ML20126D928

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Rev 0 to Special Process Procedure W-SP-12, Core Drilling of Grout Holes on Placement 19
ML20126D928
Person / Time
Site: 05000000, Waterford
Issue date: 09/16/1976
From:
J.A. JONES CONSTRUCTION CO.
To:
Shared Package
ML20125A430 List: ... further results
References
FOIA-84-426, FOIA-84-449, FOIA-84-A-55, FOIA-84-A-65 W-SP-12, NUDOCS 8506150245
Download: ML20126D928 (35)
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.Procedurc No. W-SP-12 J,. A. JONES CONSTRUCTION COMPANY.

SPECIAL PROCESS PROCEDURE FOR CORE DRILLING OF CROUT HOLES ON PLACDfENT 19 k

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%. J J. A. JONES CONSTRUCTION COMPANY ADDRESS REPLY TO:

J. A. JONES SPECIAL PROCESS PROCEDURE W-SP-12 FOR CORE DRILLING OF' GROUT HOLES ON PLACEMENT 19 Procedure for core drilling of holes in concrete structures.

1.0 Purpose The purpose of this procedure is to establish guidelines for the core drilling of holes and -to provide for documentation of this drilling.

2.0 Scope The scope of this procedure shall inclu'de the inspection and documentation of the core drilling operation.

3.0 References - None.

4.0 Definitions - None.

5.0 Responsibility 5.1 J. A. Jones Engineering shall be respons'ible for the layout, and supervision of the core drilling and determination of the depth of core holes.

5.2 J. A. Jones QV personnel shall be responsible for the inspection and documentation as outlined in this procedure.

'6.0 Procedure e.

6.1 The surface concrete in the area co'be cored shall be chipped to expose the top mat of reinforcing steel in order to avoid cutting of steel during drilling.

6.2 Holes shall be layed out and cored in accordance with applicable attached figure.

If an obstruction is encountered during drilling, the coring shall be stopped until a determination can be made.by the Engineer. Actual locations are to be located by J. A. Jones Engineering and locations documented by J. A. Jones QV personnel,.

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J. A. JONES CONSTFlUCTION COMPANY ADDRESS REPLY TO:

6.0 Proce, dure (continued) 6.3 These core holes shall be core drilled to depths as determined by J. A. Jones Engineer.

The depth of each core hole shall be recorded on the log of core drilling, Attachment A.

6.4 Immediately after coring, each segment of the core shall be adequately labelled and identified and shall be stored in a core box and photographed within 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />.

6.5.Each core shall as a minimum be documented with the following information'on log of core drilling, Attachment A.

1) Core number
2) Location as drilled
3) Number of each segment indicating top, bottom and orientation of core

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Questionable zones

5) Depth of core 6.6 All completed core holes chall be vacuu=cd and protected frem contamination of water, dust and other foreign materials.

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INCORPORATED 9 ^" NCt-J. A. JONES CONSTRUCTION COMPAjlY ASSURA ENGINEFl!NG SPECIAL PROCES OCEDURE This Dccur.e: tit:

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J.A. JONES CONSTRUCTION COMPANY PROCEDURE NO.

W-SP-25 SPECIAL PROCESS PROCEDURE issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE:

0 3-28-80 WATERFORD'SES UNIT No. 3 PHASE 1 CONCRETE CONSTRUCTION 1.0 PURPOSE The purpose of this welding procedure specification is to define and 1.1 document detailed requirements associated with the stud welding code of accepted practices AWS Dl.1-72, latest revision.

2.0 SCOPE This procedure specification shall govern stud welding on carbon steel 2.1 plate and shapes for structural applications.

3.0 REFERENCES

J. A. Jones Work Procedure W-WP-3, " Qualification of Welders".

3.1 J. A. Jones Site Inspection and Test Procedure W-SITP-3, " Verification 3.2 of Welder Qualification".

J. A. Jones Site Inspection and Test Procedure W-SITP-14, " Welding 3.3 Inspection".

J. A. Jones POP-N-708, " Quality Assurance Audits".

3.4 J'. A. Jones POP-N-713, " Discrepancy. Reporting and Corrective Action".

3.5 AWS Dl.1-72, latest revision, " Structural Welding Code".

3.6

37. 7 Ebasco Specification No. LOU-1564.723, latest revision, " Structural Steel".

TRW Nelson Division Manufacturer's recommended " Construction Applica-3.8 tions".

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l 4.0 RESPONSIBILITIES Ebasco Services, Incorporated is responsible for stud welding equip-4.l' ment, receiving, storage and issue of all weld material, nelson studs, testing services and records necessary to support J. A. Jones work i

activities.

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'bi J.A. JONES CONSTRUCTION COMPANY PROCEDURE NO.

W-SP 25.

SPECIAL PROCESS PROCEDURE Issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE:

WATERFORD'SES UNIT No. 3 PHASE I CONCRETE CONSTRUCTION O-3-28-80 J. A. Jones Quality Assurance will document all stud welding on 4.2 W-SITP-14, Attachment 7.1 (Attached), and Attachment "A".

Quality Assurance shall inspect all stud welding according to 4.3 J. A. Jones " Welding Inspection", W-SIIP-14, and AWS D1.1-72, Section 4,. latest revision.

5.0 DEFINITIONS Ebasco's Engineer unless otherwise noted.

5.1 Engineer

6.0 OPERATOR WELDER QUALIFICATIONS Operator Welder Qualifications shall be conducted in accordance 6.1 with Section 4 and 5, of the AWS Structural Welding Code, D1.1-72, latest revision, and J. A. Jones Procedure W-WP-3.

7.0 MATERIAL SPECIFICATION Carbon steel with carbon contents not exceeding 0.30%.

7.1 8.0 PROCEDURE 8.1 Prior to stud welding:

Check that studs are free from rust, rust pits, scale, oil 8.1.1 or other deleterious matter that would adversely affect the welding operation.

8.1.2 Check that the stud base is free of paint, galvanizing and cadmium plating.

Check that areas on members to which studs are to be velded 8.1.3 are free of scale, rust or other injurious caterial.

No welding is to be done when base metal temperature is below 8.1.4 zero F or when the surface is wet or exposed to falling rain or snow.

When the temperature of the base metal is below 32 F, one 8.1.5

_ stud in _each _100_ studs shall be tested in accordance with the following, in addition to the~ first two rested.

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c s ?-7 Nd J.A. JONES CONSTRUCTION COMPANY PAGE 3 0F 7 PROCEDURE NO.

W-SP 25 SPECIAL PROCESS PROCEDURE issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT No. 3 PHASE I CONCRETE CONSTRUCTION O

3-28-80 8.1.6 If studs are to be fillet welded in place, verify that the following requirements are met:

8.1.6.1 Only low-hydrogen electrodes, 5/32 or 3/16 inch in diameter may be used.

8.1.6.2 Stud base must be prepared so that the outside circumference of the stud fits tightly against the base metal.

8.1.6.3 All rust and mill scale shall be removed from the base metal and the end of the stud shall be cleaned.

8.1.6.4 Base metal shall be preheated in accordance with the raquirements of the applicable welding procedure.

8.2 After welding (Shear Connectors):

Fillet welding, where performed, shall be a minimum of 5/16 8.2.1 inch in size.

All visual inspection requirements shall apply to a minimum 8,2.2 20% of studs welded with the exception of post-weld inspection which require 100% inspection.

8.2.3 The first two studs welded by each welder for each day's welding shall be allowed to cool and bent to an angle of 3

30 degrees from its original axis by striking the stud with j

If failure occurs in the weld zone of either stud, a hammer.

the procedure shall be corrected and the process repeated until two consecutive studs have been tested and found to be satisf actory before any production welding is allowed.

i If failure occurs in the stud shank, an investigation shall l

l 8.2.4 be made to ascertain and correct the cause before more studs

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l 8.2.5 The foregoing testing shall be performed af ter any change in the welding procedure.

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PAG'E 4 OE 7 d

J.A. JONES CONSTRUCTION COMPANY PROCEDURE NO.

W-SP 25 SPECIAL PROCESS PROCEDURE issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

- PROJECT TITLE:

WATERFORD SES UNIT No. 3 PHASE I CONCRETE CONSTRUCTION O

3-28-80 Studs on which a full 360 degree weld is not obtained may 8.2.6 be repaired by adding a 5/16 inch minimum fillet weld in place of the missing weld, using the shielded metal arc process with low hydrogen electrodes, 5/32 or 3/16 inch in diameter. The repair weld shall extend 3/8 inch mini-mum beyond each end of defect being repaired.

If the reduction in the length of studs as they are welded 8.2.7 becomes less than normal, i.e., the length of stud is more than 1/16 inch greater than specified, welding shall be stopped immediately and not resumed until the cause has been corrected.

If visual inspection reveals any stud shear connector that 8.2.8 does not show a full 360 degree weld fillet, any stud that has been repaired by welding, or any stud in which the re-duction in length due to welding is less than normal, such stud shall be struck with a hammer and bent to an angle of 15 degrees from its original axis. For studs showing less than 360 degree weld' fillet, the direction of bending shall Studs that crack be opposite to the missing weld fillet.

either in the weld, the base metal, or the shank under in-spection shall be replaced.

Studs 8.2.9 Verify location of studs in accordance with drawings.

may vary a maximum of 1 inch from the location shown, pro-vided that adjacent studs are not closer than 2-1/2 inch center to center and are at least one stud diameter plus v

l 1/8 inch from the edge of a member.

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Af ter Welding (Applications Other Than Shear Connectors):

I 8.3 Fillet welding, where performed, shall be a minimum of 5/16 4

8.3.1 inch in size.

i All visual in'spection requirements shall also apply to stud 8.3.2 welding.

i Before starting the welding operations, or at the request l

8.3.3 of the Engineer, two stud connectors shall be welded to t

. separate material. in the same general position (flat, i

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J.A. JONES CONSTRUCTION COMPANY PAGE 5 0F 7 PROCEDURE NO.

W-SP 25 SPECIAL PROCESS PROCEDURE issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT NO. 3 PHASE I CONCRETE CONSTRUCTION O

3-28-80 8.3.3 vertical, overhead, sloping) and of sisilar thickness and material as the member. After being allowed to cool, each stud shall be tested by striking the stud with a ha=mer and bending it to an angle of 30 degrees from its original axis.

If failure occurs in the' weld zone of either stud, the pro-cedure shall be corrected and two successive studs success-fully welded and tested before any studs are welded to the member.

8.3.4 The foregoing testing shall be performed after any change in the welding procedure.

8.3.5 If failure occurs in the stud shank, an investigation shall be made to ascertain and correct the cause before more studs are welded.

8.3.6 Studs on which a full 360 degree weld is not obtained may be repaired by adding a 5/16 inch minimum fillet weld in place of the missing weld

., using the shielded metal-are process with low hydrogen electrodes, 5/32 or 3/16 in diameter, in accordance with the requirements of W-SP-4.

The repair weld shall extend 3/8 inches minimum beyond each end of defect being repaired.

8.3.7 If the reduction in the length of studs as they are welded becomes less than normal, i.e., the length of stud is more than 1/16 inch greater than specified, welding shall be stopped immediately and not resumed until the cause has been corrected.

8.3.8 The. areas of all components subjected to tensile stresses where a defective stud has been removed shall be made smooth and flush. Where, in such areas, base metal has been pulled out in the course of stud. removal, a shielded metal-are velding process with low-hydrogen electrodes in accordance with the requirements of W-SP-4, shall be used to fill the pockets and the weld surface ground flush.

In compression areas of members where stud f ailures are confined to shanks of studs or fusion zones of studs, a new stud may be welded adjacent to the defective area in lieu of repair and replace-ment on existing weld area.

If metal is pulled from the base 6

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I e-PAGE 6 OF 7 NDI J.A. JONES CONSTRUCTION COMPANY PROCEDURE NO.

W-SP-25 SPECIAL PROCESS PROCEDURE Issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT No. 3 PRASE I CONCRETE CONSTRUCTION O

3-28-80 metal of such areas, the repair provisions shall be the same 8.3.8 as for tensile areas except that, when the depth of defect is not more than the lesser of 1/8 inch or 7% of the base metal thickness, the defect may be faired by grinding in Where lieu of filling the defective area with weld metal.

a replacement stud is to be placed in the defective' area,

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the above repair shall be made prior to welding the replace-ment stud. Replacement shear connector studs shall be tested by bending to an angle of 15 degrees from their original The areas of components exposed to view in completed axis.

structures shall be made smooth and flush where a stud has been removed.

If visual inspection reveals any stud shear connector that 8.3.9 does not show a full 360 degree weld fillet, any stud that has been repaired by welding, or any stud in which the re-duction in length due to welding is less than normal, such stud shall be struck with a hammer and bent to an angle of 15 degrees from its original axis. For studs showing less than 360 degrees weld fillet, the direction of bending shall Studs that crack be opposite to the missing weld fillet.

either in the we'.d, the base metal, or the shank under in-spection or subsequent straightening shall be replaced.

For studs other chan shear connectors, at least one stud in 8.3.10 every 100 shall be struck with a hammer and bent to an angle If the stud fails, of 15 degrees from its original axis.

the procedure shall be checked in accordance with 8.3.3 If either and two more of the existing studs shall be bent.

of these two studs fails, all of the studs represented by the tests shall be bend-tested or rejected.

8.4 Other nondestructive inspection:

Any radiography, magnetic particle, ultrasonic or liquid 8.4.1 penetrant examination to be performed on J. A. Jones welding shall be performed by duly qualified and certified inspectors or outside agencies in accordance with SNT-TC-1A, AWS D1.1-72 latest revision, and the requirements of ASP-IV-26, latest revision.

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J.A. JONES CONSTRUCTION COMPANY PROCEDURE NO.

W-SP-25 SPECIAL PROCESS PROCEDURE Issue Date:

TITLE OF PROCEDURE:

3-13-80 STUD WELDING Rev. No. & Date:

PROJECT TITLE; WATERFORD SES UNIT NO. 3 PHASE I CONCRETE CONSTRUCTION O

3-28-80 Such nondestructive testing shall be done in conformance with 8.4.2 all applicable codes and standards and will be subject to surveillance by J. A. Jones Quality Verification Personnel.

9.0 WELD REPAIR 9.1 Defects detected upon completion of stud welding shall be re-paired according to J. A. Jones W-SITP-14 and W-SP-4 per AWS D1.1-72, latest revision, Section 4.

10.0 DOCatENTATION 10.1 All welding inspection by J. A. Jones Quality Verification Personnel will be documented on the Welding Inspection Report as shown on Attachments "A" and "B" and 7.1.

10.2 All Discrepancy Reporting shall be made out on J. A. Jones Form "A" of POP-N-713 by the Quality Verification Inspe'etor.

11.0 ATTACE!ENTS 11.1.1 - Welding Inspection Report Attachment "A" - Semi Automatic Stud Welding Check Of f List 11.2 11.3 Attachment "B" - Stud Location Log d

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(!e) Veld Procedure Approved Yes flo accordance with Procedure and Requirements of this (5) Wolding Accomplished its Proccdure Yes flo

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Welder Operator Name and I.D.

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1 Base Material Power Control Unit - Model #

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Stud Welding Gun

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Timer

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Stud Check at 200 Bent to 15' i

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Stud Check at 400 Bent to 15*

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Stud Check at 800 Bent to 15*

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Stud Check at 1000 Bent to 15' 4

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W-SP-14 1

J. A. JONES CONSTRUCTION COMPANY l

SPECIAL PROCESS PROCEDURE f

FOR REPAIR OF CONCRETE VolDS WHICH EXTEND DEEPER THAN FACE REINFORCING WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4

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ENGINEERING CONSTRUCTION QUALITY ASSURANCE REV.'

DATE REVIEWED BY DATE REVIEWED BY DATE R PROVE N DATE 3

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SPECIAL PROCESS PROCEDURE W-SP-14 TITLE OF PROCEDURE: REPAIR OF CONCRETE V0lDS WHICH EXTEND DEEPER issue Date:

THAN FACE REINFORCING 5-19-77 Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT N0. 3 CONTRACT NO. W3-NY-4 0

5-19-77 l.0 PURPOSE To specify the methods utilized by J. A. Jones to repair volds which extend deeper than face reinforcing steel.

2.0 ig1Pj, I!

This procedure defines the methods to be used for Installation of gunite on walls, slabs and overhead work. The method to back pour using forms and birds mouth. The method to " Dry-Pack" volds having surface dimensions about equal to the depth of the vold.

3.0 REFERENCES

3.1 Ebasco Services, Inc. Specification No. LOU-1564-472, Section 11, latest revision.

3.2 J. A. Jones Construction Work Procedure W-WP-7.

3.3 J. A. Jones inspection & Test Procedure SITP-

[*,

3.4 Sika Chenilcal Company Brochure for "Sikadur Epoxy Adhesives".

3.5 Field Change Request CH-379, dated 12-20-76.

4.0 DEFINITIONS None.

5.0 RESPONSIBILITIES 5.1 J. A. Jones Construction Company to assure proper preparation, Installa-tion, and finishing of repaired areas ~.

5.2 Ebasco Services, Inc., is responsible for furnishing all materials, receiving Inspection, testing and documentation of such tests as requirdt! by reference 3.1 to support J. A. Jones and their subcon-tractors In performing their work.

6.0 Pl.ACEMENT OF GtJNITE 6.1 Remove all unsound concrete.

6.2 All edges should be tapered so there are no abrupt changes in thickness of Gunite.

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FORM NO. 1122 06 JUNE '74

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J.A. JONES CONSTRUCTION COMPANY PAGE 2 0F 3 PROCEDURE NO.

SPECIAL PROCESS PROCEDURE W-SP-14 TITLE OF PROCEDURE: REPAIR OF CONCRETE ' VOIDS WHICH EXTEND DEEPER issue Date:

THAN FACE REINFORCING 5-19-77 Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 0

5-19-77 6.3 Clean surface before placement.

6.4 Wet surface two (2) hours before placement.

6.5 Repair by Dry Mix Process.

6.6 Each layer is built up by making several passes of the nozzle over the work area.

6.7 Care should be taken to encase reinforcement with sound material.

6.8 Gunite installation to commence at the bottom of vertical walls pro-coeding vertically to the top.

6.9 Cure as per specification.

6.10 Finish as required by design drawing.

7.0 Pt.ACEMENT USING F0rdi$ AND BIRDSMOUTN 7.1 Remove all unsound concrete.

7.2 Provide sloped opening for venting of all air.

7.3 Clean surface before placement.

7.4 Void to be formed from bottom towards top, covering approximately }

of the void area.

7.5 Prepare upper i of form with "birdsmouth" of sufficient size an'd height to assure complete filling of the void with concrete and provide access for vibrators.

7.6 All surfaces of void to be coated with a neat coat of Sika-dur-hi mod epoxy mixed and applied in accordance with manufacturer's reconnenda-tions.

7.7 Place upper i of the forms.

7.8 Place concrete at a low rate to allow sufficient time for consolidation and removal of all air.

7.9 Fill entire void and "birdsmouth".

eum POaM NO 1122 06 JUNE '74

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J.A. JONES CONSTRUCTION COMPANY PAGE 3 0F 3 I

PROCEDURE NO, SPECIAL PROCESS PROCEDURE W-SP-14 issue Daw TITLE OF PROCEDURE: REPAIR OF CONCRETE VOIDS WHICH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 PROJECT TITLE:

WATERFORD SES UNIT NO.3 i

CONTRACT NO. W3-NY-4 0

5-19-77 7.10 Cure as per specification.

i 7.11 After twenty four (24) hours or more, remove forms, chip "birdsmouth" to.true surface, and repa i r as per LOU-1564.472,Section II.

7.12 Cure as per specification.

8.0 Pt.ACEMENT OF " DRY PACK" 8.1 Remove all unsound concrete.

8.2 Clean surface before placement.

8.3 Coat with neat coat of Sika-Dur-HI Mod Epoxy mixed and applied in accordance with manufacturer's recomendations, or keep wet for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> prior to placement.

8.4 The mortar shall consist of one (1) part cement, two (2) parts sand by volume. The amount of water shall be sufficient to produce a mixture which will hold its shape when formed into a ball in the sand.

8.5 Dry pack material shall be placed and packed in layers having a com-pacted thickness of approximately one (1) Inch.

8.6 The surface of each layer shall be stretched to facilitate bonding with the next.

8.7 Cure as per specification.

9.0 ATTA CHMENTS Attachment "A"

Inspection Check List I

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POEM NO. 1122 06 JUNE '74

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ATTAC1 DENT "A" 9.0 QUALITY VERIFICATION CHECK 1.IST 9.1 Location of repair 9.1.1 Pour Number 9.1.2 NCR/DR.Numbe,r 9.2 Method of Repair 9.2.1 All hold points outlined in this procedure as applicable to the method of Repair have been satisfactorly executed, inspected, and accepted.

Q. V.

Date 9.3 Method of Curing was 9.3.1 Curing was acceptable.

Q. V.

Date 9.4 Discrepancies f

Date 9.4.1 Discrepancies as noted above have been satisfactory corrected.

Q. V.

Date Q. V. Inspector Date Q. V. Inspector Date

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4 Procedure No.

W-S P-14 I

J. A. JONES CONSTRUCTION COMPANY

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J.A. JONES CONSTRUCTION COMPANY PAGE I 0F 4 PROCEDURE NO.

SPECIAL PROCESS PROCEDURE W-$P-14 TITLE OF' PROCEDURE: REPAlR OF CONCRETE V0lDS WHICH EXTEND DEEPERlssue Date:

THAN FACE REINFORCING 5-19-77 PROJECT TITLE:

WATERFORD SES UNIT NO. 3 Rev No. & Date:

CONTRACT NO. W3-NY-4 2

'6-24-77 1.0 M To speelfy the methods utilized by J. A. Jones to repair volds which extend deeper than face reinforcing steel.

2.0 iq2Pg, l'

This procedure defines' the methods to be used for Installation of gunite on walls, slabs and overhead work. The method to back pour using forms and birds mouth. The method to " Dry-Pack" volds having surface dimensions about equal to the depth of the vold.

3.0 REFERENCES

3.1 Ebasco Services, Inc. - Specification.No. LOV-1564-472 section ll, latest revision.

3.2 J. A. Jones Construction Work Procedure W-WP-7.

R-l 3.3 ACI 506-66 " Recommended Practice for shoterating.

3.4 Sika chemleal Company Brochure for "$lkadur Epoxy Adhesives".

35 Field Change Request CH-379, dated 12-20-76.

4.0 DEFINITIONS None.

i 5.0 RESPON$l8ILITIES 5.1 J. A. Jones Construction Company to assure proper preparation, installa-tion, and finishing of repaired areas.

5.2 Ebasco services, Inc., is responsible for furnishing all materlats, f

receiving in'spection, testing and documentation of such tests as required by reference 3.1 to support,J. A. Jones and their subcon-tractors in performing their work.

R-2 6.0 PLACEMENT OF GUNITE IN ACCORDANCE WITH PROVISIONS $7ATED IN ACl 506-66 6.1 Remove all unsound concrete.

6.2 All edges should be tapered so there are no abrupt changes in thickness i

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J.A. JONES CONSTRUCTION COMPANY PAGE 2 0F 4 PROCEDURE NO.

SPECIAL PROCESS PROCEDURE W-SP-14 lssue Date:

TITLE OF PROCEDURE:

REPAlR OF CONCRETE VOIDS WHICH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 PROJECT TITLE:

WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 2

6-24-77 R-1 6.3 Clean surface and reinforcing before placement.

R-1 6.4 Wet surface three (3) hours before placement.

R-l 6.5 Repair by Dry Mix Process R-1 6.5.1 Mix proportions: One (1) part cement to four (4) and one haif (i) parts sand by volume.

R-1 6.5.2 Water adad at the nozzle is adjusted so that the In-place gunite appears to be adequately compacted and neither sage nor shows excessive rebound.

R-1 6.6 Each layer is built up by making several passes of the nozzle over the work area.

Layer to be one (I) Inch to a maximum of two (2) Inches.

i Delay sufficient time between layers to prevent sloughing.

6.7 Care should be taken to encase reinforcement with sound material.

~

6.8 Gunite Installation to commence at the bottom of vertical walls pro-ceeding vertically to the top.

R-l 6.9 Care should be taken to protect nearby equipment and materials.

Re-bound should not be worked back into the construction by the nozzleman.

If rebound does not fall clear,of the work it must be removed.

Rebound will not be salvaged, but will be removed from the work area as soon as possible.-

R-2 6.10 Water cured for seven (7) days.

R-1 6.11 ' Finish as required by design drawing.

R-1 6.12 Test panels one (1) foot square and three (3) Inches thick will be made before beginning repairs and at complation of repairs.

Cores or cubes extracted from panels for tests.

7.0 PLACEMENT USING FORMS AND BIRDSMOUTH 7.1 Remove all unsound concrete.

7.2 Provide sloped opening for venting of all air.

7.3 Clean surface before placement.

FORM NO i122 06 JUNE '74

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SPECIAL PROCESS PROCEDURE W-SP-14 TITLE OF PROCEDURE:

issue Date:

REPAIR OF CONCRETE VOIDS WHICH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 i

Rev. No. & Date:

I PROJECT TITLE:

WRTERFORO SES' UNIT N0. 3 CONTRACT N0. W3-NY-4 2

6-24-77 I

7.4 Vold to be formed 'from bottom towards top, covering approximately i of the vold area.

i 7.5 Prepare upper i of form with "birdsmouth" of sufficient size and height to assure complete filling of the vold with concrete and provide access for vibrators.

[

7.6 All surfaces of vold to'be coated with a neat coat of Sika-dur-hl mod epoxy mixed and applied in accordance with manufacturer's recomenda-tions.

7.7 Place upper i of the forms.

R-1 7.8 Place concrete at a low ra'te to allow sufficient time for consolidation and removal 'of al l a i r.

Large volds may be filled with concrete and vibrated before upper i of the forms are placed.

7.9 Flll entire vold and "birdsmouth".

7.10 Cure as per specification.

5-1 7.11 After twelve (12) hours or more, chip "birdsmouth" to true surface, and repair as per L00-1564.472, Section 11.

R.l.

7.12 After thirty-six (36) hours remove forms.

7.13 Cure as per specification.

8.0 - Pt.ACEMENT OF "0RY PACle' R-l 8.1 Remove all unsound concrete and square. surface edges.

Corners withl.n the volds should be rounded.

8.2 Clean surface before placement.

R-1 8.3 Coat with-neat coat of Sika-dur-hl-mod epoxy mixed and applied in accor-dance wlth manufacturer's recomendatIons.

A-l 8.4 The mortar shall consist of one (1) part cement, two (2) parts sand by volume. Minimum amount of water. shall be used to sufficiently produce f

a mixture which will hold its shape when formed into a ball in the hand.

R-1 8.5 Dry pack material shall be placed and packed in layers having a compacted thickness not to exceed one (1) Inch.

M FOAM NO. I122 Os JUNE '74

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SPECIAL PROCESS PROCEDURE t

W-SP-14 TITLE OF PROCEDURE: REPA1R OF CONCRETE 'V0lDS WHICH EXTEND DEEPER issue Date:

THAN FACE REINFORCING 5-19-77 Row No. & Date:

PftOJECT TITLE:

WRTERFORO SES UNIT NO. 3 g

2 6-24-77 CONTRACT NO. W3-NY-4 R-1 8.6 The surface of sech layer shall be scratched to facilitate bonding with the next.

8.7 Cure as per specification.

9.0 ATTACHMENTS.

R-1 Attachment HA" - quality Verification Checklist e

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9.0 QUALITY VERIFICATION CHECKLIST 9.1 Location of repair _

9.1.1 Pour Number 9.1.2 NCR/DR Number 9.2 Method of Repair 9.2.1 All hold points outlined in this procedure as applicable to the method of Repair have been satisfactorly executed, inspected, and accepted.

Q. V.

Date 9.3 Method of Curing was 9.3.1 Curing was acceptable.

Q. V.

Date 9.4 Discrepancies Date 9.6.1 Discrepancies as noted above have been satisfactory corrected.

Q. V.

Date Q. V. Inspector Date Q. V. Inspector Date e

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t REVIEW OF SITE FROCEDURE ERASCO SERVICES INCORPORATED ji WATERFORD STEAM ELECTRIC STATION - UNIT NO. 3 1

l Project Superintendent, Construction Superintendent, Senior Resident Engineer.
h. b fl To Assurance Site Supervisor, and/or Others o e r-

. I Senior quality control Supervisor, It t/

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are No. M -0 9-}'l

,andrecordyour!2 nts fI Flease review the attached copy of Comunents are required by [s 77

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.I on this form. If there are no comments, this should be so noted.

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l Senior Quality Control Supervisor, Senior Construction Accountant, or other

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REPAIR OF CONCRETE VOIDS WHICH EXTEND DEEPER THAN FACE REINFORCING 4

WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 ENGINEERING CONSTRUCTION QUALITY ASSURANCE REV.

DATE REVIEWED BY DATE REVIEWED BY DATE R PROVE N DATE o

5-19-77 f cT//f/77 ff& f43kyfY P23-27

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' ENG'NEERING Thij Documentis:

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.n JI. JOBS CONSTRUCTION COMPANY PAGE I 0F 4 PROCEDURE NO.

l SPECIAL PROCESS PROCEDURE W-SP-14

~

I TITLE OF PROCEDURE: REPAlR OF CONCRETE.V' OLDS WHICH EXTEND DEEPERlssue Date:

5-19-77 THAN FACE REINFORCING 3

PROJECT TITLE:

WATERFORD SES' UNIT NO. 3 Rev. No. & Date:

f CONTRACT N0. W3-NY-4 3

4-26-78

  • 1. 0 PURPOSE To specify the methods utIIIzed by.J. A. Jones to repair voids which extend deeper than face. reinforcing steel.

2.0 SCOPE 7

This procedure defines the methods to be used for installation of gunite on walls, slabs and overhead work. The method to back pour using forms and birds mouth. The method to " Dry-Pack" volds having surface dimensio'ns about equal to the depth of the vold..

j

3.0 REFERENCES

i 3.1 Ebasco Services, Inc. Speci fication No. LOU-1564.472,Section II, latest revision.

32 J. A. Jones Construction Work Procedure W-WP-7 1-1,

. 3,. 3 Acl.506-66 "Recomended P' actice for Sho,tereting.

r 3.4 Silka ' Chemical Company. Brochure for "SI,kadur Epox'y Adhesives".

3.5 Field Change Request CH-379, dated 12-20-76.

1,3 3.6 J. A. Jones Construction Company Site inspection And Test Procedure, W-SITP-7.

4.0 DEFINITIONS Noner.

5.0 RESPONSIBILITIES 5.1 J. A. Jcnes Construction Company to assure proper preparation, Installa-tion, and finishing of repaired areas.

'5.2 Ebasco Services', inc., is responsible for furnishing all materia,1s,

-receiving Inspection, testing and documentation of such tests as required by reference 3.1 to support J. A. Jones and their subcon-tractors in performing their work.

1 i

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PROCEDURE NO.

SPECIAL PROCESS PROCEDURE W-SP-14 issue Date:

TITLE OF PROCEDURE: REPAIR OF CONCRETE V0lDS WHICH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 Rev. No. & Date:

PROJECT TITLE:

WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 3

4-26-78

' t-2

  • 6.0 PLACEMENT OF GUNITE IN ACCORDANCE WITH PROVISIONS STATED IN ACI 506-66 6.1 Remove.all unsound concrete.,

4 6.2 All edges should be tapered so there are no abrupt changes in thickness of Gunite.

-l 6.3

.C. lean' surface and reli2 forcing before' placement.

t-1 6.4 Wet surface three (3) hours before placement.

-l 6.5 Repair by Dry Mix Process

-l 6.5.1 Mix proportionsi One (1) part cement to four (4) and one half (i) parts sand by volume.

~

6.5.2 Water added at the nozzie.is adjusted so that the in-place gunite 1-1 i

  • ppears to be adequately' compacted a,nd neither sage nor shows a

excess'I.ve rebou.nd.

' t 6.6 Each layer is built up by making several passes of the nozzle over the work area.

Layer to be one (1). inch to a maximum of two (2) Inches.

Delay sufficient time between layers to prevent sloughing.

6.7 Care should be taken to encase reinforcement with sound material.

6.8 Gunite Installation to commence at the bottom of vertical walls pro-caeding vertically to the top.

I t-1

~6.9 Care should be taken to protect nearby equipment and materials.

Re-bound should not be ' worked back into 'the construction by the nozzleman.

If rebound. does not fall clear of the work it must be removed.

Rebound

- will not be salvaged,' but will be. removed f rom the work area as soon as possible.

' t-2 6.10 Water cured for seven (7) days.

\\- 1

- 4.41 Finish as-required by design vrawing.

1-1 6.12 Test panels one (1) foot square and three (3) inches ' thick will be made before beginning repairs and at completion of. repairs.

Cores or cubes extracted from panels for tests.

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,,n JI JONES CONSTFlUCTION COMPANY PAGE 3 0F h PROCEDURE NO.

V-SP-14 SPECIAL PROCESS PROCEDURE issue Date:

TITLE OF PROCEDURE:

REPAIR OF CONCRETE VOIDS WHICH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 PROJECT TITLE:

WAT5RFORD SES UNIT NO. 3 CONTRACT NO. W3-NY 3 4-26-78

'7.0 PLACEMENT USING FORMS AND BIRDSMOUTH 7.1 Remove all unsound concrete.

+

7.2 Provide sloped opening for venting of all air.

~

7.3 Clean surface before placement.

7.4 void to be formed from bottom towards top, covering approximate,1y i of the void area.

s 7.5 Prepare upper i of form with "birdsmouth" of sufficient size and height to assure complete filling of the void with concrete and provide access for vibrators.

7.6 A'11 surfaces of void to be coated with a neat coat of Sika-dur-hi mod epoxy mixed and applied in accordanc'e' with manufact'Qrer's i econsnenda-tions..

7l.7 Place upper i of the forms.

- t

-1 7.8 Place concrete at a low rate to allow sufficient time for consolidation and removal of all air.

Large voids may be filled with concrete and vibrated before upper i of the forms are placed.

7.9 Fill entire vold and "birdsmoutn",

'l

~ 7.10. Cure as per specification.

5

.- 1 7.11 After twelve (12) hours or more, chip "birdsmouth" to true surface, and repair as per LOV-1564.472, Section ll.

.- 1 7.12 After thirty-six (36) hours remove forms.

7.13 Cure as per specification.

8.0 PLACEMENT OF " DRY PACK"

.- 1 8.1 Remove all unsound concrete and square surface edges.. Corners withi,n the voids should be rounded.

.~

8. 2' Clean surface before placement.

xL FORM NO. 1122 06 JUNE 74

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,q-J.A. JONES CONSTRUCTION COMPANY PAGE 4 0F 4 PROCEDURE NO.

W-SP-14

~

SPECIAL PROCESS PROCEDURE '

issue Date:

TITLE OF PROCEDURE: REPAIR OF CONCRETE VOIDS WHIGH EXTEND DEEPER THAN FACE REINFORCING 5-19-77 PROJECT TITLE:

WATERFORD SES UNIT NO, 3 Rev. No. & Date:

CONTRACT NO.. W3-NY-4 3

4-26-78

-I 8.3 Coat with neat coat of Sika-du.r-h'l-mod epoxy mixed and applied in accor-dance with manufacturer's reconsnendations.

.- 1 8.4 The mortar shall consist of one (1) part cement, two (2) pa rts san'd by

. volume. Minimum amount of water shall be used to sufficiently produce a mixture which will' hold its shape when formed into a. ball in the hand.

.- l 8.5 Dry pack mater'ial shall be placed' and pack'e'd in layers havin'g a compacted thickness not to exceed one (1)' inch.

.- 1 8.6 The surface of each layer shall be scratched to facilitate bondin'g with the.next.

8.7 Cure as'per. specification.

-3 9.0 QUALITY ASSURANCE

, 9.1 Repairs covered under this. procedure sha'll be documented on Attachment A".

-3

'. 9.2 Work that involves a'ddition or replacemsnt of reinforcement or other.

'. embed items shall be douemented in accordance with W-WP-7 (Ref. 3.2) and W-S ITP-7 (Ref. 3.6).

(

1 t-3 10.0' ATTACHMENTS

~

,10.1 ' quality.Verif'ication Checklist

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FORM NO 1122 0G JUNE ~74

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- i 6;. r3 ATTACHMENT "A" Revision 3 QUALITY VERIFICATION CHECKLIST Location of repair _

...' Pour ' Number NCR/DR Number

~

Method of Repair All h'old points outlined in this procedure as appl. cable to the method of Repair have been satisfactorly executed, inspected ud accepted.

l Q. V.

  • Date Method of Curing was Curing was acceptable.

(Attach Daily Concrete ins ection Report)

(Attachment "E" W SITP-7)

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Date Q. V.

Discrepancies l

l Date Discrepancies as noted above have been satisfactory cot rected.

Q. V.

Date Date Q. V. Supervi slon 4/26/78 I

m r

l

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