ML20137G734

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Rev 5 to Procedure 35-1195-CCP-10, Concrete Batch Plant Operations. Related Info Encl
ML20137G734
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 12/04/1978
From: Tyler W
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML17198A292 List: ... further results
References
FOIA-85-59 35-1195-CCP-10, NUDOCS 8512020243
Download: ML20137G734 (24)
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'3CMQ PROCEDURE ISSUE BROWN & ROOT, INC.

NUMBER REVISION E um t MAG E--- - -

^b CPSES 35-1195-CCP-10 5

12/4/78 1 of 20 JOB 35-1195

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ORIGINATOR:

REYIEWED BY:

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" CONCRETE BATCH

/ QA/0C Date Ic APPROVED BY: / [

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TONSTRUCTION ROJECT MANAGER DATE or vei TfD #1

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CONT NTS

1.0 REFERENCES

I 2

g 2.3 DEFINITIONS.

2.4 SPECIAL ITEMS AND OPERATIONS 2.5 F. UNCTIONS AND RESPONSIBILITIES 3.0 PROCEDURE 3.1 CEMENT 3.2 AGGREGATE 3.3 AGGREGATE GRADATION FAILURE 3.4 RESCREENING AGGREGATE 3.5 ADMIXTURE 3.6 WATER 3.7 CLASSES OF CONCRETE 3.8 BATCHING 3.9 CENTRAL MIXING 3.10 TRUCK MIXING 3.11 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.12 TICKETING SYSTEM 3.13 MAINTENANCE OF EQUIPMENT NOTE This document has been completely retyped for convenience in issuing Revision 5.

Vertical lines (change bars) appear-l ing in the margins indicate what information was actually l

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i JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION,.

Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 1

Notice applicable to Construction Procedure No. 35-1195-CCP-10 Rev.

5 This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Please replace / add the following pages with the attached:

Page 19 of 20 20 of 20 Add 20a of 20 p) 4 u

Reviewed by:

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,30 h(M 84 sk f$rN' PldW Origirrator Date Brown & Root Mlity Assurance Date

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Date Approved by:

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06/01/84 Construction Project Manager Date Effective Date Md w

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ARMS INDEXED JOB 35-1195 hr' COMANCHE PEAK STEAM ELECTRIC STATION DATE:

INTERIM CHANGE NOTICE NUMBER 1 This notice applies to: Construction Procedure #35-1195-CCP-10, Revision 5

The intent of this change will (X$ / will not ( ) be incorporated in the next revision to the procedure or instruction.

This Change applies:

Until Further Notice ( )

Until the next Revision is issued (XX Only as follows:

CHANGE THE PROCEDURE / INSTRUCTION AS FOLLOWS:

On Attachment 2, Part D, add to the bottom of the' list as follows:

M.

Mechanical Type 2 openings.

E.

Electrical Type 2 openings.

V.

Ventilation Type 2 openings.

I.

Instrumentation Type 2 openings.

NOTE HIJ portions of the pour numbers should coincide with the last three characters of the Gibbs & Hill block-out designation.

Reason for change:

To develop pour numbers for Typ

-pour-blocks.

This change pprove by:

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Depa tment Heaa e'

'Date ual y Arsurance 7Date Reviewed By:

Wh 4%% I2-lt*5 [*!O hcc, S, WW Procecures & Reports q7,g,fpg Date e

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4 BROWN & ROOT, INC.

PROCEDURE ISSUE r

CPSES NUMBER l

REVISION DATE PAGE JOB 35-1195 g

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35-1195-CCP-10 i

5 12/4/78 2 of 20 l.0 REFERENCES 1.

B&R Engineering Instruction 35-1195-CEI-13, "High Density Concrete" 2.

ASTM C-150, Specification for Portland Cement.

3.

B&R Construction Procedure 35-1195-ACP-3, " Material Receiving, Handling, and Storage".

4.

ASTM C-33, Specification for Concrete Aggregates.

5.

U.S. Army Corps df, Engineers Specification CRD-C119, Method of Test for Flat and Elongated Particles in Coarse Aggregate.

6.

ASTM C-494, Specification for Chemical Admixtures for Concrete 7.

ASTM C-260, Specification for Air-Entraining Admix-tures for Concrete.

8.

ASTM C-94, Specification for Ready-Mixed Concrete.

9.

ACI 301-72, Specification for Structural Concrete for Buildings

10. B&R Construction Procedure 35-1195-CCP-ll

" Concrete Placement"

11. ACI 305-72 Recommended Practice for Hot Weather Concreting.
12. ACI 614-59, Recomended Practice for Measuring, Mixing, Transporting, and Placing Concrete.
13. Brown & Root Quality Control Construction Procedure No. CP-QCP-2.2.

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BROWN & ROOT, INC.

PROCEDURE ISSUE r-*

CPSES NUMBER REVISION DATE PAGE A,)

JOB 35-1195 l

s 35-1195-CCP-10 i

5 12/4/78 3 of 20 2.0 GENERAL 2.1 PURPOSE 2.1.1 The purpose of this document is to set forth the methods and pro-cedures that will be employed in the receiving, handling and stor-ing of concrete materials and the batching, mixing and delivery of concrete.

2.2 SCOPE 2.2.1 The scope of this prQcedure covers the methods and procedures that apply to receiving, handling and storing of concrete materials and the batching, mixing and delivery of concrete including grout.

2.3 DEFINITIONS 2.3.1 ACI American Concrete Institute ASTM American Society for Testing & Materials TUSI Texas Utilities Services, Inc.

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2.4 SPECIAL ITEMS AND OPERATItNS 2.4.1 High density concrete and its associated materials and properties i

which are distinct from the other classes of concrete are discussed in Reference 1.

2.5 FUNCTIONS AND RESPONSIBILITIES 2.5.1 Project Civil Engineer - Maintains over-all technical assistance for concrete batch plants, concrete materials, trucks and associated equipment.

(CONTINUED ON NEXT PAGE)

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PROCEDURE l

ISSUE i

CPSES NUMBER REVISION DATE PAGE JOB 35-1195

! 35-1195-CCP-10 5

12/4/78 4 of 20 2.5.2 Concrete Superintendent a.

With the technical assistance and engineering information of the Project Civil Engineer, maintains over-all responsibilities for concrete bate. plants, oncrete materials, trucks and associated equipment.

b.

Supervise all phases of the concrete batching, mixing and truck delivery operations.

c.

Supervise all phases of cor. crete material receiving, handling and storing.

d.

Assures that activities are performed in accordance with this procedure, e.

Assures that activities are performed in accordance with appli-cable manufacturers equipment operating procedures and mainten-ance procedures, p

f.

Maintains daily production records and reports applicable to his responsibilities.

w 3.0 PROCEDURE 3.1 CEMENT 3.1.1 Portland Cement shall comply with ASTM C-150, Standard Spec-ification for Portland Cement, and shall be Type Il and low alkali (0.60% maximum) in accordance with the requirements of Table 1A therein.

3.1. 2 Except as otherwise approved by TUSI, all cement shall be of the same brand and manufactured at the same mill.

3.1. 3 A manufacturer's certified material test report attesting to the conformance of the cement to ASTM C-150 shall be furnished for each shipment.

3.1.4 Cement will be received in bulk truck transports and will be pneumatically loaded into clean, uncontaminated, water-tight storage silos or storage tanks at either the main batch plant or back-up batch plant where it shall remain unt'i1 concrete is batched.

1 3.1.5 Warehousing shall receive cement trucks per Refe'rence 3, and n\\

inspect certified material test report and inspect seal on truck 1

hatches to insure that it is intact. Certified material test report will be retained by warehousing and distributed to QA per Reference 3.

PROCEDURE ISSUE BROWN & ROOT, INC.

NUMBER REVISION DATE PAGE

'p)

CPSES JOB 35-1195 35-1195-CCP-10 5

12/4/78 5 of 20 m

I 3.2 AGGREGATE 3.2.1 Fine aggregate (sand) shall be graded according to the require-ments of ASTM C-33.

3.2.2 Nominal size 3/8 inch coarse aggregate shall conform to size number 8 of Table 2 in ASTM C-33.

3.2.3 Nominal size 1/2 inch coarse aggregate shall conform to the requirements of Section 202, Aggregate, of ACI 506, Recommended Practice for Shotcreting.

1/2 inch coarse aggregate shall be uncrushed gravel, graded from No. 4 to 1/2 inch size.

3.2.4 Nominal size 3/4 inch coarse aggregate shall conform to size number 67 of Table 2 in ASTM C-33.

3.2.5 Nominal size 1 1/2 inch coarse aggregate shall conform to size number 467 of Table 2 in ASTM C-33.

3.2.6 The following are descriptions of aggregate properties (except for 1/2 inch coarse aggregate which is fully described in Section 3.2.3).

3.2.6.1 Aggregate shall consist of natural or manufactured sand, crushed p

h stone, or gravel. The particles shall be clean, hard, tough, dur-able, of uniform quality and shall be free from soft thin, elongated, disintegrated stone, dirt and organic or other injurious materials occurring either free or as a coating. The aggregate when incorpor-ated in concrete, shall satisfactorily resist chemical or physical changes such.as cracking, swelling, softening, leaching or chemical alteration, and shall not contain contaminating substances which might contribute to deterioration or unsightly appearance of the concrete.

3.2.6.2 The coarse aggregate shall be well graded and shall consist of gravel, crushed gravel, crushed rock, or crushed stone fragments which are clean, rough, hard and uniform. No blast furnace slag, schist, shale or slate shall be permitted.

3.2.6.3 The potential reactivity of the aggregate shall be established by the methods described in the Appendix to ASTM C-33.

3.2.6.4 Aggregate shapes shall be rounded or cubical and shall contain less than 15 percent (by weight) flat and elongated particles as deter-mined by the U. S. Army Corps of Engineers Spec. CRD-C119, Method of test for Flat and Elongated Particles in Coarse Aggregate. A flat particle is defined as one having a ratio of width to thickness greater than three: an elongated particle is defined as one having a ratio of length to width greater than three.

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BROWN & ROOT, INC.

PROCEDURE j

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 l

!35-1195-CCP-10 5

12/4/78 l 6 of 20 3.2.7 Fine and coarse aggregates will be off-loaded from truck trans-ports into hoppers for conveyor transfer to aggregate stockpile bins which shall be arranged and operated to prevent contamination by different gradations or types of aggregates and to assure that there is pratical minimum segregation.

3.2.8 As an exception to Paragraph 3.2.7, fine and coarse aggregates may be off-loaded and stored in outside uncovered aggregate stock-pile' bins. These aggregates shall be stored and main-tained in a manner that will avoid the inclusion of aay foreign materials in the concrete. No muddy or oil leaking traction equipment shall be allowed to operate on storage piles. The placing of the material in storage and its removal shall be done in such a manner as to maintain the uniformity of the gradation.

The aggregate stockpiles in the outside uncovered bins shall be on concrete slabs, and shall have suit-able drainage. The aggregate storage piles shall be built and maintained to prevent segregation and excessive breakage.

If required, suitable bulkheads between specific size groups or aggregate shall be provided to preclude intermixing of the

((e different size groups.

3.2.9 Warehousing shall receive aggregates per Reference 3, and inspect loads to insbre! conformance to aggregate quality per this construction procedure.

3.2.10 Aggregate hoppers and conveying equipment shall be cleaned, as necessary, to prevent contamination by different gradations or types of aggregates and to assure that there is practical minimum segregation.

3.2.11 Access for inspection shall be provided in stockpiles at all times.

3.2.12 Each lot of aggregate shall be identified by signs which show size, gradation, source and controlling specification.

3.2.13 In event of equipment failure, temporary measures shall be initiated and approved by the Concrete Superintendent to expedite repair of original equipme, efforts shall be made to insure quality is maintained. All nt for operation.

3.3 AGGREGATE GRADATION FAILURE 3.3.1 In the event aggregate fails to meet the specification grada-tion requirements, the material represented by the failing

[,d test results shall be remixed, reblended or scrapped at the discretion of the Brown & Root Concrete Superintendent or his designee.

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PROCEDURE ISSUE l'

CPSES NUMBER 3

REVISION DATE PAGE JOB 35-1195 q

' 35-1195-CCP-10 5

12/4/78 7 of 20 i

j 3.3.2 Remix shall be accomplished by discharging material from one or more of the aggregate storage bins into the backup charging j

conveyor belt, into clean dump trucks, and unloading this mate-i rial into the aggregate receiving hopper back into the respec-tive storage bins via the bin (s) receiving conveyor belt and rock ladder (s). This procedure shall be repeated until, in the judgement of the Brown & Root Concrete Superintendent or his designee, the material has been thoroughly remixed. At this time, retest (s) may be requested by the Concrete Superinten-dent or his designee to check if material is within specifica-1 tion gradation.

l 3.3.3 In the case of failing gradation re-test results, it may be requested by the Concrete Superintendent or his designee to elect to scrap or re-blend the material.

If, after review of the test results, it is determined that re-blending is practical and would result in an acceptable graded material, it shall be performed by the procedure described above with the exception that another tested and approved size (s) aggre-1 ((

gate shall be injected at the time the material is recycled into the storage bin (s) receiving hopper in quantities pre-scribed by the Concrete Superintendent or his designee.

Note that only gravel-to-gravel and stone-to-stone additions shall be made.

3.3.4 To ensure material is within specification limits before use, re-sampling and re-testing shall be performed after re-blending.

3.3.5 In order to prevent the use of disapproved aggregate, the QC Batch Plant Inspector shall notify the Concrete Superinten-operation, as to which aggregate storage bin (s)y's batching dent or his designee, in writing before each da are approved for use.

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3.4 RESCREENING AGGREGATE i

3.4.1 Approved concrete aggregate may be rescreened to meet another j

ASTM Grading size only if tested and accepted aggregate is used.

3.4.2 The aggregate shall be removed from the batch plant aggregate storage bins, loaded into dump trucks and hauled to the on-site 3

.l screening plant. The aggregate liandling equipment shall be 4

clean and maintained in a manner that will avoid contamination A

of the aggregate.

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a BROWN & ROOT, INC.

PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE

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JOB 35-1195 l

35-1195-CCP-10 5

12/4/78 8 of 20 3.4.3 The screening plant shall be equipped with the proper size screens to produce the aggregate gradation desired. The screening plant aggregate hoppers and conveyors shall be cleaned of foreign material to prevent contamination of the aggregate being produced. Screens shall be in good condition and free of any rips, tears, etc.

3.4.4 The aggregate shall then be delivered to, and stored in one of the approved aggregate storage bins at the batch plant.

Different size aggregates shall not be intermixed within a bin. Each lot or bin of aggregate shall be indentified by signs which show size, gradation, source and controlling specification.

3.4.5 A monitor gradation sample may be taken from the belt at the screening plant or from the stockpile at the batch plant and tested to ensure aggregate is within the ASTM specification grading size required. However, the aggregate shall be sampled, tested and accepted prior to hauling to the storage bin (s).

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3.4.6 Aggregate meeting grading requirements of ASTM No. 7 (a inch) s

V may be used in concrete or shotcrete providing a mix design has been previously approved by the Engineer. Only aggregate from an approved storage bin shall be used.

3.4.7 If material finer than No. 200 sieve exceeds maximum limits of 1.0". the aggregate may be washed to remove dust or finer mat-erial. The aggregate shall~ then be resampled and tested as necessary for acceptance.

3.5 ADMIXTURE 3.5.1 Type A, water-reducing admixture, shall comply with ASTM C-494.

3.5.2 Accelerating admixture for shotcrete shall be a liquid per ASTM C-494 or a solid per Challenge-Cook patented formulation named "C hal l og".

3.5.3 Type D, water-reducing and retarding admixture, shall comply with ASTM C-494.

3.5.4 Air entraining admixture shall comply with ASTM C-260.

3.5.5 Manufacturers certificates as to analysis and composition of the admixture shall be furnished.

(o 3.5.6 Admixture shall be in accordance with the recommendations of C) the cement manufacturer.

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x BROWN & ROOT, INC.

l PROCEDURE ISSUE CPSES NUMBER REVISION DATE l

PAGE JOB 35-1195 35-1195-CCP-10 5

12/4/78 9 of 20 3.5.7 Type A, Type D and air entraining admixtures shall be unloaded, by pump, from bulk truck transport or drums into uncontaminated storage tanks which shall be clearly marked as to their contents, storage requirements and controlling specification.

3.5.8 Warehousing shall receive admixtures per Reference 3, and inspect manufacturers certificate and/or spectrographic analysis and dis-tribute to QA per 35-1195-ACP-3.

3.5.9 Accelerating admixture for shotcrete shall be stored per manufac-turer's recommendations.

3.5.10 All admixtures shall be protected from moisture and temperatures that could adversely effect their performance as per manufacturers' recommendations.

3.6 WATER 3.6.1 Water for mixing concrete and sprinkling aggregates, if required, shall be clean, fresh and free from deleterious amounts of acids, alkalis or organic materials.

3.6.2 Mixing water shall comply with tests required by Engineer specifi-cations.

3.6.3 Water shall be pumped from a deep well(s) and transferred to an uncontaminated storage tank (s).

3.6.3 Water for ice shall be pumped from the' storage tank into an ice plant where ice shall be manufactu"ed and stored as to prevent contamination.

3.7 CLASSES OF CONCRETE 3.7.1 Concrete is designated by classes according to the required com-pressive strength at 28 days. The class to be used in each part of the work will be shown on drawings, or will be designated by the Engineer. The method of determining the 28-day strength shall be in accordance with pertinent ASTM standards. The site test lab will furnish mix designs for the following standard classes:

a.

Class 1 Concrete Compressive Strength, 4000 psi 3/4,1/2 or 3/8 inch maximum aggregate b.

Class 2 Concrete Compressive Strength, 4000 psi 1-1/2 inch maximum aggregate c.

Class 3 Concrete Compressive Strength, 2500 psi O

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ISSUE BROWN & ROOT, INC.

PROCEDdRE CPSES NUMBER I

REVISION DATE PAGE i '

i JOB 35-1195 j

35-1195-CCP-10 l 5

12/4/78 10 of 20 d.

Class 4 Concrete (miscellaneous) e.

Class 5 Concrete Compressive Strength, 3000 psi 3/4 or 1/2 inch maximum aggregate f.

Class 6 Concrete Compressive Strength, 3000 psi 1-1/2 inch maximum aggregate g.

Class 7 Concrete Compressive Strength,1500 psi 1 1/2 inch maximum aggregate h.

Shotcrete, Class 8 Compressive Strength, 3000 psi 1/2 inch maximum aggregate 1.

Grout, Class 9

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3.7.2

" Mass concrete" is concrete which is greater than 2 feet-6 inches in the least dimension. Maximum temperature for " mass concrete" 0

is 70 F at placement.

3.7.3 Concrete Slump 3.7.3.1 The maximum allowable slump for concrete at the point of place-ment shall be as follows:

Class A, B, and C................... 4 inches Cl a s s D............................. 3 is i nc h e s Cla ss E and F....................... 5 inches 3.8 BATCHING 3.8.1 The fine and coarse aggregate will be weighed in a single batcher using cumulative weights to within a plus-or-minus one percent tolerance by weight.

3.8.1.1 Adjustments of Aggregate Weights The acceptable range for fineness modules (F.M.) of sand is 2.3 to 3.1.

However, in order to meet the; intent of Section 3.5 of ASTM C33, the following steps are incorporated into the batching procedure. These steps describe the aggregate weight adjustments that are required because of the different values of sand F.M.

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PROCEDURE l

ISSUE h.3 CPSES NUMBER REVISION DATE PAGE 1

JOB 35-1195

~ 35-1195-CCP-10 5

12/4/78 11 of 20 within the acceptable range of 2.3 to 3.1.

a.

The sand F.M. value for a day's production will be the average of the test lab reports given to the batch plant prior to batching.

b.

Design weights of sand and coarse aggregate shall be

,used when the sand F.M. is between 2.5 and 2.9.

c.

When the sand F.M. is less than 2.5, the weight of coarse aggregate shall be increased by 521bs. per cubic yard of concrete, and the weight of sand shall be decreased by the same amount.

d.

When the sand F.M. is greater than 2.9, the weight of coarse aggregate shall be dccreased by 52 lbs.

per cubic yard of concrete, anc the weight of sand shall be increased by the same amount.

i 3.8.2 Cement will be weighed in a batcher to within 1 percent tolerance p

by weight.

t 3.8.3 Water and ice will be weighed in separate batchers to within a 1 percent tolerance by weight.

3.8.4 Air entraining admixture, Type A admixture, and Type D admixture will each be measured by volume, in separate containers to within a tolerance of 3 percent.

i 3.8.5 Tolerance interlocks are provided to prevent a discharge device from being actuated until the material has been batched within applicable tolerances.

3.8.6 The batchers are equipped with platforms so that an overweight or sample can be removed.

i 3.8.7 All scales used ir, weighing concrete mix materials and volumetric measuring devices for admixtures will be calibrated in intervals not exceeding 90 days.

3.8.8 In the event the automatic ticket printer breaks down, the plant operator will fill out the ticket manually, using pen with black ink, to record the actual weights read from the scales.

3.9 CENTRAL MIXING 3.9.1 Mixing equipment will produce uniformity of consistency, cement

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and water content, and aggregate grading, from beginning to end of V

each batch.

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BROWN & ROOT, INC.

PROCEDURE.

j ISSUE NUMBER

! -REVISION DATE PAGE CPSES i

JOB 35-1195 l

j i 35-1195-CCP-10 5

12/4/78 12 of 20 3.9.2 The mixer ope:ating time will be regulated to the required mixing performance in the minimum amount of time as determined by perfor-mance tests or minimum time per ASTM C-94.

Test results shall be retained by the Concrete Superintendent.

3.9.3 Batch size will not exceed 10 c.y.

Controls shall be provided to insure that the batch cannot be discharged until the required mix-ing time has elapsed.

3.9.4 Mixer blades shall be replaced when they have lost 10 percent of their original height. Concrete Superintendent or his repre-sentative shall perform a quarterly check to insure conformance.

3.9.5 Accumulated hardened concrete shall be removed, as necessary, to maintain peak mixer performance and efficiency. Concrete Super-intendent shall insure conformity.

3.9.6 Admixtures shall be mixed into batch in accordance with Section 7.3 of ACI 301-72.

3.9.7

' Tempering and control of mixing water shall be in accordance with J

Section 7.5 of ACI 301-72.

3.9.8 Cold weather mixing and temperature of delivered concrete shall be in accordance with Reference 10.

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3. 9.9.

Hot weather mixing shall be in accordance with Section 7.6.2 of ACI 301-72, except that for " mass concrete", the maximum tempera-ture of concrete as placed shall be 700F instead of the 900F maximum permitted by ACI-305.

3.9.10 Central mixing controls provide for monitoring slump by means of a slump meter. Also, the slump will be checked periodically by visual inspection of the truck mix.

3.10 TRUCK MIXING 3.10.1 While Loading, the mixer drum will be rotating at a speed de'signated by the manufacturer as mixing speed.

3.10.2 Each batch of concrete shall be mixed not less than 70 or more than 100 revolutions of the drum at mixing speed. Any additional drum revolutions shall be done at the rate of rotation designated by the manufacturer of the equipment as agitating speed.

3.10.3 The slump will be checked periodically by visual inspection of the truck mix.

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PROCEDURE i

ISSUE i

i CPSES NUMBER i

REVISION DATE i

PAGE

>1 JOB 35-1195

' 35-1195-CCP-10 5

12/4/78 13 of 20 3.11 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.11.1 When a truck mixer contains concrete that has been completely mixed in the stationary mixer at the Main Batch Plant or concrete that has been completely truck mixed, any turning of the drum during transportation shall be at agitating speed.

0 3.11.2 When the ambient temperature is 85 F or below, the time after the addition of water to the dry materials until placement shall not exceed 90 minutes. When the ambient temperature is 1

above 85 F, the time shall not exceed 45 minutes except when 0

permitted by the Engineer on a case-by-case basis.

3.11.3 The number of drum revolutions shall not exceed 300 after mix water is added to the dry materials.

3.11.4 Each mixer truck will be equipped with an accurate revolution counter, j

3.11.5 Add Water

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3.11.5.1

" Add water" may be dispensed into the truck mixer at point of place-j ment in order to increase slump to meet specification or to increase 3

workability of mix.

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3.11.5.2 Sampling Mix l

a.

If for reasons stated in 3.11.5.1 it is determined that add water will be dispensed into truck mixer, then a sample from the mix, after add water and after truck mixer has revolved 30 times at mixing speed, must be slump tested before dis-l charge.

b.

Preceding procedure may be repeated as necessary before mix discharge until desired slump or workability is attained.

i 3.11.5.3 Maximum slump shall not be exceeded as a result of the addition of add water to the mix.

l 3.11.5.4 Quantity of add water shnll not exceed quantity recorded for " add water" on the batch ticket.

j 3.11.5.5 Add water will be measured by the sight glass or calibrated container to the nearest whole gallon and quantity shall be so noted on batch ticket in " ADD WATEP" block.

3.11.5.6 Responsible contractor representative and testing lab representative will each sign within the block, before water is added, to verify that the add water about to be added does not result in the total add water quantity exceeding the quantity recorded for " add water" on the batch ticket. For shotcrete, a B&R QA/QC representative may sign in place of the test lab representative.

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PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195

! 35-1195-CCP-10 5

12/4/78 14 of 20 4

3.11.5.7 CALCULATION OF ALLOWABLE " ADD WATER" The cards will be punched to show the total " design water" or less, such as 230 lb/cy for Mix I.D. No. 202. The batch plant operator will deduct water as outlined below using the slump control meter.

This deduction will be sufficient to provide required slump for the mix classification, i.e., 4" for Class A, B, and C Concrete.

r For Aggregate Moisture compensation, the batch plant control system automatically subtracts the free moisture contained by the fine aggregate from the total " design water" (230 lbs. for Mix I.D. No. 202). The free moisture in the coarse aggregate is calculated by the B&R batch plant personnel using the latest.

L Hunt report on the C.A. moisture. The quantity obtained by sub-tracting the F.A. free moisture + C.A. free moisture from the total " design water" is the " maximum amount

  • of water which is allowed to be dispensed into the mix.

If the " maximum amount" of water is not dispensed at the batch. plant, then " add water" may be added into the truck mixer later at the point of dis-charge. The allowable " add water" is calculated by subtracting the " water dispensed at batch plant" from the " maximum amount" and is written by B&R batch plant personnel fn the Add Water block on the batch ticket.

Add Water = Design Water - (F.A. free moisture)

- (C.A. free moisture) - (water dispensed at batch plant) i 3.11.6 Same as Section 3.9.4.

3.11.7 Same as Section 3.9.5.

3.12 TICKETING SYSTEM-3.12.1 Ticket Description The purpose of the batch ticket (Figure 1) is to record informa-tion concerning each batch of concrete. Following is an explana-tion of the information blocks on the ticket:

1.

Mix ID: explained on Mix Identification sheet (Attach-ment No. 1) 2.

Batch Size: Volume of batch (1/100 CY) 3.

Batch No.: number of consecutive batches produced by the plant.

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BROWN & A00T, INC.

PROCEDURE ISSUE h3 CPSES NUMBER

~

REVISION DATE l

PAGE

(

JOB 35-1195 j

35-1195-CCP-10 5

12/4/78 l

15 of 20 4

l 4.

M. C. Setting: compensates for moisture content in the fine aggregate (1/10 percent)

I 5.

Plant: 1 - Back-Up Plant 2 - Main Plant 4

6.

Agg. 1, Agg. 2 Agg. 3: cumulative coarse aggregate weights (1bs/ Batch)

J 7.

Sand: cumulative coarse aggregate weights plus fine aggregate weight (1bs/ Batch) 8.

Cement: cement weight (1bs/ Batch) i i

9.

Admix 1: Master Builders MB-VR air entraining admixture, meets ASTM C-260 requirements (1/2 fl. oz/ Batch) 1 l

10. Admix 2: Master Builders Pozzolith 300-R water-reducing i

and set-retarding admixture, meets ASTM C-494 i

for Type D requirements (1/2 fl. oz/ Batch)

11. Admix 3: Master Builders Pozzolith 300-N water-reducing admixture, meets ASTM C-494 for Type A require-ments (1/2 fl. oz/ Batch) 1

}

12.

Ice:

iceweight(1bs/ Batch)

13. Water: cumulative ice and water weight (1bs/ Batch) i
14. Area Pour Section: explained on Pour Number sheet (AttachmentNo.2)
15. Sand Moist: moisture in fine aggregate (1/10 percent) i I
16. Truck No.

4 i

l

17. Agg. Tare: aggregate batcher tare weight i

L

18. Cem. Tare: cement batcher tare weight i
19. Water Tare: ice and water batchers weight l
20. Time i
21. Add Water: allowable add water (1/10 gals./CY)
22. Ticket No.
23. Date 4

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BROWN & ROOT, INC.

PROCEDURE CPSES i

NUMBER REVISION DATE l

PAGE JOB 35-1195 i

35-il 95-CCP-10 5

12/4/78 16 of 20 3.12.2 Ticket Routing and Sign-Off:

1.

After batching is complete, batch plant representative signs ticket which verifies that information on ticket is correct and retains blue copy of ticket for batch plant records.

2.

The truck driver delivers white original and remaining two copies of ticket to point of concrete placement.

3.

If add water is dispensed into batch, General Contractor Representative and Test Lab Representative both sign in their respective spaces in the add water block on the right side of ticket per paragraph 3.11.5, " Add Water". For shotcrete, a B&R QA/QC representative may sign in place of the test lab representative.

4.

If no " required in-process test" are being performed on the concrete batch, the General Contractor Rep, signs in space at bottom of ticket after he is satisfied that information

(

on ticket is correct and that the concrete batch is accept-a bl e.

5.

White original and two copies of ticket are then returned by truck driver to batch plant where they are given to Concrete Superintendent or his representative.

6.

Concrete Superintendent distributes daily the following:

a.

white original to Test Lab b.

pink copy to. Engineer (if Engineer so requests) c.

yellow copy to B&R Cost Engr. Dept.

3.13 MAINTENANCE OF EQUIPMENT 3.13.1 Maintenance records of equipment shall be kept by the Concrete Superintendent.

3.13.2 Manufacturers' operating instructions for major equipment shall be available at the batch plant.

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BROWN & ROOT, INC.

PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE

's JOB 35-1195 35-1195-CCP-10 5

12/4/78 18 of 20 ATTACHMENT 1 MIX IDENTIFICATION ABC I.

tiix ID Number A.

Class Number 1.

Class 1 Concrete Compressive Strength, 4000 psi 3/4 or 1/2 or 3/8 inch maximum aggregate 2.

Class 2 Concrete Compressive Strength, 4000 psi 1-1/2 inch maximum aggregate 3.

Class 3 Concrete Compressive Strength, 2500 psi 4.

Class 4 Concrete (Miscellaneous) 5.

Class 5 Concrete 4

Compressive Strength, 3000 psi 3/4 or 1/2 inch maximum aggregate i

6.

Class 6 Concrete Compressive Strength, 3000 psi 1-1/2 inch maximum aggregate 7.

Class 7 Concrete Compressive Strength,1500 psi 1-1/2 inch maximum aggregate j

8.

Shotcrete, Class S Compressive Strength, 3000 psi 1/2 inch maximum aggregate 9.

Grout, Class 9 BC. Mix Number Numbers 00 thru 99 will define different mixes of a particular class. For example a need may exist for Class 1 concrete to have two mixes with different cement contents. Therefore, different mix numbers will be assigned to distinguish between the mixes.

II. All approved mix designs, mix design variations and mix identi-fication numbers shall be issued on an up-to-date list by the B&R Construction Engineering D t.

e f

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_ ___ _ _ _ _ _.... _ =

i s

BROWN & ROOT, INC.

PROCEDURE EFFECTIVE j

CPSES NUMBER REVISION DATE PAGE 4

\\

j JOB 35-1195 CCP-10 5

12/04/78 to of 20 i

ATTACHMENT 2 POUR NUMBER I

AB C-DEFG-HIJ 1

A.

Unit De-ignation j

0 - Common Building 1 - Unit 1 2 '- Unit 2 i

B C.

Work Area as follows:

J 01-21 BUILDINGS

(

01 Co nta inme nt j

02 Auxiliary i

03 Fuel Handling Buildirg i

04 Turbine Generator Building j

05 Sa feguards Building 06 Maintenance Building

(

07 Administration Building 08 Electrical Duct Ba nks j

09 Sanitary Sewer Manholes 10 Storm Sewer Catch Basins a

i 11 Pipe Tunnel j

12 Misc. Yard Valve Pits 1

13 Transformer Area Foundations 14 Main Transformer Foundations l

15 Auxiliary Trans former Foundations 16 Misc. Tank Foundations i

17 Misc. Yard Structures

)

18 Refueling Water Storage Tank 19 Condensate Storage Tank 20 Raactor Make-Up Water Storage Tank 21 Electrical Manholes 22 011 Spill Containment Dams & Footings at Switchyard 3

23 Class I Electrical Ductbanks Train A 24 Class I Electrical Ductbanks Train B l

25 Class I Electrical Manholes Train A 26 Class I Electrical Manholes Train B 27 Relay House 28 Waste Management System 29 OPEN

~

}

30-39 CIRCULATING WATER & ESSENTIAL COOLING WATER FACILITIES

)

30 Circulating Water Intake Structure 31 Circulating Water Intake Tunnels CCP-10 Rev. 5 DCN #1 06/01/84 Sheet 2 of 4 i

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PROCEDURE EFFECTIVE

(\\

CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CCP-10 5

12/04/78 20 of 20 ATTACHMENT 2 (CONT'D) 32 Circulating Water Discharge Structure 33 Circulating Water Discharge Tunnels 34 OPEN 35 Service Water Intake Structure 36 Service Water Discharge Structure 37 Squaw Creek Service Spillway 38 Squaw Creek Outlet Facilities 39 Pump Station 40-41 MAJOR EQUIPMENT FOUNDATIONS i

40 Turbine Pedestal 1

41 Steam Generator Feed Pump Pedestal 42-49 OPEN i

50 Potable Water Tank Foundation l

51-59 OPEN 60-99 MISCELIANEOUS D.

TYPE OF STRUCTURES AS FOLLOWS:

0.

Floor Topping 1.

Fill Slabs or Seal Slabs 2.

Footings & Mats 3.

Floor Slabs on Earth 4.

Walls-Interior 5.

Walls-Exterior 6.

Columns 7.

Elevated Slabs or Beams 8.

Roof Slabs or Dome 9.

Other Structures M.

Mechanical Type 2 openings E.

Electrical Type 2 openings V.

Ventilation Type 2 openings I.

Instrumentation Type 2 openings NOTE:

HIJ portions of the pour numbers should coincide with the last three characters of the Gibbs & Hill block-out designation'.

(O 1

i CCP-10 Rev. 5 DCU #1 06/01/84 Sheet 3 of 4 l

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PROCEDURE EFFECTIVE i

CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CCP-10 5

12/04/84 20a of 20 ATTACHMENI 2 (CONT'D)

EFG.

ELEVATION Use top of concrete elevation for all slabs, footings, mats, beams, and dome. Use bottom of wall or column section elevation for all walls and columns. On ductbanks, the G&H ductbank nuber will be used instead of the elevation. On manholes, the G&H manhole neber will be used instead of the elevation.

H.

OPEN IJ.

POUR NUMBER l

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.I-001 lR.G.TOLSON I-002 lJIMMAWINS

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