ML24164A271

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11. Equipment Specification ES-3100 Packcrete Final Lot Qualification and Production Processing
ML24164A271
Person / Time
Issue date: 08/28/2019
From:
Office of Nuclear Material Safety and Safeguards
To:
Shared Package
ML24164A259 List:
References
ES-3100
Download: ML24164A271 (1)
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EQUIPMENT SPECIFICATION SPC M801580-0003 000 00 Page i of i APPROVAL / REVISION PAGE

    • For Company Use Only - Do Not Provide To Supplier **

QUALITY LEVEL Q

PROTECTION LEVEL C

BUILDING N/A PROJECT TITLE Shipping Containers JOB TITLE Production Design Definition ITEM DESCRIPTION ES-3100 Packcrete Final Lot Qualification and Production Processing UNID YAREA-CMH-042 REVISIONS REV. NO.

DESCRIPTION OF REVISION 00 Initial issue.

REFERENCE DOCUMENTS & OTHER INFORMATION Recommended Suppliers:

TBD In-Storage Maintenance Requirements - None (Material will not be shipped to Y-12.)

References for Company Use:

Reference Receipt Inspection: NA (Material will not be shipped to Y-12.)

Design Verification Record: DV-801580-0018 Installation Drawings: M2E801580A002, Body Weldment, and M2E801580A008, Top Plug Weldment Other reference documents needed by the Seller: None This shipping package was designed for an offsite use and will not be received or used in the Y-12 National Security Complex.

Acceptance occurs at the Sellers location.

APPROVALS PRINT SIGNATURE/DATE PRINT SIGNATURE/DATE PREPARED BY L. C. Hooper DISCIPLINE MANAGER J. C. Anderson DESIGN VERIFICATION R. D. Aigner SYSTEM ENGINEER R. D. Aigner PACKAGING ENGINEER N. A. Laney OPERATIONS/SYSTEM OWNER S. K. Thomas NUCLEAR PROC. ENGINEER J. E. Cook QUALITY ENGINEER J. R. Burchfield Lloyd Hooper Digitally signed by Lloyd Hooper Date: 2019.08.28 11:51:36 -04'00' Jason (JR6)

Burchfield Digitally signed by Jason (JR6) Burchfield Date: 2019.08.28 12:47:19 -04'00' Roger D (R7A) Aigner Digitally signed by Roger D (R7A)

Aigner Date: 2019.08.28 14:47:27 -04'00' Roger D (R7A)

Aigner Digitally signed by Roger D (R7A) Aigner Date: 2019.08.28 14:47:51 -04'00' Noelani A (NL1) Laney 2019.08.28 16:49:02

-04'00' Jeffrey E (2XK)

Cook Digitally signed by Jeffrey E (2XK)

Cook Date: 2019.08.29 13:14:26 -04'00' Stan (TSW) Thomas Digitally signed by Stan (TSW)

Thomas Date: 2019.08.29 15:58:16 -04'00' Roger D (R7A)

Aigner Digitally signed by Roger D (R7A)

Aigner Date: 2019.08.29 16:10:16 -04'00' James C (J5A)

Anderson Digitally signed by James C (J5A)

Anderson Date: 2019.08.29 16:38:49 -04'00'

SPC M801580-0003 000 00 Page 1 of 24 ES-3100 Packcrete Final Lot Qualification and Production Processing TABLE OF CONTENTS

1. Scope.................................................................................................................................................................................. 3 1.1 General Description of the Item............................................................................................................................. 3 1.2 Background............................................................................................................................................................ 4
2. References......................................................................................................................................................................... 4 2.1 Definitions............................................................................................................................................................... 4 2.2 Codes/Standards/Orders/Regulations................................................................................................................... 5 2.3 Applicable Documents........................................................................................................................................... 5
3. Item Requirements............................................................................................................................................................ 5 3.1 Performance Requirements................................................................................................................................... 6 3.2 Fabrication and Assembly Requirements.............................................................................................................. 6 3.3 Schedule................................................................................................................................................................ 6 3.4 Deliverables and Submittals Documents............................................................................................................... 6 3.4.1 Approval Data Documents........................................................................................................................ 6 3.4.2 Certification Data Documents................................................................................................................... 7 3.5 Packaging, Handling, Shipping, and Storage Requirements................................................................................. 7 3.5.1 Receiving and Material Storage Instructions............................................................................................ 7 3.5.2 Damaged Packages.................................................................................................................................. 7 3.5.3 Storage of Raw Materials.......................................................................................................................... 7 3.6 Marking and Identification Requirements............................................................................................................... 7 3.7 Requests for Waiver or Deviation.......................................................................................................................... 7
4. Quality Assurance Requirements................................................................................................................................... 8 4.1 Final Acceptance Test Method............................................................................................................................... 8 4.2 Inspection/Testing Requirements........................................................................................................................... 8 4.3 Surveillance and Audits.......................................................................................................................................... 8 4.3.1 Quality Hold Points.................................................................................................................................... 8 4.3.2 Quality Observations................................................................................................................................. 9 4.4 Acceptance Criteria................................................................................................................................................ 9 4.5 Personnel Qualifications/Certifications.................................................................................................................. 9 4.6 Training and Qualification of Personnel................................................................................................................. 9 4.6.1 Operator and Witness Training and Qualifications................................................................................... 9 4.7 Documentation Retention..................................................................................................................................... 10 4.8 Nonconformance Control..................................................................................................................................... 10
5. Packcrete Raw Material Requirements......................................................................................................................... 10 5.1 Procuring Packcrete Raw Materials..................................................................................................................... 10 5.2 Receiving and Material Storage Instructions....................................................................................................... 10 5.2.1 Damaged Packages................................................................................................................................ 10 5.2.2 Storage of Raw Materials........................................................................................................................ 10 5.3 Sample Plan for Third Party Testing.................................................................................................................... 10 5.4 Material Procurement and Acceptance Criteria................................................................................................... 11 5.4.1 Vermiculite Acceptance Criteria.............................................................................................................. 11 5.4.2 Portland cement Acceptance Criteria..................................................................................................... 12 5.4.3 Airalon 3000 Acceptance Criteria............................................................................................................ 12
6. Facility and Process Equipment Requirements........................................................................................................... 13 6.1 CLEANING INSTRUCTIONS............................................................................................................................... 13 6.2 EQUIPMENT REQUIREMENTS.......................................................................................................................... 13 6.3 WORK ENVIRONMENTS.................................................................................................................................... 14 6.3.1 Mixing and Casting.................................................................................................................................. 14 6.3.2 Mixing and Casting Water....................................................................................................................... 14 6.3.3 Curing Storage........................................................................................................................................ 14 6.3.4 Portland Cement and Vermiculite Storage.............................................................................................. 14

SPC M801580-0003 000 00 Page 2 of 24

7. Packcrete Processing..................................................................................................................................................... 14 7.1 Processing Setup Requirements.......................................................................................................................... 15 7.2 Mixing Setup Approval Control Number............................................................................................................... 15 7.3 Processing Preparation for SES3100, ES-3100, and Samples........................................................................... 15 7.4 ProcessMixing and Vibration Casting, Curing, and Baking for Samples and Parts......................................... 15 7.5 Setup Approval Process Verification4.5-gal Pail or 30-gal Drum..................................................................... 16 7.6 Lot Qualification and Packcrete Sample Pipes.................................................................................................... 16 7.7 Final Lot Qualification CastingsSES3100 Body and Plug................................................................................ 16 7.7.1 SetupMixing and Vibration Casting an SES3100 Body or Plug.......................................................... 16 7.7.2 ProcessMixing and Vibration Casting an SES3100 Body or Plug....................................................... 17 7.7.3 ProcessCuring an SES3100 Body or Plug.......................................................................................... 17 7.7.4 ProcessBaking an SES3100 Body or Plug.......................................................................................... 17 7.8 Production Processing an ES-3100 Body or Plug............................................................................................... 17 7.8.1 SetupMixing, Vibration Casting, and Curing an ES-3100 Body or Plug.............................................. 17 7.8.2 ProcessMixing and Vibration Casting an ES-3100 Body or Plug........................................................ 18 7.8.3 ProcessCuring an ES-3100 Body or Plug........................................................................................... 18 7.8.4 ProcessBaking an ES-3100 Body or Plug........................................................................................... 18
8. Packcrete Lot Qualification and Production Test Samples........................................................................................ 19
9. Packcrete Material Lot Qualification Properties Limits.............................................................................................. 19 Attachments......................................................................................................................................................................... 20 Attachment A: Submittal CheckList................................................................................................................................ 20 Attachment B: ABBREVIATIONS AND ACRONYMS.................................................................................................... 22 Attachment C: Packcrete Processing Form.................................................................................................................... 23 Form ES3100 Packcrete Vibration Casting......................................................................................................... 24 FIGURES Fig. 1. Full-scale close-up view of a baked Packcrete section............................................................................................... 3 Fig. 2. ES-3100 shipping container......................................................................................................................................... 4 Fig. 3 ES-3100 Packcrete FLQ and production processing................................................................................................. 15 TABLE Table 1. Recommended vibration settings............................................................................................................................ 15

SPC M801580-0003 000 00 Page 3 of 24

1. SCOPE This specification incorporates aspects of SPC M801794-0003, Packcrete Preliminary Lot Qualification. The Seller shall produce a preliminary lot qualification, via SPC M801794-0003, for casting Packcrete in generic applications. The preliminary lot qualification provides the quality assurance and technical requirements for qualifying the Seller for casting Packcrete in a specific application known as the ES-3100 shipping package.

This specification provides the Sellers production requirements for production units of the ES-3100 shipping package. Since these two specifications must work closely together in sequence in order to document and accomplish final lot qualification (FLQ), and production processing, the information in the two specifications that applies to both will be referenced when necessary in this specification.

The Company (Y-12 National Security Complex) will provide training and direct oversight for the casting Packcrete when the Subcontractor does not have prior Packcrete casting experience.

The product produced from this specification is protected under U.S. Patent 6,299,950 B1. The U.S. Government has rights in this product pursuant to Contract No. DE-NA0001942 between the U.S. Department of Energy and Consolidated Nuclear Security, LLC.

1.1 General Description of the Item Packcrete is a fireproof, lightweight cast refractory. It is comprised of water, Airalon 3000 (air entraining agent),

Portland cement, and vermiculite defined in SPC M801794-0003. A full-scale sample section of Packcrete is shown in Fig. 1 with a centimeter scale.

Fig. 1. Full-scale close-up view of a baked Packcrete section.

SPC M801580-0003 000 00 Page 4 of 24

1.2 Background

The ES-3100 is a Type-B shipping package for fissile hazardous materials that must comply with strict manufacturing standards. Packcrete is a noncombustible impact and thermal barrier that will be cast into the ES-3100 shipping container to protect the containment vessel from damage. Figure 2 shows the Packcrete casting as a light brown color.

Fig. 2. ES-3100 shipping container.

2. REFERENCES 2.1 Definitions See SPC M801794-0003 for definitions that are not included here. Those definitions also apply to this work in this specification.

Confinement Boundary Assembly (CBA) - An assembly with an assigned serial number that is made from components uniquely manufactured following JS-YMN3-801580-A002 (Equipment Specification ES-3100 Drum Assembly) and process serial-numbered components specified in M2E801580A002 (Body Weldment) and M2E801580A008 (Top Plug Weldment).

ES-3100 body - The ES-3100 body is defined by M2E801580A002. The body has an estimated empty weight of 88 lb without the bottom cover and 103 lb with the welded bottom cover. The estimated fillable Packcrete volume is 4.8 ft3.

ES-3100 plug -The ES-3100 top plug is defined by M2E801580A008. The top plug has an estimated empty weight of 7.4 lb without the bottom sheet and 9.6 lb with the welded bottom sheet. The estimated fillable Packcrete volume is 0.43 ft3.

SPC M801580-0003 000 00 Page 5 of 24 SES3100 body - A simulated ES-3100 (SES3100) body for casting a mock-up of the ES-3100 drum assembly made from two standard carbon steel drums. The simulated ES-3100 consists of a 55-gal carbon steel open-head drum which has a 20-gal carbon steel drum secured to the bottom center. The 20-gal drum is secured by tack welding or suitable fasteners. The lid of the 55-gal drum has an opening 15 in diameter through which Packcrete can be poured into the drum. The SES3100 body has an estimated empty weight of 77 lb and a fillable Packcrete volume of ~4.7 ft3. The SES3100 body is used to qualify the casting process.

SES3100 plug - The SES3100 plug for casting a mock-up of the ES-3100 top plug made from cylindrically rolled carbon steel sheet welded to a circular carbon steel sheet bottom. The rolled carbon steel cylinder is 0.06-in. thick with an inner diameter of 14.0-in. and height of 5.0-in. The carbon steel sheet bottom is 0.06-in. thick with a diameter of 14.12-in. The SES3100 has an estimated empty weight of 6.6 lb and a fillable Packcrete volume of

~0.45 ft3. The SES3100 plug is used to qualify the casting process.

2.2 Codes/Standards/Orders/Regulations ASME NQA-1-2017 Quality Assurance Requirements for Nuclear Facility Applications 10 CFR Part 71 Packaging and Transportation of Radioactive Material ASTM C114 Standard Test Methods for Chemical Analysis of Hydraulic Cement ASTM C136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C150/C150M Standard Specification for Portland Cement ASTM C233/C233M Standard Test Method for Air-Entraining Admixtures for Concrete ASTM C260/C260M Standard Specification for Air-Entraining Admixtures for Concrete ASTM C494/C494M Standard Specification for Chemical Admixtures for Concrete ASTM C516 Standard Specification for Vermiculite Loose Fill Thermal Insulation ASTM C520 Standard Test Methods for Density of Granular Loose Fill Insulations ASTM C860 Standard Test Method for Determining the Consistency of Refractory Castable Using the Ball-In Hand Test ASTM C862 Standard Practice for Preparing Refractory Concrete Specimens by Casting ASTM C1113 Standard Test Method for Thermal Conductivity of Refractories by Hot Wire (Platinum Resistance Thermometer Technique)

ASTM E70 Standard Test Method for pH of Aqueous Solutions with the Glass Electrode ASTM E228 Standard Test Method for Linear Thermal Expansion of Solid Materials with a Push-Rod Dilatometer ASTM E1269 Heat Capacity by Differential Scanning Calorimetry ANSI/ISO/IEC 17025 General requirements for the competence of testing and calibration laboratories 2.3 Applicable Documents The following documents apply when casting Packcrete into the ES-3100 shipping containers.

JS-YMN3-801580-A002 Equipment Specification ES-3100 Drum Assembly M2E801580A002 Body Weldment M2E801580A008 Top Plug Weldment SPC M801794-0003 Packcrete Preliminary Lot Qualification

3. ITEM REQUIREMENTS Packcrete must be cast into a stainless-steel shell specified in M2E801580A002 and M2E801580A008, collectively known as the CBA. The manufacturing controls are based on a finished baked density of 22.4 +/- 3 lb/ft3 that controls the proper thermal and impact properties. The in-process serial numbers for the plug and drum body shall be recorded on Form ES3100 of Attachment C, Packcrete Processing Form. The final CBA serial number shall include references to the in-process serial numbers.

SPC M801580-0003 000 00 Page 6 of 24 3.1 Performance Requirements The Seller has no responsibilities for performance of Packcrete beyond the measured density of 22.4 +/- 3 lb/ft3 when the requirements of this specification are completed.

3.2 Fabrication and Assembly Requirements See production processing in Sect. 7.8.

3.3 Schedule A manufacturing plan with written, step-by-step process plans shall be submitted to the Company [Y-12 National Security Complex, Consolidated Nuclear Security, LLC (CNS)] for approval and used by the Seller to comply with requirements in this specification. At a minimum, the plan shall include:

material control and materials to be procured, subtiers to be used, and control thereof, quality program used to buy and manufacture, major fabrication steps and sequence of operations, Packcrete sampling schedule (see note below),

hold points to be determined for Company involvement, all in-process inspection/examination, and dimensional inspections and testing.

Note: Additional Packcrete sample sets are required for future material testing. As such, a Packcrete sample set must be generated at the end of test unit production, at the end of full-scale production, and as required during full-scale production. A Packcrete sample set is to consist of one 30-gal drum and eight sample pipes as described in SPC M801794-0003.

3.4 Deliverables and Submittals Documents There are two types of submittals associated with this specification: (1) approval data documents and (2) certification data documents. The submittal schedule, submittal format, number of copies, and submittal purpose are shown in Attachment A, Submittal Checklist. Some of these quality records are generated following SPC M801794-0003.

All records shall be identified based on ES-3100 assembly serial numbers. The Seller shall maintain quality-related documentation in accordance with requirements in the purchase order and this specification. The Company reserves the right to request any such documentation and to witness all aspects of the manufacturing process in accordance with this specification.

3.4.1 Approval Data Documents Approval data documents are identified in Attachment A. Approval data documents include written procedures and personnel qualifications, which must be approved by the Company prior to conducting the work defined in Sect. 7.

With each submittal transmitted to the Company, the Seller will include an updated submittal checklist using an Excel spreadsheet. The checklist shall identify all of the documents to be submitted and the status of each.

All submitted documents shall be identified with document title, document number, revision level, computer filename, and submission date. The reply date of and disposition by the Company shall be included in the Excel spreadsheet for documents already submitted and dispositioned by the Company.

The Seller shall generate documentation in compliance with the Company-approved quality assurance plan (QAP). All records shall be identified based on the component serial numbers traceable to the CBA serial number.

SPC M801580-0003 000 00 Page 7 of 24 The Company reserves the right to request any additional documentation used in fabrication or raw material qualification.

Procedures shall be submitted to the Company for approval prior to use in accordance with Attachment A and shall identify all mixing and vibrating equipment models and settings required to complete the casting process.

Approvals of submittals must be received from the Company prior to implementing any activities involving these procedures. Submittal version control must be exercised to ensure correct and approved versions are used. All fabrication activities used to make Packcrete must be described in approved written procedures.

3.4.2 Certification Data Documents Certification data documents are identified in Attachment A and documentation of measurements, testing, and calculations created during the performance of the work described in Sect. 7 are documented in Form ES3100 of Attachment C.

Certification data documents include raw material test reports in accordance with the requirements of Sect. 5.

The Seller shall provide a certification data package that connects all specified processing data collected to the particular ES-3100 serial number prior to delivery of the ES-3100 assemblies.

3.5 Packaging, Handling, Shipping, and Storage Requirements 3.5.1 Receiving and Material Storage Instructions Packcrete raw materials procured per this specification shall be marked and received with a traceable Certificate of Conformance (COC).

3.5.2 Damaged Packages The Seller shall not accept and/or use damaged packages of Packcrete raw materials. Damaged packages are those that are visually determined to be wet, have been wet, have been torn open, or are leaking.

3.5.3 Storage of Raw Materials Packcrete raw materials shall be stored in a dry location and protected from damage and moisture with an air temperature range of 70 +/- 20°F and compliant with the manufacturers recommended practices.

3.6 Marking and Identification Requirements Packcrete as a material is not marked in any way. The procurement and processing records (forms) for Packcrete raw materials and procedures used shall be tracked by the manufacturing serial numbers for the drum body and plug.

3.7 Requests for Waiver or Deviation Any requested exceptions, deviations, or proposed changes to the requirements of this specification by the Seller after award and before acceptance shall be submitted using UCN-13816B. The Seller shall request an electronic copy of the form with instructions from the subcontract technical representative or subcontract administrator.

SPC M801580-0003 000 00 Page 8 of 24

4. QUALITY ASSURANCE REQUIREMENTS The Seller shall have implemented and maintain a quality system in accordance with ASME NQA-1 2008, 1a-2009, Part 1, Sections 1-18 and/or 10 CFR 71 Subpart H and DOE O 414.1D Attachment 3, with respect to Suspect Counterfeit Items. A copy of the Sellers QA Program Manual shall be submitted with the bid in accordance with Attachment A for review and approval. The Seller shall comply and conduct all work in accordance with their Quality Assurance program and this Equipment Specification.

The Seller shall submit a QAP for the scope of this work that describes the quality assurance policies and practices to be implemented in fabricating the ES3100 shipping container, and identifying, controlling, and verifying the quality of Packcrete processes (weighing, mixing, pouring, vibrating, curing, and baking). The Sellers QAP shall ensure full compliance with all requirements, tests, inspections, reports, documentation, and approvals contained within this specification. The Sellers QAP shall include the requirements for the process controls for the operations, the qualifications of the operator(s) and witness(es), and verification records. In addition, Sellers Quality Assurance (QA) Program shall comply with Subpart 2.14, Quality Assurance Requirements for Commercial Grade items and Services. Company will provide the critical characteristics for any items or services to be dedicated.

4.1 Final Acceptance Test Method The final acceptance test method includes verification that 100% of the ES-3100 shipping packages contain Packcrete with a finished baked density of 22.4 +/- 3 lb/ft3 and the process used to achieve that density followed the prescribed steps included in Sect. 7.

Final acceptance will be based on compliance with the approval data documents as verified through surveillance activities by the Company, compliance with the technical requirements in this specification as verified through surveillance activities by the Company, and final review and acceptance of the certification data package documents that apply to Packcrete.

4.2 Inspection/Testing Requirements See Sect. 7 and 8 for additional information.

4.3 Surveillance and Audits The Company shall reserve the right to evaluate the Sellers QAP and subtiers to ensure compliance with this specification at the Company's discretion. The Company shall be allowed to witness any of the processes associated with this specification during the performance of the contract.

4.3.1 Quality Hold Points 4.3.1.1 Raw Material Lots Must Be Qualified Before any materials are used in FLQ castings and production castings, the material test reports shall show that the materials meet the testing requirements and acceptance criteria specified in SPC M801794-0003, Sect. 5.4. Documentation of the material qualifications from SPC M801794-0003 shall be part of the certification data package for this specification.

4.3.1.2 Components Must Pass Geometric Inspection Requirements Before the ES-3100 drum body weldment (M2E801580A002) and top plug (M2E801580A008) are cast with Packcrete, the Seller must have evidence (a Company-approved inspection report plan) that the design requirements, which cannot be verified after the casting, have been met. Additional precautions must be taken to ensure that the bottom diameter of the drum (casting opening) stays within a tolerance of +/-0.03 in. prior to casting the Packcrete (M2E801580A002) and within a tolerance of +/-0.12 in. throughout casting, weighing, handling, vibrating, curing, and baking of the Packcrete filled drum.

SPC M801580-0003 000 00 Page 9 of 24 The Seller shall not cast Packcrete into the drum body or top plug until (1) the Company has reviewed and provided its documented approval of the Certified Material Test Reports for the metals involved, (2) the Company has reviewed and provided its documented approval of the diamond I dimensional data on the metal parts that cannot be verified after casting, and (3) the authorized nuclear inspector has reviewed and provided its documented approval of the welds that cannot be verified after casting.

4.3.1.3 Company Approval that Raw Materials and Setup are Lot Qualified Each change to the final setup approved on Form A (SPC M801794-0003) must be documented on a new Form A and reapproved by the Company. These changes may include hardware, mixing amounts, mixing rotation speed, mixing times, vibration speed setting (Sect. 7.3), and vibration time. Vibration force changes for each unique casting shall be documented on Form ES3100 of this specification.

Modifications to the vermiculite dry weight percent shall require FLQ testing and written Company approval.

Changing from one lot of raw materials to another shall require FLQ testing and written Company approval.

Approval requires positive testing results of FLQ testing defined in SPC M801794-0003 in Sect. 9. Several months of lead time will be needed to perform these tests and for the results to be evaluated by the Company.

4.3.2 Quality Observations The Company reserves the right to perform quality observations of the Packcrete casting process at any time.

Observations will include, but not be limited to, LQs, first article evaluation casting, and initial production casting.

4.4 Acceptance Criteria The acceptance criteria for fabrication and assembly requirements are based on the baked density of 22.4 +/- 3 lb/ft3, and evidence that Packcrete was cast in compliance with this specification.

4.5 Personnel Qualifications/Certifications Personnel qualified and trained as operators and witnesses shall be able to follow and perform written instructions and procedures and accurately record operations involving weighing, mixing, casting, vibrating, curing, and baking processes.

4.6 Training and Qualification of Personnel Note: If the Subcontractor does not have prior experience in Packcrete casting, the Company will provide training and direct oversight on the processes.

The Seller shall provide the Company (1) a plan for qualifying and training personnel and (2) documented evidence that personnel have been qualified and trained in accordance with the Sellers procedures approved by the Company to ensure their competence in the use of process procedures and specifications. The Seller must ensure all operators use and follow written procedures for the respective processes. Submit the training plans for Company approval.

4.6.1 Operator and Witness Training and Qualifications Each operator and witness who performs Packcrete processing activities shall be trained and qualified. This requires the operator and witness to (1) have read the operating procedures and (2) have experience making the measurements, filling out the forms, and successfully performing the activity. Operator and witness qualifications shall be documented and submitted to the Company for approval with the casting forms as evidence that personnel have been qualified and trained.

4.6.1.1 Packcrete mixing and vibration casting training shall consist of successfully completing mixing and casting activities described in Sects. 7.2 and 7.3.

SPC M801580-0003 000 00 Page 10 of 24 4.6.1.2 Packcrete curing and baking process training shall consist of successfully completing curing and baking activities described in Sect. 7.4.

4.7 Documentation Retention Documentation of all inspection and test results shall be maintained by the Seller for 3 years after acceptance by the Company. The Company shall have access to this documentation to ensure compliance with all requirements.

The Seller shall not destroy quality records without notifying the Company in advance to confirm that the Company does not have a need for the records.

4.8 Nonconformance Control The Seller shall have an approved procedure for the control of non-conformances, waivers, and deviation requests during the execution of this specification. A nonconforming component shall not be used unless it has been specifically approved by the Company (see Sect. 3.12). The disposition of a nonconforming component shall be documented. Any nonconforming component shall be clearly identified, and each nonconformance report shall be traceable to the actual component affected. A copy of each approved nonconformance report for a component shall be provided to the Company as a part of the certification data package.

5. PACKCRETE RAW MATERIAL REQUIREMENTS This section defines the requirements for Packcrete raw material procurement, receiving, storage, sampling, testing, and acceptance.

5.1 Procuring Packcrete Raw Materials The Seller shall procure the Packcrete raw materials (i.e., vermiculite, Portland cement, and Airalon 3000) in accordance with the requirements in Sect. 5.4.

5.2 Receiving and Material Storage Instructions Packcrete raw materials procured per this specification shall be marked and received with a traceable Certificate of Conformance (COC).

5.2.1 Damaged Packages The Seller shall not accept and/or use damaged packages of Packcrete raw materials. Damaged packages are those that are visually determined to be wet, have been wet, have been torn open, or are leaking.

5.2.2 Storage of Raw Materials Packcrete raw materials shall be stored in a dry location and protected from damage and moisture with an air temperature range of 70 +/- 20°F and compliant with the manufacturers recommended practices.

5.3 Sample Plan for Third Party Testing Packcrete raw materials must be purchased in accordance with Sect. 5.4. The plan will require each lot of sampled material to be tested by an independent third party. A sample plan must be created by the Seller to determine the definition of appropriate lot and sample size(s) in order to achieve reasonable assurance that the sample size chosen provides an adequate representation of the purchased item(s) quality. The sample plan shall comply with guidelines as directed by the Company. The lot size is defined in Sect. 5.4.

SPC M801580-0003 000 00 Page 11 of 24 5.4 Material Procurement and Acceptance Criteria Packcrete raw MTRs shall be provided with the COCs. The Seller shall also provide a CMTR from a qualified third party testing laboratory in accordance with the requirements in this section.

Note 1: One lot of Airalon 3000 is comprised of a single 55-gal drum that is (1) marked with a manufacturers lot number and (2) noted in the manufacturers COC.

Note 2: One lot of Portland cement is comprised of bags received against the same purchase order that have a date code (1) noted in the COC and (2) within the time period noted on the MTR provided with the manufacturers COC.

Note 3: One lot of vermiculite is comprised of bags received against the same purchase order that have the same manufacturers lot number noted in the manufacturers COC.

5.4.1 Vermiculite Acceptance Criteria The raw material manufacturer shall provide a COC package that includes the following, as a minimum: (1) the Buyers purchase order number; (2) the date(s) of manufacture; (3) a statement that the material complies with ASTM C516; (4) a signature by the suppliers official or quality manager; and (5) a Certificate of Analysis in accordance with ASTM C516 for bulk density and grading. The COC shall also include the lot numbers in the order and the number of bags for each lot number.

All bags in the order shall come from a single manufacturing run in order to ensure consistency from bag to bag in terms of chemical composition, bulk density, and particle size distribution.

The manufacturer shall mark each bag as being vermiculite, Type 1, Grade 3, per ASTM C516 requirements. The manufacturer shall also mark each bag with (1) the lot number, (2) the manufacturing line identifier, and (3) a date code showing when the material was manufactured and bagged.

The manufacturer shall maintain quality records that connect the lot number, manufacturing line identifier, or date codes to the raw materials, manufacturing processes, operating procedures, and other manufacturing specifics associated with the manufacturing run.

Bagged vermiculite shall be stored in an area where vibrations from adjacent equipment and handling or movement are minimized, and be stored and transported in a manner that protects the bags and materials from exposure to water.

Bulk density and grading shall be independently tested by a third party testing laboratory in accordance with ASTM C516 (Type 1, Grade 3 Fine). When tested in accordance with Sect. 9.1.1 of ASTM C516 and ASTM C520, third party testing must show each sample has a bulk density between 6.4 and 8 lb/ft3. When tested in accordance with Sect. 9.1.2 of ASTM C516 and ASTM C136, all samples must have a particle size distribution that complies with Table 1.

Table 1. Particle size distribution acceptance criteria U.S. Sieve No.

Weight % passing through the sieve 8

90 to 100 16 40 to 82 30 0 to 35 50 0 to 20 100 0 to 10 200 0 to 2

SPC M801580-0003 000 00 Page 12 of 24 If all samples do not pass the bulk density and particle size distribution acceptance criteria, the lot shall be rejected by the Seller and the Company should be notified.

5.4.2 Portland cement Acceptance Criteria The manufacturer shall provide a COC package for each purchase order that includes the following, as a minimum: (1) the Buyers purchase order number; (2) the date(s) of manufacture; (3) a statement that the material complies with ASTM C150; (4) a signature by the suppliers official or quality manager; (5) an MTR in accordance with ASTM C150; and (6) a statement that all bags in the order were bagged during the time period stated in the MTR. The COC package shall also include the lot number in the order and the numbers of bags in each lot number.

The manufacturer shall mark each bag as being Portland cement, Type III, per ASTM C150 requirements. The manufacturer shall also mark each bag with a date code showing the week and year the material was bagged.

All bags in the order/lot shall have a date code that is within the valid time period stated in the MTR.

The manufacturer shall maintain quality records that connect the lot number or date codes to the raw materials, manufacturing processes, operating procedures, and other manufacturing specifics associated with the manufacturing run.

The packaging practices of the manufacturer are acceptable unless stated otherwise in the Buyers purchase order. Material shall be stored and transported in a manner that protects the bags and materials from exposure to water.

A CMTR shall be provided from a third party independent testing laboratory showing that all samples comply with ASTM C150, Table 1, Type III standard chemistry requirements when tested in accordance with the test methods specified in ASTM C114, Table 1.

If all samples do not pass the acceptance criteria, the lot shall be rejected by the Seller, and the Company should be notified.

5.4.3 Airalon 3000 Acceptance Criteria The manufacturer shall provide a COC package with each purchase order that must include the following as a minimum: (1) the Buyers purchase order number; (2) the date(s) of manufacture; (3) a statement attesting to the fact that the material complies in concentration, composition, and performance to ASTM C260 requirements; (4) a statement providing the chloride content of the material; and (5) a signature by the suppliers official or quality manager. The COC package shall also include the lot number, the date codes, and the number of containers in the order for each date code.

The manufacturer shall mark each container as being Airalon 3000 per ASTM C260 requirements. The manufacturer shall also mark each container with (1) the lot number and (2) a date code showing when the material was manufactured and containerized.

The manufacturer shall maintain quality records that connect the lot number or date codes to the raw materials, manufacturing processes, operating procedures, and other manufacturing specifics associated with the manufacturing run.

A CMTR shall be provided from a third party independent testing laboratory that shows that each 55-gal drum of Airalon 3000 complies with the acceptance criteria in Table 2.

SPC M801580-0003 000 00 Page 13 of 24 Table 2. Airalon 3000 55-gal drum acceptance criteria Reference Test Original lot Acceptance criteria*

ASTM C494, C260, or C233 Infrared analysis** Attachment C in Essentially similar to SPC M801794-0003 Attachment C in SPC M801794-0003 ASTM C494, C260, or C233 Specific gravity 1.01 S.G 0.91 to 1.13 S.G.

ASTM C260 or C233 pH 10.25 pH 9.15 to 11.48 pH ASTM C260 or C233 Residue (solids) 3.15 wt %

2.82 to 3.52 wt %

  • The acceptance criteria are based on the measurements of the original lot and a 12% range.
    • ASTM C260 for air-entraining admixtures does not require infrared analysis. Therefore, the infrared analysis for chemical composition testing is determined by ASTM C494 using the oven-dried residue as determined by ASTM C260/C233. If the sample does not pass the acceptance criteria, the Airalon 3000 55-gal drum shall be rejected, and the Company shall be notified.

5.5 Mixing Water Water that has been filtered through at least a 20-micron filter and has a chlorine content that is <4 mg/L (4 ppm, 0.0004% by mass) shall be used for the mixing of Packcrete. Record the manufacturer, model number, and serial number of the water filter showing that it is at least a 20 micron filter on Form B (Attachment E). The water temperature shall be between 50 and 80F. Form B in Attachment E shall be used to document and record the water temperature and that the chlorine requirements are met each day before mixing starts.

6. FACILITY AND PROCESS EQUIPMENT REQUIREMENTS A written plan shall be submitted to the Company for approval that defines the cleaning process, including cleaning solutions used, equipment, and work and storage environments.

6.1 Cleaning Instructions NO CHLORINE PRODUCTS (sodium hypochlorite) shall be used in the cleaning materials. Potable water shall be used and, if required, some mild soap (tri-sodium phosphate) may be included to clean all processing equipment and manufactured drum bodies and lids before casting. Chlorine is known by many names on the ingredient list (e.g., sodium hypochlorite, hypochlorite, chloramine, bleach, hydrochloric acid, trihalomethanes, and generic disinfection by-products). Not all cleaning products list their ingredients; therefore, only cleaning materials that disclose all ingredients shall be used.

If the mixer sits for >15 min between mixer batches, the mixer shall be flushed thoroughly with potable water before reuse. Before the start of mixing operations described in Sect. 7, the mixer shall be clear of foreign materials or loose previous mixing residues from the inner surface of the mixer.

Manufactured drum bodies and lids that have passed geometric inspection must be cleaned and protected prior to the casting operation to prevent the introduction of foreign materials into the assemblies. The assemblies shall be inspected and wiped clean prior to casting to ensure no visible contaminants are present inside the casting cavity.

6.2 Equipment Requirements All process equipment used for mixing, casting, and baking of the Packcrete shall be (1) identified in the Sellers operating procedures with the operational tolerances and (2) in good working condition. See SPC M801794-0003 Section 6.2 for these requirements.

SPC M801580-0003 000 00 Page 14 of 24 6.3 Work Environments The temperature and humidity of the material storage, casting, and curing environments can have a major impact on casting densities. Variations in mixing air, water, and curing temperatures can also influence the baked density. The Company requires controlled work and material storage environments.

6.3.1 Mixing and Casting Mixing and casting operations shall be performed out of direct sunlight and rain with an air temperature of 70 +/- 20ºF.

6.3.2 Mixing and Casting Water Mixing and casting operations shall be performed with water that complies with the requirements in Sect. 5.5.

6.3.3 Curing Storage Curing storage shall be in an environment with an air temperature of 70 +/- 20F with the containers covered with plastic.

6.3.4 Portland Cement and Vermiculite Storage Bags of Portland cement and vermiculite that have been opened for more than one work shift shall be discarded unless they are stored in a waterproof container in a dry location.

7. PACKCRETE PROCESSING This specification utilizes portions of SPC M801794-0003. If conflicts occur between this specification and SPC M801794-0003, this specification shall supersede. SPC M801794-0003 uses casting Forms A, B, C, D, E, and F, and this specification uses casting Form ES3100. The casting forms from both equipment specifications become part of certification data for this specification.

SPC M801794-0003, Packcrete Preliminary Lot Qualification Form A Packcrete Setup Approval Form B Packcrete Mixing for Samples and Parts Form C Packcrete Sample 4.5-Gal Pail Vibration Casting Control Form D Packcrete Sample 30-Gal Drum Vibration Casting Control Form E Packcrete Sample Pipes Vibration Casting Control Form F Packcrete Furnace and Baking SPC M801580-0003, ES-3100 Packcrete Final Lot Qualification and Production Processing Form ES3100 Packcrete Vibration Casting SES3100 and ES-3100 for Body and Plug ES-3100 Packcrete FLQ and production processing is shown in Fig. 3.

SPC M801580-0003 000 00 Page 15 of 24 Fig. 3 ES-3100 Packcrete FLQ and production processing.

7.1 Processing Setup Requirements See SPC M801794-0003, Section 7.1 for these requirements.

7.2 Mixing Setup Approval Control Number See SPC M801794-0003, Section 7.2 for these requirements.

7.3 Processing Preparation for SES3100, ES-3100, and Samples The purpose of the processing preparation for samples and parts is to create and document a controlled Packcrete casting that follows an approved mixing setup defined on Form A (SPC M801794-0003, Attachment E).

The same processes are used for casting samples and parts with the vibration force being adjusted for the EWCW of the container. A partially filled container is vibrated for 10 s, vibrator is turned off, and a completely filled container is vibrated for 1 min (SPC M801794-0003, Sect. 7.3). These and other processing data are recorded on Forms C, D, E, and F in SPC 801794-0003 and Form ES3100 (Attachment C).

Table 1. Recommended vibration settings Casting SCR-1000 Set No. a Vibration force b (lb)

Estimated wet cast weight c (lb)

Vibration intensity d SES3100 plug 1.1 74 31 2.39 ES-3100 plug 1.1 74 31 2.39 SES3100 body 3.1 688 330 2.08 ES-3100 body 3.3 735 347 2.12 a Vibration force setting numbers for the VIBCO SCR-1000 are shown in Attachment D in SPC M801794-0003. For other vibration motors, document the changes in Form A of SPC M801794-0003 and Form ES3100 and contact the Company for force settings and approval.

b Recommended vibration force settings for the VIBCO SCR-1000 are shown in Attachment D in SPC M801794-0003. Vibrate 10 s for partial fills and 1 min after filling is completed.

c The EWCW is for one full casting mold using an estimated wet casting density of 53.9 lb/ft3.

d The vibration intensity has a tolerance of +/-0.6 that may change the setting number and the vibration force.

7.4 ProcessMixing and Vibration Casting, Curing, and Baking for Samples and Parts Process mixing and vibration casting, curing, and baking for samples and parts are found in SPC M801794-0003, Section 7.4.

SPC M801580-0003 000 00 Page 16 of 24 7.5 Setup Approval Process Verification4.5-gal Pail or 30-gal Drum The 4.5-gal pail or 30-gal drum have been used to verify the mixing setup control number (SACN) process that generates an acceptable wet and baked density following the requirements in Sects. 7.3 and 7.4. The 4.5-gal pail needs Forms A, B, C, and F from SPC M801794-0003, while the 30-gal drum needs Forms A, B, D, and F (Attachment E) from SPC M801794-0003 are needed to document this effort. Use these small castings if needed to verify the lots of material and process settings. Once these are verified, proceed to shipping package specific specification and perform a process and LQ castings.

7.6 Lot Qualification and Packcrete Sample Pipes Pipe samples are required for both preliminary and final lot qualifications. The pipe sample casting requires a different stand-alone vibration table setup that vibration casts at least two pipe samples for each mixer load going into the production run mixes. This stand-alone table needs a maximum force of 100 lb and a speed of 3200 vibrations per minute, generating a frequency of 53 Hz. VIBCO supplies a standalone table that meets these requirements. The SACN used will be different than the SACN for the VIBCO SCR-1000. Follow Sects. 7.3 and 7.4 and use Forms A, B, E, and F (Attachment E) to document pipe sample casting. Section 8 describes pipe sample preparation requirements, and Sect. 9 describes pipe sample testing. Send the manufacturing and testing results to the Company for evaluation. Once the testing data is accepted by the Company, the current Form As will be approved and signed by the Company.

7.7 Final Lot Qualification CastingsSES3100 Body and Plug The purpose of FLQ is to create and document a full-scale test of Packcrete casting (SES3100 body or plug) to validate (qualify) the raw materials, equipment, and process necessary to achieve an acceptable end product with an acceptable baked density. Furthermore, raw material testing shall be performed in accordance with Sect. 9 in SPC M801794-0003 before the raw materials are released for production processing. After the Company accepts the SES3100 castings and documentation, the Seller may proceed to the production process documented in Sect. 7.8. Optional samples for testing and their required forms are described in Sect. 8, but they will use the setup and processes described in Sect. 7.6 (SPC M801794-0003).

Process qualification (PQ) acceptance testing requires test articles from an SES3100 body and plug and sample pipes qualified in accordance with Sect. 9 (SPC M801794-0003). Section 8 of SPC M801794-0003 defines how the samples are to be made, and Sect. 9 (SPC M801794-0003) describes how the samples are to be tested. After the Company has evaluated the testing results, the Seller may be approved to start production castings or may be asked to reject the lots of raw materials and repeat the SES3100 FLQ process. During production, additional sample testing may be necessary to gather information to assure the process can be repeated on parts.

Each PQ shall document the entire manufacturing process using the materials that have successfully completed the material testing and are approved by the Company on Form A (SPC M801794-0003). The Packcrete setup approval process is documented in Sect. 7.2 (SPC M801794-0003). The Packcrete mixing setup shall follow the approved setup on Form A (SPC M801794-0003). Additional adjustments to the vibration force shall be made in accordance with Sect. 7.3 to properly manufacture a SES3100 body and plug Packcrete castings.

7.7.1 SetupMixing and Vibration Casting an SES3100 Body or Plug To cast the SES3100 container, the active Setup Approval Control Number (SACN) mixing setup approval settings on Form A (SPC M801794-0003) shall be identified and followed. The Packcrete setup approval process is documented in Sect. 7.2 (SPC M801794-0003). It is required that the Seller complete casting using an SES3100 body and plug and record data on Forms B and F in SPC M801794-0003 and Form ES3100 (Attachment C) prior to proceeding to the production process described in Sect. 7.8.

The Seller shall complete setup in accordance with Sect. 7.3 for an SES3100 body or plug, recording data measurements on Form E (checking the appropriate boxes for PQ and body or plug).

SPC M801580-0003 000 00 Page 17 of 24 7.7.2 ProcessMixing and Vibration Casting an SES3100 Body or Plug For an SES3100 container, the active SACN mixing setup approval settings on Form A (SPC M801794-0003) shall be identified and followed. The Packcrete setup approval process documented in Sect. 7.2 (SPC M801794-0003) shall be followed for an SES3100 body or plug and the data recorded on Forms B and F in SPC M801794-0003 and Form ES3100 (Attachment C) prior to proceeding to the production process described in Sect. 7.8.

Each unique casting of a container must have the vibration force calculated as described in Sect. 7.3 that shall match the body or plug setting on Form ES3100 (Attachment C) with the vibration force adjusted to the proper setting. The Seller shall complete Sect. 7.4.1 (SPC M801794-0003) for an SES3100 body or plug, recording measurements on Forms A, B, and F in SPC M801794-0003 and Form ES3100 (checking the appropriate boxes for PQ and body or plug).

7.7.3 ProcessCuring an SES3100 Body or Plug The Seller shall follow the requirements in Sect. 7.4.2 (SPC M801794-0003) for curing an SES3100 body or plug and record measurements on Form ES3100 (checking the appropriate boxes for PQ and body or plug).

7.7.4 ProcessBaking an SES3100 Body or Plug After casting, initial curing, scraping, and final curing, place a thermocouple in at least one SES3100 body at the top center of the casting with the tip 5-to 6-in. deep to record the core temperature. It is acceptable to use a rod or drill to generate the proper depth thermocouple hole. The SES3100 body shall be baked with the core temperature thermocouple in place to determine the minimum baking time at 500°F. A bottom center thermocouple (BCT) can be used to determine the temperature of the bottom center of the inner liner for the current furnace loading. The minimum baking time at 500F may be determined by no increase in the BCT over 2°F in 6 h of baking. Each SES3100 body has ~4.7 ft3 of casting and will lose ~148 lb of water. If required, the furnace set point temperature may need to be adjusted to ensure that the temperature near the package is within the tolerance of +/-10°F for the setting requirement.

7.7.4.1 Calculate and record the baked density using the equation at the bottom of Form ES3100. The acceptable baked density is 22.4 +/- 3 lb/ft3 (19.4-25.4 lb/ft3) for the SES3100 casting.

7.7.4.2 If the baked density is acceptable, follow Sect. 9 (SPC M801794-0003) and send samples for lot qualification testing. Submit completed SES3100 Forms A, B, and F in SPC M801794-0003 and Form ES3100 (Attachment C) with the sample pipe casting Forms A, B, E, and F in SPC M801794-0003 to the Company for approval. Once Company has approved, production processing may start following Sect. 7.8.

7.8 Production Processing an ES-3100 Body or Plug The purpose of the production process is to create and document the production Packcrete casting (ES-3100 body or plug) based on approved lot qualified materials and processes documented in Sect. 7.7. This practice has validated the raw materials, equipment, and processes necessary to achieve an acceptable end product and baked density. Optional samples may be required for testing and their required forms are described in Sect. 8, but they will use the setup and processes described in Sect. 7.6 (SPC M801794-0003). Each production process shall follow an approved Form A (SPC M801794-0003) identified by a SACN. The production processing shall be documented on Forms B and F in SPC M801794-0003 and Form ES3100 (Attachment C).

NOTE: It is important that the runout (roundness) of the drum body casting opening stays within +/-0.03 in. prior to the Packcrete casting process as stated on M2E801580A002. In-process inspections are used to verify that the container stays acceptable during the casting and baking processes. Failure to meet the diametrical tolerance after the Packcrete casting and baking is grounds for rejection.

7.8.1 SetupMixing, Vibration Casting, and Curing an ES-3100 Body or Plug Each production process shall follow an approved Form A (SPC M801794-0003) identified by a SACN and PQ as described in Sect. 7.6 (SPC M801794-0003).

SPC M801580-0003 000 00 Page 18 of 24 The Seller shall complete the following steps:

7.8.1.1 Vibration table force and speed settings shall meet the requirements defined in Sect. 7.3, and they shall be documented on Form ES3100.

7.8.1.2 Processing as described in Sect. 7.3 shall be completed for an ES-3100 body or plug, recording measurements on Form B in SPC M801794-0003 (checking the appropriate boxes for production process and body or plug).

7.8.2 ProcessMixing and Vibration Casting an ES-3100 Body or Plug Each production process shall follow an approved Form A in accordance with Sect. 7.4 (SPC M801794-0003) that is identified by a SACN.

The different vibration table force settings are shown in Sect. 7.3, shall match the body or plug setting in Table 1, and shall be documented on Form ES3100.

The Seller shall complete Step 7.4.1 (SPC M801794-0003) for an ES-3100 body or plug, recording measurements on Form B (SPC M801794-0003) and Form ES3100 (checking the appropriate boxes for production process and body or plug).

The Seller shall record on Form ES3100 that the drum casting opening and drum plug sheet metal diameters are within the manufacturing tolerances of +/-0.12 and +/-0.06, respectively. These measurements must be made after weighing and handling and before casting.

7.8.3 ProcessCuring an ES-3100 Body or Plug Each production process shall follow an approved Form A identified by a SACN and PQ described in Sect. 7.4 (SPC M801794-0003) and recorded on Form B (SPC M801794-0003).

The Seller shall complete the steps described in Sect. 7.4.2 (SPC M801794-0003) for an ES-3100 body or plug and record measurements on Form ES3100 (checking the appropriate boxes for production process and body or plug).

7.8.4 ProcessBaking an ES-3100 Body or Plug After casting, initial curing, scraping, and final curing, place a BCT on the bottom center of the inner liner of the ES-3100 body. The BCT shall be used to determine the temperature of the bottom center of the inner liner for the current furnace loading. The minimum baking time at 500°F may be determined by no increase in the BCT over 2°F in 6 h of baking. If required, the furnace set point temperature may be adjusted to ensure that the temperature near the package is within the tolerance of +/-10°F for the setting requirement.

Each ES-3100 body and plug has ~4.8 ft3 of casting and will lose ~151 lb of water. Therefore, each unique furnace loading must be qualified with thermocouple readings to determine the minimum baking time at 500°F for that volume of castings, or real time temperature measurements may be recorded. For real time temperature measurements, the ES-3100 body shall be baked with the BCT in place to determine the temperature of the bottom center of the inner liner for the current furnace loading. A real time measurement furnace may be used in the future as a Baking Qualification Control Number-Vol (BQCN-Vol) that controls the minimum baking time for a volume of cast material loaded into the furnace. The cast Packcrete volume in cubic feet is recorded on Form F (SPC M801794-0003). The BQCN-Vol time at 500°F may be used for oven loads up to the qualified volume without real time measurements being required.

SPC M801580-0003 000 00 Page 19 of 24 The Seller shall complete the final following steps.

7.8.4.1 Complete the steps in Sect. 7.4.3 (SPC M801794-0003) for an ES-3100 body or plug and record measurements on Form ES3100 (Attachment C) and Form F in SPC M801794-0003 (checking the appropriate boxes for production process and body or plug).

7.8.4.2 Calculate and record the baked density of the cured mixture using the equation at the bottom of Form ES3100.

The acceptable baked density is 22.4 +/- 3 lb/ft3 (19.4-25.4 lb/ft3).

7.8.4.2.1 If the baked density is not acceptable, reject the part and contact the Company for information and future casting improvements.

7.8.4.2.2 If the baked density is acceptable, follow the instructions in Attachment A and submit completed Forms A-F (SPC M801794-0003) and Form ES3100 to the Company for approval.

7.8.4.2.3 Weld the covers on to complete the drum body weldment or top plug weldment in accordance with M2E801580A002 or M2E801580A002 and JS-YMN3-801580-A002.

7.8.4.3 Insert copies of the approved raw material test reports; SACN, SES3100 casting, and lot qualification reports; and production casting forms into the certified data package that are used to define the production process in accordance with the instructions in Attachment A.

7.8.4.4 Verify that the stainless-steel shell, as shown in M2E801580A002 and M2E801580A008, have passed geometric inspection before casting begins.

8. PACKCRETE LOT QUALIFICATION AND PRODUCTION TEST SAMPLES The Packcrete lot qualification and production test samples requirements are found in SPC M801794-0003. The 30-gal drum may be used to replace the SES3100 casting in the production sampling set once equivalences have been demonstrated with test results.
9. PACKCRETE MATERIAL LOT QUALIFICATION PROPERTIES LIMITS Packcrete material lot qualification properties limits are found in SPC M801794-0003.

SPC M801580-0003 000 00 Page 20 of 24 ATTACHMENTS ATTACHMENT A: SUBMITTAL CHECKLIST

SPC M801580-0003 000 00 Page 21 of 24 SUBMITTAL CHECKLIST Item No.

Reference Requirement Description Schedule Format a No. of Copies Submittal Purpose 3.8 Manufacturing plan PTF EP 1

FA 3.9.1 Submittal checklist (Excel spreadsheet)

Q EM, EN AR FI 3.9.1 Packcrete processes procedures for weighing, mixing, pouring, vibrating, curing, and baking.

PTF EP 1

FA 3.9.2 a Raw material test reports and third party test laboratory Certificate of Conformance PTF EP 1

FA 3.9.2 a Copy of mixing materials Certificate of Conformance PTF EP 1

FA 3.9.2 a Certification data package PTD EP 1

FA 4

Quality assurance plan WP EP 1

FA 7.8 Production processing an ES-3100 body or plug PTF EP 1

FA Form A b Packcrete Setup Approval PTD EP 1

FA Form B b Packcrete Mixing for Samples and Parts PTD EP 1

FA Form D b Packcrete Sample 30-Gal Drum Vibration Casting Control PTD EP 1

FA Form E b Packcrete Sample Pipes Vibration Casting Control PTD EP 1

FA Form F b Packcrete Furnace and Baking PTD EP 1

FA Form ES3100 c Packcrete Vibration Casting (SES3100 and ES-3100 for body and plug)

PTD EP 1

FA a The certification data package must also have one printed hard copy of the entire certification data.

b SPC M801794-0003.

c Attachment C.

SPC M801580-0003 000 00 Page 22 of 24 ATTACHMENT B: ABBREVIATIONS AND ACRONYMS See SPC M801794-0003 for acronyms that are not included here.

ASME American Society of Mechanical Engineers CBA Confinement Boundary Assembly LLC Limited Liability Company QA Quality Assurance SES3100 Simulated ES-3100

SPC M801580-0003 000 00 Page 23 of 24 ATTACHMENT C: PACKCRETE PROCESSING FORM Form ES3100 Packcrete Vibration Casting Note: The following forms are in Attachment E of SPC M801794-0003.

Form A Packcrete Setup Approval Form B Packcrete Mixing for Samples and Parts Form C Packcrete Sample 4.5 Gal Pail Vibration Casting Control Form D Packcrete Sample 30 Gal Drum Vibration Casting Control Form E Packcrete Sample Pipes Vibration Casting Control Form F Packcrete Furnace and Baking

SPC M801580-0003 000 00 Page 24 of 24 Form ES3100 Packcrete Vibration Casting

[ ] Lot Qualification (SES3100) [ ] Production Process (ES-3100)

[ ] Plug

[ ] Body Specification Number Revision Issue date (mm/dd/yy)

Revision date (mm/dd/yy)

Casters company name Y-12 observers present Packaging name (i.e., ES-3100 or SES3100) a Part Serial Number Measurement Comment Measure Units Operator Witness Clean and empty lb Filled with water c Water temp. °F lb Container volume ft3 Wet cast weight Estimate lb Vibration table force setting d SES3100 plug: #1.1, 74 lbf ES-3100 plug: #1.1, 74 lbf SES3100 body: #3.1, 688 lbf ES-3100 body: #3.3, 735 lbf lb Vibration table speed setting d 80%

Vibration intensity ~1.1 to 3.3 Force / wet weight Ensure ES-3100 casting:

Drum body opening Ø+/-0.12 in.

Drum plug body Ø+/-0.06 in.

Pass Fail Operation Mix Control Number (MCN)

Vibration duration e Time Operator Witness Pour Start 1 e 10 s

Pour Start 2 e 10 s

Pour Start 3 e 10 s

Full vibration time 1

min Measurement Comment Measure Units Operator Witness Wet cast weight Actual lb Wet density Target 53.9 +/- 5.6 lb/ft3 lb/ft3 Measured wet density (48.3 - 59.5 lb/ft3) acceptance Accept Reject f Scrape the top and weigh lb Cure time (at least 7 days)

BCN - MCN1 days Baking Control Number (BCN) b After baking weight lb Baked density Target 22.4 +/- 3 lb/ft3 lb/ft3 Density Wet Density Baked Measured baked density (19.4 - 25.4 lb/ft3) acceptance Accept Reject f a ES-3100 drawings are M2E801580A002, Body Weldment, and M2E801580A008, Top Plug Weldment or SES3100 Body or Plug.

b B are alpha prefixes plus a 10-digit control number is used to document the date and time that process qualification was started using a 24-h format (i.e., B1021081515 is used for October 21, 2008, at 3:15 p.m.).

c Record the water weight and temperature within 10 min from completion of the weighing process.

d Document the vibration force and frequency settings (Sect. 7.3) and duration established by the PQ.

e For partial casts, vibrate the drum 10 s and stop. Once full, vibrate for 1 min.

f Upon rejection, contact the Company and send the casting records.

Volume =

62.3

)

(

pty CleanAndEm WithWater ft3 @ 70°F Wet density =

Volume

)

(

pty CleanAndEm WetCast lb/ft3 Baked density =

Volume

)

(

pty CleanAndEm g

AfterBakin

lb/ft3

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