Text

Forwards Response to RAI Re Issues Concerning Plant Containment Basemat Concrete
	ML20134Q096
Person / Time
Site:	Millstone
Issue date:	11/27/1996
From:	Cowan J; NORTHEAST NUCLEAR ENERGY CO., NORTHEAST UTILITIES SERVICE CO.
To:	; NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
	B15985, NUDOCS 9612020124
	Download: ML20134Q096 (248)
	v • d • e

"'N gg gg 107 Selden Street, Berhn, CT 06037 h Utilities System sortheut uutitie. senice company P

P.O. Box 270 Ilartford, CT 06141-0270 (203) 665-5000 November 27,1996 Docket No. 50-423 815985 U.S. Nuclear Regulatory Commission Attention: Document Control Desk Washington, D.C. 20555 Millstone Nuclear Power Station Unit 3 !

Response to Reauest for Additior,al Information On Erosion of Cement from the !

Underivina Porous Concrete Drainaae System. Millstone 3 By . letter dated October 18, 1996, the NRC staff transmitted nine (9) requests to Northeast Nuclear Energy Company (NNECO) regarding issues related to the Millstone Unit 3 Containment Basemat Concrete. Accordingly, in Attachment 1 to this letter, NNECO hereby submits its response to the requests defined in the letter. NNECO's ,

ccmmitments associated with this letter are provided in Attachment 5. '

i Should you have any questions regarding this submittal, please contact Mr. James M.

Peschel at (860) 437-5840. j l

Very truly yours,

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NORTHEAST NUCLEAR ENERGY COMPANY l k&Q [

John Paul Cowan Recovery Officer j

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Millstone Unit 3 9612O20124 961127 PDR ADOCK 05000423 p PDR (E1422 REY.1-94 R

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, B15985\Page 2 '

Attachments (5) cc:- H. J. Miller, Region 1 Administrator I W. D. Travers, Dr., Director Special Projects l A.C. Cerne, Senior Resident inspector, Millstone Unit No. 3 ;

V. L. Rooney, NRC Project Manager, Millstone Unit No. 3 '

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Docket No.50-423 B15985 Attachment 1 Millstone Nuclear Station Unit 3 Response to Reauest For Additional information On Erosion of Cement From The Underivina Porous Concrete Drainaae System. Millstone 3 Nuvember 1996

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4 U.S. Nuclotr Rcgulatory Commission B15985\ Attachment 1\Page 1

,RJ_ qui $T 1 Provide a complete description and findings from Phase I, Phase 11, and Phase 111 (to the extent available) mockup testing.

RESPONSE 1 This response is divided into three portions, one for each phase of the testing.

l PHASEI PURPOSE OF PHASE I TESTING j The Phase I test was designed to assist in an understanding of the residue phenomena emanating from under the Millstone 3 Containment Structure. The mock-up test molds I were intentionally constructed differently than the field conditions, by elimination of i some of the intermediate layers, as a conservative model of the containment structure i with a breached membrane. In addition during the concrete placement, the objective I was to loosely place the concrete to maximize the voids between the aggregate which would provide the worst case for potential accumulation of laitance and concrete j washout from the aggregate surface due to the hydrodynamic force of the introduced water.

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1 MOLD CONSTRUCTION / MATERIALS i

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A total of three test molds were constructed in the Phase I test. One mold consisted of a 9 inch thick single layer of calcium aluminate based porous concrete sandwiched between (1) Portlant cement based mortar at the bottom, and (2) calcium aluminate

cement based mortar on top. The other two molds consisted of 10 inches of Portland i

, cement based porous concrete and a 9 inch layer of calcium aluminate cement based

porous concrete, placed directly on top of the Portland cement based porous concrete. l The top of the mold was sealed with a calcium aluminate cement based mortar layer.

The molds were provided with inlet orifices on the side forms to allow for the

introduction of water, and two 6 inch diameter internal perforated drain pipes installed in the top porous concrete layer for removal of the water.

The materials and mix proportions of the concrete and mortar mixes duplicated the

original construction mixes to the extent possible, including procurement of aggregate from one a the quarries used during original plant construction. The molds, were cured for 7 days prior to hydraulic testing.

i HYDRAULIC TESTING

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Water was applied laterally to the test mold through the inlet orifices on the side of the i test mold at a hydraulic pressure of 22 psi, and removed from the media through the l

embedded perforated drain pipes. The mold was subject to four 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests, during I

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i U.S. Nucl:ar R:gulatory Commission i B15985\ Attachment 1\Page 2 l i l l which any residue emanating from the test mold was filtered and collected. After the l completion of the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests, the test mold was subject to a 30 day hydraulic test at the same applied pressure.

OBSERVATIONS White residue similar to that from the Containment underdrain system was collected in i

the two layered test molds.

No white residue leached out from the single layer mold Some of the core samples were damaged during the coring process in the double layer mold and could not be tested for compressive strength.

Core samples were successfully removed from the single layer test mold.

CONCLUSION A more representative test was required for any conclusions related to the affects on the porous concrete to be reached.

i A complete copy of the Phase I test results is included as Attachment 2.

1 PHASE ll !

PURPOSE OF PHASE ll TESTING l The Phase ll test was designed to study any effects on the porous concrete that may be occurring due to removal of the concrete laitance or concrete washout, and to evaluate: the potential for cement erosion to occur as a result of the hydraulic pressure.

The test molds for Phase ll were constructed to be more representative of the actual geometry of the Containment underdrain system, such that some correlation could be made with respect to the effect on the porous concrete layers.

MOLD CONSTRUCTION / MATERIALS !

A total of three test molds were constructed in the Phase ll test. Mold A consisted of 10 !

inches of Portland cement based porous concrete, and a 9 inch layer of calcium i aluminate cement based porous concrete placed directly on top of the Portland cement I based porous concrete and a 2 inch layer of calcium aluminate mortar was used to seal i the top. Molds B & C consisted of 10 inches of Portland cement based porous concrete !

and a 9 inch layer of calcium aluminate cement based porous concrete separated by a !

l rubber membrane protected by a 2 inch thick Portland cement seal mortar. A 2 inch layer of calcium aluminate mortar was used to seal the top of the mold. The molds were i provided with intet orifices in the side forms to allow the introduction of water, and an internal perforated drain pipe for removal of the water. The rubber membrane and seal

U.S. Nucirr R:gulatory Commission B15985\ Attachment 1\Page 3 mortar were intentionally breached to prcvide a flow path through the encapsulated ,

layer of porous concrete which simulates the leaking containment structure membrane. l The materials and mix proportions of the concrete and mortar mixes duplicated the original construction mixes to the extent possible, including procurement of aggregate from one of the quarries used during original plant construction. The molds were cured for 7 days prior to hydraulic testing.

HYDRAULIC TESTING l

Water was applied to the test mold through the inlet orifices on the side of the test mold at a water pressure of 5 psi. This water then passed through the intentionally breached rubber membrane and seal mortar. The water is removed from the media through the embedded perforated drain pipes. The mold was subjected to four 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests, during which any residue emanating from the test mold was filtered and collected. After the completion of the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests, the test mold was subjected to a 30 day hydraulic test at the same applied hydraulic pressure.

TEST RESULTS The average of the laboratory cured Portland and calcium aluminate cylinders prepared at the time of the placement were 2152 psi at 28 days and 1787 psi at 28 days respectively. ,

1 The average of the unconfined compressive strength cores from mold A, after hydraulic testing, were 1094 psi for Portland cement and 1119 psi for calcium aluminate cement.

The average of the unconfined compressive strength cores from mold B, after hydraulic testing, were 1355 psi for Portland cement and 1394 psi for calcium aluminate cement.

The average strength of the unconfined compressive strength cores from mold C, after hydraulic testing, were 1531 psi for Portland cement and 1263 psi for calcium aluminate cement.

OBSERVATIONS No variation in compressive strength porous concrete samples with respect to location of water flow was observed.

Residue similar to that from the Containment underdrain system was collected.

Some of the test samples were damaged during the coring process and could not be tested for compressive strength, i

A complete copy of the Phase ll test results is included as Attachment 3.

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B15985\ Attachment 1\Page 4 i PHASE Ill Note: As previously committed in Reference 3 the results of Phase ill testing are scheduled to be completed and forwarded to NRC by the end of 1996. Where

available the data has been provided here, in a preliminary form. This data will be confirmed, observations assembled and conclusions drawn as part of the final i report.

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PURPOSE OF PHASE Ill TESTING l 1

The purpose of the Phase ill test is two fold. One objective is to study the long term l effects that water flow creates on the porous concrete strength, and the second

purpose is to test the Portland concrete on top of the test mold to determine if there is l any impact on the Containment mat. The concrete reprosenting the mat is placed on top of the porous concrete mold similar to the design condition. This testing is

corapleted by subjecting the test mold to water flow and periodically removing core samples for compressive strength testing. Similarly for the concrete representing the Containment basemat, cores were periodically removed and simultraeously core samples were removed from a sister mold which was not exposed to the porous concrete or water flow. Laboratory cured cylinder samples were also cast during the i concrete placement. Core and cylinder samples were tested for compressive strength 2

at predetermined intervals.

MOLD CONSTRUCTION / MATERIALS CEMENT PORTLAND CEMENT Portland Cement is Type ll (Iow Alkali) conforming to ASTM C150.

Cement Properties (Mill Test Report)

SiO2, percent 20.7 Al2O3, percent 4.7 Fe2O3, percent 3.1 CaO, percent 63.4 MgO, percent 3.4 SO3, percent 3.1 Na2,O, percent 0.58 Ignition Loss. percent 0.8 Insoluble Residue, percent 0.23 l

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B15985\ Attachment 1\Page 5 Physical Fineness, Blaine m2/kg 367 Time of Setting (VICAT)

Initial (minutes) 110 i

Final (minutes) 230 Air Content, percent 6.3 Compressive Strength at 3 days (psi) 3840 j 7 days (psi) 4820 l 28 days (psi) 6250 3

CALCIUM ALUMINATE CEMENT t

Chemical Properties (Mill Test Report)

AL203, + TiO3. percent 50.22 CaO, percent 35.83 SiO2, percent 7.11 Fe2O3, percent 5.49 MgO, percent 0.50 i SO3, percent 0.46 Ignition Loss, percent 0.39 Physical Properties Time of setting (VICAT),

ASTM C403:

Initial hours: min. 2.38 Final hrs: min. 3.38 Fineness, Blaine m2/kg 331 Compressive Strength, at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , ASTM C109 (Mpa) 39.5 AGGREGATE COARSE Coarse aggregates were obtained from the Wauregan Quarry, owned and operated by Tiicon Connecucut incorporated. The # 4, # 57, & # 67 gradations are in accordance with ASTM C33 and C136. Table 1 shows the gradation analysis of these aggregates.

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B15985\ Attachment 1\Page 6 I i

i FINE Fine aggregates were Millbury Sand from Concrete Service Company, no I gradation analysis was performed.

CONCRETE MIXES Mix A - Porous Concrete with Portland Cement Type ll, quantities per cubic yard Cement, pounds / sacks 560/5.96 Coarse Aggregate #57, pounds 2670 Water to Cement Ratio (maximum) 0.384 l

Mix B - Porous Concrete with Calcium Aluminate Cement, quantities per cubic yard Cement, pounds / sacks 560/5.96 Coarse Aggregate #57, pounds 2670 :

Water to Cement Ratio (maximum) 0.320 Mix C - Mortar Seal with Calcium Aluminate Cement, quantities per cubic yard Cement, pounds / sacks 900/9.57 Coarse Aggregate #57, pounds 2757 Water to Cement Ratio (maximum) 0.439 Mix D - Mortar with Portland Cement Type ll, quantities per cubic yard Cement, pounds / sacks 900/9.57 Coarse Aggregate #57, pounds 2757 Water to Cement Ratio (maximum) 0.439 Mix E - Containment Foundation with Portland Cement Type 11, quantities per cubic yard (10 foot thick mat)

Cement, pounds / sacks 500/5.32 Fine Aggregate, pounds 1315 Coarse Aggregate #4, pounds 7t2 Coarse Aggregate #67, pounds 1127 Percent Air Admixture 3 to 6 Water to Cement Ratio (maximum) 0.532

- U.S. Nucinr Regulatory Commission-B15985\ Attachment 1\Page 7 MEMBRANE The membrano consists of two layers of waterproof membrane installed as recommended by the membrane manufacturer.

FORMS The concrete forms and boundaries for the water separations consist of poly

- coated plywood for waterproofing.

WATER The water used for the concrete batching and curing were tested and found to - -

be' free of' unacceptable quantities of oils, acids, alkalides, salts and organic materials in accordance with ASTM C94. The results of the chemical analysis-are presented in Table 2.

DESCRIPTION OF TEST MOLD The test mold represents a typical cross section of the Containment porous concrete and basemat. It has nominal dimensions of 11 feet by 11 feet with an inlet water reservoir constructed at the water inlet end and outlet pipes at the discharge end of the 1 mold. One half of the mold contains a rubber _ membrane similar to the actual l Containment layers and in the other half of the mold the rubber membrane has been l intentionally eliminated. !

The cross section of the mold in the area of the membrane consists of: the bottom form; a 10 inch layer of Mix A Portland cement porous concrete; the waterproof membrane; a j

- two inch layer of Mix D Portland cement seal mortar; the 9 inch layer of Mix B calcium l aluminate cement porous concrete; a two inch layer of Mix C calcium aluminate cement j seal mortar; and a 12 inch layer of Mix E Portland cement structural concrete on top. l The cross section in the portion without the rubber membrane is similar except the rubber membrane, the M!x D mortar on top of the membrane and the Mix E concrete have been omitted. The center wall of the mold as well as the inlet end wall have been provided with perforations to allow water entrance. One inch diameter orifices are provided for draining of the mold prior to the coring operations. Details of the test mold !

are shown in Figure 1(a-c). !

MOLD CONSTRUCTION Table 3 includes the placement schedule of each layer of porous concrete and seal l mortar. The number of days indicated in the table between pours are the conservatively selected curing days before the placement of the next pour.

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B15985\ Attachment 1\Page 8 l 5 .

POROUS CONCRETE MIX A (Portland cement) !

i Mix A was placed in a 10 inch thick layer of porous concrete on top of the bottom of the mold form. The concrete was consolidated by the rodding method to represent a density of approximately 118 to 131 pcf. This concrete layer was wet i cured for 5 days prior to further construction activities.

MEMBRANE I i

Two layers of waterproof membrane were placed on top of the Mix A. The l

membrane extends to the top of the mold, such that it encases subsequent layers of the concrete.

I MORTAR MIX D (Portland cement) l Mix D was placed in a two inch layer on top of the waterproof membrane as protection for the subsequent concrete placement. This mortar was cured for a minimum of 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months prior to further construction activities. '

s FLOW PATH l As a flow path for subsequent testing, the rubber membrane and Mix D are

, intentionally breached at the predetermined locations of subsequent core-bore samples. .l POROUS CONCRETE MIX B (calcium aluminate cement) i Mix B is placed in a 9 i'ich thick layer of porous concrete on top of the .l waterproof membrane. The concrete was consolidated by rodding to represent a

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density of approximately 118 to 131 pcf. This concrete was cured by applying a thin spray of water at the top surface to remove the heat. This process was continued for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months after initial set of the porous concrete.

MORTAR MIX C (calcium aluminate cement) 5 i Mix C is placed in a two inch layer on top of the 9 inch layer of porous concrete.

This mortar was cured similar to Mix B for 7 days prior to further construction

activities.

STRUCTURAL CONCRETE MIX E Mix E was placed in a 12 inch layer on top of the 2 inch layer of calcium aluminate cement mortar. An additional sister mold, measuring 3 feet x 3 feet x ,

12 inches high, of M,ix E was also constructed from the same batch of concrete, I and maintained separate from the mockup (Figure 2). The sister mold was 4

constructed in a wooden form carefully constructed to be free from any calcium

l U.S. NucInar R:gulttory Commission B15985\ Attachment 1\Page 9 1 aluminate cement products. Both sections of Mix E concrete were wet cured for 1 7 days' prior to any flow testing. Five concrete test cylinders were made at the time of the placement in accordance with ASTM C31.

HYDRAULIC TESTING i

The Sequence of the Flow Testing is as follows:

CYCLE 1

1. The 6 inch diameter inlet # 2, the 6 inch diameter outlet #1, and the two 1 inch diameter drain orifices are closed, (refer to Figure 1).

2. The 6 inch diameter outlet # 2 is maintained open.

3. The inflow of water is regulated through the 6 inch diameter inlet # 1.

4. The water is stopped for 7 days and the mold is drained through the two 1 inch diameter orifices located at the far end of the mold.

5. Core samples are removed from the mold in the sequence identified in the i results section. l l

6. Cored holes are filled with crushed stone. l l

7. The water flow is restarted in the reverse direction in the sequence !

outlined below: I Close inlet # 1 Close outlet # 2 and the two drain orifices Open outlet # 1 Regulate the water flow for 21 days Stop the water for 7 days and drain the mold for the coring operation.

8. Continue the same cycle for the duration of the testing. The rate of flow of I water through the test mold for the first twelve months is presented in !

Table 4*.

The information provided in Table 4 was previously submitted to the NRC in Reference 19, (October 10,1996, Response for Additional Information), however i the data had two errors. Corrections have been made to the Total Flow in the tenth j month as well as the total flow for the year.

U.S. Nucl:ar Regulatory Commission B15985\ Attachment 1\Page 10 RESULTS TEST CYLINDERS PORTLAND CEMENT POROUS CONCRETE (Mix A) AND CALCIUM ALUMINATE POROUS CONCRETE (Mix B)

Laboratory Cured Test Samples Five (5) test cylinders measuring 6 inches x 12 inches high, were made from concrete Mix A (Portland cement porous concrete) and also from Concrete Mix B (calcium aluminate cement porous concrete) at the time of placement into the test mold. These cylinders were cured in a laboratory fog room for Mix A, and water misted for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months for Mix B. Two cylinders from each mix were tested at 7 days and the remaining 3 cylinders were tested at 28 days. Table 8 shows the cy;inders weighed between 127 to 130 pcf. The cylinders cast from Portland cement had an average unconfined compressive strength of 2130 psi at 7 days and 2357 psi at 28 days, about an 11%

increase in strength. Where as the porous concrete containing calcium aluminate cement, with an average weight of 129 pcf had an average unconfined compressive strength of 2367 psi, and no strength gain was evident after 7 days.

PORTLAND CEMENT CONCRETE (Mix E)

Laboratory Cured Test Samples l Five 6 inch diameter by 12 inch high cylinders were prepared for compression testing from Mix E, in accordance with ASTM C31 and C39, at the time of concrete placement in the mold. After laboratory curing, two cylinders were tested for comprestive strength at 28 days and three cylinders were tested at 56 days. At 150 pcf deasity of the cylinders, the average unconfined compressive strength was determined to be 4935 psi and 5257 psi corresponding to the age of 28 and 56 days respectively. The results are included in Table 5.

CORE BORE SAMPLES FROM THE MOCK-UP MOLD PORTLAND CEMENT POROUS CONCRETE (Mix A)

Table 7 show the average unconfined compressive strength of the core samples taken at the end of each hydraulic flow cycle. In the 12 month test, the Portland cement based porous concrete maintained its strength without any degradation. The minimum tested strength of 1570 psi occurred at the end of 3rd cycle and a maximum tested strength of 1887 psi occurred at the end of the 11th cycle.

1 U.S. Nucirr Regulatory Commission B15985\ Attachment 1\Page 11 CALCIUM ALUMINATE POROUS CONCRETE (Mix B) i Table 6 shows the average unconfined compressive strength of the core samples taken at the end of each hydraulic flow cycle. The strength of the cores varies with the duration of water flow. An average unconfined compressive atrength of 1333 psi occurred at the end of the 1st cycle. The successive specimen s+rength varied with respect to the first month samples. An average maximum strength of 1667 psi occurred

, at the end of the 5th cycle, which is approximately a 25% increase in strength. The minimum tested strength of 877 psi occurred at the end of 10th cycle, which is approximately a 34% below the initial strength, and approximately a 47 % below the maximum strength.

PORTLAND CEMENT CONCRETE (Mix E)

After being exposed to a continuous flow of water for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months a day and 21 days, the following core samples have been extracted at the specified time intervals. The cores from the test slabs (both the test mold and sister mold), were tested for unconfined compressive strength at 40 days,60 days and 98 days after construction. The location of these core samples are shown in plan view, Figure 1a.

At 40 days; Two cores located at C-6 and E-6, At 60 days; Two cores located at D-7 and E-7, At 98 days; Two cores located at C-8 and E-8 The average compressive strength values of the cored samples have been summarized in Table 5. The 60 day average strength of 4925 psi corresponds to a core density of 149 pcf, with water flow.

CORE BORE SAMPLES FROM THE SISTER MOLD PORTLAND CEMENT CONCRETE (Mix El Concrete Mix E in the sister mold was constructed and cured similar to the mock-up but it was not subjected to either water flow or contact with calcium aluminate cement. Two sets of two 5.72 inch diameter core samples were removed from the 3 foot x 3 foot x 12 inch high sister mold. A set of two cores were removed from locations SM-1 and SM-2 at 40 days, and a second set of two cores were removed from locations SM-3 and SM-4 at 60 days (Figure 2). The samples were then tested for unconfined compressive strength. A 60 day average compressive strength of 4695 psi was achieved, at a core density of 148.5 pcf. Table 5 summarizes the test data for the sister mold samples.

OBSERVATIONS PORTLAND CEMENT POROUS CONCRETE (Mix A) AND CALCIUM ALUMINATE CEMENT POROUS CONCRETE (Mix B)

The observations for this portion of the test are in the process of being assembled, and will be prcvided in the final Phase ill test report.

U.S. Nucirr R gulatory Commission B15985\ Attachment 1\Page 12 PORTLAND CEMENT (Mix E)

During the 21 day flow test into the mold, close observations were made regarding white residue.

Upon core sample removal all cores were inspected for their structural integrity and sound appearance. No visual differences were noted between the cores from the slab on top of the calcium aluminate cement mortar mock-up, and the cores removed from the sister mold.

The 3 foot x 3 foot x 12 inch thick concrete slab on top of the mock-up with water flow remained in position until the end of the sixth month. The slab was removed with little effort. When removed, the concrete slab showed lack of bonding to the seat mortar at the interface. The impression at the interface was smooth with any adverse affect between the cements limited to the face of the surfaces.

CONCLUSIONS PORTLAND CEMENT POROUS CONCRETE (Mix A) AND CALCIUM ALUMINATE CFMcNT POROUS CONCRETE (Mix B)

The conclusions for this portion of the test are in the process of being assembled, and will be provided in the final Phase lll test report. The results of the Phase ill test have been factored into the operability determination contained in Reference 2.

PORTLAND CEMENT (Mix E)

The Containment structure is designed for the loads and load combinations presented in the Millstone 3 FSAR. Section 3.8.1.3.1. The allowable stresses are in accordance with ACI 318-71. Mix E was used to construct the mock-up of the Containment mat slab interface with the calcium aluminate cement layer below the Containment mat.

From Table 5, it can be seen that there is a close correlation among 60 day strength of the concrete samples cored out either from the mock-up mold subjected to water flow or from the sister mold which was not subjected to the water flow. The variation in strength is insignificant and their value, to a degree is influenced by their densities.

This indicates there has been no degradation of the concrete as a result of the exposure to the calcium aluminate concrete and the water flow . In addition when all cores were removed from the mock-up slab and inspected, as well as from the sister mold, the concrete integrity was intact with no visual difference. Therefore it can be concluded from the mock-up test that the Containment mat concrete containing Portland cement has not experienced any decrease in strength as a result of interacting with the porous concrete layer containing calcium aluminate cement.

Even though lack of bond at the mating surfaces of Containment mat slab with the porous concrete layer was observed in the mockup testing, this is not expected to have

U.S. Nucl::cr Regulatory Commission B15985%ttachment 1\Page 13 any adverse impact on the structural integrity of the Millstone 3 Containment basemat, as discussed in the response to Request 3.

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B15985\ Attachment 1\Page 14 1

I REQUEST 2 !

Reference 3 describes the Phase lli mock-up test as related to the study of interaction between the calcium aluminate concrete, and the portland cement concrete of the basemat. Provide the information regarding the relative detE,rioration of the two concrete types by comparing the 60-day strengths of (1) portland cement mold before and after the test, and (2) that for the high alumina cement concrete. Comparisons with 1 the specified strengths (as shown in the Conclusion) is inappropriate. J RESPONSE 2 1

(1) Portlant Cement A comparison of the strength of cores samples representing the Containment !

basemat is included in Table 5. This table compares the strength of core i samples exposed to water flow to samples removed from the sister mold which, !

was not e: posed to water flow, and to laboratory cured cylinders.

(2) High Alumina Cement Concrete I Further explanation is contained in the Phase ill portion of the response to Request i using cycle number 1 for the baseline strength.

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REQUEST 3 l

l The Phase 1ll mock-up test also indicated that there was a complete lack of bond i between the portland cement concrete mold (representing the basemat concrete), and )

the calcium aluminate concrete of the test mold. Provide information regarding the consequences of the lack of bond on the load transfer to the foundation, and on the dynamic behavior of the structure.

RESPONSE 3 The impact of the lack of bond at the interface of the Containment Structure foundation structural concrete and the porous concrete layer containing calcium aluminate cement are addressed in Reference 13. This calculation addresses two aspects related to the loss of bond: (1) The ability to transfer vertical loads across the interface of the Containment foundation and the porous concrete, and (2) The ability to transfer the I horizontal shear force from a seismic event across the interface of the Containment '

foundation and the porous concrete.

Section 3.8 of the Millstone 3 FSAR provides the applicable load combinations for the l 4

design of the Containment Structure. Load combination No. 9 Abnormal / Extreme !

Environmental 1.0D + 1.0L + 1.0Pa + 1.0Ta + 1.0SSE + 1.0Ra is considered the limiting load combination for this condition. The SSE case includes loads from both the vertical and horizontal excitations acting simultaneously. The loads at this location are:

1.0D + 1.0L + 1.0Pa + 1.0Ta + 1. ora = 155,617 kips 4 SSE Vertical Force = 29,087 kips i SSE Horizontal Force = 55,152 kips

The impact of the lack of bond is summarized below:

(1) Vertical direction The net vertical force from this load combination is 126,530 kips in compression resulting from a vertically upward SSE force and the resulting downward force from the remainder of the loads. No bond between the Containment Structure foundation and the porous concrete layer is required to transfer this net compression load.

(2) Horizontal Direction For the horizontal direction the load transfer can be accomplished by friction resulting from the net vertical downward load of 126,530 kips at this interface. In the condition of concrete to concrete the coefficient of friction ( ) of 0.6, and a interface reduction factor (y) of 0.8 is used to account for the porous concrete interface with the normal weight structural concrete, per ACI 318-89 Chapter 11.

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, B15985\ Attachment 1\Page 16 Net Compressive Force (N) = 126,530 kips Frictional Coefficient (p) = 0.6

Reduction Factor (y) = 0.8 Resisting Capacity ( yN) = 60,734 kips j Horizontal SSE Force = 55,152 kips Margin of Safety 60,734/55,152 = 1,10 In summary, during an SSE event there is sufficient net compressive force which produces enough frictional resistance to transfer the inertia loads without crediting any bond at the interface of Containment Structure foundation and the porous concrete. 1 4

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U.S. Nucl:ar R:gulatory Commission l B15985%ttachment 1\Page 17 i

REQUEST 4 UFSAR Section 3.0.1.6.1. states, "In general, concrete mixes were of a 28-day strength of 3,000 psi unless otherwise specified by the Engineer." However, in response to ]

question 1.1 (Ref.1), the strength of the containment basemat concrete is indicated as 3,000 psi at 60-days. Provide information on what was really used. If available, provide information regarding the strength of lab-cured and field-cured cylinders taken from the basemat concrete during construction. This information is useful in comparing the degradation effects, if any, with the results of the mock-up tests.

, RESPONSE 4 in preparation of the responses for Reference 1, project specification 2199.141-281

" Mixing and Delivering of Concrete" (Reference 10) was reviewed. This specification indicates that concrete mix 302 is a 3000 psi at 60 day mix. A review of the actual pour records indicate that the laboratory cylinders were tested at 28 days and had an average strength of 4451 psi.

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U.S. Nucisar Reguintory Commission !

c B15985%ttachment 1\Page 18 i REQUEST 5 l j- Provide, a relationship between the grain size distribution of the sump slurry ?

(Attachment 3, Ref.1), and the finer particles and cement particulates in the porous concrete layers. This information is useful in understanding and predicting the ability of i j the erosion process to continue. .

RESPONSE 5 t

1 The particle size distribution for (1) the calcium aluminate cement used in the Phase lll !

mock-up test and (2) the Portland cement type ll of a representative sample has been I provided in Attachment 4. The particle size distribution for the porous concrete i aggregate is similar to that presented in Table 1 for the # 57 aggregate. The grain size distribution of the . residue removed from the sumps was previously provided in Reference 1. We do not believe that a direct comparison of these particle sizes is 1 appropriate, since the calcium aluminate residue is removed from the Containment l structure foundation in a ground water solution it appears that once the water enters the sumps in the Engineered Safety Features Building the residue crystallizes from solution and the particle sizes may be different in this state.

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U.S. Nucl ar R:gul: tory Commission B15985\ Attachment 1\Page 19 REQUEST 6 An Operability Determination (OD) has been provided in Attachment 2 to Reference 2.

In item F.1a, a gross assumption has been made that the full 800 feet of drainage pipes are filled with eroded cement. Figure 11.2-3 attached to Reference 1 shows the daily count of the total amount of water collected in the sumps in the year 1994. The peak i flow shown is about S,700 gallons of water per day. Such a large flow is not feasible if i the pipes were even half filled with the hardened cement. There is a vast uncertainty in l estimating the yearly accumulation of dry weight of the cement residue. Based on the results of the mock-up tests and other information (e.g., the latest estimate of 1996 l cement residue), provide one reasonable scenario in your OD that can be compared i against future accumulation of cement slurry in the sumps.

RESPONSE 6 The operability determination referenced intentionally assumed conservative hypothetical scenarios to maximize the potential loss of cement emanating from the porous concrete layers. This was partially due to uncertainties in the total amount of residue that may have been removed from the Containment foundation. We recognize that it may not be possible to receive such large amounts of water if the drainage pipes were even partially full, but since the amount of data available on the residue is limited we provided the conservative approximations. As mentioned in response to question IV in Reference 1 some of the variability in the amount of residue collected is explained by the duration between the sump cleanings. Since this time frame was not constant, variability in the data would be expected.

With the average of 80 pounds of dry weight of residue being received in the sump each year, an estimate of 100 pounds per year may be more reasonable, considering small amounts of residue may have passed through the underdrain sumps in solution and some residue may be retained under the Containment foundation. Based on the data to date, we believe that the 100 pounds per year accumulation of residue is the most reasonable for prediction of future quantities.

U.S. Nucirr R gulatory Commission B15985\ Attachment 1\Page 20 REQUEST 7 Four additional hypothetical scenarios have been postulated in the OD (Attachment II, Ref. 2). In the evaluation of each scenario, a statement is made at the end of the evaluation, "The containment mat has sufficient rigidity to span over these hypothetical gaps without any impact on the mat qualification." The results of the calculations, if any, have not been provided. Provide the results of the calculations (stresses and deflections) for the fourth scenario (where a 5-foot diameter gap has been assumed) considering the gap to be under the heavily loaded area, for example, under the fully loaded crane wall, or reactor (primary shield) wall.

RESPONSE 7 In this hypothetical scenario a total of five areas were considered to have degraded in a 5 foot diameter pattern. Four of the areas considered were at intersections of the drainage pipe sections, and the fifth was at the centerline of the Containment Structure.

The 10 foot thick containment mat was determined to have sufficient structural rigidity to redistribute vertical loads over the hypothetical gaps without any impact on the Containment mat qualification. This scenario was based on engineering judgment considering the classical load distribution method by shear transfer mechanism of the vertical load from the mid plane of the mat section-to the bottom porous concrete support. Industry practice indicates a 45 degree shear angle for load distribution in normal weight concrete is appropriate. Conservatively using a 30 degree distribution as a lower bound from the vertical plane a gap of approximately 5.77 feet could be predicted, which bounds the conservative gap of 5 feet.

Alternately this has been verified by computing the rigidity of the Containment Mat by employing the classical method of Beams on Elastic Foundations, as proposed in Reference 18. Here it is proposed that the limits of the variable AL can be used to determine the rigidity. If AL is less than x/4 then in local areas the bending is not influenced by the subgrade stiffness.

. A=tf y4D D= 2 12(1- v )

L=0 42 Where:

D = Flexural Rigidity of the Mat h = Thickness of the Mat k = Porous Concrete Spring Stiffness E = Modulus of Elasticity of the structural concrete L = Rigid Length of the Beam

i U.S. Nucl: r Regulitory Commission )

B15985%ttachment 1\Page 21 i

Containment Mat Parameters '

i h = 10fect fc = 3000 psi Ec= 2.9x10' psi l v = 0.167 h' l I= = 85.72ft' '

12(1 - v')

Porous Concrete Parameters Total th'ickness of the two layers is 19 inches (1.583 feet).

Minimum average monthly unconfined compressive strength from the Phase til mockup test was 877 psi (Table 6).

y = 110pcf fc = 877Psi Ec= y"338, = 1.12x10' = 162,355ksf (Reference 15) k AE _ (1)l62,355 - 102,540k / ft -

1 1.583 I From Reference 13 the following values have been computed:

D = 35,798,38Ik/t 2 A = 0.164 L = 4 8fect )

From this it can be stated that the 10 foot thick reinforced concrete mat would behave as rigid to a gap up to approximately 5 feet and the load path would be in the shear '

transfer mode.

. _ - _ _ _ _ . . ~ . _ _ _ . _ . _ _ _ . . _ _ _ _ . _ . ..

U.S. Nuciser Regul tory Commission l 815985\ Attachment 1\Page 22 '

REQUEST 8

. 1 Erosion of cement from the porous concrete layers is continuing, and it is necessary to )

monitor the movement of the foundation basemat under heavily loaded areas of the !

basemat (e.g. crane wall and primary shield wall). Provide information regarding your plans for monitoring the settlements under such areas.

RESPONSE 8 The response to this request is included in the response to Request 9.

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, U.S. Nucinar Regulatory Commission B15985\ Attachment 1\Page 23 REQUEST 9 4

i The effects of uniform and differential settlements could be monitored by inspecting the surface conditions of the walls near discontinuities, and pipe alignments around piping penetrations in the containment wall, crane wall, and the primary shield wall. Provide your plans to implement augmented inspections for this purpose.

4 RESPONSE 8 & 9 Permanent benchmarks have been installed on the Containment exterior shell since plant construction. These benchmarks have been periodically monitored since '

installation for any signs of Containment settlement. The latest survey results have been previously reported in Reference 2, and no differential settlement has been observed to date. Periodic monitoring of these benchmarks will continue as part of our Condition Monitoring of Structures for compliance with the Maintenance Rule. i Visual inspections will be performed to monitor potential settlement of the containment internal structure. This monitoring will be included in our existing program for Condition Monitoring of Structures in compliance with the Maintenance Rule. A baseline ,

inspection will be completed in our present outage and subsequent inspections will be completed each refueling outage.

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U.S. Nuclsar Regulatory Commission e B15985\ Attachment 1\Page 24 l 1

i -

REFERENCES:

o

1. Northeast Utilities Letter B15803 to NRC, dated July 12, 1996, Pertinent ;

i information Related to the issue of Erosion of Cement from the Millstone Unit-1 No. 3 Containment Mat. i 4

2. Northeast Utilities Letter 815825 to NRC, dated August 1,1996, Additional ;

2 Information 'Related to the issue of Cement from the Millstone Unit No.- 3 l l ' Containment Mat.

3. Northeast Utilities Letter B15850.to NRC, dated August 9,1996, Additional i

information Related to the issue of Cement from the Millstone Unit No. 3 Containment Mat.

! ' NRC Letter TAC No. M96402 to Northeast Utilities, dated October 18, 1996, 4.-

]

Request for Additional Information, Erosion of Cement from the Porous Concrete !

! Drainage System Millstone Unit 3.

]; 5. Alden Research Laboratory Report No.178-92/M295F-R Revision 1, dated ;

j November 1996, Phase i Porous Concrete Mock-up Testing for Millstone Unit 3. i

. 6. Alden Research Laboratory Report No.161-93/M295F-R Revision 1, dated November 1996, Phase ll Porous Concrete Mock-up Testing for Millstone Unit 3.

[ 7. NUSCO Specification SP-CE-354, Revision 1, Porous Concrete Mock-up Testing (Phase 1), dated March 10,1992.

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l 8. NUSCO Specification SP-CE-363, Porous Concrete Mock-up Testing (Phase 11),

j . dated February 18,1993.-

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9. NUSCO Specification SP-M3-CE-0001, Revision 1, Porous Concrete Mock-up i

Testing Phase ill with Containment Mat Concrete, dated December 2,1994 ,

l l 10. . Stone and Webster Specification 2199.141-281 Revision 1, with Addendum 1, 4

dated February 14,1984, Mixing and Delivering Concrete.

i 11. Stone and Webster Calculation 12179-NS(B)-025, Millstone 3 Seismic Analysis l of the Reactor Containment.

l l

12. Stone and Webster Calculation 12179-NS(B)-002, Millstone 3 Containment i l Structure Static Analysis and Design. l

! - 13. NUSCO Calculation 96-ENG-1263C3, Response to NRC inspector Findings,

- dated June 6,1996.

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U.S. Nucle:r Reguletory Commission B15985\ Attachment 1\Page 25

' 14. Millstone 3 FSAR Section 3.7, Seismic Design, and Section 3.8 Design of Structures. i

15. ACI 318-1989 Building Code Requirements for Reinforced Concrete.

16. ACI 349-1980, Code Requirements for Nuclear Safety Related Concrete

. Structures.

I

17. Roarks Formulas for Stress and Stress and Strain,6th Edition.

18. Foundation Analysis and Design, by Joseph E. Bowles,2nd Edition, McGraw Hill )

Publication,1968. !

19. Northeast Utilities Letter B15934 to NRC, dated October 10,1996, Additional !

Information Related to Millstone Unit No. 3 Containment Mat. l

)

U.S. Nucl=r Rcgul: tory Commission B15985\ Attachment 1\Page 26 l TABLE 1 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE lil MOCK-UP TEST l

GRADATION ANALYSIS OF COARSE AGGREGATES l ASTM DESIGNATION: ASTM C33 and C136 RESULTS SAMPLE No.67 No. 57 No.4 Retained on 11/2 inch - -

O sieve, (percent) I 1 inch sieve - -

58 l

> 3/4 inch sieve 1 4 96 1

1/2 inch sieve 34 47 99 3/8 inch sieve 77 82 99

4 sieve 98 96 99 l

8 sieve 99 97 100 i

Fineness Modulus 6.76 6.82 7.94 The gradation distribution of the 3 samples meet the requirements of ASTM C33-92a for concrete cggregates.

U.S. Nucl::gr R::gul: tory Commission

B15985\ Attachment 1\Page 27 TABLE 2

MP3 CONTAINMENT MAT POROUS CONCRETE !

PHASE Ill MOCK-UP TEST

. CHEMICAL ANALYSIS OF WATER

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i SOURCE I SPECIMEN A: WELL WATER FROM ALDEN RESEARCH LAB i.

SPECIMEN B: BATCH WATER FROM CONCRETE SERVICES INC.

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TEST PROCEDURE

1. STANDARD METHODS FOR EXAMINATION OF WATER AND WASTE WATER. APHA-i AWWA-WPCF,17TH EDITION,1989

^

2. METHODS FOR CHEMICAL ANALYSIS OF WATER AND WASTES. EPA 600/4-82-055, 1983 RESULTS

! DESCRIPTION SPECIMEN A SPECIMEN B l

. (expressed in ppm) (expressed in ppm)

ACIDITY 7 7 l l

l ALKALINITY 7 94 l

SOLIDS 70 180 (includes salts)

ORGANIC None None (3.0% NaOH)

OILS & GREASE None None The water samples analyses are well within the limits of ASTM C94-92a requirements for ready-mixed wash water as presented in Table 11 of that Standard.

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U.S. Nucirr Regulatory Commission B15985\ Attachment 1\Page 28 TABLE 3 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE Ill MOCK-UP TEST CONCRETE PLACEMENT SCHEDULE DATE MIX PLACEiAENT REMARKS MAY 11,1995 Place Mix A 10 inch thick Portland cement porous concrete ;

l Place Mix D 2 inch thick Portland cement seat mortar on the membrane !

MAY 16,1995 l MAY 18,1995 Place Mix B 9 inch thick calcium aluminate cement porous concrete MAY 25,1995 Place Mix C 2 inch thick calcium aluminate cement seal mortar JUNE 1,1995 Place Mix E 12 inch thick structural concrete with Portland cement representing the 10 foot thick containment mat, and also constructed in a 3 foot x 3 foot x 1 foot thick sister mold.

JUNE 8,1995 N/A Water flow test started i

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U.S. Nucl :r R:gulatory Commission B15985\ Attachment 1\ Pace 29 TABLE 4 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE Ill MOCK-UP TEST FLOW TEST I (based on a 24 hour2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months day for 21 days in a one month period) i l

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^

MONTH GALLONS / MINUTE GALLONS / MONTH 1

1 32.0 967,680

]

2 26.9 813,456 3 18.5 559,440

4 29.7 898,128 5 21.6 653,184 I 6 21.9 662,256 7 16.6 501,984 8 18.0 544,320 9 21.6 653,184 10 19.0 574,560 11 18.0 544,320 12 19.0 574,560 TOTAL 7,947,072 GALLONSIYEAR l

U.S. Nucl: r R:gulatory Commission B15985\ Attachment 1\Page 30 TABLE 5 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE Ill MOCK-UP TEST UNCONFINED COMPRESSIVE STRENGTH STRUCTURAL CONCRETE (MIX E)

LAB CURED CORES FROM MOCK-UP CORES FROM DESCRIPTION OF CYLINDERS SLAB SISTER MOLD TEST NO WATER FLOW WITH WATER FLOW NO WATER FLOW AGE OF TEST 28 56 40 60 98 40 60 (in days)

CORE DIAMETER 6 6 5.72 5.72 5.72 5.72 5.72 (inches nominal, 12 inches high)

AVERAGE 150 150 151.5 149 152 151 148.5 DENSITY (pcf)

AVERAGE 4935 5257 5335 4925 5260 4640 4695 COMPRESSIVE STRENGTH l (Psi) l l

k From the above table it can be concluded: l I

1. The compressive strengths are in very close agreement.

2. The strength variations are insignificant and related to the density of the specimens.

3. The presence of water flow has no effect on the strength and the integrity of the core samples ;

removed from the mock-up slab.

4. In three monthr, of water flow there is no degradation of concrete strength observed.

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U.S. Nuclear Regulatory Commission B15985\ Attachment 1\Page 31 1

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TABLE 6

MP3 CONTAINMENT MAT POROUS CONCRETE j PHASE Ill MOCK-UP TEST

! UNCONFINED COMPRESSIVE STRENGTH CALCIUM ALUMINATE POROUS CONCRETE

! (MIX B)

Age Of The Sample Density (pcf) Strength Ave. Density Ave. Strength i Tests (Months) Location (PSI) (PSI)

1 1C 120 1420.

1E 119 1200.

2 1G 122 1380. 120 1333.

} 2 2C 115 1020.

! 2E 122 1390.

! 2G 122 1440. 120 1283.

3 3C 115 1220.

1 3E 114 1370. l

3K 125 1760. 118 1450.

4 4D 118 1310.

l 4E 122 1970.

4H 118 1510. 119 1597.

5 SD 118 1650.

I SE 122 1910.

5H 122 1440. 120 1667.

l 6 6C 120 1010.

1 6E 118 1170.

6K 127 1730. 122 1303.

7 7D 115 1110.

7F 123 2340.

7H 121 1480. 120 1643.

8 BC 119 1170.

8F 118 1130.

8K 120 1390. 119 1230.

9 9C 118 1120.

9E 113 840.

9G 115 1050 115 1003.

10 10C 115 850.

10E 116 840.

10G 119 940. 117 877.

11 11D 115 1050. l 11E 112 730. l 11G 118 960. 115 913.

12 12E 114 860. !

12F untestable 12K 120 1150. 117 1005.

U.S. Nuclear Regulatory Commission B15985\ Attachment 1\Page 32 Note:

1. The average strength of the 3 test samples showed a net gain in strength for the first 5 months and a decline in compressive strength for the next 7 months.

2. The maximum increase in strength from month one is approximately 25%, and the maximum decrease in strength from month one is approximately 34%, occurred in 10th month of the flow test.

3. Refer to Figure 1a for Test Sample Coordinates.

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U.S. Nucl:ar Regulatory Commission B15985\ Attachment 1\Page 33 TABLE 7 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE Ill MOCK-UP TEST UNCONFINED COMPRESSIVE STRENGYH PORTLAND CEMENT POROUS CONCRETE (MIX A)

Age Of The Sample . Density (pcf) Strength Ave. Density Ave. Strength Tests (Months) Location (PSI) (PSI) 1 1C 123 1490.

, 1E 124 1550.

1G 125 1750. 124 1597.

i 2 2C 126 1640.

i 2E 129 1790.

2G 124 1350. 126 1593.

3 3C 123 1620.

3E 124 1640.

3K 124 1450. 124 1570.

4 4 4D 128 1900.

4E 128 1620.

i 4H 126 1690. 127 1737.

5 SD 126 1890.

SE 125 1850.

5H 126 1740. 126 1827.

6 6C 126 1710.

GE 123 1820.

6K 123 1470. 124 1667 j 7 7D 123 1600 7F 127 1970.

l 7H 122 1540. 124 1703 8 8C 125 1810.

8F 125 1910.

8K 108 1220. 119 1647 f

9 9C 126 1910.

9E 125 1560.

l 9G 126 1520. 125 1663 i 10 10C 126 1570.

10E 127 1640.

10G 128 1740. 127 1650 11 11D 127 1940.

11E 129 2020.

11G 126 1700. 127 1887 12 12E 127 1750.

. 12F 127 1920.

4 12K 122 1390. 125 1687 i

U.S. Nucl::ar Regulstory Commission B15985\ Attachment 1\Page 34 :

i l

Note: 1

1. The average strength of the three test samples from the 1st month to the 12th month showed no loss of strength.

2. The maximum increase in strength from month one is approximately 19%, oc:.;urred in 11th month, and the maximum decrease is about 1.5% occurred in the 3rd month.

, 3. Refer to Figure ia for Test Sample Coordinates.

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.S. Nucl:ar Regulatory Comr. ission i 159851 Attachment 1\Page 35 TABLE 8 MP3 CONTAINMENT MAT POROUS CONCRETE PHASE Ill MOCK-UP TEST UNCONFINED COMPRESSIVE STRENGTH POROUS CONCRETE LABORATORY CYLINDERS ,

2 b

DIMENSIONS: 6" x 12" High Cylinders Description of Test Mix A Mix B (Portland) (Calcium) ;

Age of Test (Days) 7 28 7 l 28 Average Density (pcf) 127.5 127.7 129. 129.3 Average Compressive Strength (psi) 2130. 2357. 2505. 2367.0 :

t Note:

1. Mix A - Porous Concrete with Portland Cement, shows an 11% increase in strength fro day 7 to 28.

2. Mix B - Porous Concrete with Calcium Aluminate Cement, shows no strength increase after 7 days.

. _ m.__.___-____m _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . ____

$k 5 5

++ + +

N a

a 7 * *********** C x- u + +++++++++++ -" --W"h

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g

'- $ u4_ _!$

e I-G $ + ++++++++++*

o y + +++++++++++

o ( PERFORATED WALL o Yi n ^ Yi L

+ +++++++++++

w # + + + + + + + + + + + +

H 0- $ + +++ +++ ++++*

'o. m z

'e u-M M - ct

+ +++ +++ +++++ #

mo $

"o $

Q W$

a M .

I

+1 + + +

AA R N N -O O Q b e O v M N -

l'-0" _

11'-0" _

PLAN VIEW

+ - INDICATES THE LOCATION OF 6" O CORE BORES.

+ - INDICATES THE PO;1 TION OF PERFORATED METAL CAGES.

p Northeast Utilities System

MILLSTONE NUCLEAR POWER STATION UNIT 3 T11LE POUROUS CONCRETE MOCK-UP TEST !

TESTING MOLD - PHASE Ill Bf K. FULLER Ot:D. APP. APP.

DAI[ 8-6-96 DAl[ DAT[ CAI[

sat eu.s **

, PA* NO. DAf( Kv!5106 81 CHK. APP. APP. PA' FIGURE la l

I

1 l

OUTLET #1 OUTLET #2

".c N

5 .

,f 3 u O! l 0 I

, t' u t a

2"- 1" e ORIFICE 1" e ORIFICE 12"

=

5'-0" 4 '- 0" 12"

.==

SECTION X2-X2 s e inter i geintET.2

" D .

e a .

a I SECTION X3-X2 :

1 1" e 0 12" C/C _

In u + + + + + + + + + +++

g . + + + + + + + + + +++

. + + + + + + + + + +++

a S ECTION Yi -Y1 (ELEVAUON)

PERFORATED WALL p Northeast Utilities System

"* MILLSTONE NUCLEAR POWER STATION UNIT 3 IlfLE POUROUS CONCRETE MOCK-UP TEST TESTING MOLD - PHASE III BV K. FULLER Ota #P. APP.

DATE 8-6-96 DAIC DATE DATE SCALE N.T.5 DWG. NO.

1 ru .o. oAiE asm er o e. a. ,, FIGURE lb

=

3'-0" T.

18"

= -

MIX C MIX C 2"- l , o o MIXI@ Of 2" a -

cn MIX @ l MIX h MIX @

h ulx@ \ ulx @

2 PLY-MEMBRANE

SECTION Xi-Xi 4

= {" 0 - 6" C/C ; = }" 0 - 6" C/C 2

'I

: : : : : n !

O O O O O O O O O il _4H O O O O O O O O O O O - 3" ;

-3" 3"

m

n '

3 " 2" SECTION X4 -X4 l

E i

O Nordieast Utilities System

WILLSTONE NUCLEAR POWER STATION UNIT 3 ft1LL POUROUS CONCRETE MOCK-UP TEST TESTING MOLD - PHASE III Bf K.F ULLER OKD, WP. #f.

DATI 8-6-96 DATE DATE DAIL SLM N.I.S DWG. W-

, P.A

NO. DAll REV1510NS SY CHK. APP. APP. P.A*

4 i 3'-0" _

i l i

Y2 . 4>f> SM-3 LM-4 : ^Y2 o, -

p

<><> LM-1 LM-2 l t

l P_Ah

MIX E L$id5!%@ k

SECT: :Oh Y2 -Y2 e

. NOTE:

(F LOCATION OF CORE SAMPLES.

l SM-1 & SM COMP. TEST a 40 DAYS

} SM-3 & SM COMP. TEST e 60 DAYS a CONCRETE MIX DESIGN "E" MIN DESIGNED COMP. STRENGTH

] fc' = 3000 PSI e 60 DAYS O Northeast Utilities System

"* MILLSTONE NUCLEAR POWER STATION UNIT 3 a itiLE POUROUS CONCRETE MOCK-UP TEST j SISTER MOLD - PHASE !!!

BY K. FULLER OKD. M. M.

DATI 8-6-96 DA10 DATE DATE SC4.0 N.T.5 DWG. ND.

1 eu ao. oArt misas er o.c e. n. e. FIGURE 2 1

2 I

Docket No.50-423 {

B15985 d

j i

e Attachment 2 i

i Millstone Nuclear Station Unit 3 Phase i Test Report i Millstone 3 Erosion of Cement From The Porous Concrete Drainaae System 1-i a.

I November 1996 l

1 il

, , i i :

j POROUS CONCRETE MOCK-UP TESTING l 1

FOR MILLSTONE UNIT 3 WATERFORD, CONNECTICUT l i

i By l

l Dean K. White i

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SUMMARY

OF TEST RESULTS 6 Aggregate Voids 6 '

Test Cylinders 7 ,

Flow Testing 8 Core Testing 10 ;

REFERENCE 12 i FIGURES 1 APPENDIX A - MATERIAL SPECIFICATIONS AND DOCUMENTATION APPENDIX B - CONCRETE BATCH WEIGHTS APPENDIX C - CONCRETE CONTROL APPENDIX D - CONCRETE TESTING LABORATORY INSPECTION REPORT APPENDIX E - VOID RATIO TESTS APPENDIX F - TEST OF CONCRETE SPECIMENS APPENDIX G - CEMENT RESIDUE ANALYSIS APPENDIX H - CEMENT WASHOUT ANALYSIS APPENDIX I - SINGLE LAYER SLAB CONCRETE STRENGTH APPENDIX J - DOUBLE LAYER SLAB CONCRETE STRENGTH i

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i n .l i INTRODUCTION j i !'

i 1 This report covers all work conducted under Northeast Utilities Specification SP-CE-354 both !

j . by the Alden Research Laboratory, Inc. (ARL) and its subcontractor, Trow Protze Consulting

} . Engineers (TP). All technical matters related to the project were coordinated with Mr. K. .

i 12kshmipathiah of Northeast Utilities Service Company (NU). j j SCOPE OF WORK

i j

The ARL and its subcontractor were to provide all the necessary materials, equipment, and l

$ technical requirements for the construction of three (3) porous concrete test slabs and for testing l

of the test slabs to evaluate potential cement erosion resulting from the flow of water through

{ the porous concrete. l' 1

1 i

i CONSTRUCTION OF APPARATUS 4

i Three (3) concrete test slabs were constructed. One (1) test slab was a single layer.while two (2) test slabs were double layers. The wooden forms built to contain the test slabs were heavily l j reinforced to minimize deflection.

d The 6 x 10 foot form for the single layer slab was 13 inches high to accommodate a 9 inch layer of porous concrete between two 2 inch layers of grout. One 10 foot long side of the form

_ contained groups of one quarter inch holes to introduce water into the test slab. The holes were drilled over size, and a plastic sleeve was pressed into each hole to insure uniformity. The single layer test slab contained two 6 inch perforated plastic drainage pipes to collect the water i

introduced through the one quarter inch holes. The drainage pipes contained four (4) rows of five eighths inch diameter holes spaced 3 inches center to center. The rows of holes were i located at 2 o' clock, 4 o' clock, 8 o' clock, and 10 o' clock around the pipe. Figure 1 is the plan l of the single layer test slab.

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I The two double layer test slab forms were 6 x 10 feet x 21 inches high. These forms contained !

a 9 inch layer of porous concrete on top of a 10 inch layer of porous concrete. A 2 inch layer of grout was on top of the 9 inch layer of porous concrete. One 10 foot long side of the form ]

contained groups of one quarter inch holes to introduce water into the test slab. The holes were j drilled over he, and a plastic sleeve was pressed into each hole to insure uniformity. The b 4i double layer it t slabs contained two 6 inch perforated plastic drainage pipes in the 9 inch

~

porous concrete Myer to collect the water introduced through the one quarter inch holes. The drainage pipes contained four rows of five eighths inch diameter holes spaced 3 inches center to center. The rows of holes were located at 2 o' clock, 4 o' clock, 8 o' clock, and 10 o' clock :

- around the pipe. Figure 2 is the plan of the double layer test slab. A partially filled two layer slab is shown in Figure 3. j i

Water was supplied to the boxes through pumps capable of developing 50 feet of head of water l (22 psig) discharge pressure at the slab. Flow from the pump was introduced into a manifold !

where smaller lines carried flow to each of the one quarter inch holes. A calibrated pressure gauge was located on the manifold and a valve on the inflow to the manifold was provided to I:

regulate pressure. .j i

I Water discharging from the drainage pipes was collected in a settling box and the residue washed ;

from the slab was recovered by filtering the water from the box using a 5 micron filter. For :

the tests of 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months duration, all water was filtered. For the 30 day test, only the residue in the !

box at the conclusion of the test was collected. '

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PROCUREMENT AND TESTING OF MATERIALS !

i The ASTM #57 coarse aggregate to be used in the porous concrete slabs was procured from t I

. Tilcon Connecticut, Inc., the quarry providing the coarse aggregate to the Millstone Plant during the original construction. Review of the gradation logs for the original aggregate, aggregate being shipped from the quarry today and a sieve analysis of the aggregate actually used for this 2-

.---,r-,- - - -

l h

j test showed that the aggregate used in the test was similar to the aggregate used at Millstone and l

was within the ASTM specifications for #57 aggregate, see Appendix A. l

i F: *

j The calcium aluminate cement was produced by the Lehigh Portland Cement Company of Gary, lt 4 .

4

Indiana at the Buffington Plant. The mill test report indicates that the cement meets the -

l l requirements of Section 8.3 of the NU Specifications. In addition, TP conducted check tests of li the Lumnite cement which confirm the mill test report. Both the mill test report and the check ;

tests conducted by TP are in Appendix A. -

i I I i -

The Portland Cement Type II produced by the LaFarge Corporation Northeast Cement Plant !

complies with current ASTM C-150 as well as A.A.S.H.T.O. M-85 specifications called for in

- Section 8.2 of the NU Specifications, see Appendix A.

1 The concrete used in the test slabs required careful preparation of transit mixing equipment since 4 l- l Calcium. Aluminate Cement is not in common usage (all local concrete plants use Portland

]

jg Cement). Concern for the possible contamination of Calcium Aluminate Cement with Portland i

)' Cement prompted tests on how the initial setting time of Calcium Aluminate Cement was

[ effected by Portland Cement contamination. The results of these tests indicated that contamination up to 10% did not significantly effect the setting time of Calcium Aluminate I Cement. The results of these tests are shown in Appendix A.

! BATCHING AND PLACING OF CONCRETE

'Ihe test slabs contained very small quantities of concrete and to better control the batching process, the minimum batch sizes was set at 3 cubic yards of concrete. The mix designs were i based on this yardage and can be found in Appendix B. The mixes containing Portland Cement

were batched at the transit mix batch plant and sent to the site with only a small fraction of the

. water requirement added at the plant. The remaining water was added at the site and carefully j controlled to produce the proper consistency. The mixes containing Calcium Aluminate Cement J :

I

only added the aggregate at the transit mix batch plant and the cement was added at the site by the bag to minimize the potential of rapid setting of the concrete in the truck mixing drum.

Water was added at the site and carefully controlled to produce the proper consistency. Due to the stiffness of the mixes using the #57 aggregate slump was not sufficient to determine the proper water content. The mix was inspected visually for the consistency of the concrete paste - -

on the aggregate.

The preparation of each concrete and grout mix was monitored by TP inspectors, both at the concrete batch plant and during placement. Reporting of these inspections is contained in Appendix C.

DESCRIPTION OF WORK Three (3) test slabs were constructed. Two (2) slabs contained two layers of porous concrete.

The lower layer was 10 inches thick, made with Portland Cement Type II and the upper layer was 9 inches thick, made with Calcium Aluminate Cement (Lumnite Cement). A 2 inch thick grout layer (sand cement mix) made with Lumnite Cement was used to seal the top. The third slab contained a single porous concrete layer 9 inches thick, made with Lumnite Cement and placed on a 2 inch thick layer of grout made using Portland Cement Type II. A 2 inch thick grout layer made with Lumnite Cemem was also used to seal the top of the single layer slab.

To preserve porosity as called for in section 10.3.1.1 of the specifications (Ref.1), the porous concrete layers were compacted in 4 to 5 inch layers by walking on the concrete (" booting").

Each layer of concrete placed in the slab was allowed to cure 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months before the next layer was placed. The concrete placing schedule is shown in Table 1.

^ !

.i

-TABLE 1 CONCRETE PLACING SCHEDULE

! DAY TWO LAYER MOLDS ONE LAYER MOLD ;

l 1 10" Portland concrete 2" Portland grout l 3 9" Lumnite concrete

9" Lumnite concrete

l i

j. 5 2" Lumnite grout 2" Lumnite grout -

- 1 I' ,

Layer containing 6" drain pipes.

!I i

', , In the two layer slabs only, within 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months of the pour the perforated drain pipes were cleaned out and the recovered concrete residue was weighed and analyzed.

l The single layer slab and one of the double layer slabs were cured for 7 days before being pressurized with water. The remaining double layer slab was cured for 30 days and is being stored for future testing.

After 7 days of curing, water was applied to one hole in group A in each of the slabs. Four 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests were conducted in each slab using this hole. The scope of work was modified to use only one hole of the original four holes labeled as holes A for the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months test series. Water was i introduced at a pressure of 22 psig (50 feet of water) and allowed to flow for 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months . All water ]

i collected from the 6 inch perforated pipes was filtered and the residue collected, dried, and weighed. Samples of the residue were analyzed to determine the type of cement. ,

].. ,

In the two layer slab, one hole of group B was opened and four 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests were conducted with a single hole in both groups A and B open to water at a pressure of 22 psig. As was the '!

1 case for hole A, only one of four holes labeled holes B was open for the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months test series. All ;

l m , - .._ e-- - .v- ,,.-n

r I

3. .

i l water collected from the 6 inch perforated pipes was filtered, and the residue collected, dried, l{,

and weighed. Samples of the residue were analyzed to determine the type of cement.

i At the conclusion of the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months testing sequence, both molds were subject to a 30 day test with

! all holes open. This included four holes for holes A and four holes for holes B plus all holes -

labeled C. The water exiting the 6 inch perforated pipes discharged into a settling box that was g !

l 4 inspected for residue five times a week. The residue was collected at the end of the test. ,

i LABORATORY CERTIFICATION ,

i '

The latest CCRL (Cement and Concrete Reference Laboratory) certification for the laboratory of TP is in Appendix D. ;

i

SUMMARY

OF TEST RESULTS l 1

AGGREGATE VOIDS !

The volume of the voids in the Tilcon #57 coarse aggregate was 46%. The volume of the voids ,

.,in the Mix B laboratory prepared sample was 32.7%, in the test cylinders prepared when Mix .

B was placed, the volume of the voids was 30%, and the volume of the voids in cores removed i

from the single layer slab was 33.5%. The volume of the concrete paste is approximately 16%

of the total volume which accounts for the difference in the volume of the voids in the aggregate ;

I compared to the volume of the voids in the concrete. Void ratio test results are in Appendix E.

The variation in the volume of the voids in the mixes may have some influence on the ;

compressive strength of the concrete. i 1

TEST CYLINDERS Six (6) test cylinders were made from concrete Mix A (Portland cement porous concrete) and six (6) test cylinders were made from concrete Mix B (Lumnite porous concrete) at the time of pouring. In addition, three (3) test cylinders were made in the TP laboratory using Lumnite .

. cement and Tilcon crushed stone (Mix B). The laboratory cylinders were kept in the laboratory fog room and were tested at 28 days. The cylinders made at the time of the pour remained at the site for three (3) days and then were held in the laboratory fog room. Two (2) cylinders from each mix were tested at 7 days,14 days, and 28 days. The average 28 day strength of the three Mix B (Lumnite cement) laboratory cylinders was 1,310 psi. The average strengths of the ;

two Mix B cylinders from the pour broken at 7 days,14 days, and 28 days were 985 psi,1,035 psi, and 1,060 psi, respectively. The increase in strength from the 7 day strength to the 28 day I strength was approximately 8% for Mix B. There were no laboratory cylinders made from Mix A (Portland cement). The average strengths of the two Mix A cylinders from the pour broken at 7 days,14 days, and 28 days were 470 psi,480 psi, and 565 psi, respectively. The increase in strength from the 7 day strength to the 28 day strength was approximately 20% for Mix A. l

' The test reports are contained in Appendix F.

i The residue in the 6 inch drain lines of the two layer slabs was removed 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months after i 1

placement of the porous concrete layer. The residue samples were weighed and the chemical l content analyzed. The pipes of the 7 day cure two layer slab contained 33.07 grams of material.

This material consisted of dry concrete particles and small pieces of cement coated aggregate.

The size of the aggregate was limited by the diameter of the holes in the drain pipe. The pipes l of the 28 day cure two layer slab contained 9.70 grams of material. This material was similar to that found in the other slab. The report on the chemical content of the residue is in Appendix G. l 1

i FLOW TESTING i

>1 At the conclusion of the 7 day curing period, both the single layer slab and one of the two layer ,j slabs were introduced to flowing water at a pressure of 22 psi for a series of tests, each 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months I i.

in duration. The water which circulated through the slabs was filtered through a 5 micron filter f ,l ,

upon leaving the slab. The residue was dried and weighed. During each test, the flow rate was measured. The weights and flow rates are shown in Tables 2 and 3. ;

TABLE 2 {

SINGLE LAYER SLAB RESIDUE WEIGHT AND FLOW RATE TEST WEIGHT FLOW DESCRINION grams gpm ,

Gray Powder 1 4.84 2 23.30 4.94 Gray Powder 3 11.27 6.66 Gray Powder l 4 11.62 - 3.50 Gray Powder

Flow not measured.

t 6

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TABLE 3 ,

I DOUBLE LAYER SLAB RESIDUE WEIGHT AND FLOW RATE l HOLE A ONLY I

. TEST . WEIGHT FLOW. DESCRIPTION -

grams gpm )

4

White Residue 1 120.35 2 52.26 1.35 White Residue ,

3 49.19 1.36 White Residue 4 47.59 0.88 White Residue i

j HOLES A & B ,

TEST WEIGHT FLOW DESCRIPTION grams gpm !

l' 1 69.37 8.20 White Residue l

2 91.87 8.26 White Residue l

l 3 60.26 8.43 White Residue 4 53.22 8.12 White Residue l

l

Flow not measured.

During the curing process, a white residue leached from both of the two layer slabs. This material deposited on the wooden box and on the floor any where the curing water went, see Figure 4. In the case of the single layer slab, no such white residue leached from the slab.

When the flowing water was introduced into the slabs, the two layer mold produced a similar appearing white residue which was filtered out and collected as the material tabulated above.

The single layer slab did not produce any white residue. The material washed from the single l

l t

layer mold was more granular and gray in color. The results of the chemical analysis to l determine the type of cement contained in the residue is in Appendix' H. j i

t i

At the conclusion of the 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months tests, both slabs were tested for 30 days introducing water l through all holes shown in Figures 1 and 2. The rate of flow through the slabs was measured .

during the test period. The average flow through the single layer mold was 50 gpm. There was a decreasing trend in flow from a high of about 64 gpm to a low of 40 gpm. The average flow j through the double layer mold was 140 gpm, and there was no trend ofincreasing or decreasing !

flow. No material was found in the water discharging from either mold. j The two layer mold that did not undergo flow testing was cured by remaining flooded for j approximately 28 days. 'Ihe curing water level was maintained at the top of the Lumnite cement :

grout layer. Only enough water was added to make up for leakage and evaporation. The water l that leaked from the mold deposited a white residue on the wooden mold, the building floor and j on the surface any standing water. At the conclusion of the curing period and after the curing l water leakage had evaporated 15 pounds, dry weight, of the white residue were removed from I[ the outside surface of the mold and from the floor. During curing, no special precautions were taken to ensure that the residue transported by the leaking curing water was all captured. Some leaking curing water did run into the building floor drain system while the remainder evaporated on the floor. It is estimated that roughly 70 percent of the residue transported by the leaking curing water was collected in the weighed sample.

i CORE TESTING l I

After the 30 day test period, twelve (12) 4 inch diameter cores were taken from each slab at the locations shown in Figures 1 and 2. Eight (8) of the cores were broken in compression and four (4) cores were split in the longitudinal direction. The coring operation was successful in the !I single layer slab. The compression tests of the single layer slab cores ranged from a high of 600 1

1, psi to a low of 440 psi with the average for 7 test of 520 psi. This average strength is l

l

l t

l l -

l j

approximately one half the 28 day strength of the test cylinders for Mix B. Since there appears I to be no correlation of compressive strength with location within the slab, i.e., some cores were exposed to flowing water and others were not, the reduced strength does not appear to be related to the flowing water. Other factors, such as curing and density of the mix may account for the differences. If the compressive strength of the cylinders made at the time of the pour of Mix -

l B is compared with the strength of the laboratory test specimens, it can be seen that the cylinders made at the time Mix B was poured broke at 1,060 psi while the laboratory test cylinders broke l

at 1,310 psi. A discussion of the relative strengths of the cylinders and the cores is in l Appendix I.

l In the double layer slab, the cores broke under the drilling action. Increasing the core diameter to 6 inches did not prevent the cores from breaking. Anticipating that this might happen, 6 inch

! diameter steel perforated cages were placed in the slabs during the pour, see Figure 3. These cages were extracted from the slab by cutting an 8 inch core around the cage and breaking away l the slab. Three of the cages were cut away from the concrete in an attempt to produce specimens for testing. The bond of the concrete, however, was not strong enough to hold the g

S aggregate together when the cages were removed and only one specimen from each layer was recovered for testing. The two recovered cores were used to conduct split tensile strength tests.

i The Mix A (Type II) broke at 17 psi while the Mix B (Calcium Aluminate) broke at 40 psi. The Mix B specimen strength was much lower than the average of the single layer slab split tensile strength tests. Since the compression test could not be conducted, specimens contained in the remaining cages were tested in a confined compression test by sealing the specimen in a rigid steel cylinder using leadite and an impermeable barrier to keep the leadite out of the voids in the concrete. The confined compression tests were made on four (4) specimens measuring both loading and deflection. Each specimen contained equal lengths of Mix A and Mix B concrete.

The results of the confined compression tests are shown in Figures 5 through 8. The compression tests indicated that at loadings ranging from 385 psi to 654 psi, the specimens began to compress rapidly due to breaking of the bond and rearrangement of the aggregate.

Examination of one of the confined compression test specimens after testing showed that there l

i l l .

,1

i l was more aggregate destruction in Mix A with Type II cement than in Mix B with Calcium Aluminate cement. The laboratory test reports for the two layer slab are presented in -

Appendix J.

REFERENCE ..

e l

- 1. Northeast Utilities Service Company Specification SP-CE-354; Specification for Porous Concrete Mock-up Testing; January 8,1992; Revision 1, March 9,1992.

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'd 2b0 4b0 6b0 8b0 1000 1200 1400 1600 STRAIN /0.001 IN .

t FIGURE 7 CONFINEDCOMPRESSIONTESTSAMPLE F 6

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i APPENDIX A MATERIAL SPECIFICATIONS AND DOCUMENTATION l

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A SIEVE. ANALYSIS OF #57 AGGREGATE FROM ORIGINAL CONSTRUCTION 3

% PASSING 1 1

k- I l SAMPLE SIEVE SIZE !

DATE 1-1/2 1 1/2 #4 * #8 #200 l 1

! - 2/27/75 100.0 99.0 41.0 6.0 4.0 2/28/75 100.0 99.0 37.0 5.0 3.0 j' 3/3/75 100.0 98.0 26.0 4.0 3.0

' 3/5/75 100.0 99.0 30.0 2.0 2.0 I 3/4/75 100.0 100.0 44.0 3.0 2.0 0.9 3/7/75 100.0 100.0 36.0 3.0 2.0 0.6 l 3/7/75 100.0 100.0 40.0 4.0 2.0 0.9

3/21/75 100.0 100.0 49.0 5.0 3.0 I i

3/26/75 1.00.0 99.0 42.0 5.0 3.0 l_ 3/27/75 -100.0 98.0 31.0 2.0 2.0 3/29/75 100.0 99.0 41.0 5.0 3.0 3/31/75 100.0 100.0 49.0 8.0 5.0 1.2 4/1/75 100.0 99.0 40.0- 5.0 3.0

4. l' 4/2/75 '100.0 99.0. 37.0 4.0 2.0 4/7/75' 100.0 97.0 36.0 5.0 3.0 1.2 3 AVG 100.0 99.1 38.6 4.4 2.8 i

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'o RECENT TILCON CRUSHED STONE GRADATIONS

% PASSING SAMPLE SIEVE SIZE DATE 1 3/4 1/2 3/8 #4 F.M.

4/7/92 100.0 90.2 37.0 9.8 1.6 4/8/92 100.0 90.0' 37.3 10.7 1.2 4/6/92~ 100.0 85.9 35.9- 9.4 1.2 4/6/92 100.0 90.9 39.1 11.2 0.6 4/3/92 100.0- 89.5 37.1~ 10.1 2.1 4/2/92 100.0 93.2 44.3 13.7 1.8 3/30/92 100.0 86.0 32.3 7.0 1.1 3/31/92 100.0 83.7 24.5 12.0 1.6 f

AVG 100.0~ 88.7 35.9 10.5 1.4 7.0 i MIN 100.0 83.7 24.5 7.0 0.6 7.1 MAX 100.0 93.2 44.3 13.7 2.1 6.9

57 ASTM 95-100 70-85 25-60 15-25 0-10 7.0 l

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NidAnnorti StH,%W ,I

. . 70 Jaconnet Street Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow Protze coneutting snsinoore i

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FAXMITTAL !

TROW PROJECT NO T8- o e/5/f-A DATE $ 9 2. ,

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TO: C0MPANY: ___d leffa l eJ_ga M __M da_ca d ry , [ Ze2 ___

1 FAX NUMBER: /-f48- F2_9 - 5939 _____

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- TOTAL NUMBER OF PAGES (including this one) / l ATTENTION: A&: Dean /d N)hYe.,}. Er .,_

SUBJECT:

Ci- d M g __ D /een Oh>ne. ___

FROM: _ _

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____ Y'2 Original Will Be

_f.AQ_$_$-f Sent to you Yes - Courier Yes Mail No -

If you do not receive the total number of pages indicated above, or if these pages are unclear, please en11 Trow Protze at 617 332 8460.

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m W M B &1 U@2 11:19 FRCH KESSEL!/ MORSE CO. PAGE.002 APR-23-8992 09:29 FRDM LEHlGH CMT BJFFINGTON PLT. TO S35087537078 e P.02 i _- __ __ _

MILL TEST REPORT

! LEH GH PFLA\D CEV E\T CC.

BUFFINGTON PLANT - GARY, INDIANA i

l CONSIGNEE: NessEN &Nos e ADDRESS: Alb. BeA A'es scN l

DATE SHIPPED: -_ _

CEMENT TYPE: TRUCK / CAR NUMBER l PHYSICALTEST DATA: CHEMICAL ANALYSIS:

FINENESS, SILICA, % SiO: _

6.12 BLAINE,(m'/kg) 354 ALUMINA, % Al:0, 52 J9 ;

INITIAL SET IRON OXIDE, % Fe:0, __ 5.30 VICAT (br: min) 08: 03- CALClUM OXlDE, % Ca0 -34 11 MAGNESIA, % Mgo _

0.78 COMPRESSIVE STRENGTH SULPHURTRIOXIDE, % SO: 0.34 ASTM C 109,24 HOURS LOSS ON IGNITION, % 0.33 (g 6556 l

i WE WARRANT THAT TEST RESULTS SHOWN WERE OBTAINED USING GENERALLY ACCEPTED LABORATORY PRACTICES, INCLUDING ASTM METHODS AND PROCEDURES WHERE APPLICABLE.

DATE: / 3 !f2- _ huPER SOR ^

l /

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' 70 Jaconnet Street Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow Protze Consultin9 Engineers FAX: (617) 332-3914 Project No. TP-04518-A April 15,1992 Alden Research Laboratory, Inc.

30 Shrewsbury Street Holden, MA 01520 Attn: Mr. Dean K. White, P.E.

Porous Concrete -

Mock Up Testing Gentlemen:

i This will confirm that the Lumnite Cement mill test report, dated 4/13/92, indicates that this cement l fully satisfies the Northeast Utilities specification dated January 14,1992. Inquiry No. CB0-636, page 3 of 13 for calcium aluminate cement, chemical and physical properties.

l ,

Yours very truly, TROW PROTZE d n Herman G. Protze, P.E.

1-Alden Ref. No. 92C-476 I l gc'

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l A division of Trow Engineering Consultants, Inc.

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t 4 e CHECK TESTS OF LUMNITE CEMENT l,

Normal Consistency 26.8 % -!

Initial Set (Vicat Needle) 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months 54 min. ,

.}

Compressive Strength,24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months 4360 psi !

4120 !

4150 .>

4210 These tests confinn those by the 12high Portland Cement Co. i t

I i1 Herman G. Protze '!

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3 70 Jaconnet Street Newton Highlands, klA 02161 Tel.: (617) 332-8460 Trow Protze Consultin9 Engineers FAX: (617) 332-3914 Project No. TP-04518-A May 21,1992 ,

Alden Research Laboratory, Inc.

30 Shrewsbury Street Holden, MA 01520 Attn: Mr. Denn K. White. P.E.

Time of Set Tests Lumnite & Type II Cements -

Gentlemen:

We have madc some time of set tests on Lumnite Cement contaminated with varying amounts of normal type II cement using such combinations as could occur in a transit mixer truck. The samples were stored in laboratory air at 730F,65% RH during the test period.

Lumnite Type II Distilled Initial Cement Addition Water StL._

l 200 gm 0% ,

50cc 7 Hours 200 " 1 50 7" l

200 " 2 50 7" 200 " 3 55 7" 200 10 60 6" The tests were carried out essentially in conformity with ASTM Methods C191. These results indicate that it would take a major amount of contamination of normal Portland cement to cause excessively quick setting of concrete containing Lumnite cement. Hence, we expect no problems l during casting of the test boxes. However, the writer will maintain sharp consciousness during the casting process and be ready to dump the involved concrete should any unexpected rapid setting !

start to occur.

Sincerely yours, l

TROT PROTZE w /

Herman G. Protze, P.E 1-Alden i 1-DeFalco 1 Ref. No 92C-669 NOTG MAY ,' r A division of Trow Engineering Consultants, Inc

06/15/92 14:06 C 508 839 7418 EMARAL EASI libOO2 i

. . . ;1 ll LAFARGE CORPORATION Northeast remont CEMENT TEST REPORT -

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. St-Constant Plant Dese May 25, 1992 Cement test report -

Period covered 1 May 11 17.1992 Identification: Moderste, type II Cement Physical tests Chemical tests t .

Spec. surf. (elef rw) : 3)50 cm2/g st(Ice (s102): 21.2 %

fineness (Eleve) 45 un: 86.7 spessing Alunine (At203): 4.6 1 Initlet setting time : 145 minutes Final setting time : Iron oxide (re203) : 3.2 % l 260 minutes Catetun oxide (Ce0) total : 62.9 I Autoctave Expansion 0.01 1 Catclun oxide (Coo) free : 0.9 %

Air content of morter : 8.1 1 sulphur Trioxide (so3)

2.7 %

Coapresolve strength at : 3 days : 3250 pet Magnesium oxide (Moo) : 2.5 %

T days : 4000 pel Attell equivalent (We20) :

April 6 - 12 0.84 I 28 days $410 pel Loss on Ignition : 1.0

Insoluble sesidue : 0.3 1 Potential Compounds : I C3A 7 1 I C4ar: 10 x C3s: 51 I C2$: 22 1 l Rtf tRthCE $PitiflCAfl0NS Thf e cement coept les with current Astm C 150, for both tpe I and 11, es well es A.A.S.H.T.0. M 85 specificatione CertIffed L.C)id LJ., l' Joame Lectetc

, Quellty Control Jr. Eng.

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APPENDIX B

! CONCRETE BATCH WEIGHTS I

I

$v-ACTUAL BATCH WEIGHTS EMPLOYED !

_ Tune 8 Grout Mix D (3 cu. yds.) Concrete Mix A (4.5 cu. yds.)

TypeII cement 2940 lb. Type II cement = 2012 lb ,

Sand 6360 + 4% 6614 Stone 11870+2% = 12107 lb Water (201) Actual: 100+20+5 gal. Water (79) Actual: 4(k10+5+2+1 gal Slump 2" Max Consistency: Slightly sticky; not runny ;

(glossy) j i

June 10 Do Not Use This Use 2 Batches Concrete Mix B (6.0 cu. yds) 6.3 cu.yd. total CaA1 Cement 2682 lbs = 28.5 sacks 15 sacks (1410 lb)

Stone 17010+2% 17350 " 9135 lb Water (105) gal -

22+5+3+1+1 gal 20+5+2+1+2+1+1 f Consistency Slightly sticky, not runny (Glossy)

June 12 Do Not Use This Use Grout Mix C (3 cu. yds.) 2.98 c.y.

CaA1 Cement 2940 lb = 31 1/4 sacks 2914 (31 sacks)

Sand 6360+4% 6614 6561 Water (201) gal -

116+2+1+1*

Slump 2" Max

Molds 2,3 at 2" slump. Mold 1 @ 5" slump

{

Do not Use All the Water Bring slumps to the conditions indicated

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l APPENDIX C CONCRETE CONTROL -

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A Ww-FIELD BATCH DATA I

, .6-8-92 Grout Mix D .

Northeast typeII Cement i

into one mold (#1) . j batched- 10:15 arrivejob 11:15 !

completed 12:00 '

water 100+20+5 gal.

(

6-8-92 Concrete Mix A- Northeast typeII Cement j 830F Mix . 'into two molds (#2,3) ;

batched 1:20 i arrivejob 2:10 i completed 3:30 l water 40+10+5+2+1 gal !

610-92 Concrete Mix B Calcium Aluminate Cement .. i into two molds (#1,2)

Total time cement - batched - 7:50 in mixer 1:45 Hr. ardvejob _

8:30 cement @ site 8:40-8:45 start deposit 9:00 i end deposit 10:00 & 10:30 (

I water 22+5+3+1+1 = 32 gal ;

Dumped when started to stiffen rapidly. I il' L*

6-10-92 Concrete Mix B Calcium Aluminate Cement into two molds (#2,3) f i

l Total time cement batched 11:15 i in mixer 1:10 Hr. arrivejob 11:55 !

cement @ site . I1:57 - 12:00 l start deposit 12:20 l'

'end deposit '12:30 & 1:10 ;

water 20+5+2+1+2+1+1=32 gal ;

l Du'mped @ 1:15 when staned to stiffen very rapidly t Tmck was hot; stayed in sun between loads at plant ,

6-12-92 Grout Mix C

< )I ' Calcium Aluminate Cement into three molds (#2,3,1) .

Total time cement batched 8:20 l

' in mixer 50 min. arrivejob 8:58 '

cement @ site 9:00-9:10 Deposit #2 ~ 9:10-9:20

3 9:28-9:33

1 9:35-9:40 Water 116+2+1+1 Slumps #2-2"; #3-1 1/2"; #1-5" (too wet) -

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70 Jaconnet Street Newton Highlands, MA 02161 ,

Trow Protze Consultin9 Engineers [l M $ $ ;

I Project No. TP-04518-A June 16,1992 l l

ALDEN RESEARCH LABORATORY,INC. ,

HOLDEN, MASSACHUSETI'S 'l l

INSPECTION OF CONCRETE TEST SAMPLES FOR NORTHEAST UTILITIES MILLSTONE UNIT 3 WATERFORD, CT REFERENCE NUMBER 92C-831 DATE OF INSPECTION June 8,1992 BATCH CONTROL See Appended Log Sheet TEST SPECIMENS Series No. lA-H Class, psi Mix A Mix D Load No. 2 Slump, in Zero PLACEMENT OF Concrete Mix A Northeast Type II cement in lower 10" area of boxes 2 and 3 REMARKS Re writer performed plant inspection of batching of concrete for the subject project.

His work was done at the North Grafton Plant of the Emaral Concrete Company. De work consisted of the following:

Visually examined sand and coarse aggregate for cleanliness and gradation.

Sampled sand for laboratory analysis.

Determined moisture content of sand and Tilcon Connecticut crushed stone.

Verified cleanliness of truck mixer before grout was batched and before Mix A was batched.

Established Grout and Mix A batch weights.

Established batching sequence for Mix A (1/2 stone, cement,1/2 stone).

Checked weigh boxes for cleanliness.

Checked scales for zero readings during empty weigh boxes. ;

Witnessed scales while each load was batched.

Recorded relevant data and wrote inspection tickets.

Followed load of grout to site for consistency control. l Followed load of Mix A to site for consistency control and fabrication of test specimens.

He work was satisfactorily carried out. De grout was mixed and placed at 2" slump in Box #1 (Mix D). It was brought to proper slump at the site by additions of 20+5 gallons of water to the load. Mix A concrete was placed into Boxes #2 l and 3. 40 gallons of water was added at the plant and another 10 gallons were added at the site to provide a wet sticky mix that adhered to the stone thoroughly without any dripping. During filling of the lower 10" of forms B and C another 5+2+ 1 gallons were added as needed to keep the consistency uniform.

A division of Trow Engineering Consultants. Inc.

CONCRETE CONTROL FOR ALDEN RESEARCH LABORATORY LOG SHEET 1 HOLDEN, MASSACHUSETFS LOCATION OF PLACEMENT: Northeast Utilities Research June 8,1992 Models,1, 2, 3 TYPICAL BATCH QUANTITIES Vendor Emaral Plant North Grafton (Dauphinais)

Mix No. D A Class Concrete, psi - -

Time 10:15AM 1:20PM Size Load, Cu.Yd. 3 4.5 Cement,Ib 2980 2012 Fine Agg " 6678 -

Coarse Agg " -

12107

. Water Added, gal 100+25 40+18

, Moisture in FA,% 5.0 -

Moisture in CA,% -

2.0 W/C Ratio, gal / sack 5.0 3.5 Admixture None None ,

I 4

ANALYSIS OF AGGREGATES l jl Sigyv_q Millburv Sand Sieve Tilcon Stone I i' #4 0% 11/2" i

8 10 1 0%

l 16 31 3/4 28 i

5 '

30 53 1/2 73 50 76 3/8 94 100 22_ #4 99 F. M. 2.62 F.M. 7.21 Organic 0+ 0+

. MISCELLANEOUS INFORMATION J

Weather Cloudy, 72-840F Cement Brand Northeast type II No. Loads Inspected 2 Inspection Ticket Nos. HGP5904-5905 C.Y. Inspec. this date 7.5(1-3.0;2-45)

C.Y. Inspec. to date 7.5 Plant Inspection Time 51/2 hour (9:00 - 1:30PM + travel)

Plant Inspector E.S. Van Buren REMARKS Equipment satisfactory and clean Scales checked during batching 3

Aggregates satisfactory 4

Special Items: Mixer washed with gravel and water after grout mix and at end of day.

HERMAN G. PROTH, INC., NEWTON HIGHCNDS, MA55. GURGnglC GUM lMUL DATE g g' , o y CLIENT N . '" h h 2 4 w. Gb de ARRIVE #U f ASSIGNED START TIME 7" PROJECT hp.cg/ [/Id,'h DEPART ACTUAL JOB RELEAFE .-3 -e ,

PLANT 8~@/Je of /ve,, $,f 77v. WEATHER OPERATOR ASSIGNMENT

,,. ['i s u [ hi4 1 ge INSPECTm . I /Q.,,[sQ CEMENI /(oFu9, % G w h.< ,J -

Q g SCALE CHECK CAR NO Y N k W O +'E/g u j 4

ATER ~

' LOAD TICKET CY TRUCK TIME CLASS Ct FA CA ADMIXES REMAkKS~

PLANT + JOB CY I

/ 57)f' ?> /% lO{tf %zzt Dhgo Gyg /go.: 4- -

x D.,~[ F ^"

su. 8' c,. . ,

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O 70 Jaconnet Street Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow Protze Consulting Engineers FAX: (617) 332-3914 Pmject No. TP-04518-A June 16,1992 ALDEN RESEARCH LABORATORY,INC.

HOLDEN, MASSACHUSETFS - '

INSPECTION OF CONCRETE TEST SAMPLES FOR NORTHEAST UTILITIES MILLSTONE UNIT 3 WATERFORD, CT REFERENCE NUMBER 92C-832 DATE OF INSPECTION June 10,1992 BATCH CONTROL See Appended Log Sheet TEST SPECIMENS Series No. 2A-H Class, psi Mix B Load No. 1 Slump, in Zero PLACEMENT OF Concrete Mix B Calcium Aluminate / Stone mix in boxes 1,2 and 3 to 2" below top surface.

REMARKS The writer arrived at Emaral-Dauphinais, North Grafton plant and met with Mr. Stephen Charist. We discussed the intended mix for this day's placement. The writer then inspected the interior of the transit mixer drum and approved it for use. (Documents herewith). We then witnessed the batching of coarse aggregate and water, and followed the truck to the site where the Lumnite calcium-aluminate cement was introduced into the mixer.

. i Mr. Herman G. Protze, P.E., of our office, was present at the site and assisted in final water adjustments of the mix to produce the desired consistency for use. This consisted of a sticky mix of I

cement plus water adhering to the coarse aggregate.

I Placement operations began with the discharge of the mix from the truck's chutes into five-gallon pails; then the mix was spread for half the total thickness, followed by tamping into place by booting. Then the forms were filled level to 2" below the top of each box, tamped into place by booting and screeded exactly level at 2" below the top surface of the form.

The writer obtained a representative sample from the middle of the first load of concrete and fabricated eight 6x12" test specimens following the normal method of rodding, etc., per ASTM.

As placement continued it became necessary several times to add a gallon or two or more of water to the mix. Before completion of the load we made a decision to discard the remaining mix and prepare a second load.

'Ihe writer then inspected the mixer drum for post-placement cleanliness prior to returning to the plant to witness the next batch.

A division of Trow Engineering Consultants, Inc.

W r- '

I * '

At the plant after further cleaning of the mixers drum, we again inspected the drum for pre-batch cleanliness followed by the introduction of coarse aggregate-and water.

The writer again retumed to the site and assisted our Mr. Protze in the inspection of the placement !

of this load. '

At this time we made preparations to transport the eight test specimens, fabricated by us on June 8, l

1992, to our laboratory for testing at various ages. -

l Upon completion of placement operations we assisted in attempts to clean the mixer drum.

Inadequate quantities of water were immediately available at the site; therefore, final cleaning was to take place at the plant. The writer then followed the mixer tmck back to the plant where approximately two cubic yartis of 1 1/2" nominal size aggregate and much water were deposited ,

into the mixer.

After continued clean-out procedures were employed the driver climbed into the mixer drum to j

discover that significant amounts of the mix had adhered to the drum face and the edge of the mixer i blades. We then discussed this matter with Mr. George DeFalco, Jr. of Emaral and concluded that additional cleaning efforts were required. These would be carried out the following day, in l preparation for the Lumnite grout mix intended for placement on June 12,1992.

We then left the plant without signing off the post placement clean-out inspection slip.

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' CONCRETE CONTROL FOR ALDEN RESEARCH LABORATORY LOG SHEET 2 HOLDEN, MASSACHUSETTS LOCATION OF PLACEMENT: NonhEast Utilities Research June 10,1992 i l Models,1, 2, 3 l TYPICAL BATCH QUANTITIES t Vendor Emaral l Plant North Grafton (Dauphinais)

Mix No. B ,

l Class Concrete, psi -

Tune 7:50AM and 11:15AM Size Loa'd, Cu.Yd. 3.15 Cement,Ib 1410 (15 sacks) i Fine Agg " -

Coarse Agg " 9135 Water Added, gal 22+10 Moisture in FA,% -

Moisture in CA,% 2.0 W/C Ratio, gal / sack 3.1 I Admixture None l l

l MISCELLANEOUS INFORMATION Weather Fair, 72-840F

, , Cement Brand Lumnite, Calcium Aluminate L No. Loads Inspected 2 i

Inspection Ticket Nos. HGP 2057-2058 C.Y. Inspec. this date 6.3 l C.Y. Inspec. to date 13.8 !

l Plant Inspection Time 10 hours1.157407e-4 days 0.00278 hours 1.653439e-5 weeks 3.805e-6 months (7:00 - 3:00PM + travel)

Plant Inspector Steven Harvey REMARKS Equipment clean and suitable Scales checked before and during batching Aggregates satisfactory Special Items: Mixer dmm inspected for cleanliness prior to and after each use.

Cement batched @ site by the sack l

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- -- -- SUne./07/992, CLIENT alt a vEtoiten t Acocu. rouv ARRIVE % oo A ~ ASSIGNED START TIME ~T . oo PROJECT 64ew e*J , w::wassem DEPART ~3.co DM ACTUAL JOB RELEASE 3:co '

PLANT E *** = 1 - h p ki=* i s H Cw N WEATHER %i, , 72 'F ASSIGNMENT 5 yels Spee ~ l m/w - -

j OPERATOR 4% Lavallee / Joe3W Mvo , !

INSPECTCR T4ewm \4e.uey CEMENT 4 Osa'ea'ef e !

L e&3h. nlJe AI. ..,aie l

CAR NO SCALE CHECK 3 eke Abor'. 3 WATER TOTAL

.D TICKET CY TRUCK TIME CLASS Ct FA CA ADMIXES REMARKS PLANT + JOB CY . ,

02oS7 5 553 Tso o t 4o Co "Ik h45 22 *'o N'" 3 C/ *//./ e r.ie 02ose 5 133 ths- - it ss - - -

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70 Jaconnet Street Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow Protze Consultin9 Engineers FAX: (617) 332-3914 Project No. TP-04518-A June 16,1992 ALDEN RESEARCH LABORATORY,INC.

HOLDEN, MASSACHUSETTS INSPECION OF CONCRETE TEST SAMPLES FOR NORTHEAST UTILITIES MILLSTONE UNIT 3 WATERFORD, G REFERENCE NUMBER 92C-833 DATE OF INSPECTION June 12,1992 BATCH CONTROL See Appended Log Sheet TEST SPECIMENS None made this date PLACEMENT OF Topping grout, Mix C to top-off boxes 1,2 and 3.

REMARKS We reported to the Emaral-Dauphinais North Grafton plant and thoroughly inspected the interior of the mixer drum. Mr. Stephen Charist of Emaral and the writer both signed off the pre-batch inspection documents, separately herewith. The previous day Mr.

Protze, of our office, and Mr. DeFalco of Emaral discussed measures to assist in the prevention of the f mix adhering to the interior of the mixer drum. It was determined that the batching operation would take place at the Emaral-DeFalco, Millbury Street plant. This selection was due to the water tempemtures being considerably lower at Millbury Street (520F) than at Grafton. The writer followed the truck from North Grafton to Millbury Street where we then witnessed the weighing and metering of the desired quantities of Fine Aggregate and water and subsequent introduction into the mixer.

The writer then followed the truck to the site where again we witnessed the introduction of Lumnite-Calcium Aluminate cement,into the mixer. After mixing the constituents, we assisted our Mr. Protze in the inspection of placement of the mix. We also assisted your staffin placement and consolidation of the mix.

Upon completion of placement operations, the remainder of the load was dumped at the site. The writer retumed to the Nonh Grafton plant where the drum was cleaned in the same manner as previously described. We inspected the thoroughly cleaned mixer drum interior and then Mr. Charist and the writer signed off the post placement documents, see attached copies. The drum was thoroughly clean.

A division of Trow Engineering Consultants. Inc.

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CONCRETE CONTROL FOR ALDEN RESEARCH LABORATORY LOG SHEET 3 i HOLDEN, MASSACHUSETTS LOCATION OF PLACEMENT: Northeast Utilities Research June 12,1992 Models,1,2, 3 TYPICAL BATCH QUANTITIES Vendor Emaral

Plant Millbury Street (DeFalco)

Mix No. C Class Concrete, psi -

Time 8:20AM Size Load, Cu.Yd. 2.98 .

Cement,Ib 2914 I Fme Agg " 6561 Coarse Agg " -

Water Added, gal 116+4 Moisture in FA,% 5.0 Moisture in CA,% -

' W/C Ratio, gal / sack 5.7 Admixtum None MISCELLANEOUS INFORMATION Weather Fair, 64-750F '

Cement Brand Lumnite Calcium Aluminate '

No. Loads Inspected 1

. Inspection Ticket Nos. 2059 l>

i C.Y. Inspec. this date 2.98 C.Y. Inspec. to date 16.8

Plant Inspection Time 61/2 hours (7:00 - 11:30AM + travel)

Plant Inspector Steven Harvey l

REMARKS Equipment clean and well maintained l

. Scales checked before and during batching j Aggregates clean and well graded j

Special Items: Cement batched @ site. Mixer dmm clean before and after cleaning with

, gravel and water.

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== c. nom. i~c ~mou o,oumuos. os. CONCRETE CONTROL DATE d vwe 12,1992.

, CLIENT ALDEP4 it. m c4 Lass ARRIVE 7:co[9 oo

ASSIGNED START TIME ~7: 00 J

PRQJE'CT Mobb04 M SsAca vsg Trs DEPART so:35/113o ACTUAL JOB RELEAFE 11* 3 0 i PLANT EMARAL - / // key 54 WEATHER N /r, 64*F ASSIGNMENT j

OPERATOR 7elwd D[ A sa '

1

2. 9 6 y,/3 Gw/ p,i c *

' , INSPECTOR 3 /,sa. Sevey CEMENT 4vmn//.

4 ,4.j4.e,/cv J/-,.,wl*

f SCALE CHECK Be b i hude CAR NO

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!.nD TICKET CY TRUCK TIME CLASS Ct WATER TOTAL FA CA A PLANT + JOB CY

,, o2o59 2.98 15 5

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CEMENT AND C2NCRETE REFERENCE LAB'JRATCRY g.

l AT THE ~

3 l } a's . NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY , f.$

~

. GAITHERSBURG. MARYLAND 20899 (301) 975-6704

l. * -

SPONSORED 8Y COMMITTEE C-1 oN CEMENT COMMITTEE C 9 oN CONCRETE ANO CONCRETE AGGREGATES August 27, 1991 ,

AMERicAN SOCIETY FoR TESTING AND MATERIALS INTRODUCTION :

TO j

REPORT ON INSPECTION j OT ~

l CONCRETE TESTING LABORATORY

~

This report covers an inspection, designated Inspection No. S-970, which was performed by a representative of the Cement and Concrete Reference -

Laboratory in the concrete testing laboratory of Trow-Protze, Consulting Engineers, at Newton Highlands, Massachusetts, on July 3, 1991. -

~

The report has one, two or three parts, depending on the scope of the inspection. Part I covers the inspection of concrete testing facilities; Part _

II, when included, covers the inspection of aggregate testing facilities; and Part III, when included, covers the inspection of the testing facilities for -

concrete reinforcing bars.

Each part has three sections. The first section describes the scope of the inspection. The second section contains a summary of the findings. The third jlL .

section contains a series of footnotes in which departures from specification 1i requirements, mechanical deficiencies in apparatus, and other important matters -,

are covered in detail. In addition, there is a closure.

Several pieces of apparatus in the laboratory have been assigned CCRL iden-tification numbers. Some of these numbers are listed in the summary and foot- -

note sections.

In the interest of brevity, any minor adjustments of apparatus which may _

have been made while the inspection was in progress have not been mentioned.

When necessary, additional explanatory information about the inspection will be _

furnished in separate correspondence, g

Information concerning the qualifications of supervisory personnel is included where appropriate.

Unless otherwise indicated, the specifications and methods of test to which references are made are standards of the American Society for Testing and 1 Materials. j Copies of this report, or parts thereof, are not to be used for promotional

c' purposes.

p 1/91

' m.

00

W

}

l Concret'e - 1

. 5

~

PART I: INSPECTION OF CONCRETE TESTING FACILITIES l DESCRIPTION OF INSPECTION 1

The inspection of concrete. testing facilities was designed to include an i examination of the apparatus prescribed for use in the methods of test for concrete indicated in Section 7.2 of ASTM C1077; a review of the laboratory's quality assurance system; an examination of the apparatus or procedures pre-scribed in any optional test methods presented for inspection; and an observa-tion of several of the procedures used in the testing of concrete.

The ASTM Standards on which the work was based are as follows: C31-90, C39-86, C138-81, C143-90, C172-90, C173-78, C231-89, C470-87, C511-85, C617-87, C1077-90, E4-89, and E171-82.

T Apoaratus i

! Tamoino Rods (Cl43) l The 5/8-inch diameter tamping rods which were immediately available for i use in various rodding operations were checked for conformance to the design and dimensional requirements of Cl43.

Slump Cones (C143) i' Each slunp cone presented for inspection was checked for conformance to the design and dimensional requirements of C143, and the physical condition .

was observed.

Unit Weicht Apparatus (C138)

The capacity of each scale or balance used in determining the unit weight of plastic concrete was recorded, and the accuracy checked for conformance to ,

the requirements of Section 4.1 of Cl38. The design, dimensions, and physical I condition of each unit weight measure presented for inspection was checked for conformance to the requirements of Section 4.4; a check was made to determine if the required flat strike-off plate was available; and inquiry was made as to whether the measure had been calibrated in accordance with Section 5.

Accaratus for Air Content of Plastic Concrete (Volumetric Method) (C173)

The design of each air meter used in determining the air content of concrete by the volumetric method was checked for conformance to the design

, requirements of C173, and observations were made to determine that the

., necessary funnel, strike-of f bar, metal measuring cup, syringe, pouring vessel, tamping rod, trowel, and scoop'were on hand.

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Concrete - 2

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Apparatus for Air Content of Plastic Concrete (Pressure Method) (C231) ,

The design of at least one of the air meters used in determining the air content of freshly mixed concrete by the pressure method was checked for confor-mance to the design requirements of C231, and observations were made to determine that the necessary trowel, syringe, tamping rod, mallet, strike-off bar, and pouring vessel were on hand.

Compression Test Aeoaratus (C39. C470 and C617)

" ~ ~

Aiparafus~used in making compressive strength tests of concrete not covered elsewhere in this report includes the cylinder molds and vibrators used in fabricating specimens, the capping equipment and materials used to obtain smooth load bearing surfaces on specimens, and the compression machine in which specimens are tested.

Cylinder Molds. - Cylinder molds are classified according to intended use-as reusable molds and single-use molds. Where reusable molds were employed, the design, dimensions, and watertightness of several molds considered to be typical of those used by the laborate-' were checked for conformance to the requirements of C470. Where single-use molds were employed, the design, dimensions, and water absorption characteristics of several molds considered to be typichl of those used by the laboratory were checked for conformance to the specification.

Vibrators. - Each vibrator used in consolidating test specimens made from low-slump concrete was checked for conformance to the requirements for such devices set forth in Section 4.5 of C31.

Capoino Ecuipment and Materials. - The apparatus and material used in ;

capping concrete cylinders were checked for conformance to the requirements of C617, with particular attention being given to the dimensions, planeness, {

surface condition, and thickness of capping plates; and to the preparation and '

use of the capping material. In addition, the planeness of the caps on several specimens was checked.

Comoression Machine. - Unless otherwise noted, only one testing machine I was inspected. During this inspection, several of the more important J; mechanical and design features were noted; the design, dimensions, and surface j' planeness of bearing blocks used in testing concrete cylinders were checked for conformance to the requirements of C39; and the accuracy of load indication was verified.

The verification tests were made using force measuring instruments calibrated at the National Institute of Standards and Technology. In these tests, each load indicator was set at the zero position customarily employed by I the laboratory. Test loads were approached by increasing the load from a lower I load as specified in Method E4; the force-measuring instrument and the machine were individually operated as is considered to be good practice; and all load

,, readings were corrected for differences between the test temperature and the temperature at which the instrument was calibrated. '

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Concrete - 3

l-Facilities for Curinst Test Specimens (C31 and C511)

An investigation was made to determine if storage facilities for curing of concrete test specimens were available. Each tank or moist room used for curing .

compression specimens were then checked for conformance to the requirements of C511.

During the examination, temperature and relative humidity readings were taken as appropriate to detemine if the curing environment confomed to the requirements of applicable standards; an observation was made to detemine if all specimens in storage had free water on the entire surface area; and a check was made to determine if each unit was equipped with thermostatic temperature control and with a recording thermometer as required by C511. In addition, it was asked if the water in each tank was saturated with line, and the state of cleanliness of the water and the condition of the interior surfaces of the tank were noted.

j Niscellaneous The temperature of the air in the laboratory was checked for confomance with the range (200 to 30 C) set forth in E171.

l The containers and packing materials which the laboratory prescribes for use in transporting cylinders were inspected for obvious deficiencies.

A check was made to detemine if the laboratory had been supplied with a g copy of the latest edition of the ASTM Book of Standards pertaining to the testing of concrete.

Optional Methods At the discretion of the laboratory, selected optional test methods as set forth in Section 7 31 of C1077 may be presented for inspection. If presented, the inspection of these test methods for concrete may consist of an examination of prescribed equipment, specified procedures, or both, es the individual test method should warrant.

The apparatus examined and the procedures observed for any optional test method presented by the laboratory were checked for compliance with the refer-enced specification.

Quality Assurance System Written records maintained by the laboratory and reviewed for compliance with C1077 included the following: an inventory of equipment and its required calibrations; personnel training and performance evaluations, including relevant certifications; general laboratory practice for fabrication, transfer and testing of concrete specimens; end test reports confoming to the requirements of Section 9.4 It was also ascertained whether the laboratory was under the

,' .. technical direction of a registered engineer.

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. Concrete - 4

.- i Procedures ,

i The concrete testing procedures which were observed and discussed during the inspection were as follows: Sampling Freshly Mixed Concrete, Slump of Concrete, Unit Weight Test, Air Content Test (Volumetric Method), Air Content j Test (Pressure Method), and Determination of the Compressive Strength of Molded j Concrete Cylinders. The review of the strength test covered fabrication of ,

cylinders, capping, storage after capping, measurement before testing, and '

testing. The laboratory's conformance to specified procedures was as indicated I in the summary of findings.

All departures noted were reviewed in detail with laboratory personnel with particular attention being given to those matters described in the i footnote section. !

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SUMMARY

OF FINDINGS * .

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Inspection Item 4 Accaratus,

Status . o

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,1. 'Tamoina Rod (s)..r..2........................................ See footnote (a)

.2. Slumo conefs)...............................................

Satisfactory -

' '3 . Unit Weicht Apoaratus

.4

. Scale"or Balance..............;............................. Satisfactorv '

-c.

b. " Unit Weight' Measure (s)...............;...................... See footnote (b)

c. Accessory Apparatus......................................... Satisfactory b

4. Air content Apoaratus (Volumetric) '

i

c. Air Meter (s)................................................ Satisfactory P

b. Accessory Apparatus......................................... Satisfactory

5. Air Content Apoaratus (Pressure)

a. Air Meter (s)................................................ Satisfactory

b. Accessory Apparatus......................................... See footnote (c) l

6. Compression Test Apparatus l c. Cylinder Holds:

W (1) Reusable Holds......................................... - -------

(2) Single-use Molds....................................... Satisfactorv ;

b. Vibrator (s)................................................. Satisfactorv {

c. Capping Equipment and Materials: !

(1) Capping Equipment...................................... See footnote (d) i (2) Capping Material....................................... Satisfactorv )

(3) Planeness of Caps...................................... Satisfactory -f

d. Compression Testing Machine: }

(1) Maker: Baldwin' '

(2) Serial No.: 482195 (3) Capacity: 300.000 lbf (4) Accuracy of Indication:

(a) Range: 300.000 lbf From: 50.000 to 200,000 lbf Satisfactory (b) Range: 50.000 lbf From: 6.000 to 45.000 lbf Satisfactory (c) Range: From: to - -------

(d) Range: From: to -- - - ----

(e) Range: From: to -- - - ----

(f) Range: From: to -- - -----

t (5) Mechanical Condition................................... See footnote (e) .

't ,

(6) Design................................................. ._Satisfactorv '

(7) Bearing Blocks for Cylinders........................... Satisfactorv O. Additional Compression Machines............................. None

Entry covers availability, physical condition, and/or conformance to specifi-cation requirements. Where reference is made to a footnote in which one or more .

ty deficiencies are described, it may be concluded that the item or items in ques-tion were judged to be satisfactory in all respects other than as described in

[l j;

the footnote. *l

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Inspection Item

Status

7. Curino Facilities

..i a. Moist Air Storage Facilities.......................... See footnote (f) r

'. : b. Water Storage Facilities.............................. -------- . . ,

PL

8. Miscellaneous ',

[p a. Temperature of. Air in Laboratory...................... Satisfactorv

b.

~ Specimen Shipping Containers..........................

Satisfactory -

g

.c.'... Additional Observations of Interest to Laboratory..... None' -

. . . o.

,d.

.Q..ualifications of Supervisor.,y Perso.nnel...............

. . . - ~ . . -.

See attachment'

9. Octional Methods...................................... None ,

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10. Ouality System i

a. Organization.......................................... See footnote (c) ,

b. Human Resources....................................... See footnote (c)

c. Operations............................................ See footnote (c)

d. Quality Assurance..................................... See footnote (c) ,

e. Equipment............................................. See footnote (c) l

. Procedures 4

3 Technique in Exact Method Agreement With ,

Test Reference Standard Practice '

i Sampling Freshly Mixed Concrete....... C172-90 ............ See footnote (h) l Slump of Concrete..................... C143-90 ............ Yes Unit Weight of Concrete............... C138-81 ............ Yes Air Content (Volumetric Method)....... C173-78 ............ Yes Air Content (Pressure Method)......... C231-89 ............ See footnote (i)

Compression Test:

a. Fabrication of Cylinders.......... C31-90 ............ Yes I

b. Capping of Cylinders.............. C617-87 ............ Yes l

c. Storage After Capping............. C617-87 ............ Yes

d. Measurement Before Testing........ C39-86, C617-87..... See footnote M)

e. Testing of Cylinders.............. C39-86 ............ Yes i

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FOOTNOTE SECTION

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Tampino Rods: ,

j- -

(a) The small tamping rods examined were not 3/8 inch in diameter as ,

required. These rods were subsequently replaced during the inspection. ,,

4 Unit Weicht Accaratus (C138-81): ; '

s (b) The top rim of the one-third cubic foot unit weight measure was not I' plane to 0.01 inch as required. This measure was replaced with an apparatus 1 that conformed to the requirements of C138. !

Air Content Apparatus (Pressure Method) (C231-891: ;

1 (c) The calibration vessel used with the Type A apparatus, which was designed to be placed in the meter during calibration, was found not to comply !

with the requirement that its inside depth be 1/2 inch less than that of the l bowl.

Cappino Equipment and Materials (C617-87):

1 (d) Four capping plates, designed for use in capping 4 x 8 inch cylinders, '

were checked and all were found not to conform to the requirement of C617 that the alignment device be located so that no cap will be off-centered on a test .

l specimen by more than 1/16 inch.

Compression Testino Machine (C39-86 and E4-891:

1 (e) The maximum hands with which the 300,000-lbf and 50,000-lbf dials were equipped were checked and found not to be in satisfactory operating condition.

It was recommended that the necessary repairs be made.

Facilities for Curino Test Specimens (C511-85):

I g

(f) It was noted that several of the specimens in storage were not in a surface moist condition as required by C511, and it was recommended that several of the spray nozzles be redirected in an effort to correct this deficiency.

Ouality System (C1077-90):

(g) No documentation or records pertaining to the quality system of the laboratory, as set forth in ASTM Standard Practice C1077, were presented for inspection.

Procedures:

.. (h) Sampling Freshly Mixed Concrete (C172-90): The concrete was sampled at only one. interval, rather than at two or more intervals from the middle.por-tion of the discharge batch as specified.

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(i) Air Content Test (Pressure Method) (C231-89): It was understood that an aggregate correction factor had not been determined for the aggregates and !

that no aggregate correction factor was used in determining the air content of the concrete.

(j) Measurement before Testing (C39-86 and C617-87): It was understood .

that the laboratory did not check the planeness of caps at intervals that would include the minimum prescribed in C617.

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,- . Concrete Aggregates - 1 l' 4 ? PART II INSPECTION OF AGGREGATE TESTING FACILITIES i

~

j f DESCRIPTION OF INSPECTION !

i The inspection was designed to include an examination of'the apparatus ,

f l prescribed.for use in the methods of test for concrete aggregates listed in ,

ASTN C1077; a review of the apparatus or_ procedures prescribed in any optional j j test methods presented for inspection; and an observation of several of the i 1

procedures used in the testing of concrete aggregates. )

i The ASTN Standards on which the work was based are as follows: C33-90, i C40-84, C117-87, C127-88, C128-88, C136-84, C566-89, C702-87, C1077-90, D75-87,

) E11-87 and E171-87.

1

[ Anoaratus Drvina Accaratus l

! The physical condition of the apparatus used in drying samples of aggregates for testing purposes was observed, and a check made to determine if i the operating temperature was being maintained at less than 115 0C.

Samole Solitters (C702) i The apparatus available for use in reducing field samples of aggregates to jl testing size was checked for conformance to the design requirements of C702,

! and its physical condition was observed. Note was taken as to whether the-i laboratory had .t least one riffle sampler with no less than twelve chutes 1/2

inch in width for u e with fine aggregate, and one riffle sampler with no less j than 8 chutes of the appropriate chute width for use with coarse aggregate.

1 l Sieves-(E11) i i The physical condition of each sieve presented for inspection was noted, j and a check made to determine if the size of opening was marked on the side as

I required by E11.

j . l- With the exception of such omissions as may be set forth in the footnote

eaction, the group of sieves presented for inspection contained one or more of i cach of the sieves with nominal openings ranging from 52 to .150 mm listed by.

j ' size or number in C33, and one or more of each of.the sieves listed by size or i number in the various methods of test to which reference is made in this report.

j- The particular sizes and numbers are: 2 in., 1 1/2 in., 1 in., 3/4 in., 1/2 in.,

3/8 in., No. 4, No. 8, No. 16, No. 30, No. 50, No. 100, and No. 200.

IlI Mechanical Sievina Acoaratus The physical condition of each mechanical sieving device presented for inspection was noted.

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Concrete Aggregates - 2 . ,

Balances The requirements for balances to which reference is made during the j inspection were derived from a number of sources. !

I A sensitivity requirement of 0.01 g is believed to be applicable to balances with capacities of less than 1000 g (

Reference:

Method D854). A basic i maintenance tolerance (0.1 percent of the test load) considered to be appropri- !

cte for equal-arm balances used in the testing of aggregates (

Reference:

Hethod ;

C136) is given in Paragraph T.3.2 of the Scales Section of the 1986 Edition of '

NIST Handbook 44. Tolerances believed to be applicable to the accuracy of indi-cation of the direct-reading dials with which some small balances are equipped are given in Paragraph T.3 of the Weights Section of Handbook 44. i Sensitivity requirements for balances with capacities of 1000 g or more l are found in Methods C127 and C128. The basic maintenance tolerance to which 1 reference is made above is applicable. A tolerance of 1 0.2% for the accuracy l of indication of beams or dials on balances which are so equipped is suggested ll by information given in Paragraph T.3.1. of the Scales Section of Handbook 44.

Each balance with a rated capacity of less than 1000 g presented for inspection was tested for conformance to the selected sensitivity requirement at zero load. When of the two-pan, equal-arm type, it was subsequently tested ,

for conformance to the selected accuracy requirement at its maximum capacity. ;

When of the single-pan type, the accuracy of indication of the direct-reading indicating system was subsequently tested for conformance to the selected tolerances at 50, 100, 200, 500 and 700 g as appropriate for the capacity of the system.

Each balance with a capacity of 1000 g or more presented for inspection l'!

was tested for conformance to the selected sensitivity requirements at 500, i 1000, and 2000 g, as appropriate for the capacity. When of the two-pan, equal-arm type, it was subsequently tested for conformance to the selected accuracy requirement at the said three test points, and the dial or beams, if any, were tested separately for accuracy of indication at five points over l' their respective capacities. When of the single-pan type, the accuracy of indication of the direct-reading indicating system was subsequently tested for ,

conformance to the selected tolerance at five points over the capacity of the i

'1 system, or to 10,000 g, whichever was the lesser.

I Testina Weichts !'

All metric weights presented for inspection were checked for conformance l to the maintenance tolerances for metric weights specified in Paragraph T.3 of ;

the Weights Section of the 1986 Edition of NIST Handbook 44. When the weights '

in a set were within the specified limits and were suitably stored, each ,

storage container was assigned a CCRL identification number. i

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Concrete Aggregates - 3 I

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Organic Impurities Apparatus (C40) l The glass bottles, the reagent, and the color standaMe used in testing for i organic impurities in sands were checked for conformance to the requirements of C40.

Accaratus for SDecific Gravity and Absorption of Fine Anrremate (C128) i

' Observations were made to detemine if one or more pieces of each ites of 4 equipment (pycnometer, conical mold, and tamping rod) needed to detemine the a specific gravity and absorption of fine aggregates in accordance with the re-i quirements of C128 were available for use and in good physical condition.

Apparatus for Specific Gravity and Absorption of Coarse Amaregate (C127)

, l a

Each basket used for holding samples of coarse aggregate during the

specific gravity determination was checked for conformance to the requirements of C127, each suspending apparatus was examined, the capacity of each balance being used in conjunction with the foregoing items was noted, and a check was

made on the temperature of the immersion water.

!g 5 1

Sample Containers for C117 and C566 j The size, physical condition, and shape of the pans used in the test for I

determining fine materials in aggregate (C117), and in the test for determining !

il the total moisture content by drying (C566) were observed.

a Miscellaneous The temperature of the air in the laboratory was measured 0

at random for 0

comparison with the range for room temperatures (20 to 30 0) set forth l in E171.

4 The containers used for transporting samples of aggregate to the labora- 4 l

tory were checked for cleanliness and to detemine if they were so made that !

there would be no loss of fines during shipment.

A check was made to determine if the laboratory had been supplied with a .

copy of the latest edition of the ASTM Book of StandaNs pertaining to the testing of concrete aggregates.

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Optional Hethods t

." , , At the discretion of the laboratory, selected optional test methods es set forth in Section 7 3 1.2 of C1077 may be presented for inspection. If presented, the inspection of these test methods for concrete aggregates :may conaist of an examination of prescribed equipment, specified procedures, or both, as the individual test method should warrant.

l The apparatus examined and the procedures observed for any optional test '

1i method presented by the laboratory were checked for compliance with the ref-erenced specification.

l Precedures The concrete aggregate procedures which were observed and discussed during the inspection were as follows: Minus No. 200 Wet Sieving, Organic Impurities Test, Sieve Analysis of Aggregates, Specific Gravity and Absorption of Fine and Coarse Aggregate, Moisture Content by Drying, and Reducing Field Samples to Testing Size.

The laboratory's conformance to specified procedures was as indicated in the summary of findings. All departures noted were reviewed in detail with laboratory personnel with particular attention being given to those matters described in the footnote section.

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Inspection No. S-970.I,' , ' i .,

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SUMMARY

OF FINDINGS Insoection Item

Status l

1. Drvino Accaratus

c. Oven (s): *

(1) Maker: __Quir.cv ID No. 15744B ........ Satisfactorv

. (2) Maker: Laborhtory desion ID No. ---- ........ Satisfactorv (3) Maker: ID No. ........ --------

."(,,,.,

b. Hot Plate (s): Number Inspected: 0 ............. - - - - -

~f- -

2. Sanole Solitter(s) b

8. For' Coarse Aggregates: ................................. See footnote'(a)

+

b. For Fine Aggregates:................................... See footnote (a) .

1 Sieves 3.

c. Number Inspected: 27 ............................ Satisfactorv , ,

b. Missing Sizes or Numbers:.............................. None )

i

4. Mechanical Sievino Aeoaratus Gilson ID No. 11306 Satisfactory I

^ (1) Maker: ........

g (2) Maker: Tvier ID No. 3227 ........ Satisfactory (3) Maker: ID No. ........ - -------

g ,

5. Balances j d

(1) Maker: Mettler Capacity: 2400 o CCRL No.: S-4811 ........ Satisfactory (2) Maker: Mettler l Capacity: 12 ko CCRL No.: S-4812 ........ Satisfactory l (3) Maker: Mettler i Capacity: 12 ko CCRL No.: S-4813 ........ Satisfactory (4) Maker: ]

Capacity: CCRL No.: ........ - -------

6.

Testina Weichts (1) CCRL No.: S-4810 No. Weights Checked 13 ..... Satisfactory (2) CCRL No.: No. Weights Checked ..... - -------

(3) CCRL No.: No. Weights Checked .....

i

Entry covers availability, physical condition, and/or conformance to specifi-cation requirements. Where reference is made to a footnote in which one or more deficiencies are described, it may be concluded that the item or items in question were judged to be satisfactory in all respects other than as described in the footnote.

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' Insoection Item

Status i l

7. Oraanic Impurities Anoaratus ................'....... Satisfactorv

8. Snecific Gravity and hbaorotion A m ratus (F.A.) ... Satisfactory -

9. Soecific Gravity and Absorntion Accaratus (C.A.i ..., Satisfactorv

==le Cont 51ners *"

10. -

s. For Minus No. 200 Sieve Test - C117 ................ Satisfactory

b. For Test for Total Moisture Content by Drying - C566 Satisfactory I J 1

11. Miscellaneous

a. Temperature of Air in Laboratory ................... Satisfactorv

b. Sample Shipping Containers ......................... Satisfactorv

c. ASTM Standards ..................................... Satisfactorv !

d. Additional Observations of Interest to Laboratory .. See footnote (b) '

12. Dotional Methods.................................... None Procedures I Technique Agrees .l Method with

2331 Reference Standard Practice Minus No. 200 Wet Sieving ............C117-87............ Yes '

Organic Impurities Test...............C40-84............. Yes Sieve Analysis of Aggregates..........C136-84............ Yes Specific Gravity and Absorption:

a. Fine Aggregate...................C128-88............ Yes ;

b. Coarse Aggregate.................C127-88............ Yes Moisture Content by Drying............C566-89............ Yes Reducing Field Samples................C702-87............ Yes

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!I.ft s FOOTNOTE SECTION

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Samole Solitters (c702-87): ,

(a) It was understood that the laboratory used the quartering method for

', reducing field samples of aggregate to testing size, J

> s, -

9 + l Miscellaneous:

(b) No equipment for the testing of steel reinforcing bars was presented for inspection; therefore, with reference to paragraph two of the Introduction, this report has only two parts.

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ADDENDUM l

The Coment and Concrete Reference Laboratory has been in existence -

since 1929. In April of that year, a Research Associate Program, known as the Cement Reference Laboratory, was established at the National Institute of Standards and Technology (formerly the National Bureau of Standards) under the sponsorship of Committee C-1 on Cement of the American Society for Testing Materials. The principal responsibility of the CRL was to promote unifomity in the testing of hydraulic cements through the inspection of laboratories.

In.1948, the first steps were taken in a gradual expansion of the field work to include some of the more important procedures used in the ;

testing of concrete. On March 1, 1958, the resulting new inspection j

service was made available to any interested concrete testing laboratory within the prescribed areas of operation, and shortly thereafter Committee C-1 invited Committee C-9 to become a joint sponsor. The invitation was accepted and on July 1, 1960, the name "Coment and Concrete Reference Laboratory" was adopted in recognition of the new arrangement.

l]i At the time of the redesignation, a joint C-1, C-9 Subcommittee on the Coment and Concrete Reference Laboratory, consisting of seven represent-atives of each of the parent committees, was created to work with the I National Institute of Standards and Technology in administering the CCRL program. The'new administrative plan perpetuated the earlier arrangements whereby selected representatives of the Federal Agencies, materials .

producers, construction and design firms, and national associations, who furnish either financial or technical assistance, participate in the direc-tion of the activity through membership on the supervising ASTM Subcommittee.

As of January 1, 1991, organizations who were furnishing financial or l technical support were as follows: .,

Federal:

Federal Highway Administration National Ready Mixed Concrete Assn.

~

National Institute of Standards National Aggregates Association and Technology Portland Cement Association U.S. Army Corps of Engineers W. R. Grace and Company Non-Federal:

American Concrete Institute ASTM 9 l

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...,, , ,, .c., t

,s.

I CLOSURE ,

4

~ ' '

This inspection was performed by the writer. While the work was in j i

progress, many of the details covered by this report.were discussed with -

5.' laboratory personnel. At..the' conclusion of,the inspection the special work .

2

' sheets,.on which'all observations were recorded,..were made available 4or.

. review by members of the laboratiory staff, and'all of the entries . thereon. i

.- 'were discussed in detail.. 4,s7,;.s 4 I ' Testing equipment that'was used during the inspection to make temper- '

ature' determinations, to determine compliance of selected apparatus to'spe-

cified weights, and to verify the accuracy of indication of compres'sion i testing machines is identified as follows: '

s Thermometers : CCRL Nos. S33, S32, C164, C189 and C169 ' '

s 1 i '

Test Weights : NIST Nos. 172810 and 163683 .I Proving Rings : Serial Nos. 585, 4893 and 3374B f

'I* It is recommended that this report be compared with the report. of' thd - .- .4i preceding. inspection which was made in March 1989. ,

l This report is not to be used for advertising, publication, or promo-tional purposes. /

.g CEMENT AND CONCRETE REFERENCE LABORATORY ho c . %-

Paul C. Burns Inspector i

Report Approved By:

p .

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,. 1/91 4

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SUMMATION OF QUALIFICATIONS OF MANAGERIAL AND SUPERVISORY PERSONNEL

(

Reference:

Section 6, ASTM Specification C1077) '

i I Name cf laboratory: Trow-Protte, Consulting Engineers '

Location : 70 Jaconnet Street, Newton Highlands. MA 02161 c

l Director of Innoection and Testino Services N:me and title : Herman C. Protze, P.E.

Mailing address: 24 Greystone Road Dover, MA 02030 Full time employee of laboratory?...................................... yes R gictered engineer?................................................... yes Number of years experience in inspection and testing of construction materials............................................... 53 Suoervisino Laboratory Technician Nam) and title : Edgar S. Van Buren Mailing address: 23 Hadley Road Framingham, MA 01701 Number of years of experience performing tests on construction materials?........................................... 34 Supervisino Field Technician N:m3 and title : Edgar S. Van Buren Mailing address: 23 Hadley Road Framingham, MA 01701 Number of years of inspection experience in kind of work '

involved on construction projects?.................................. 45 I Foregoing entries certified to be correct.

Signature: NI A4ea u m .

4 -

Title : Executive Encineer 4~ '

v' 00to Julv 3. 199]

t 4

n 5 SUNNATION OF QUALIFICATIONS OF MANAGERIAL AND SUPERVISORY PERSONNEL t * .*e. (

Reference:

Section 6, ASTN Specification C1077)

I Name of laboratory: Trow-Protre. Consulting EnRineers Location : 70 Jaconnet Street. Newton Highlands. MA 02161 I

Director of rnmoection and Testina Services Name and title : Herman C. Protze, P.E.

Mailing address: 24 Greystone Road Dover, MA 02030 I

Full time employee of laboratory?...................................... yes Regi Ctered engineer? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y e s Number of years experience in inspection and testing of construction materials.............................................. 53 l

Supervisina taharatory Technician !

I Name and title : Edgar S. Van Buren Mailing address: 23 Hadley Road Framingham MA 01701 i

Number of years of experience performing tests

on Construction materials?.......................................... 34 jI i Suoervisinu Field Technician j Nama and title: Edgar S. Van Buren Mailing address: 23 Hadley Road Framingham, MA 01701 i

Number of years of inspection experience in kind of work involved on construction projects?.................................. 45

]

4 Foregoing entries certified to be correct.

! Signature: i -

A i Title : Executive Encineer /f' V

~

, .Dato July 3. 1991 4

. l 3 . . .

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i. i ADDENDUM i s

i 8 The Cement and Concrete Reference Laboratory has been in existence

{ since 1929. In April of that year, a Research Associate Program, known as the Cament Reference Laboratory, was established at the National Institute of Standards and Technology (formerly the National Bureau of Standards) undet

the sponsorship of Committe C-1 on Cement of the American Society for Testing Materials.

The principal responsibility of the CRJ was to pror.ote i uniformity in the testing of hydraulic cements through the inspection of '

laboratories.

i In 1948, the first steps were taken in a gradual expansion of the field work to include some of the more important procedu:res used in the l testing of concrete. !

On March'1, 1958, the resulting new inspection service was made available to any interested concrete testing laboratory i within the prescribed areas of operation, and shortly thereafter Committee C-1 invited Committee C-9 to become a joint sponsor. The invitation was _,

accepted and on July 1, 1950, the name " Cement and Concrete Reference ;

Laboratory" was adopted in recognition of the new arrangement.

At the time of the redesignation, a joint C-1, C-9 Subcommittee on the i Cement and Concrete Reference Laboratory, consisting of seven represent-

' atives of each of the parent committees, was created to work with the

National Institute of Standards and Technology in administering the CCRL program. The new administrative plan perpetuated the earlier arrangements whereby selected representatives of the Federal Agencies, materials producers, construction and design firms, and national associations, who '

I furnish either financial or technical assistance, participate in the direc- !

' tion of the activity through membership on the supervising ASTM Subcommittee. l 1

As of January 1, 1991, organizations who were furnishing financial or technical support were as follows: .

i T.ts13.ul:

Federal Highway Administration $

National Ready Mixed Concrete Assn. ' '

National Institute of Standards National Aggregates Association and Technology Portland Cement Association U.S. Army Corps of Engineers W. R. Grace and Company i

Non-Federal: ;

' American Concrete Institute ASTM l l i !

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l APPENDIX E VOID RATIO TESTS I

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[ VOID RATIO TESTS l Laboratory Voids within compacted coane aggregate

46,46,46%; aver 46% = Va Laboratory Voids within rodded Mix B concrete

33,33,32%; aver 32.7% = Ve 46.0 - 32.7 equals 13.3% less voids Mix B for one cylinder:

Aluminous Cement 1363 grams equiv. to 447 lb Tilcon Aggregate 8647 "" "

" 2835 "

Water 442 "

" 17.5 gal 1363 gm cement in cylinder batch 1363 3.14 x 62.5 x 453 = 0.0153 cu.ft. of cement 442 453 x 62.5 = 0.0156 cu.ft. of water Total 0.0309 cu.ft. of cement paste l

Volume of cylinder mold equals 0.1963 cu.ft.

13.3% of 0.1963 = 0.0261 cu.ft.

0.0261 is 85% of 0.0309 i

This is a reasonable check for this size test specimen.

Also the yield of cement + water to produce cement paste is not quite equal to the sum of the two !

individual volumes.

NOTE: Field cylinders Reference Number 92L-439AB Exhibit Vc void ratios of 30% and 30%.

Here Va-Vc = 46.0 - 30.0 equals 16% less voids Then translating (as above) 16.0% of 0.1963 = 0.0314 cu.ft. voids Thus voids 0.0314 are 1.6% greater than 0.0309 cu.ft. of cement paste Hence, it appears that average voids Vc in the stone and aluminous cement + water mixture varies l somewhat dependent upon gradation and compaction of the mixture in the cylinder and at times does i approach the original volume of the plain aggregate voids minus the volume of the cement paste.

As detennined by filling voids with water.

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4 APPENDIX F TEST OF CONCRETE SPECIMENS

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1 RECEIVED redy b JJ_ l>F>d

. 70 Jaconnet Street JUL 161992 Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow Protzb%nsulting Engineers FAX: (617) 332-3914 Project No. TP-04518-A July 6,1992 TEST OF LABORATORY SPECIMENS CLIENT ALDEN RESEARCH LABORATORY, INC., H OLDEN, M ASS ACHUSETTS PROJECT FABRICATION OF POROUS CONCRETE MOCK UP SLABS FOR NORTHEAST UTILITIES SERVICE COMPANY, WATERFORD, CT l Reference Number 92L 394ABC Date Made 6-4-92 by us Source Laboratory Trial Mixture g Class Concrete Mix B Water Cement Radio 3.3 gals / sack (0.30)

Cubic Yards 1.0 Cement 447 lbs Lumnite (calcium aluminate) i Coarse Aggregate 2835 lbs. Tilcon 3/4" Crushed stone Water 16.0 gals. total (excluding absorption)

Admixture None i Air Temperature 750F,659cRH Concrete Temperature 730F g Slump Zero Workability None .

Appearance Satisfactory, glistening, sticky Storage Laboratory fog room Date of Test 7-2 92 Age of Test 28 days i Specimen Number IA IB IC l Dimensions 6x12" 6x12" 6x12" Density 1bs/cu.ft. 117 117 119 l

Voids 33 % 33 % 32 % l Compressive Strength 1350 1390 1190 Remarks Strength low but accepoble Respectfully Submitted, TRO 'PROTZE Herman G. Protze, P.E. '

2-Alden I

HDTED JUL16 c.E.: .

A division of Trow Engineerina Consultants, Inc.

e 70 Jaconnet Street Newton Highlands, MA 02161

Tel.: (617) 332-8460 Trow Protze Consultin9 Engineers FAX: (617) 332-3914 Project No. TP-04518-A June 17,1992 June 24,1992 July 15,1992 TEST OF CONCRETE SPECIMENS CLIENT ALDEN RESEARCH LABORATORY, INC., HOLDEN, MASSACHUSETTS PROJECT FABRICATION OF POROUS CONCRETE MOCK-UP SLABS FOR NORTHEAST UTILITIES SERVICE COMPANY, WATERFORD, CT Reference Number 92L-439ABCDEF Date Received 6-12 92 -

Date Sampled 6-10-92 by us Location Used Box 1 and upperlayerin Box 2 Truck Number DeFalco 133 load Number I inspected by us Ticket Number HGP 2057/Emaral 48834 Class Concrete Mix B Cubic Yards 3.15 Cement 1410 lbs. (15 sacks) Calcium Aluminate Lumnite Fine Aggregate None Coarse Aggregate 9135 lbs. Tilcon, Conn. 3/4" Crushed stone Water 3.3 gallons / sack Admixture None Time Sampled 9:20AM Weather Fair,720F Mix Temperature 750F Slump Zero Entrainted Air Voids 307o and 309c respectively Appearance Satisfactory, glistening, sticky Storage With models, then laboratory fog room ,

Date of Test 6-17-92 6-24 92 7 8-92 Age of Test 7 days 14 days 28 days Specimen Number 2A 2B 2C 2D 2E 2F Dimensions 6x12" 6x12" 6x12" 6x12" 6x12 6x12 Densky Ibs/cu.fL 116 115 116 116 116 118 Compressive Strength 980 psi 990 psi 980 1090 1070 1050 Remarks Strength low; no gain with time Respectfully Submitted, TRO PROTZE d _

2-Alden A division of Trow Engineering Consultants, Inc.

70 Jaconnet Street Newton Highlands, MA 02161 Trow Protze consultin9 Engineers Tel.: (617) 332-8460 FAX: (617) 332-3914 Project No. TP-04518-A June 16,1992 June 24,1992 July 14,1992 TEST OF CONCRETE SPECIMENS CLIENT ALDEN RESEARCH LABORATORY,INC., HOLDEN MASSACHUSETTS PROJECT FABRICATION OF POROUS CONCRETE MOCK UP SLABS FOR NORTHEAST UTILITIES SERVICE COMPANY, WATERFORD CT Reference Number 92L-438ABCDEF Date Received 6 10-92 Date Sampled 6 8 92 by us -

Location Used Bottom layer in Molds #2&3 Truck Number DeFalco 133 Load Number 2-inspected by us l Ticket Number HGP 5905 Class Concrete Mix A Cubic Yards 4.5 Cement 2012 lbs. Northeast Type II l Fine Aggregate None Coarse Aggregate 12107 lbs. Tilcon, Conn. 3/4" Crushed stone Water 3.5 gallons / sack l Admixture None Time Sampled 2:40PM Weather Cloudy,860F Mix Temperature 830F Slump Zero Entrainted Air Voids 35% and 34% resp:ctively Appearance Satisfactory for the project Storage With models, then laboratory fog room Date of Test 6-15 92 6 22-92 7-6-92 '

Age of Test 7 days 14 days 28 days Specimen Number lA IB IC ID IE 1F Dimensions 6x12" 6x12" 6x12" 6x12" 6x12" 6x12" Density lbs/cu.ft. 108 110 108 111 111 112 !

Compressive Strength 440 psi 500 psi 440 psi 520 psi 560 psi 570 psi !

Remarks Strength poor; little gain with age l l

Respectfully Submitted, TRO\\ PROTZE 1 I

2-Alden '

A division of Trow Engineering Consultants, Inc.

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l APPENDIX G CEMENT RESIDUE ANALYSIS i

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@b j j 7 Jaconnet Street OCT 2 61992 Newton Highlands, MA 02161 Y ARL, INC-Tel.: (617) 332-8460 Trow Protze Consulting Engineers FAX: (617) 332-3914 1

Project No. TP 04518-A October 21, 1992 Alden Research Laboratory, Inc.

30 Shrewsbury Street Holden, MA 01520 Cement Washout Analyses Northeast Utilities Service Company Millstone Unit #3 i Waterford, Connecticut I Attn: Mr. Dean White. Project Encineer Gentlemen:

We enclose herewith the analyses of the two samples of cement residue received by us in September.

It appears that 307c or less of the SiO2 derives from the calcium aluminate cement, and the l remainder from the type II. It appears that 107o or less of the Al203 derives from the type Il cement and the remainder from the calcium aluminate. It appears that 50% or less of the Fe203 derives from the type B cement and the remainder from the calcium aluminate cement. The j g analyses of the virgin cements were approximately as follows:

Tvpe H Calalum g SiO2 20.0% min 6.1%

I Al 023 6.0 max 53.0 Fe203 6.0 , max 5.3 l The variations of the constitutional solubility is a function of time and relative solubility of each theoretical compound.

l Herma'n G. Protze, P .

I Ref. No. 92C-337A,B 1-White

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I Samples --

Two samples of cement residue identified as

-I

, - A, 92C-337A, 30-day cure, 2 layer mold, i

! Pipes ~A and B, Material in pipe per )

(- section 12.1.1

- B, . 92C-337B, 7-day cure, 2 layer mold,

)

Pipes A and B, Material-in pipe per

section-12.1.1-J I

Test Procedure --

ASTM: C 114 on sub #80' portions '

l . Results --

The following data have been obtained:

j Samole Mark"" A R i

SiO2, .% 14.9 11.2 I Al 23 0 , % 40.8 44.2 I

Fe2O 3, % 5.4 4.4 i

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APPENDIX H CEMENT WASHOUT ANALYSIS I

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RECEIVED N n&d4'. #

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70 Jaconn:t Str;:t I

. AUG 141992 Newton Highlands, MA 02161 Tel.: (617) 332-8460 Trow ProtMbonSulting Engineers FAX: (617) 332-3914 l

Project No. TP 04518-A August 12, 1992 )

Alden Research Laboratory, Inc.

30 Shrewsbury Street .

Holden, MA 01520 Attn: Mr. Dean White. Project Enemeer i Tests for Presence of Cement Washout Northeast Utilities Service Compant .

Millstone Unit 3 Waterford, Connecticut )

Gentlemen:

The tests of the six residue cement samples submitted by you on July 21 have been completed in accordance with Section 12.0 of the project specifications (Procedure for Mock-up Tests). The samples were identified as follows:

A First 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months test, Residue 1 Layer Mold l B Fourth " 1 C First Hole A 2 l D Fourth " Residue 2 E Test 1, Holes A&B 2 layer mold Filter #30 g F Test 4, 2 The samples were first tested for moisture content with the following results:

A B C D E F 1.2% 3.4% 2.7% 1.57c 5.57c 3.5 %

The samples were then analyzed chemically in confom1ity with standard methods of analysis per ASTM C-114. The following results were obtained:

Samnle SiQ2 A1073 A 13.3 % 6.0%

B 11.3 4.7 C 0.5 17.1 D 1.5 7.5 E 4.8 8.0 F 13.2 19.7 A division of Trow Engineering Consultants, Inc.

$r-Project No.TP-04518 A Page 2 The previous tests on the cements employed in this investigation exhibited the following constitutions: * '

Comoound Type 11 Ca61 -

SiO2 21.2 % 6.1% .

A103 2 4.6 53.0 i CaO 62.9 34.1 l 1

1 From the above infonnation we have computed how much type II and calcium aluminate cement i I

each residue contains:

,1 Sample Residuts Content I A 10:1 Type 11 and CaAl cement i

B 13:1 "

i C- Essentially all CaAl cement (Large SiO2 loss)

D 1:4 Type 11 and CaAl cement I E l-0.7 Type 11 and CaA1 cement F 1-0.6 Type 11 and CaAl cement - '

l These results appear unusual (panicularly for samples A and B where the only type II cement available was in the base seal monar). The type 11 cemen't is slower in attaining strength than the rapid calcium aluminate cement. Results C,D,E,F are more reasonable due to the location of the i

exit sampling holes.

il Yours very truly, I I

TROW PROTZE !

am Herman G. Protze, P.E.

Ref.No.92S-279

See Appendix A.

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APPENDIX I !

1 SINGLE LAYER SLAB CONCRETE STRENGTH I

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RECEIVED N Mb hfN, kfk,t.lh 70 Jaconnet Street AUG 271992 Newton Highlands, MA 02161 r Tel.: (617) 332-8460 TYOW P[Olhe Consulting Engineers FAX: (617) 332-3914 Project No. TP 04518 A August 19, 1992 Alden Research Laboratory, Inc.

30 Shrewsbury Street -

Holden, MA 01520 Attn: Mr. Dean White. Project Engineer Tests of Concrete Cores Northeast Utilities Service Company Millstone Unit 3 Waterford, Connectico, Gentiemen:

We made the compression and split tensile tests of the cores recently drilled from the test panel shown in " Fig.2" of your test instruction sheets. The cores were received on August 10 and the tests were conducted on August 13 at an age of 9 weeks after time of fabrication. The lower layer of Type 11 cement monar separated from the cores during coring and the upper layer of calcium aluminate cement monar was then sawed off of all test specimens. The compression test specimens of calcium aluminate cement concrete were capped normally with leadite and tested in accordance with ASTM l Methods C39. The split tensile specimens were tested flatwise with 1/8" wooden strips on top and bottom sides per ASTM C496. One specimen was saved without testing, which Dr. Lakshmipathiah took with him c,n his visit of August 19,1992.

Comoression Tests I Capped Compress Snecimen Dia Length Density Strength

, ~Al 3.69" 8.72" 114 pcf 540 psi B1 8.62 116 600 3

C1 Saved for review D1 7.90 110 440 El 7.65 108 440 I F1 8.30 110 540 G1 8.05 110 500 H1 7.72 110 580 Solit Tensile Strencth Tests Split Sawed Tensile Fractured Specimens Dia" Length Density Strength Accregate K1 3.69 7.75" 114 pcf 87 psi - 107c L1 8.00 114 106 15 M1 7.30 109 70 15 i

" 1 N1 7.80 105 44 10 A division of Trow Engineering Consultants, Inc.

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v-Project No.TP-04518 A Page 2 All strength results were ver/ ow l due to the porous nature (high voids) of the concrete. The densities of typical samples drilled from the test box tabulated above and described in Fig. 2 of the instruction sheets varied from 105 to 116 pcf(averaging 111 pcf). Consolidation of the porous :

concrete in the test boxes was attained by walking on the concrete at half and full depth (" booting").

The strengths of companion test cylinders (Ref. No. 92L-439EF) averaged 1060 psi at 28 days because those samples were better compacted (averaging 117 pcf) and were not affected by possible '

reduction in bond by flowing water as in the core concrete. Earlier test of similar cylinders made in a laboratory trial mixture by us Ref.No. 92L-394ABC (averaging 117.7 pcf) exhibited an average strength of 1310 psi with the still less voids. The split tensile results were also y.cly low and variable due to the high and variable voids ratio compared with normal concrete specimens containing sand mortar to fill the voids and increase the bond.

We understand that the voids in the concrete in the parent structure are significantly less than those '

described herein due to greater compaction of the site concrete by vibration and perhaps as well, due to use of a more uniform stone gradation than the gap gradation (with less fines) employed in this study as shown on page 2 of Appendix C in our report dated June 19,1992.

Yours very truly, TROW PROTZE d

Herman G. Protze, P.E Ref. No. 92C-1164B l-Alden l

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APPENDIX J DOUBLE LAYER SLAB CONCRETE STRENGTH l

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,. 70 Jaconnet Street OCT 131992 Newton Highlands, MA 02161 A Tel.: (617) 332-8460 Trow ProlL,INC.ze Consultin9 Engineers FAX: (617) 332 3914 l l

Project No. TP-04518-A October 9,1992 ALDEN RESEARCH LABORATORY,INC. !

HOLDEN, MASSACHUSETTS SPLITTENSILE TESTS 1 SAMPLES FROM SPECIMEN 1K l REFERENCE NUMBER 92S-353 DATE OF TEST October 9,1992 APPROXIMATE AGE 4 months METHOD Sample K from the first double mold described in Fig.1, Sect.1-1 i of the Specifications for Porous Concrete Mock-Up Testing I transmitted on January 14,1992 was supplied by you in the perforated metal mold. Sample K was sawed in half diametrically at the intersection of the type II l and calcium aluminate cement concretes. They were each then cut into 8" lengths and the metal enclosures were carefully removed.

l Each specimen was then individually subjected to a careful split tension test in accordance with ASTM C 496-90, until failure.

1 RESULTS Sample T3 II Cal. Alununate l Imad 13 lbs 3000lbs Stress 17 psi 40 psi Both samples crumbled at ma> imum load, breaking bond between the pieces of coarse aggregate and causing small chips on contact areas. Approximately 20% of l aggregate in the failed area was chipped in each sample. There was no shinyness in aggregate in each case.

REMARKS The test results are very low. We shall withhold further testing until you advise us as to the disposition of remaining test specimens.

Res tfully subm' erman G. Protze, P.E.

2-Alden A division of Trow Engineering Consultants, Inc.

mea-nue%

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SEP.181992 N en f 70.saconnet street Newton Highlands, MA 02161" *1 ARL, INC. i Trow Protze Consultin9 Engineers Tel.: (617) 332-8460 FAX: (617) 332-3914 Project No. TP-04518-A September 14, 1992 Alden Research Laboratory, Inc. ~

30 Shrewsbury Street Holden, MA 01520 Concrete Core Strain Test Northeast Utilities Service Company Millstone Unit #3 Waterford, Connecticut Attn: Mr. Denn White. Project Encineer Gentlemen:

On September 3,1992, (at an average age of 12 weeks after casting) we tested Sample D as removed from the first of two test panels shown in " Fig.1." of your test instruction sheets. This sample including the perforated steel form was removed by you from the in-place concrete casting and delivered to us on August 14.

The sample was free of cement mortar etc., on the outside of the perforated steel jacket. The sample was sawed by us to provide flat ends perpendicular to the axis at a total length of 14 5/8 -

inches, with equal lengths of the type Il cement concrete (Mix A) and calcium aluminate cement concrete (Mix B)in the sample. The sample diameter was slightly less than 6". A layer of thin rice paper was fastened around the perforated cylinder by us to prevent intrusion of the capping compound described below.

A 7" I.D. steel pipe,13 5/8" long with 3/8" walls (provided by you with ends machined square to i its axis) was placed over the test sample centered lengthwise and diametrically. The lower gap was caulked with flexible pipe caulking and the circular gap was slowly filled with leadite capping compound to avoid " piping" and assure a completely filled area. Both ends of the sample were then capped with leadite flat and perpendicular to the sample. The totallength of the sample +

capping was 14 3/4" The outside edges of the capping compound did not touch the steel pipe.

After several days (on September 3, M) the sample was tested in our 300,000 lb. hydraulic Baldwin-Southwark testing machine recently verified for test accuracy. Two Ames dials (reading directly in 0.001" and accurate to 0.0001") were arranged on diametrically opposite locations to read changes in length of the interior concrete at each load application. The outside steel tube was A division of Trow Engineering Consultants. Inc.

4 j - Project No. TP-04518-A Page 2 $T l supported on three steel nuts to prevent disloging, because the pipe was free to move due to the -

shrinkage of the leadite during hardening. There was approximately a half a thousandth of an inch '

freedom between the leadite and the pipe. !

l The test data are appended hereto. On the first test ("Run No.1") we could hear aggregate , l l breakage staning at 10,000 lb. load. At 10,000 lb and after all subsequent load applications, ;

' aggregate breakage continued; this required bringing a given load somewhat higher than the desired !

load so that after the aggregate splintered the recorded load became stable as noted. At 17,900 lbs.

[

, a definite " yield point" was reached. Run No.1, was stopped at 25,000 lbs (962 psi) load. I

! (

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} At the end of Run No.1, the load was removed, and then loading was repeated (staning at the new l

} zero) to 20,000 lb. Note that the deflection from zero to 10,000 lb. was approximately 9% greater j than with Run No.1. Then the latter curve continued almost as a straight line to 20,000 lb (quite j different from Run No. I whose deflections were greater due to continued aggregate breakage, which l

)' did not occur again).

1 i After this 20,000 lb. test, the nuts supponing the steel restraining pipe were changed to thin j wooden strips.

i $

4 Run No. 3 was a duplicate of Run No. 2. Note that total squeeze at 10,000 lb. was 45% greater

) than with Run No.1.

l Run No. 4 was another duplicate. Here there was more aggregate breakage from 16,900 to -

l 18,000 lbs and the total squeeze at 10,000 lbs was 50% greater than with Run No.1.

l

1 In examining the test specimen after the fourth test we noted that aggregate breakage involved

} moderate chipping of numerous pieces of the coarse aggregate. There was more aggregate l destruction in Mix A with the type 11 cement than in Mix B with calcium aluminate cement.

l We await your instructions regarding funher tests of remaining samples.

Yours very truly, 2 g

,l TR VPROTZ i

i i erman , tie, ..

j Ref. No. 92C-1343 1 2-White (/

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Run No.1

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Rurt,No.2 CenferJ.oad ' Change k Leng/f Cedte L oc.4 C%se A, Lem%. . . . . .

Ibs psi L J2 AV. Ibs pst , L R AV.

Zere .o. . .. .u- . A .... A. . . . . _ .

l

.2ey_e_ _o. _ _ 395 4 4 5. tJ.2o.

. 2 o o_ .. 9 _. _ i __ l i 1ee. .__3' _

. . _ _3 % . _ 4.4.6 4-2I . , ,

. . . J.9e o -- . 3% M 4 4 J.ce.o 53 398. M.4.9...&2%5... ,

1sro. . 13__ ._ _& . ._ &

.f . . . ... .D o.o. .LY2 .. . 4 10 46o... 935. .

j hora . . IIS - it ). R..2 %_ . . . . . . .1Osave. b1C ,.189 ..!+49 4K't t

. 'lvvo. . yJ.Pt .. . l.0. . ) . ..I o )..J 0 ..

1519.90. 532 425. 436... MSoh ClTVO. .t 92. . IL. . : It .y, n. opo ..bSk.. .+1.*I

. 12- .. - . . .

. 438 9 514 .

4 uro . t5i f.'f ..] 13 i .H5L .. . 20,oo.o.769 9-5l 472. . 4 r4r,.

Jorv . 2.69 If. . lf . 15 ' ' ** ' "

Sruvo . 607 .17 . 17 : l']

9erv . se. 19 ' .19

. j 11 Run No 3

. 10,07t) , 3ff 2A ; z 2- l E1 . Z.ero _o 395 4-41 'fl 3 1 11, ore.' 925 7f ., . 91 v3 zoo .y 5.9 9 . y q 6 4 22 d.

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! SEP 3 01992 70 Jaconnet Street, , l Newton Highlands, MA 02161 y ARL, INC. Tel.: (617) 332-8460 Trow Protze consultin9 Engineers FAX: (617) 332-3914 Project No. TP-04518 A September 30, 1992 Alden Research Laboratory, Inc. 30 Shrewsbury Street Holden, MA 01520 Concrete Core Strain Tests Northeast Utilities Service Company Millstone Unit #3 Waterford, Connecticut Attn Mr. Dean White. Profect Engineer Gentlemen: On September 25,1992, (at an average age of 15 weeks after casting) we tested Samples B, F, H as removed from the first of two test panels shown in " Fig.1." of your test instruction sheets. These samples including the perforated steel forms were removed by you from the in-place concrete casting and delivered to us on August 14. As described for the first Sample D in our report of September 14,1992, (Ref.No.92C-1343), the appearance of these new samples were similar to those the prior sample. Dimensions were the ! same as previously. Area of the concrete in the cage of the test sample again was 26.0 square inches. These three samples were tested in the same general manner as previously described with the following differences: A. Thidtrips of soft wood on edge were used to support the encompassing steel cylinder instead of the previous steel nuts. B. Each specimen was " massaged" twice from zero load to 10,000 lbs prior to conducting the formal stress / strain test to significantly reduce the amount of hysteresis loop. C. Only one detailed sequence ofloading was made on each specimen after massaging. (A short-fonn secondary rerun at large load increments was made on each sample after the formal run. You will note that again there is no relation between the original and secondary runs). l Aggregate chipping and load fluctuations occurred with the various specimens as follows: A division of Trow Engineering Consultants, In.c.

Project No. TP-04518-A Page 2 ; Sample B 9900lbs load fluctuations and aggregate popping l 11000 more popping 17700 small fractures and fluctuations 20500 fluctuations ofload ' 21000 cracking,long holding ofload 22600 cracking, maximum load Sample F - 14900lbs big pop and loadloss to 7000 17700 fluctuationsin loading 22700 load fluctuation 22900 maximumload Sample H 18000lbs fluctuations in load - 18900 end of fluctuations i 25000 stoppedloading; no popping

l See appended data sheets and plots. l l Yours very truly, TR V PROT rman G. Protze, P.E. Ref. No. 92C-1390 2-White 4 I I 9 h 9 J

Applied CHANGE IN L ENG7*H - -D.001 /NCHES .* l 4

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l ! l l l Docket No.50-423 I B15985 -! l l l I i l l l l ) l l l l l Attachment 3 Millstone Nuclear Station Unit 3 Phase 11 Test Report , Millstone 3 Erosion of Cement From The Porous Concrete Drainaoe System ' l l l l 1 l l i November 1996 l l l I l l

i l i i e li i POROUS CONCRETE MOCK-UP TESTING i FOR MILLSTONE UNIT 3 i WATERFORD, CONNECTICUT l + l l i i l i l

l l

By j Dean K. White i l ' I i i j . Sponsored by l NORTHEAST UTILITIES SERVICE COMPANY } i i i l gQ ALDEN RESEARCH LABORATORY,INC. ! Sofving 9' Cow 9 hob 0 ems Since 1894 { 161-93/M295F-R November 1993 l

!                                                                                                     Revised - November 1996

? j 1 a _- - -_ .

4 l

POROUS CONCRETE MOCK-UP TESTING ) FOR MILLSTONE UNIT 3

WATERFORD, CONhTCTICUT J

a By i Dean K. White I 4 l 1 Sponsored by NORTHEAST UTILITIES SERVICE COMPANY l i ,. [ t i November 1993 Revised - November 1996 d 1 1 ALDEN RESEARCH LABORATORY, INC.

 .                                 30 Shrewsbury Street Holden, MA 01520

                      -   .  = - . .       . - - -    . . . . -

TABLE OF CONTENTS 1 l I INTRODUCTION 1 SCOPE OF WORK 1 CONSTRUCTION OF APPARATUS 1 PROCUREMENT AND TESTING OF MATERIALS 3 EATCHING AND PLACING OF CONCRETE 5 DESCRIPTION OF WORK 5 LABORATORY CERTIFICATION 7

SUMMARY

OF TEST RESULTS 8 Aggregate Compaction Test 8 Test Cylinders 8 Flow Testing 9 Core Testing 12 i .

            . Confined Compression Testing of Cores                  14 CONCLUSIONS                                                 15 REFERENCE                                                   17 FIGURES APPENDIX A - MATERIAL SPECIFICATIONS AND DOCUMENTATION APPENDIX B - CONCRETE BATCH WEIGHTS AND MIX CONTROL' APPENDIX C - CONCRETE TESTING LABORATORY INSPECTION REPORT APPENDIX D - AGGREGATE CONSOLIDATION TEST APPENDIX E - CYLINDER TESTS APPENDIX F - RESIDUE ANALYSIS                                     j APPENDIX G - CORE BORING LOGS AND CORE COMPRESSIVE STRENGTH APPENDIX H - CONFINED COMPRESSION TESTS

- I I

INTRODUCTION 3 ! a t This report covers all work conducted under Northeast Utilities Specification SP-CE-363, }. Supplement to SP-CE-354 by both the Alden Research laboratory, Inc. (ARL) and its l i subcontractor, Trow Protze Consulting Engineers (TP). All technical matters related to the project were coordinated with Mr. K. I.akshmipathiah of Northeast Utilities Service Company i (NU). Work under this specification has been subject to the independent review of Harstead Engineering Associates, Inc. 4 2 SCOPE OF WORK ii i : ! The ARL and its subcontractor were to provide all the necessary materials, equipment, and i iI;. - technical requirements for the construction of three porous concrete test molds and for testing of the test molds to evaluate potential cement erosion resulting from the flow of water through lI >~ the porous concrete. I ! l1

CONSTRUCTION OF APPARATUS i

i l Three concrete test molds were constructed. One test mold was a double layer mold with no l membrane between the layers of porous concrete while two test molds were double layer molds l with a membrane between the two layers of porous concrete. The wooden forms built to contain 1 i the test molds were heavily reinforced to minimize deflection. ,' 'Ihe 6 x 10 foot form for the double layer mold without the membrane was 21 inches high to l f accommodate a 9 inch layer of porous concrete on top of a 10 inch layer of p,orous concrete. l i A two 2 inch layers of grout was placed on top of the 9 inch layer of porous concrete. One 10 ! foot long side of the form contained groups of one quarter inch holes to introduce water into the test mold. The holes were drilled over size, and a plastic sleeve was pressed into each hole to insure uniformity. Each test mold contained two 6 inch perforated plastic drainage pipes in the l 9 inch (top) layer of porous concrete to collect the water introduced through the one quarter inch holes. The drainage pipes contained four rows of five eighths inch diameter holes spaced 3 m- .. - - ,. , - - - , . - .,. - , -- - , , , , - , - .

l l inches center to center. The rows of holes were located at 2 o' clock, 4 o' clock, 8 o' clock, and'

?O o' clock around the pipe. Figure 1 is the plan of the test mold without the membrane.             !

The forms for the two test molds with the membranes were 6 x 10 feet x 23 inches high. These forms contained a 10 inch layer of porous concrete using Portland cement covered by a membrane that was intentionally punctured at several locations. A 2 inch layer of grout usmg l Poitland cement was placed on top of the membrane and holes were formed in the grout above j t the location of each hole in the horizontal portion of the membrane. A 9 inch layer of porous concrete using Calcium Aluminate cement was placed on top of the grout. A 2 inch layu # j grout using Calcium Aluminate cement was placed on top of the 9 inch layer of porous concrete. ! One 10 foot long side of the form contained groups of one quarter inch holes to introduce water f into the test mold. The holes were drilled over size, and a plastic sleeve was pressed into_each l hole to insure uniformity. The test molds with the membrane also contained two 6 inch ' perf6 rated plastic drainage pipes in the 9 inch porous concrete layer to collect the water introduced through the one quarter inch holes. The drainage pipes contained four rows of five eighths inch diameter holes spaced 3 inches center to center. The rows of holes were located at 2 o' clock,4 o' clock, 8 o' clock, and 10 o' clock around the pipe. Figure 2 and 3 are the plans of the test molds with the two configurations of membmne. A partially filled mold is shown in j Figure 4. I 1 I Water was supplied to the mold boxes through a single pumping system capable of providing sufficient flow and pressure to the three test molds. Flow from the pump was introduced into a manifold where smaller lines carried flow to each of the one quarter inch holes. A calibrated ) pressure gauge was located on the manifold and a valve on the inflow to the manifold was I provided to regulate pressure. Water discharging from the drainage pipes was collected in a settling box and the residue washed from the mold was recovered by filtering the water from the box using a 5 micron filter. For 2 4 l

i i l the tests of 8 hour duration, all water was filtered. For the 30 day test, only the residue in the 4 ! box at the conclusion of the test was collected. 3 PROCUREMENT AND TESTING OF MATERIALS i i ne ASTM #57 coarse aggregate to be used in the porous concrete slabs was procured from Tilcon Connecticut, Inc., the operators of the Wauregan Quarry which provided the coarse

aggregate to the Millstone Plant during the original construction. Review of the gradation logs

! for the original aggregate and aggregate being shipped from the quarry today indicated that the

     ,                  present day Tilcon Stone from the Wauregan Quarry should meet the ASTM #57 aggregate jl                       specifications and be similar to the material used at Millstone. A sieve analysis of a 300 pound

. sample of the aggregate obtained from the. quarry in April 1993 also indicated that the aggregate 'l l would meet specifications, see Appendix A, page A1. Tests of the aggregate delivered to the ! ( )- concrete batch plant for the pouring of the concrete on June 16,1993 indicated that the material ll gradation lacked fines and therefore was slightly outside of the ASTM #57 specifications, see Appendix A, page A2. The aggregate, however, was considered acceptable by NU and was ll. s 2 used to conduct the test program. l ll l The calcium aluminate cement was produced by the 12high Portland Cement Company of Gary, i j- Indiana at the Buffington Plant. The mill test report indicates that the. cement meets the j I requirements of Section 8.3 of the NU Specifications. The mill test report is in Appendix A, i page A3. i l l De Portland Cement Type Il produced by the LaFarge Corporation Northeast Cement Plant i 2 complies with current ASTM C-150 as well as A. A.S.H.T.O. M-85 specifications called for in j $' Section 8.2 of the NU Specifications, see Appendix A, page A4. ! ' l i !

Water chemistry at both the concrete batch plant and ARL were tested per ASTM requirements l for batch water and curing water. The water analysis is shown in Appendix A, page AS. ;

i 1 . 1 2 1

1 l

The concrete used in the test slabs required careful preparation of transit mixing equipment since ; P) ) Calcium Aluminate Cement is not in common usage (all local concrete plants use Portland Cement). Concern for the possible contamination of Calcium Aluminate Cement with Portland !

Cement prompted tests to determine how the strength of the concrete is effected by the l contamination of one cement with the other. Porous concrete mixes were prepared with 100%

l l Portland Cement,100% Calcium Aluminate Cement, a 10% Portland Cement to 90% Calcium

Aluminate Cement mix, and a 10% Calcium Aluminate Cement to 90% Portland Cement mix.

! An 18 inch diameter by 12 inch high mold and three six inch cylinders were cast from each mix. i The molds and all cylinders were rodded to achieve maximum density. The concrete mix j proportions are shown in Appendix A, page A6. Results of the testing of the cores and cylinders are shown in Appendix A, page A7. The void ratios and the densities of the l

specimens were very consistent indicating that the compactive effort was well controlled. The l I Lumnite Cement concrete showed a greater decreased in strength when mixed with 10% Portland Cement (20% decrease) than did the Portland cement concrete mixed with 10% Lumnite Cement l (9% decrease).

5 l In addition to the testing oflaboratory prepared mixes of porous concrete five mixes of cement paste and five mixes of cement mortar were made with varying amounts of Portland Cement and Calcium Aluminate Cement. Three inch diameter cylinders were prepared from each mix. ' l ! Compressive strength tests were conducted on the cylinders after 28 days of curing. The results a ! of these tests are shown in Appendix A, page A8.

The Lumnite Cement paste strength was reduced approximately 58% when 10% Portland

! Cement was added while the Portland Cement paste strength was reduced approximately 19% when 10% Lumnite Cement was added. When there were equal parts of Portland Cement and Lumnite Cement the strength was approximately 17% of the average of the unmixed strengths. The motar mixes indicated that when Lumnite Cement motar has 10% Portland Cement added ; i the strength is decreased only 6% while when Portland Cement motar has 10% Lumnite Cement W

                   ,.,,.,.,.,.-a       -n ___w-  , . . a, . , - - - -      - - - , , ,           -   , , - , , -

i l ! added the strength decreases 12%. When the motar was prepared with equal parts of Lumnite 1 .

Cement and Portland Cement the strength was approximately 27% of the average of the unmixed: strengths.

i i BATCHING AND PLACING OF CONCRETE 4

De test molds contained very small quantities of concrete and to better control the batching ymcss, the minimum batch sizes was set at 3 cubic yards of concrete. The mix designs were l based on this yardage. The mixes containing Portland Cement were batched at the transit mix I

batch plant and sent to the site with only a small fraction of the water requirement added at the f plant. The remaining water was added at the site and carefully controlled to produce the proper consistency. The mixes containing Calcium Aluminate Cement, only added the aggregate at the j transit mix batch plant and the cement was added at the site by the bag to minimize the potential 4 ! of rapid setting of the concrete in the truck mixing drum. Water from the batch plant was added l at the site and carefully controlled to produce the proper consistency. - Due to the stiffness of i the mixes using the #57 aggregate slump was not sufficient to determine the proper water content. The mix was inspected visually for the consistency of the concrete paste on the aggregate. j i l The preparation of each concrete mix and each grout mix was monitored by TP inspectors, both ! at the concrete batch plant and during placement. Reporting of these inspections is contained 4 m Appendix B, pages B1 through B4. 1 DESCRIPTION OF WORK

Three test molds containing two layers of porous concrete were constructed. Two molds labeled i

j Mold "B" and Mold "C", see Figures 2 and 3, respectively, contained a water proof membrane 3 and a 2 inch thick layer of Portland Cement grout (sand cement mix) between the two layers of i porous concrete. Each membrane was intentionally punctured at certain locations by cutting a 1 i : i i

~

   , 3" long by 1/8" wide slit. An opening was left in the grout layer where it covered a slit in the

- membrane, Figures 5 and 6 show the location of these slits for Mold "B" and Mold "C", respectively. The lower layer of porous concrete was 10 inches thick, made with Portland Cement Type H and the upper layer of porous concrete was 9 inches thick, made with Calcium Aluminate Cement (Lumnite Cement). A 2 inch thick grout layer (sand cement mix) made with

     - Lumnite Cement was used to seal the top. The third mold labeled Mold "A" was similar to the other two molds described above with the exception of the water proof membrane and the 2 inch grout layer between the two layers of porous concrete, i.e., the two porous concrete layers were poured one on top of the other with nothing in between, see Figure 1.

The porous concrete layers were co pacted in 3 to 4 inch layers by rodding to produce a concrete of a density similar to that produced in the concrete laboratory while making the trial mixes. Each layer of concrete placed in the mold was allowed to cure according to the concrete , placing schedule is shown in Table 1. TABLEI CONCRETE PLACING SCHEDULE DAY MOLD WITH MEMBRANE MOLD WITHOUT MEMBRANE ' 1 10" Porous Portland 10" Porous Portland 6 2" Portland grout No Activity - i 8 9" Porous Lumnite* 9" Porous Lumnite* 15 2" Lumnite Grout 2" Lumnite Grout 22 Hydraulic Testing Hydraulic Testing

12yer containing 6" drain pipes.

I

J j In Molds "A" and "B" only, immediately prior to water tests the perforated drain pipes were l cleaned out and the recovered concrete residue was weighed and analyzed. I l . After the 7 day curing period of the Lumnite Grout seal, water was applied to one hole in hole group A in Mold "A" and one hole in hole group B of Molds "B" and "C". Four 8 hour tests were conducted in each mold using these holes. Water was introduced at a pressure of. approximately 5 psig (11.5 feet of water) and allowed to flow for 8 hours. All water collected from the 6 inch perforated pipes was filtered and the residue collected, dried, and weighed. Samples of the residue were analyzed to determine the type of cement. l

i During the second group of four eight hour tests in Mold "A", one hole in each of hole groups a

A and B was open and in Molds "B" and "C", one hole of hole group B was open. All water I collected from the 6 inch perforated pipes was filtered, and the residue collected, dried, and weighed. Samples of the residue were analyzed to determine the type of cement. At the conclusion of the 8 hour testing sequence, all molds were subject to a 30 day test with g all holes open. This included four holes for holes A and four holes for holes B plus all holes labeled C. The water exiting the 6 inch perforated pipes discharged into a settling box that was inspected for residue five times a week. The residue was collected at the end of the test. l LABORATORY CERTIFICATION i l ne latest CCRL (Cement and Concrete Reference Laboratory) certification for the laboratory l of TP is in Appendix C. I t I

I 1 4 t j ,

SUMMARY

OF TEST RESULTS l 5 AGGREGATE COMPACTION TEST i , REVISED (Intentionally left blank) : i i I TEST CYLINDERS r ! Eight test cylinders were made from concrete Mix A (Portland cement porous concrete) and six , f test cylinders were made from concrete Mix B (Lumnite porous concrete) at the time of pouring. , I In addition, four test cylinders were made from each grout layer. The cylinders made at the l time of the pour remained at the site until the next pour, see Table 1 for time interval, and then l 4 were held in the laboratory fog room. Four cylinders from Mix A and three cylinders from Mix ; I B were tested at 7 days and 28 days. ' The average strengths of the Mix A cylinders from the ,! pour broken at 7 days and 28 days were 1,678 psi and 2,152 psi, respectively. The increase in j strength from the 7 day strength to the 28 day strength was approximately 28% for Mix 'A. ! t j l These cylinders weighed between 124 and 126 lbs/cuft. The average strengths of the Mix B l i : ! cylinders from the pour broken at 7 days and 28 days were 1,706 psi and 1,787 psi, l respectively. The increase in strength from the 7 day strength to the 28 day strength was i

;   approximately 5% for Mix B. The Mix B cylinders weighed between 123 and 126 lbs/cuft.                             i

I Compression tests were also conducted on the motar layers used in the molds. The test reports

} for all compression tests are contained in Appendix E. t I

4 4 . . 5 FLOW TESTING i j 'Ihe residue in the 6 inch drain lines of Mold A and Mold B was removed prior to hydraulic 4 testing. The residue samples were weighed and the chemical content analyzed. Mold A pipes j , contained 32.7 grams of material while Mold B pipes contained 45.0 grams of material. This , material consisted of dry concrete particles and small pieces of cement coated aggregate. The size of the aggregate was limited by the diameter of the holes in the drain pipe. The report on ! the chemical content of the residue is in Appendix F as samples 9 and 10. 1 i l At the conclusion of the 7 day curing period, flowing water was introduced into the three molds at a pressure of approximately 5 psi for a series of tests, each 8 hours in duration. The water j which circulated through the slabs was filtered through a 5 micron filter upon leaving the slab. l I The residue collected was dried and weighed. During each test, the flow rate was measured. The weights and flow rates are shown in Tables 2,3, and 4. ; !l l t l !l I 1 ? i j l 'l d 1 1 i e

TABLE 2 , MOLD A RESIDUE WEIGHT AND FLOW RATE TEST WEIGHT FLOW DESCRIPTION grams gpm 1 84.4 2.3 Light Brown Powder 1 2 92.1 2.7 Light Brown Powder ) 3 68.0 2.6 Light Brown Powder 4 50.3 2.4 Light Brown Powder ; 1 83.5 4.6 Light Brown Powder 5 6 38.1 4.6 Light Brown Powder i 7 32.2 4.3 Light Brown Powder j 8 41.3 4.1 Light Brown Powder l l TABLE 3 l MOLD B RESIDUE WEIGHT AND FLOW RATE -j TEST WEIGHT FLOW DESCRIPTION grams gpm 1 111.1 1.9 White Residue 2 136.1 2.3 White Residue 3 35.4 2.5 White Residue 4 25.4 2.3 White Residue 5 22.2 2.5 White Residue 6 3.2 2.4 White Residue 7 4.5 2.3 White Residue 8 20.9 2.3 White Residue l . _ .

l i 1 TABLE 4 i l MOLD C RESIDUE WEIGHT AND FLOW RATE i TEST WEIGHT FLOW DESCRIPTION grams gpm l , 1 45.4 0.5 White Residue ( , 2 173.7 2.4 White Residue ! ] 3 46.7 2.7 White Residue

4 49.4 2.4 White / Brown Residue 5 24.5 2.5 Light Brown Residue J

6 12.7 2.5 Light Brown Residue jl 7 13.1 2.5 Light Brown Residue l 8 27.7 2.2 Light Brown Residue l 1 During the curing process, a white residue leached from all three of the me 'is. This material ! !! deposited on the wooden box and on the floor any where the curing water went, see Figure 8. l When the flowing water was introduced into the slabs, the molds produced a similar appearing I white residue which was filtered out and collected as the material tabulated above. The results of the chemical analysis to determine the type of cement contained in the residue is in Appendix F and indicate that the residue is from both cements with no conclusive results as to what fraction of the residue is from the two types of cement used in the molds. l At the conclusion of the 8 hour tests, all three molds were tested for 30 days introducing water through all holes shown in Figures 1, 2, and 3. The rate of flow through the slabs was i measured during the test period. The average flow through Mold "A", Mold "B", and Mold i "C" was 23.4 gpm,27.8 gpm, and 15.7 gpm, respectively. Each collection box was cleaned and material shown in Table 5 was collected. l 1

TABLE 5

RESIDUE COLLECTED AFTER 30 DAY TEST MOLD WEIGHT OF RESIDUE (grams) . A 73.0 B 87.0-C 145.0 CORE TESTING j

            . After the 30 day test period, fourteen 6 inch diameter cores were taken from each slab at the locations shown in Figures 1,2, and 3. Each core consisting of a core of Portland Cement porous concrete and a core of Lumnite Cement porous concrete was tested in compression. The coring operhtion was successful in all three molds. Appendix G contains the boring logs for '                        ,

each mold. The cores from Mold "A" were recovered in two pieces with the break coming at the interface between the two pours. This was expected since there was little opportunity for the upper layer of the porous concrete to bond to the bottom layer of concrete. Four cores damaged in the i lumnite concrete section as well as at the interface. The cores from Mold "B" and Mold "C" genemlly broke into three sections. The upper layer of porous concrete separated from the layer of motar below it and this layer of motar was separated from the lower layer of porous concrete by the membrane. Only five cores from Mold l 1

               "C" broke into more than three sections. All of the damaged cores were broken in the lumnite                           .j concrete section of the core. All Mold "B" cores were recovered.

After the cores were removed, the water was again applied to the molds to determine the water . level in the mold at each core location. A column in each of the boring logs records the water I i li

depth above the horizontal floor of the mold at each core location. The water depth measurements indicate that all core locations had a similar water elevation and that there was no measurable hydraulic gradeline in the molds. It was initially thought that there might be a measurably higher water level in the cores near the water inlet ports Each core was trimmed and prepared for a compression test. Of the 84 cores removed from the molds, 69 were tested. The remaining 15 cores were broken or damaged during removal and could not be tested. The results of the compression tests are in Appendix G. The variation in strength was compared first with the weight of the concrete presuming that heavier concrete, i.e., more dense, more tightly compacted concrete, would have a higher compressive strength. The Lumnite Concrete core strengths are shown in Figure 9 and in general, there is a trend for greater strength with higher density. The Lumnite Cement Concrete in Mold "B" was the most compacted and had the highest strength. A similar result was found in the Portland Cement Concrete with strengths increasing with increased density, see Figure 10. The core strength data was also analyzed based on location in the mold as it related to the flow of water. In Mold "A", if the flowing water had a tendency to remove cement then it would

. be expected that both Lumnite cement cores and Portland cement cores located between the water source and the drain lines, cores A, B, G, K, J, and M, would show a reduced strength when compared to cores E, F, I, and N located on the opposite side of the mold taking into consideration the density of the cores. In Mold "B", the Portland cement cores were all subject to the same flow and were not used in the analysis. The Lumnite cement cores in Mold "B" I were used in the analysis because cores A, B, E, F, G, I, J, K, M, and N were subjected to flow'mg water where cores C, D, H, and L were not subject to flow. Cores from Mold "C" made from both Portland cement and Lumnite cement were considered in the flow when there were slits in the membrane at the cores. Cores exposed to flow were B, C, F, H, K, and M.

Cores not exposed to flow were A, D, E, G, I, J, L, and N. ! } 1 1 ' The core strength vs. weight plotted for Lumnite Cement Concrete, see Figure 11, indicated that !- the strength of the cores was not effected by the flowing water. Similarly, the Portland Cement ; f Concrete did not show any change in concrete strength due to flowing water, see Figure 12. i i ! CONFINED COMPRESSION TESTING OF CORES ' t I i Cores removed in the steel perforated cages from selected locations in each mold were tested l in confined compression and the stress vs strain was recorded. The confined compression test l was conducted by removing the perforated steel cylinders and sealing the specimen in a rigid j 4

. steel cylinder using leadite and an impermeable paper barrier to keep the leadite out of the voids l in the concrete.

i

Two specimens were tested from Mold "A" namely cages AH and AE. Each specimen was i 4

i prepared by cutting the ends of the specimen square to the axis of the cylinder and by placing 1 . equal lengths of Lumnite porous concrete and Portland porous concrete in the steel pipe cylinder. - , f The interface between the two layers of concrete was the interface created by pouring the l Lumnite porous concrete on top of the Portland porous concrete in the mold. The displacement as a function ofload for the two specimens is shown in Figure 13. Core AH had significantly l more displacement after reaching a load of 500 psi than did core AE. Examination of the two , i i specimens indicated that crushing of the aggregate had taken place only in specimen AH. Test ! logs are contained in Appendix H. ! Specimens contained in the steel cages taken from Molds "B" and "C" were tested in two l sections, i.e., the Lumnite porous concrete section of the specimens were tested individually as f were the Portland porous concrete sections of the specimen. 'Ihese sections were separated since t i there was no direct contact between the two concretes, i.e., they were separated by a membrane i j and a layer of motar. 3 J 4 j : O r - -y-..- c -_..n,y

!L f . . l The stress strain relationship for Lumnite porous concrete for specimens BE, BT, BH, and CJ , r are shown on Figure 14. The curves for all four cylinders are very nearly parallel indicating that after an initial displacement which varied for each specimen the units of displacement for each unit ofload was nearly the same for all specimens. At a load of 900 psi, the displacement } ranged from 0.022 inches to 0.025 inches in specimens that were nine inches high. This is j roughly a 0.02% change in height. There was no evidence of aggregate crushing. 1 j The Portland porous concrete specimens taken from the same locations behaved very similar to the Lumnite concrete, see Figure 15. The displacement at a load of 900 psi was slightly more than the Lumnite concrete ranging from 0.023 inches to 0.028 inches in specimens that were ten s

inches high. The change in height expressed in percent ranged from 0.02 to 0.03%. There was no evidence of crushing aggregate.

CONCLUSIONS These conclusions have been drawn on the experimental work conducted under this study. No attempt has been made to relate this data to existing field conditions. i i

1. The aggregate used to conduct these tests was obtained from the same source, the Wauregan Quarry operated by Tilcon Connecticut, as that used during construction of the porous concrete at Millstone. ,

1

                  - 2. The aggregate used in the tests lacked fines but generally met the required ASTM #57    j specifications.                                                                         j

3. Both the Calciam aluminate cement (Lumnite) and the Portland Cement Type 11 met the requirements of specification SP-CE-363.

i 1

l f 4. The water chemistry at the concmte plant and at ARL met ASTM requirements for batch water and curing water, respectively. )

5. Contamination of either cement with the other cement during batching causes a loss in stmngth of the concrete.

6. All concrete handling equipment was cleaned before usage to avoid contamination of cements.

7. During the confined compression test of aggregate alone, the aggregate compacted ,

approximately 40% at a 910 psi load. I

8. Portland cement porous concrete cylinders made at the time of the pour weighed approximately 125 lbs/cuft and had a 28 day strength of 2,152 psi. ,

I

9. Lumnite cement porous concrete cylinders made at the time of the pour weighed approximately 125 lbs/cuft and had a 28 day strength of 1,787 psi.

10. The compressive strength of both the Portland cement porous concrete and th'e 1,umnite cement porous concrete was not effected by the location of the core as it is related to the flowing water. In both concretes, the strength, however, was related to the density of the concrete. I i

11. The confm' ed compression tests indicated that the stress strain relationship was similar for all cores made from the same cement, i.e., all Lumnite cores exhibited similar behavior.

1

                                                          ,.   .--n  ,                         ,   -,

l

12. At a loading of 900 psi, the specimens decreased in height, 0.02% and 0.03% for ,

Portland cement porous concrete and Lumnite cement porous concrete, respectively. There was no crushing of aggregate. REFERENCE

1. Northeast Utilities Service Company Specification SP-CE-354; Specification for Porous Concrete Mock-up Testing; January 8,1992; Revision 1, March 9,1992.

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B15985, Forwards Response to RAI Re Issues Concerning Plant Containment Basemat Concrete

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B15985, Forwards Response to RAI Re Issues Concerning Plant Containment Basemat Concrete

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