ML20215C056

Forwards TVA 860626 Generic Study Re Concrete Quality for Interim Criteria for Cable Tray Supports,Per 860909 Telcon. Study Performed to Ascertain That Concrete Issues Specific to Watts Bar Plant Not Applicable to Other Plants

ML20215C056
Person / Time
Site:	Sequoyah
Issue date:	09/30/1986
From:	Gridley R TENNESSEE VALLEY AUTHORITY
To:	Youngblood B Office of Nuclear Reactor Regulation
References
NUDOCS 8610100060
Download: ML20215C056 (19)

Text

{{#Wiki_filter:- TENNESSEE VALLEY AUTHORITY CH ATTANOOGA. TENNESSEE 374ol l SN 157B Luokout Place SEP 30 886 Director of Nuclear Reactor Regulation Attention: Mr. B. Youngblood, Project Director PWR Project Directorate No. 4 g Division of Pressurized Water Reactors (PWR) i Licensing A U.S. Nuclear Regulatory Commission Washington, D.C. 20555

Dear Mr. Youngblood:

In the Matter of ) Docket Nos. 50-377 Tennessee Valley Authority ) 50-328 During our telephone conference of September 9, 1986, regarding the Sequoyah Nuclear Plant interim acceptance criteria for cable tray supports, reference was made to a TVA generic study of concrete quality at the Sequoyah, Browns Ferry, Bellefonte, and Watts Bar Nuclear Plants. This internal review vas performed to ascertain that concrete issues specific to the Watts Bar Nuclear Plant were not generically applicable to other TVA nuclear plants. The issue date of this report was June 26, 1986. In order to assist in your review of current concrete issuen specific to the Sequoyah units, enclosed is a copy of this TVA report. If you have any questions, please call M. R. Harding at (615) 870-6422. Very truly yours, TENNESSEE VALLEY AUTHORITY / R. Gridley, Di ctor Nuclear Safety and Licensing Enclosure cc: See Page 2 8610100060 860909 0 PDR ADOCK 05000327 h0 P PDR g L An Equal Opportunity Employer

. Director of Nuclear Reactor Regulation SEP 30 086 cc (Enclosure): U.S. Nuclear Regulatory Comission Region II Attn: Dr. J. Nelson Grace, Regional Administrator 101 Marietta Street, NW Suite 2900 Atlanta, Georgia 30323 Mr. Carl Stahle, Sequoyah Project Manager U.S. Nuclear Regulatory Comission 7920 Norfolk Avenue Betheada, Maryland 20814 Mr. G. G. Zech Director TVA Projects U.S. Nuclear Regulatory Comission Region II 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 l i i Mr I { 1 l l l I i

Generic Review of Concrete Quality for Sequoyah (SQN), Browns Ferry (BFN), and Bellefonte (BLN) Nuclear Plants ~ rag)nround The evaluation of concrete quality for Watts Bar Nuclear Plant (WBN) has identified several deficiencies which are being addressed in the following nonconformances: NCR 6719 - Low Concrete Compressive Strength Results ~ NCR 6720 - Use of Bedding Mortar in Structural Concrete Piscenents NCR 6721 - Frequency of Sampling Concrete General Discussion of Generic Evaluations NCR 6719 identified periods of time when the percentage of low concrete compressive strength test results exceeded the G-2 specification requirements. Based on the individual specific evaluations for other l plants, it was determined that this NCR should not be generic to other plants. NCR 6720 identified the use of a spucial mix, lack of proper sampling, and low strength test results of grout used as bedding mortar. ACI 318-71 recognizes the use of bedding mortar but requires that it be the morcar f raction of the concrete being placed. The application and the use of bedding mortar were not specifically noted in C-2, but were acceptable practices in accordance with ACI 318-71. ACI 318 is the licensing basis ' ~ ~ ~ ~ for WBN as well as other TVA nuclear plants. Therefore, the use of a special bedding mortar, without it being specified in G-2, could have taken -- place at the other plaats. A generic evaluation was performed to determine if the use of bedding mortar was properly controlled in structural concrete placements at BFN, SQN, and BLN. It was determined that bedding mortar was not used at EFN or BLN, and only nonroutine, controlled use at SQN. NCR 6721 identified a failure to always follow the procedures specified in I construction specification G-2 and WBN-QCP 2.02 for Frequency of Sampling l Concrete Mixes. The investigation for this NCR showed that the sampling frequencies used at WBN substantially complied with G-2. It did indicate ^ that 57 deviations from the specification have occurred. However, in view of the relative small percentage of samples this represents (57 out of l approximately 6100 total samples for less than 1 percent), the overall ~ i effect is negligible and this NCR is not considered to be significant. Plant-specific evaluations performed at the other plants indicates that any violations to the sampling frequency would have been minor in nature and expected. i ( 026154.01 v ~ 4 f 9 %- 8 d w 4

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. _ - ~ Generic Evaluations of Specific Plants y' J Seouovah Nuclear Plant Discussions were held with T. Wright, D. McNabb, and S. Carr, materials engineers directly involved in the concrete placement during the construction of SQN, and other personnel knowledgeable of concrete design placement and testing for SQN and a partial review of SQN concrete records was conducted (Attachment 1). This assessment revealed the following: Strength test data from test blocks used to study long-term concrete strength at SQN shows very consistent test results.

• An ef fective working relationship existed between the NU CONS materials

. engineers and DNE concreting specialists along with very good experience levels at both positions.

• The required monthly reports were submitted by NU CONS and evaluated by DNE.
• Concrete six adjustments were frequently made by NU CONS to maintain strength levels and major adjustments were reviewed by DNE.

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• Concrete compressive strength levels generally exceeded the G-2 requirements.

Small deviations in low strength test results occurrad on individual mixes and were corrected by mix adjustments. Confirmatory in-place tests were also performed. I

• Concrete six designs were prepared by SME.
• Congested areas vere encountered, especially in the reactor building.
• High mortar volume, 3/8-inch-maximum aggregate size concrete mix was developed by SME.

This or the specified concrete mix / class with a one-step size reduction in the maximum size aggregate was used in congested areas. l

• Grout was used to lubricate the concrete pump line.

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• A specially designed high strength grout six was developed by SME to be 1

i used as bedding mortar for the control building walls. This was required because reinforcing bar congestion due to building the walls as column sections to support the roof and a gantry crane. This mix was controlled as a separate class concrete mix. Further use of this grout as bedding l mortar may have occurred elsewhere within the plant, but its use was nonroutine and this is not censidered significant. 'i'

• The frequency requirements for test sampling specified is G-2 were adhered to.

Deviations f rom the specification would have been minor in nature, and expected. Based upon the above, the concerns identified for WBN do not apply to SQN. . 026154.01 l +, . N ;i, i et s. [ .~ g T w..

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Atteehuent 1 Sequoyah Nuclear Flant Concrete Records A cursory review of the DNE files on Sequoyah concrete was performed and some typical documents are attsched. This review facluded the review of eight 3-inch bladers, test reports, and summaries in the DRE files. Typical reports reviewed included monthly concrete reports, production records, daily concrete reports, field QC worksheets, charts of frequency distribution strengths, and compressive test strength results. l t s-N l 026090.04

LW Memorandum nuwssses viu.sv unnoam

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• 10 F. P. !acy, Chief Civil Engineer, Civil Desten Branch, W1 UB-K FROM Charles Boeine, Jr., Project Manager, Sequoyah Nuclear Plant June 5, 1542 DAfr susJEct:

SEQUDYAH NUCIEAR PIAFf UNDS 1 AND 2 - MDimLT CONCRETE REPORT We are submitting the concrete report for the month of May 1572. Attached and listed belev are the quality centrol data which cover concrete production frcan January 30,1570, to May 30,1542. 1. Slump test charts fran strength samples for mixes 3015 BN, 3015 AN, and 300 75 AN 2. Addi'tional slump test charts for mixes 3015 BN, 3015 AN, and 300 75 AW 3. cocpressive strength charts for mixes 301.5 BN, 301.5 AW, and 300 75 AW

h. Moving average of five consecutive tests of slump and 3-day ca:pressive strength chart for mixes 3015 BN, 301.5 AN, and 300 75 A N 5

Normal frequency distribution chart for mix 300 75 AN 6. Sieve analysis test charts for 1 - 1 / 2, 3 / 14, and3/8-inch agEregate and concrete sand IICORI JUN 6.72 7 Sieve analysis of 1-1/2-inch EA combinations cmt, o::seces RM*.H l m l l On - 8. Montaly and total concrete production graph 7 ' '. m [',I, -r - am i ' 6 ear 9. curent test data of cEent and fly ash f 'M E RN The concrete mixes and quantities used are listed be: ',5 l w, i . as. M_ix Month (Yd3) To nati Odn 'g

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/ 301 5 BN 1,170.0 76,7M.) !3 i } 301 5 A W 1,228.0 31,3: sA i i wu i 300 75 AN

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11,1; ;.b " r,. 'f g 500 75 A N 266.0 1,11 Md M m-- ~3_M 0thers 1 "25.0 _l1,2OdC ,,"k- -- .f$< ,a r SGC:D' Tctal: ' M2.0 I 1,6 '1 ', ', - ~')h I I,r Attach::enir k,.:r 7 ~iw.._ 1 CC. Atiaci:.e..ts : 1i r-p-Yr r - - i [,J Ii. c. Lane, 3L'-F. '_r. s. v g,

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i x. Boo.7S BPW .... _.4-Ea __t7o. 75 Ar# MllX DATA LEDGER PKsE NUMSER - - / , v: DATE TEST AIR SLUMP TOTAL M. A. $-DAY TOTAt-M.A. ~ObY 7~OAY 26'MY 90'NYjd NO. ObU"IP PO' 83 Mme CO CO C. TEST PSI PSI PSI pse ~ l TEST i 4. <,. 4.so ~ 3 s sS__ c1sc vin g' _ _9 g_t_rf, l.. ;

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Cerald C. 3 k, Project Manas , Seq ah Buclest Plant R. O. Lane, Civil Engineer, Materials Engineering laboratory, SHW, Knoxville December 19, 1973 SEQUOTAE NUCLEAR PUuff UNITS 1 AMD 2 REAC1M BUILDING CollCRETE IN BLOCK RB-2-16A VEST TEST RESULTS in compliance with R. M. Pierce's memorandum of October 1,1973, to you, our laboratory completed compressica testing of concrete cores. 3-5/8 inch diameter by 71/4 inches long in accordance with appitcable AS1H otandard procedures. The results were as follove. Concrete p. laced September 19, 1973. 14-Day Test Compressive Unit ~ Core llo. Load _lbs. Strentth. pai Weinht Corrected to Actust 6 by 12 to. 1-3P 62,000 6,008 5.777 154.50 2-BP 64,000 6,202 5,963 153.00 3-3P 66,500 6,444 6,196 153,82 90-Day Tag 1-TP 100,000 9,690 9.317 154.13 2-TP 105,000 10,175 9.784 152.13 3-p 121,000 y25 _, 11,274 1M.82 ~' ) I (') O Denotationst f,f 3F Botton portion of core 2 ft. long nominally. TP Top portion of core 2 f t. long acainally. i R. O. Lane i ROL:BCJ g-CC R. C. Dome r, 104 UB-K ' X' 'iL.il3n'h ra.' 5'05 TBS E ~ R' S ' ',: g - Cene Farmer, 305 NB-K 'y' R. M. Pierce, 315 L3-K h e#,#&p$[/ g .\\* I ~ VY A... $ 9 '2

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