction over soils placement. Geo-Tech was not able to provide this individual so Construction retained the services of an l individual with a masters degree in civil engine'ering (soils) and 3 years I., SB 19135 ,_._.._,,-...,._---..,,-...._,_..,,,m.
s ~ 6-consulting experience. This person was deaned to raet the requirenents of being _ a qualified soils engineer. All soils testing on the project has been perforned by a subcontractor (U.S. Testing, lec.). Their responsibilities include taking tests in accordance with ASTM Standards at locations specified by Bechtel or Cannonia, While not explicitly stated in their contract, in the past U. S. Testing also accepted the job of soils classification to facilitate tes ting. This has been changed in that the specification now requires "U.S. Testing to run a proctor for each clay test and a relative density for each sand test. Soils placement by Bechtel has been done in the past under the technical direction of Bechtel field engineers assigned to specific plant areas
- 1. e., yard facilities, hwf14ary Building, etc.
There was not a designated soils field engineer on the jobsite. Because they were assigned responsibilities in addition to soils placenant (1. e.,,rebar and formwork inspection, material requisitioning, etc.) the field engineers were not always physically present during the fill placanent. Labor -forement were utilized to help call of soils tests under the direction of the field engineer. Technical acceptance of plant fill was based on satisfactory test results. Aa stated previously, the specification now requires that all fill be placed under the continuous direction of the on site Geotechnical Soils Engineer. His responsibilities include in part: 1. Approval of all subgrade preparations. SB 17136' )' ~ ~w-- y-arw,.ep-- ,.9 .wv._9-- .g.y p.., 7pp99 .-%qe9.yi,--- i,,-p.w,,www,g. w:wwp-.,m--- y9-w- y.w w n-9y--,w-y yw -q,gy-r -gg-w-,,. 9
. 2.' Suitability of materials used for random fill. 3. Approving the use of different. random fill caterials in layers and zones so that the structural integrity of buried utilities and supported structures is not jeopardized. 4. Selection of lif t thicknesses for the equipment used for compaction. 5. Maintaining moisture control during the placement. 6. Proper performance and application of compacting This includes speed, frequency, number of equipment. passes, proper overlap, and lif t thickness. 7 Calling for soil tests within the required specification frequencies. 8. Reviewing the acceptability of all soil test reports. 3echtel field Quality Control Engineers performed su.ieillance inspection of Cannonia's placement of Q-listed plant fill. They also provided surveillance over Q-listed plant fill placed by Bechtel. In general, this meant that two to three times a day the Q. C. field engineer observed the fill placement and testing operations. Tull ti=e inspection was not implemented. Quality Control has now revised its inspection program to provide field and laboratory Q. C. Engineers to provide continuous surveillance over the placement and testing activities. The settlement of the Diesel Generator Building was noted during routine construction survey work. Settlement markers were assigned and an extensive soil boring program was undertaken to ascertain the extent of the problen. 58 17137
. The results of the boring program which are included in MCAR 24 show material with highly variable properties in the first 15 feet under the . structure. This fill'which consists essentially of sand over 'the northern half of the building and clay over the southern half, was placed by Bechtel in 1977. As a result of the problems with the Diesel Generator Building an extensive settlement monitoring and soil boring program was undertaken for-the balance of the plant. This program included borings taken through building base slabs. The results of this investigation are included in NCAR 24. As a general rule, in those instances where "sof t" fill was encountered the fill was placed by Bechtel using h2nd held equipment. It has been determined that remedial actions vill be required to correct the discrepant soils conditions. The most noteworthy is a plan to provide a permanent plant devacering system for the power block. It is felt that a draw down of the water table v111 eliminate the potential for liquefaction of sand fill under a seismic event. A summary of other remedial actions is'provided below. Proposed Structure Remedial Action - Diesel Generator Building Surcharge Program (In progress since 4/79) -Unit #1 Surcharge progran Main Transformer Area (In progress since 6/79) Condensate Tank Area Provide flexible pipe connections to tanks to acccanodate anticipated settlement SB 17138 ,e ,-----.,,-%y.--, ,,,v-.-- e-m.,--,v---: ---e--- e....~,y.- ,..+- -.
, Structure Proposed Remedial Action Service Water Structure (North Corner) Piles and pile cap to provide vertical support Diesel Generator Fuel g Storage Tanks Proof Load by filling with water b (In progress since 3/79) Borated Water Storage Tanks Proof load by filling vith water Auxiliary Building Train Bay None Units 1 & 2 Feedvater Isolation Valve Pits Remove and replace defective soil. Will require local devatering Units 1 & 2 Electrical Penetration Rooms Remove and replace part or all of the defective material. Will require local devatering and temporary underpinning The above actions are described in more detail in Eechtel's respons e to the NRC's 50.54 (f) request for information. As investigation into the soil problems on the Midland jobsite conti nues certain conclusions are being reached by individuals as to the probable cause. No single root cause has been identified; the general consensus is that several items combined to produce the problem. The items cost prominently suggested are su=marized belov vich the field's co=ments on them. " Item l - Far too great a reliance was placed on testi ng for acceptance of the fill. When combined with questionable test results (as observed by a detailed review of U. S. Testing operations and some 6,000 soil test reports) this could produce pl'acements not neeting specification requirements without raising questions. SB 19133
10 - Tield Coccent - The acceptance of plant fill was based on acceptance of_in place density tests by Project Engineering specification direction. All parties (Bechtel Field, Q..C. and Project Engineering-and CPCO) participated in the selection of U. S. Testing as the on site testing laboratory and the eventual monitoring of their activities. No adverse trends were uncovered in audits of their soil testing activities. Item 2 - The lift thicknesses at which the fill was placed were excessive. The required compaction could not be achieved using these thicknesses and the equipuent that was used. Field Coment - The lif t thicknesses used were within the specification limits and were qualified by in place density production tests. Item 3 - A "que.lified" soils engineer was not on site to provide continuous technical direction over plant fill placement and This individual vould have identified that associated testing. the testing was questionable and the lift thicknesses excessive. Field Coment - Project Engineering's failure to include this requirement in the project specifications and Geo-Tech's failure to provide an overview of plant fill have been identified earlier The current On Site Geotechnical Soils Engineer in this report. who fills this requirement has a Masters negree in Civil J SB 19140 9 w
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s 11 - I Without Engineering (soils) and 3 years consulting experience. i specifically directed, the field would not have been being expected to use seneone with these qualifications as the field engineer assigned to soils placement. Item 4_ - If test pads had been run on the caterial for varying lift thicknesses, moisture content and equipment use, the field would have known that their placement techniques were improper. Field Co= cent - This seems unlikely since the qualification i tests were run and accepted, albeit, as part of product on tests. Item S_ - There was insufficient inspection of the fill place =ent and too much responsiblity and reliability was placed on the foreman of the soils crew. Field Com=ent - The quality of soils placement, or any other The techniques activity, is not achieved by inspection. used by craf tsmen, field engineers and supervision were the i equivalent of those used previously and appeared to ach eve satisf actory results when checked in accordance with specification requirements. (Note that specification relies on testing for acceptance.) Ite= 6 - The nuclear densiometer (Troxler device) can give This can lead to erroneously high moisture contents. erroneous conclusions about compaction of clay soils. SB 17141 9
, {s ' . :~ F 's . ;t Field Co==ent - It appears that this'is a true statement. Although initial correlations with traditional techniques for moisture content determination vere utilized to approve the use of the Troxler device, subsequent correlation checks were not made. Use of the Troxler device has A 'been discontinued. ' Item 7 - If clay is under ccmpacted and is on the dry side of the . optimum moisture contenc, the uncompacted clay lumps may soften when saturated by groundwater. Field Comment - This appears-logical, however, it is difficult to assess the actual moisture content at the time of placement in light of the reliability of the' Troxler device. Item 8 - Quality Assurance problems with reinforcing steel in the 1975-1977 time period detracted from the effort required to ensure a proper program for plant fill-soils placement. Field Comment - This is a highly subjective comment and if applicable was not a major cause. It could have been contributory, however, as rebar did take top civil priority during this time period. General Field Comment - It appears that no one item will be traced which caused the " soil problem," however a ~ series of probable causes could be put together as follows: 1. Site fill is designed as a " saturated area (il e., the impervious dike follows the site perimeter allowing free flow of cooling pond water into the site fill). SB l'1112 s
/ e _ 13 - 2. Random fill is specified for the plant fill which allows significant use of sand (around pipe, duct runs, j buildings, general backfill, etc.) and concrete. The sand provides flow paths for water as do the interfaces i j between the various fill types (concrete / sand, I i concrete / clay, sand / clay). 3. Decrease in compaccion require =ents from 95" ASTM 1557-D to 95% BMP (about 90: ASTM 1557-D). f 4. Design material was not available on site and a material containing significantly more fines was substituted. The substitute material was much more dif ficult to handle, particularly in ter=s of moisture control. Small, hand held equipment may not have been able to properly compact even though tests were OK. Also, this material was subject to " pumping" and breakdovu when exposed to vater flov, perhaps as seen at soil type boundaries. 5. Soils testing apparently gave erroneous results both from the point of Troxler use and generally poor testing results and errors. 6. inadequate Non-Manual control of the placement process to ass 1=11ste the various deviations from ideal and recognize the potential problem. This would include Field SB 17113 +
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- 14'- Engineering Supervision and Field Quality Control, Quality I Assurance, Project Engineering and Geo Tech were also contributory.
- Note as of 8-24-79 it has become necessary to abandon efforts to compact random fill to 95: ASTM 1357-D as we have not been able to consistently achieve such compaction vich any hand held or (except jumping jacks inventoried earlier) motori:ed equipment available to the field.
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? . J -.o ,i e t' Y MAVA4 /qh UNITED STATES NUCLEAR REGULATORY COMMIS$10N / WASNefeGT000. O. C. 20005 \\.....j, / ocket hos:.50-329/330 OM. OL D J. / .,. :: ( j + / /[7, / APNICANT: y Consumers Power Company FACILIT'f: Midland Plant. Units 1 and 2 SUSJLCT: SulhnRY OF JnNUARY 26, 1982 TELLPHONE O!SLUS$10N REGARDING j SURCHANGE RthuLTS F0k Tht bwST FOUNunTIONS On Janua'ry' ^ 26,1982 Messrs. J. Kane anc U. Hood of the NNC staff received 9l a telephone call from Consumers Power Company ano Bechtel, to aiscuss the 3 ' ' settiament measurements obtained since the valve pits for the Borated water storage Tank were filled witn weter on uctober 28.19el. Participants in the call are listed by Enclosure 1. as a basis for this aiscussion. ' Enclosures 2 ane 3 were deliverse just prior to the call by Lonsumers' bethesda Licensing Representative. These enclosures plot the settlement ' for one point on each of the two valve pits since the time of initial 'r, filling. Lonsusaur's discussion or the et closures included the following points: 1. The criteria for maximum settlement is 0.5". Although the curve for marker U-41 on January 12.1W2 reacs 0.5". Consumers does not constoer this to be an accurate reading, as demonstrated by the January 16,1%2 reading which shows about 0.4". 2. Other measured points also show the dip which occurred on January 12 122. Consumers speculates that survey inaccuracies may be at fault for the January 12.1W2 readings. 3. Consumers feels tne current data demonstrate that the fill beneath the unhT founoations is now in secondary conso11dation. The secondary consolidation rete for the tanks has been estimated to be 1/2" per. decade. i Itr. Kane replieo that the settlement data for markers D-29 ano U-41 do not clearly Indicate that the foundation solls beneath the valve pit are in secondary consolidation. If the quebttonable reauings of January 12.-1982 dre excluded, and everage sr.acoth settlement curve through the plotted points could to drawn since hoves.eer 24.19ul (tne date for placing tne third and rinal surcharge load increraent) which woulo indicate the founaation sotis are still in primary consolidetton. Hr. Kane requested that the settlevnent data for tne otner marAvrs be provided for review. h,.) \\ '\\ Darl 5. nood. Project Handger Licensing uranch No. 4 Division of Licensing inclosures: as statea cf. : See next page { /1 h K h > l A /) A /) 0
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Co.c;me, s Edub.t 4 i j - .. e w PROFESSI0flAL QUALIFICATIONS AND EXPERIENCE. t NAME: Joseph D. Kane 4 ADDRESS: 7421 Miller Fall Road Derwood, MD 20855 1961 EDUCATION: B.S. Civil Engineering Villanova University M.S. Civil Engineering 1973 Villanova University t l Post-degree studies, Soils and Foundation Engineering i University of California 1972 l University of Maryland 1978 PROFESSIONAL REGISTRATION: l Registered Professional Engineer (1966) - Pennsylvania 12032E l PROFESSIONAL SOCIETY: American Society of Civil Engineers t l EMPLOYMENT POSITI0flS: February 1980 - Present Principal Geotechnical Engineer l U.S. Nuclear Regulatory Connission My 1977 - February 1980 Geotechnical_ Engineer-i U.S. Nuclear Regulatory Comission I October 1975 - May 1977 - Soils Engineer - N U.S. NuclearJtegulatory ConnissioC ___ August 1973 - October 1975 Supervisory Civil _ Engineer ___ Chief. Soils Design Section U.S. Anny Corps of Engineers Philadelphia District January 1963 - August 1973 Civil Engineer Soils Design Section. U.S. Anny Corps of Engineers Philadelphia District January 1962 - January 1963 Design Engineer McCormick - Taylor Associates Philadelphia, Pa. e e P i
r Professional Qualifications and Experience = Joseph D. Kane PROFESSIONAL EXPERIENCE SIM1ARY: 1975 to Present In NRC Division of Engineering, Geotechnical Engineering Section, Mr..Kane has specialized in soil mechanics and foundation engineering. Experiences in this position have included the following: a. Evaluation of the foundation adequacy of proposed sites for nuclear facilities with respect to design and operational safety.' This work has included evaluation of geotechnical, soils and rock mechanics, foundation and earthquake engineering related aspects. The results of this review effort are surinarized in a safety evaluation report for each of the proposed facilities which have included nuclear power plants, nuclear fuel reprocessing plants and uranium mill tailings waste systems. b. Serving as a technical adviser for soil and foundation engineering related aspects in the development of regulatory guides. acceptance and performance criteria that.are intended to assure construction and operational safety of nuclear facilities. c. Scrying as a technical representative for the Office of Nuclear Reactor Regulation on.the NRC Advisory Group concerned with federal dam-safety. d. Serving as an instructor for the Office of State Programs in the training of state personnel who are responsible for construct 1on and: operational inspections of uranium mill tailings embankment retention systems. 1963 to 1975 During th.is period Mr. Kane was employed with the U.S. Anny Corps of Engineers, Philadelphia District and attained the position, Chief, Soils Design Section, Foundations and Materials Branch, in 1973. Professional experiences with the Corps of Engineers have included the following: a. The embankment and foundation design of four large multi-purpose earth and rockfill dams with appurtenant structures (spillways,inletandoutletstructures, control towers, flood protection facilities, etc.). Responsibilities ranged from the initial planning of
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- and Experience Joseph D. Kane subsurface investigations to select the most feasible sites through all design stages which were culminated in the final preparation of construction plans and
. specifications. This work included planning and evaluation of laboratory testing programs, studies on slope stability, seepage control and dewatering systems, settlement, bearing capacity, liquefaction embankment safety instrumentation and slope protection. b. Served as a technical consultant to field offices charged with construction inspections for assuring completion of structures in compliance with design analysis and contract specifications. Participated in the development of needed modifications during construction whenever significant changed site conditions were uncovered. c. Directed the efforts of engineers in the Soils Design Section in other fields of civil work projects that included the embankment and foundation design of levees, waterfront pile supported structures and disposal basins for the retention of hydraulic dredge waste. 1962 to 1963 Served as design and project engineer for private consulting fi rm. This work included the design of large federally funded highways,-a race track and various structures-.---. -_. constructed to provide a Pennsylvania State park marina. HONORS AND AWARDS: - - ~ ~ - - 1972 High Quality. Award _ Outstanding Performance Award 1978 ,,,,.-v-- ---,-,w -v --.,,.w. --e-.--------,-
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