ML20137J664
| ML20137J664 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 03/18/1975 |
| From: | Jerrica Johnson BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML17198A292 | List:
|
| References | |
| FOIA-85-59 35-1195-CCP-10, NUDOCS 8512030018 | |
| Download: ML20137J664 (12) | |
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March 18, 1975
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JOB 35-1195 l
COMANCHE PEAK STEAM ELECTRIC STATION CONSTRUCTION PROCEDURE 35-1195-CCP-10 CONCRETE BATCH PLANT OPERATIONS I
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APPROVED.BY Pf9N] BY '
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4 L. A. Ashley H. C. Dodd, Jr.
Assistant Construction Manaaer Construction Project Manaaer PREPARED BY REVIEWED BY 0?fY_
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W J. M. Johnson P. L. Bussolini
_ Civil Engineer Qual ty Assurance i
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0512030018 851106 PDR FOIA GARDE 85-59 PDR
s 35-1195-CCP-10, Mar.18,1975 1 -..
REVISION 0 PAGE 2 of 12 1
4 LIST OF EFFECTIVE PAGES I
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i The total number of pages in this document is 12. The page number sequence and revision status of each page is as follows:
l PAGE REVISION STATUS DATE l
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March 18,1975 l
2 thru 12 0
March 18,1975 i
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(~~s 35-1195-CCP-10, Mar.18,1975 N. /
REVISION O PAGE 3 of 12 TABLE OF CONTENTS S ECTION TITLE PAGE 1
INTRODUCTION.........................................
4 1.1 PURPOSE..............................................
4 1.2 SCOPE................................................
4 a
2 DEFINITIONS OF TERMS, ABBREVIATIONS AND SYMBOLS......
4 3
SPECI AL ITEMS AND OPERATIONS.........................
4 3.1 CLASS 4..............................................
4 4
CONCRETE MATERIALS RECEIVING HANDLING, STORING AND i
CONCRETE BATCHING, MIXING AND D ELIVERY...............
4 4.1 FUNCTIONS AND RESPONSIBILITIES.......................
4 4.2 C EM E NT...............................................
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i 4.3 AGGREGATE............................................
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l' 4.4 ADMIXTURE............................................
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4.5 WATER................................................
8 4.6 CLASSES OF CONCRETE..................................
8 4.7 BATCHING.............................................
9 4.8 CENTRAL MIXING.......................................
10 4.9 TRUCK MIXING 10 4.10 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF 1
PLACEMENT............................................
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$9 35-1195-CCP-10, Mar.18,1975 N
REVISION 0 PAGE 4 of 12 1.
INTRODUCTION 1.1 PURPOSE 1.1.1 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.
1.2 SCOPE 1.2.1 The scope of this procedure 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.
j 2.
DEFINITIONS OF TERMS, ABBREVIATIONS AND SYMBOLS 2.1 (NONE)
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3.
SPECIAL ITEMS AND OPERATIONS 3.1 CLASS 4, high density, concrete and its associated materials and properties which are distinct from the other classes of concrete are not discussed herein at this time and shall be added in a subsequent revision.
4.
CONCRETE MATERIALS RECEIVING, HANDLING, STORING AND CONCRETE BATCHING, MIXING AND DELIVERY 4
4.1 FUNCTIONS AND RESPONSIBILITIES 1
4.1.1 Project Civil Engineer 4.1.1.1 Maintains over-all technical assistance for concrete batch plants, concrete materials, trucks and associated equipment.
4.1.2 Batch Plant Superintendent 4.1.2.1 With the technical assistance and engineering information of the Project Civil Engineer, maintains over-all responsibilities for concrete batch plants, concrete materials, trucks and associated equipment.
h 35-1195-CCP-10, Mar.18,1975
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REVISION 0 PAGE 5 of 12 4.1. 2. 2 Supervise all phases of the concrete batching, mixing and truck delivery operations.
4.1.2.3 Supervise all phases of concrete material receiving, handling and storing.
4.1.2.4 Assures that activities are performed in accordance with approved work procedure 35-il95-CCP-10.
4.1. 2. 5 Assures that activities are performed in accordance with applicable manufacturers equipment operating procedures and, maintenance procedures.
4.1. 2. 6 Maintains daily production records and reports applicable to his responsibilities.
4.2 CEMENT 4.2.1 Portland cement shall comply with ASTM C-ISO and shall be Type II, 4.2.2 Except as otherwise approved by TUSI, all cement shall be of the same brand and manufactured at the same mill.
4.2.3 A manuafacturer's certified material test report attesting to the conformance of the cement to ASTM C-150 shall be furnished for each shipment.
4.2.4 Cement will be received in bulk truck transports and will be pneumatically loaded into clean, uncontaminated, water-tight storage silos at either the Main Batch Plant or Back-Up Batch Plant where it shall remain until concrete is batched.
4.2.5 Warehousing shall receive cement trucks per 35-1195-ACP-3, and inspect certified material test report and inspect seal on truck hatches to insure that it is intact. Certified material test re-port will be retained by warehousing and distributed to QA per 35-1195-ACP-3.
4.3 AGGREGATE 4.3.1 Fine aggregate (sand) shall be graded according to the require-ments of ASTM C-33, except that the Fineness Modulus shall be not less than 2.30 and not more than 3.10.
4. 3.2 Nominal size 1/2 inch coarse aggregate shall conform to the re-quirements of Section 202, Aggregate, of ACI 506, Recommend Prac-tice for Shoterating. 1/2 inch coarse aggregate shall be uncrushed gravel, graded from No. 4 to 1/2 in~ch size.
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REVISION O PAGE 6 of 12 4.3.3 Nominal size 3/4 inch coarse aggregate shall conform to size number 67 of Table 2 in ASTM C-33.
4.3.4 Nom'inal size 1 1/2 inch coarse aggregate shall conform to size number 4 of Table 2 in ASTM C-33.
4.3.5 The following are descriptions of aggregate properties (except for 1/2 inch coarse aggregate which is fully described in Section 4.3.2).
4.3.$.1 Aggregate shall consist of natural or manufactured sand, crushed 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.
4.3.5.2 The coarse aggregate shall be well graded and shall consist of gravel, crushed gravel, crushed rock, or crushed stone fragments 7-',
which are clean, rough, hard and uniform. No blast furnace slag, j
schist, shale or slate shall be permitted.
i 4.3.5.3 The potential reactivity of the aggregate shall be established by the methods described in the Appendix to ASTM C-33.
4.3.5.4 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.
4.3.6 Fine and coarse aggregates will be off loaded from truck transports 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 practical minimum segregation.
4.3.7 Warehousing shall receive aggregates per 35-1195-ACP-3, and inspect loads to insure conformance to aggregate quality per construction procedure 35-1195-CCP-10.
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35-1195-CCP-10, Mar.18,1975 REVISION 0 k
PAGE 7 of 12 4.3.8 Aggregate hoppers and conveying equipment shall be cleaned, as necessary, to prevent contamination by different gradations or types of aggregate and to assure that there is practical minimum segregation.
4.3.9.
Access'for inspection shall be provided in stockpiles at all times.
4.3.10 Each lot of aggregate shall be identified by signs which show size, gradation, source and controlling specification. The delivery ticket shall remain with the aggregate during delivery.
4.3.11 In event of equipment failure, temporary measures shall be initiated and approved by the Batch Plant Superintendent to insure quality is maintained. All efforts shall be made to expedite repair of original equipment for operation.
4.4 ADMIXTURE 4.4.1 Type B, retarding admixture, shall comply with ASTM C-494.
4.4.2 Accelerating admixture for shotcrete shall be a liquid per ASTM C-494 or a solid per Challenge-Cook patented formulation named "Challog".
4.4.3 Type D, water-reducing and retarding adnixture, shall comply with ASTM C-494.
~4.4.4 Air entraining admixture shall comply with ASTM C-260.
4.4.5 Manufacturers certificates as to analysis and composition of the admixture shall be furnished.
4.4.6 Admixture shall be in accordance with the recommendations of the cement manufacturer.
4.4.7 Type B. Type 0 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.
4.4.8 Warehousing shall receive admixtures per 35-1195-ACP-3, and inspect manufacturers certificate and/or spectrographic analysis and dis-tribute to QA per 35-1195-ACP-3.
4.4.9 Accelerating admixture'for shotcrete shall be stored-per manufac-turers' recomendations.
4.4.10
- All admixtures shall be protected from moisture and temperatures that could adversely effect their performance as per manufacturers' recommendations.
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REVISION 0
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PAGE 8 of 12 4.5 WATER 4.5.1 Water for mixing concrete and sprinkling aggregates, if required, shall be clean, fresh and free from deleterious amounts of acids, alkalis or organic materials.
4.5.2 Mixing water shall comply with tests required by Engineer specifi-cations.
Water shall be pumped from a deep well(s) and transferred to an uncontaminated storage tank (s).
4.5.3 Water for ice shall be pumped from the storage tank into an ice plant where ice shall be manufactured and stored as to prevent contamination.
4.6 CLASSES OF CONCRETE 4.6.1 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 independent
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test lab, R. W. Hunt, will furnish mix designs.for the following standard classes, a.
Class 1 Concrete Compressive Strength, 4000 psi 3/4 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 d.
Class 4 Concrete (later) e.
Class 5 Concrete Compressive Strength, 3000 psi 3/4 inch maximum aggregate f.
Class 6 Concrete Compressive Strength, 3000 psi 1 1/2 inch maximum aggregate
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Class 7 Concrete Compressive strength,1500 psi l
1 1/2 inch maximum aggregate I
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REVISION 0
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PAGE g of 12 h.
Shotcrete, Class 8 Compressive Strength, 3000 psi 1/2 inch maximum aggregate
- i. Grout, Class 9-4.6.2
" Mass concrete" is concrete which is 2 feet - S inches or more in the least dimension. " Mass concrete" will be denoted from regular concrete by a "0" following the class number. ' For example, " Class 2" concrete designates a regular pour with 4000 psi,1 1/2 inch maxi-mum aggregate; whereas " Class 20" concrete des.ignates a " mass con-crete" pour with 4000 psi,1 1/2 inch maximum aggregate. Maximum slump for " mass concrete" is 3 inches. Maximum temperature for
" mass concrete" during hot weather conditions is 70 F at placement.
4.6.3
' Concrete Slump 4.6.3.1 Maximum slump of 4 inches for all concrete, except " mass concrete",
unless so directed otherwise by TUSI.
4.6.3.2 Maximum slump of 3 inches for " mass concrete".
4.7 BATC'HING 4.7.1 The fine and coarse aggregate will be weighed in a single batcher using cumulative weights to within a 2 percent tolerance by weight.
4.7.2 '
Cement will be weighed in a batcher to within 1 percent tolerance by weight.
4.7.3 Water and ice will be weighed in separate batchers to within a 1 percent tolerance by weight.
4.7.4 Air entraining admixture Type B adnixture, and Type D admixture will each be measured by volume, in separate containers to within a tolerance of 3 percent.
4.7.5 Tolerance interlocks are provided to prevent a discharge device from being actuated until the material has been batched within i
applicable tolerances.
4.7.6 The batchers are equipped with platforms so that an overweight or sample can be removed, i
j 4.7.7 All scales used in weighing concrete mix materials and volumetric j
measuring devices for admixtures will be calibrated at intervals not exceeding 90 days.
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O 35-1195-CCP-10, fiar.18,1975 REVISION 0 v
PAGE 10 of 12 4.7.8 In the event the automatic ticket printer breaks down, the plant operator will fill out the ticket manually, with an ink pen, using the acutal weights read from the scales.
4.8 CENTRAL MIXING 4.8.1 Mixing equipment will produce uniformity of, consistency, cement and water content, and aggregate grading, from beginning to end of each batch.
4.8.2 The mixer operating 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 Batch Plant Superintendent.
4.8.3 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.
4.8.4,
Mixer blades shall be replaced when they have lost 10 percent of their original height. Batch Plant Superintendent or his repre-sentative shall perform a quarterly check to insure conformance.
4.8.5 Accumulated hardened concrete shall be removed, as necessary, to Batch Plant Super-maintain peak mixer performance and efficiency.-
intendent shall insure conformity.
4.8.6 Admixtures shall be mixed into batch in accordance with Section 7.3 of ACI 301-72.
4.8.7 Tempering and control of mixing water shall be in accordance with Section 7.5 of ACI 301-72.
4.8.8 Cold weather mixing and temperature of concrete when delivered at the site in cold weather, shall be in accordance with Section 7.6.1 of ACI 301-72.
4.8.9 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 70 F instead of the 90 F maxi-mum permitted by ACI-305.
4.9 TRUCK MIXING 4. 9.1 While loading, the mixer drum will be rotating at a speed designated by the manufacturer as mixing speed.
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REVISION O PAGE 11 of 12 4.9.2 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.
4.10 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 4.10.1 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 dur-ing transportation shall be at agitating speed.
4.10.2 The time after the addition of mix water to the dry materials to placement shall not exceed 45 minutes. Longer time limits may be permitted by TUSI, but in no case shall time exceed 90 minutes.
4.10.3 The number of drum revolutions shall not exceed 300 after mix water is added to the dry materials.
4.10.4 Each mixer truck will be equipped with an accurant revolution counter.
4.10.5 Add Water
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4.10.5.1
" Add water" may be dispensed into the truck mixer at point of place-ment in order to increase slump to meet specification or to increase workability of mix.
4.10.5.2 Sampling Mix a.
In order to determine whether or hot add water.is allowed to be added to mix, the initial sample (less than 1/8 cubic yard) shall be slump tested before concrete is discharged, b.
If for reasons stated in 4.10.5.1 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 discharge.
c.
Preceding procedure may be repeated as necessary before mix discharge until desired slump or workability is attained.
4.10.5.3 Maximum slump shall not be exceeded as a result of the addition of add water to the mix.
4.10.5.4 Quantity of add water shall not exceed cuantity recorded for " add water" on the batch ticket.
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35-1195-CCP-10, Mar.18,1975 REVISION O PAGE 12 of 12 4.10.5.5 Add water will be measured by an accurate water meter or cali-brated container to the nearest whole gallon and quantity shall be so noted on batch ticket in " ADD WATER" block.
4.10.5.6 Responsible contractor representative and testing lab represent-ative will each sign within the block to verify that add water quantity is valid, before water is added.
4.10.6 Same as Section 4.8.4.
4.10.7 Same as Section 4.8.5.
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