ML24164A272
| ML24164A272 | |
| Person / Time | |
|---|---|
| Issue date: | 06/15/2023 |
| From: | Office of Nuclear Material Safety and Safeguards |
| To: | |
| Shared Package | |
| ML24164A259 | List: |
| References | |
| Download: ML24164A272 (1) | |
Text
EQUIPMENT SPECIFICATION DOC TYPE SPC DOC #
M801794-0003 PART #
000 REV. #
01 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 ITEM DESCRIPTION PACKCRETE PRELIMINARY LOT QUALIFICATION UNID REVISIONS REV. NO.
DESCRIPTION OF REVISION 00 01 Initial issue.
Per SPC M801794-0003 001 00, SPC M801794-0003 002 00, EC 801580 0033 000 00, EC 801580 0036 000 00 added NCS approval and removed old RFWD form.
REFERENCE DOCUMENTS & OTHER INFORMATION Required Supplier (not defined):
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-801794-0003 Installation Drawings: None 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 G. A. Byington PACKAGING ENGINEER R. Whittenbarger DESIGN VERIFICATION M. L. Ensley NCS A. D. Wilkinson DISCIPLINE MANAGER R. D. Turner OPERATIONS/SYS. OWNER NA NUCLEAR PROC. ENGINEER J. E. Cook QUALITY ASSURANCE R. J. Fisher This document has been reviewed by a Y-12 DC/UCNI-RO and has been determined to be UNCLASSIFIED and contains no UCNI. This review does not constitute clearance for Public Release.
- Name, Date G A (GAB) Byington Digitally signed by G A (GAB)
Byington Date: 2023.06.15 10:06:16 -04'00' Alan D. (WA9)
Wilkinson Digitally signed by Alan D. (WA9)
Wilkinson Date: 2023.06.15 11:24:23 -04'00' Ross M (RWM)
Whittenbarger Digitally signed by Ross M (RWM)
Whittenbarger Date: 2023.06.15 11:59:11 -04'00' Jeffrey E (2XK) Cook Digitally signed by Jeffrey E (2XK)
Cook Date: 2023.06.15 12:38:38 -04'00' Roger D (R7A) Aigner Digitally signed by Roger D (R7A)
Aigner Date: 2023.06.18 19:19:09 -04'00' Michael L (MER)
Ensley Digitally signed by Michael L (MER) Ensley Date: 2023.06.22 14:15:49 -04'00' Ryan J (RJF) Fisher Digitally signed by Ryan J (RJF)
Fisher Date: 2023.06.27 06:46:57 -04'00' Richard D (RT9)
Turner Digitally signed by Richard D (RT9) Turner Date: 2023.06.27 07:07:43 -04'00'
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 1 of 43 TABLE OF CONTENTS
- 1. Scope.................................................................................................................................................................................. 4 1.1 General Description of the Item............................................................................................................................. 4 1.2 Background............................................................................................................................................................ 5
- 2. References......................................................................................................................................................................... 5 2.1 Definitions............................................................................................................................................................... 5 2.2 Acronym List........................................................................................................................................................... 8 2.3 Codes/Standards/Orders/Regulations................................................................................................................... 8 2.4 Applicable Documents for CNS Y-12s use only.................................................................................................... 8
- 3. Item Requirements............................................................................................................................................................ 9 3.1 Performance Requirements................................................................................................................................... 9 3.2 Design Requirements............................................................................................................................................. 9 3.3 Service Conditions................................................................................................................................................. 9 3.4 Fabrication and Assembly Requirements.............................................................................................................. 9 3.5 Installation Requirements....................................................................................................................................... 9 3.6 Requirements......................................................................................................................................................... 9 3.7 Government-Furnished Material, Equipment, Services......................................................................................... 9 3.8 Schedule................................................................................................................................................................ 9 3.9 Deliverables and Submittals Documents............................................................................................................... 9 3.9.1 Approval Data Documents...................................................................................................................... 10 3.9.2 Certification Data Documents................................................................................................................. 10 3.10 Packaging, Handling, Shipping, and Storage Requirements............................................................................... 10 3.11 Marking and Identification Requirements............................................................................................................. 10 3.12 Requests for Waiver or Deviation........................................................................................................................ 10
- 4. Quality Assurance Requirements................................................................................................................................. 11 4.1 Final Acceptance Test Method............................................................................................................................. 11 4.2 Inspection/Testing Requirements......................................................................................................................... 11 4.3 Surveillance and Audits........................................................................................................................................ 11 4.3.1 Quality Hold Points.................................................................................................................................. 11 4.3.2 Quality Observations............................................................................................................................... 12 4.4 Quality Requirements........................................................................................................................................... 12 4.5 Acceptance Criteria.............................................................................................................................................. 12 4.6 Personnel Qualifications/Certifications................................................................................................................ 12 4.7 Training and Qualification of Personnel............................................................................................................... 12 4.7.1 Operator and Witness Training and Qualifications................................................................................. 12 4.8 Documentation Retention..................................................................................................................................... 12 4.9 Nonconformance Control..................................................................................................................................... 12
- 5. Packcrete Raw Material Requirements......................................................................................................................... 13 5.1 Procuring Packcrete Raw Materials..................................................................................................................... 13 5.2 Receiving and Material Storage Instructions....................................................................................................... 13 5.2.1 Damaged Packages................................................................................................................................ 13 5.2.2 Storage of Raw Materials........................................................................................................................ 13 5.3 Sample Plan for Third Party Testing.................................................................................................................... 13 5.4 Material Procurement and Acceptance Criteria................................................................................................... 13 5.4.1 Vermiculite Acceptance Criteria.............................................................................................................. 13 5.4.2 Portland cement Acceptance Criteria..................................................................................................... 14 5.4.3 Airalon 3000 Acceptance Criteria............................................................................................................ 15 5.5 Mixing Water........................................................................................................................................................ 15
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 2 of 43
- 6. Facility and Process Equipment Requirements........................................................................................................... 16 6.1 Cleaning Instructions............................................................................................................................................ 16 6.2 Equipment Requirements..................................................................................................................................... 16 6.2.1 Scales Requirements.............................................................................................................................. 16 6.2.2 Plaster or Mortar Mixers.......................................................................................................................... 16 6.2.3 Low Profile Platform Vibrator.................................................................................................................. 16 6.2.4 Table Vibrator.......................................................................................................................................... 16 6.2.5 Time Clocks............................................................................................................................................. 17 6.2.6 Furnace with Temperature Recorded and Controller.............................................................................. 17 6.3 Work Environments.............................................................................................................................................. 17 6.3.1 Mixing and Casting.................................................................................................................................. 17 6.3.2 Mixing and Casting Water....................................................................................................................... 17 6.3.3 Curing Storage........................................................................................................................................ 17 6.3.4 Portland Cement and Vermiculite Storage.............................................................................................. 17
- 7. Packcrete Preliminary Lot Qualification....................................................................................................................... 17 7.1 Processing Setup Requirements.......................................................................................................................... 18 7.1.1 Setup Verification.................................................................................................................................... 18 7.1.2 Preliminary Lot Qualifications (PLQs)..................................................................................................... 18 7.1.3 Final Lot Qualifications............................................................................................................................ 18 7.1.4 Change ControlHardware or Process Settings for Mixing, Vibrating, Curing, and Baking................. 19 7.1.5 Mixing Recipe Amounts and Adjustments.............................................................................................. 19 7.2 Setup Approval Control Number (Form A) for Process Qualification................................................................... 21 7.3 Processing Preparation for Samples and Parts................................................................................................... 22 7.3.1 SetupMixing, Vibration Casting, and Curing Samples and Parts........................................................ 22 7.4 ProcessMixing and Vibration Casting, Curing, and Baking for Samples and Parts......................................... 24 7.4.1 ProcessMixing and Vibration Casting for Samples and Parts............................................................. 24 7.4.2 ProcessCuring for Samples and Parts................................................................................................ 25 7.4.3 ProcessBaking for Samples and Parts................................................................................................ 26 7.5 Setup Approval Process Verification4.5-gal Pail or 30-gal Drum..................................................................... 27 7.6 Packcrete Pipe Samples for Preliminary and Final Lot Qualification................................................................... 27
- 8. Packcrete PLQ and Production Test Samples............................................................................................................. 27 8.1 Packcrete 4.5-gal Pails........................................................................................................................................ 28 8.2 Packcrete Production Sampling Set..................................................................................................................... 28 8.3 Packcrete 30-gal Sample Drum........................................................................................................................... 28 8.4 Packcrete Brick Samples per ASTM C862.......................................................................................................... 28 8.5 Packcrete Sample Pipes...................................................................................................................................... 28
- 9. Packcrete Final Lot Qualification Properties Limits.................................................................................................... 28 9.1 Wet and Baked Densities..................................................................................................................................... 28 9.2 Dynamic Impact Crush Strength.......................................................................................................................... 28 9.3 Chemical Compositions of the Constituents........................................................................................................ 29 9.4 Thermal Conductivity........................................................................................................................................... 29 9.5 Specific Heat Capacity......................................................................................................................................... 29 9.6 Linear Thermal Coefficient of Expansion............................................................................................................. 29 9.7 Elastic Modulus.................................................................................................................................................... 29 9.8 Poissons Ratio..................................................................................................................................................... 29
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 3 of 43 Attachments......................................................................................................................................................................... 30 Attachment A: Submittal Check List............................................................................................................................... 30 Attachment B: Request for Waiver/Deviation Sample Forms......................................................................................... 34 Attachment D: VIBCO Vibration Force Settings............................................................................................................. 36 Attachment E: Packcrete Processing Forms.................................................................................................................. 37 Form A Packcrete Setup Approval....................................................................................................................... 38 Form B Packcrete Mixing For Samples and Parts............................................................................................... 39 Form C Packcrete Sample 4.5-Gal Pail Vibration Casting Control...................................................................... 40 Form D Packcrete Sample 30-Gal Drum Vibration Casting Control.................................................................... 41 Form E Packcrete Sample Pipes Vibration Casting Control................................................................................ 42 Form F Packcrete Furnace and Baking............................................................................................................... 43 FIGURES Fig. 1. Packcrete sample section without magnification......................................................................................................... 4 Fig. 2. Packcrete preliminary lot qualification........................................................................................................................ 18 Fig. 3. Mixing Packcrete........................................................................................................................................................ 19 Fig. 4. Mixing Packcrete, continued...................................................................................................................................... 20 Fig. 5. VIBCO SCR1000 default eccentric counter weight set at 3 (675 lb)....................................................................... 24 TABLES Table 1. Particle size distribution acceptance criteria........................................................................................................... 14 Table 2. Airalon 3000 55-gal drum acceptance criteria........................................................................................................ 15 Table 3. Nominal recipe for a large batch and a small batch at wet density of 53.9 lb/ft3.................................................... 21 Table 4. Extreme recipes for a large Packcrete batch at wet densities of 52.9 and 55.0 lb/ft3............................................. 21 Table 5. Vibration settings..................................................................................................................................................... 23
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 4 of 43
- 1. SCOPE This specification describes the quality assurance and technical requirements for Packcrete raw materials and preliminary lot qualification (PLQ). It includes procuring, inspection and accepting raw materials; weighing, mixing, casting, vibrating, curing, and baking Packcrete in a 30-gallon and other sizes of containers. For successful completion of the PLQ, samples shall pass verification tests. Once verification tests are complete and affirmed by the Company [Y-12 National Security Complex, Consolidated Nuclear Security, LLC (CNS)], the Seller is approved (but not yet qualified) to start the Packcrete casting process into a specific shipping package (SSP). Separate equipment specifications will specify the qualification requirements for each SSP.
If conflicting requirements appear in this specification and an SSP equipment specification (SSPES), the SSPES shall supersede this equipment specification. If additional conflicting requirements appear in this document, the Seller shall immediately notify the Company for resolution. Waivers and deviations from these requirements are not allowed without the Companys written approval on UCN-13816B, Request for Waiver or Deviation (RFWD),
[Attachment B]. The subcontract technical representative (STR) will provide an electronic copy of the RFWD form upon request.
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 CNS.
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. Fig. 1 shows a sample section without magnification of Packcrete with a centimeter scale.
Fig. 1. Packcrete sample section without magnification.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 5 of 43
1.2 BACKGROUND
Packcrete is a non-commercially available mixture that was developed as an insulation material for Type-B radioactive material shipping packages. Mixtures of Packcrete must comply with strict manufacturing standards, outlined in this specification.
- 2. REFERENCES 2.1 DEFINITIONS 4.5-gal pail - A metal container that is at least 4.5 gal and is >18-in. deep. The McMaster-Carr tin-plated steel pail and lid (Part 4243T16) with 43/4-gal capacity and 9-in. top outer diameter is acceptable.
Acceptable Raw Materials - Upon the purchase of new lots of raw materials they must pass Sect 5.4 testing before use in preliminary lot qualification. (Before production use, the raw materials must also pass final lot qualification testing for each simulated specific shipping package and unique casting volume and weight before production approval.)
Baking Control Number (BCN) - B alpha prefix control number that defines the date and the time when baking is started and recorded on Forms C through F (Attachment E).
Baked density - The calculated density of the Packcrete after baking using the following equation.
Baked density =
Volume
)
(
pty CleanAndEm g
AfterBakin lb/ft3
[see equation names below]
Baking Qualification Control Number-Vol (BQCN-Vol) - BQ alpha prefix control number with a volume in cubic feet suffix used to document the date and time the baking process qualification is started and the volume of Packcrete casting used. The BQCN-Vol shall be recorded on each production baking form if used (Form F, Attachment E) to define the appropriate baking process qualification settings.
Certificate of Conformance (COC) - A declaration from a Seller/Supplier stating that the referenced product/material meets all requirements, standards, and/or specifications, but it is not a summary of test results.
At minimum, the COC should include the following information:
Certification on Seller/Suppliers letterhead Seller/Supplier name Manufacturers name Manufacturing location Purchase order number Part/item number Lot number (if available)
Date codes Quantity Seller/Supplier contact information Purchased material or equipment Procurement requirements met/not met Certification system followed Means of verification Appropriate Seller/Supplier signature Certified material test report (CMTR) - A document attesting that the materials are in accordance with specified requirements, including the actual results of all required chemical analyses, tests, and examinations from a third party testing facility.
Company - The Company, as used in this specification, is the Y-12 National Security Complex.
Control Number (CN) digit control number is used with an alpha prefix to document the date and time that process was started using a 24-h format (i.e., B1021081515 is used for starting baking on October 21, 2008, at 3:15 p.m.).
Deviation - A specific written authorization initiated by the supplier and granted by the Company prior to the manufacture of an item to depart from a subcontract requirement.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 6 of 43 Equation names - Equation names are used to calculate the wet and baked densities on the casting forms. The following definition of terms clearly states how this data is to be used.
Name Equation Name Definitions After baking cycle AfterBaking The baked Packcrete and metal containers weight after it has finished the baking cycles.
Before baking BeforeBaking The weight of the metal container with cured Packcrete scraped to the finished casting level before baking.
Clean and empty CleanAndEmpty The weight of the metal container that is dry, clean, and empty.
Wet after casting WetCast The weight of the scraped and cleaned actual wet cast Packcrete in the container after the vibration process has stopped.
Filled with water WithWater The weight of the metal container filled with water to the level of the finished casting.
Final lot qualification (FLQ) - Is required for new lots of raw materials before production castings may start.
FLQ shall generate acceptable material property testing results using sample pipes and samples cut from a simulated specific shipping package lid and body casting following written procedures approved by the Company as described in Sect. 9.
Material test report (MTR) - A document attesting that the materials are in accordance with specified requirements, including the actual results of all required chemical analyses, tests, and examinations from the Seller.
Mix Control Number (MCN) - M alpha prefix control number for starting the mixing process.
Nonconformance - A deficiency in characteristic, documentation, or procedure that renders an item to be in noncompliance with specified requirements.
Operator (on casting forms) - A qualified individual, other than the witness, who is responsible for recording the casting measurement, or an individual other than the witness who made a density calculation using the recorded measurements. Multiple operators are acceptable on the forms.
Preliminary lot qualification (PLQ) - Is required before production castings and after raw materials passes the Sect 5.4 testing. It is accomplished using a 30-gallon drum to gain experience in casting and testing process control. The same 30-gallon drum tests may be acceptable to use during production to obtain verification material properties if there is a correlation made between the 30-gallon drum test results of the simulated specific shipping package PQ casting material properties test results.
Process qualification (PQ) - An individual process procedure following this or a SSPES used to verify that the mixing, vibration casting, curing, baking for a unique container size and weight that generates acceptable material properties. Qualified processes may vary process equipment, vibration force, and baking time. For a PQ of a SSP a SSSP lid and body casting must pass FLQ. The vibration force and baking time of each process may vary the most. For PQ of the sample pipes Forms A, B, E, and F are needed and a different vibration table. For PQ of the SSSP lid or body requires Forms A, B, and F and form(s) in the SSPES.
Sample Pipes - Successful dynamic testing results is required following Sect. 9.2 for LQ. A 4NPS Schedule 40 carbon steel pipe, 6.5 +/- 0.02-in. long with no sharp edges, used for compression testing Packcrete samples. The inside of the pipe must be smoothed to a maximum surface roughness of 125 microfinish. The Packcrete casting in the pipe is finished to a depth of 0.3 +/- 0.09-in. and 4.5 +/- 0.09 in. from the fill hole, for a cast height of 4.2 in.
Each finished end shall be finished flat to within 0.02. A large flat bottom drill bit and a small drill press works well to finish the cured casting flat.
Setup Approval Control Number (SACN) - SA alpha prefix control number to document the date and the time that the setup approval is started. The SACN shall be recorded on each mixing form (Form B, Attachment E) to define the appropriate Packcrete mixing process and casting materials amounts. A particular setup of hardware, settings, mixing times, and vibration speeds for mixing and casting Packcrete defined on Form A with casting records and submitted to the Company for approval. The sample pipes and SSSP may each have a unique SACN
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 7 of 43 to follow the PQ testing for approval. The Company approval SACN date gives the Seller authorization to cast record parts following the SACN. Due to changes in the mixing or vibration hardware, the Seller may have more than one SACN for the same lot of materials.
Seller - The organization or person(s) entering into a subcontract with the Company to provide the product(s) described.
Specific shipping package (SSP) - The final placement of Packcrete will be following the SSPES. This PLQ specification must be completed before and as part of the SSPES. Since the references, drawings, size, and weight of the shipping package or container are defined by the SSPES. Final acceptance of the Packcrete material properties shall be when the SSSP is cut and tested following Sect. 9 of this specification.
Simulated specific shipping package (SSSP) - Is defined in the SSPES and will have a body and lid that reasonably match the volume and weight of the SSP body and lid. The SSSP is used to verify the Sellers operating procedures produce parts that are acceptable to the SSPES.
Subcontract administrator - A Company person, called the buyer, who is responsible for overall subcontract administration.
Subcontract technical representative (STR) - A Company person responsible for managing, monitoring, and ensuring compliance with technical requirements of a subcontract.
Supplier - The organization or person(s) entering into a subcontract with the Seller to provide the product(s) described.
Technical representative (TR) - A Company person who identifies technical and quality requirements necessary to support development of a procurement specification.
Third party - An independent test organization, person, or company that tests products and materials in accordance with the contract requirements. The organization cannot be affiliated with the producer or the user of the item being tested. These independent testing facilities are sometimes called third party testing facilities. The third party test agency shall be certified to ANSI/ISO/IEC 17025 or be evaluated and accepted to meet the Sellers Company-approved quality assurance program, as applicable.
Volume - The calculated casting volume in cubic feet using the equations below.
For a metal container filled to Packcrete casting level.
Volume =
62.3
)
(
pty CleanAndEm WithWater ft3 @ 70°F For pipes or cylinders the internal diameter (ID) and the baked internal height (BIH) in inches.
Volume = 2200.16 BIH ID 2
ft3 Waiver - A specific written authorization initiated by the supplier and granted by the Company to accept a configuration item or other designated items that, during production or inspection, are found to depart from specified requirements but are considered suitable for use as is or after rework by an approved method.
Wet density - The calculated density of Packcrete after the container is filled and scraped, but not cured, using the equation below.
Wet density =
Volume
)
(
pty CleanAndEm WetCast lb/ft3 Witness (on mixing and casting forms) - A qualified individual other than the operator trained in mixing and casting Packcrete who has verified that the data is accurately recorded. If a density is to be calculated, then the witness is an individual other than the operator who independently checked and verified the density calculation.
Multiple witnesses are acceptable on the forms.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 8 of 43 2.2 ACRONYM LIST BCN Baking Control Number BCT bottom center thermocouple BIH baked internal height BQCN Baking Qualification Control Number CMTR Certified Material Test Report CN Control Number CNS Consolidated Nuclear Security, LLC COC Certificate of Conformance DOE U.S. Department of Energy EWCW estimated wet cast weight FLQ final lot qualification MCN Mix Control Number MTR material test report PLQ preliminary lot qualification PQ process qualification QAP quality assurance plan RFWD Request for Waiver or Deviation RMLQ Raw Material Lot Qualification SACN Setup Approval Control Number SSP specific shipping package SSPES SSP equipment specification SSSP simulated specific shipping package STR subcontract technical representative TR technical representative VOL volume 2.3 CODES/STANDARDS/ORDERS/REGULATIONS 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 2.4 APPLICABLE DOCUMENTS FOR CNS Y-12S USE ONLY The following documents apply when casting Packcrete.
RP-802282-0002 Packcrete Material Properties Y/DW-2345 Impact Properties of Packcrete Material at 40ºF and 100ºF
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 9 of 43
- 3. ITEM REQUIREMENTS Packcrete must be cast into a steel container specified in this equipment specification. 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 serial numbers for the casting shall be on the casting and recorded on proper casting forms.
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 satisfied.
3.2 DESIGN REQUIREMENTS NA 3.3 SERVICE CONDITIONS NA 3.4 FABRICATION AND ASSEMBLY REQUIREMENTS See production processing in Sect. 7.7.
3.5 INSTALLATION REQUIREMENTS NA 3.6 REQUIREMENTS NA 3.7 GOVERNMENT-FURNISHED MATERIAL, EQUIPMENT, SERVICES NA 3.8 SCHEDULE A manufacturing plan with written, step-by-step process plans shall be submitted to the Company 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 plan used to procure materials and manufacture Packcrete, major fabrication steps and sequence of operations, hold points to be determined for Company involvement, all in-process inspection/examination, and dimensional inspections and testing.
3.9 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. All records shall be traceable to the casting and identified by 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.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 10 of 43 3.9.1 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 casting serial number. 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.
3.9.2 Certification Data Documents Certification data documents are identified in Attachment A, and document measurements, testing, and calculations created during the performance of the work described in Sect. 7 as documented in Attachment E forms.
Certification data documents include raw material test reports (MTRs) in accordance with the requirements of Sect. 5.4.
The Seller shall provide a certification data package that connects all specified processing data collected to the particular casting.
3.10 PACKAGING, HANDLING, SHIPPING, AND STORAGE REQUIREMENTS See Sect. 5.2 for storage requirements for raw materials.
3.11 MARKING AND IDENTIFICATION REQUIREMENTS Packcrete as a material is not marked in any way. For production the procurement and processing records (forms) for Packcrete raw materials and procedures used shall be tracked by the manufacturing SSP serial numbers for the drum lid and body.
3.12 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 STR or subcontract administrator.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 11 of 43
- 4. QUALITY ASSURANCE REQUIREMENTS The Seller shall perform this work under a Company-approved quality assurance program that meets the applicable requirements of ASME NQA-1 2008, 1a-2009, Part 1, Sections 1-18 (excluding requirement 3), and 10 CFR Part 71, Subpart H, for packaging and transportation of radioactive materials.
The Seller shall submit a QAP for the scope of this work that describes the quality assurance policies and practices to be implemented in 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.
4.1 FINAL ACCEPTANCE TEST METHOD The final acceptance test method includes verification that 100% of the castings 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 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 LQ castings, the MTRs shall show that the materials meet the testing requirements and acceptance criteria specified in Sect. 5.4. The MTR number and the water weight shall be documented on Forms A and B (Attachment E).
Raw materials shall not be used until the Company has reviewed the MTRs and provided documented approval to use the materials.
4.3.1.2 Components Must Pass Geometric Inspection Requirements NA 4.3.1.3 Company Approval Setup for Lot Qualified Raw Materials Each change to the approved setup on Form A 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. 7.3.1.5), and vibration time.
Modifications to the vermiculite dry weight percent within the limits of Table 4 shall require written Company approval. Changing from one lot of raw materials to another shall require LQ testing and written Company approval. Approval requires positive testing results of LQ testing defined 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.
Changes to a Form A shall not be implemented for production castings until the Company has approved the changes. This approval process requires PLQ testing results. The Company may witness implementation
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 12 of 43 of the changes through PQ and review third-party qualification testing results/reports, and then provide its documented approval to proceed via second signatures on the Form As.
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 QUALITY REQUIREMENTS NA 4.5 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.
4.6 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.
4.7 TRAINING AND QUALIFICATION OF PERSONNEL 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.
4.7.1 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.
4.7.1.1 Packcrete mixing and vibration casting training Shall consist of successfully completing mixing and casting activities described in Sects. 7.2 and 7.3.
4.7.1.2 Packcrete curing and baking process training Shall consist of successfully completing curing and baking activities described in Sect. 7.4.
4.8 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.
4.9 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
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 13 of 43 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.
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.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 14 of 43 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 8.7 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 Samples shall be taken from all pallets selected at random and tracked to the pallet from which they were obtained. Pallets will remain in quarantine until the results of testing are obtained. Sampling and rejection criteria are in accordance with ASQ/ANSI Z1.4, Table II-A [general inspection level I, Acceptance Quality Level (AQL4)].
For example, a lot/batch size (bags) of 26 to 50 requires 5 samples. Seller to reject the entire lot/batch, if one or more samples do not meet the bulk density and particle size distribution acceptance criteria. For another example, a lot/batch size (bags) of 281 to 500 requires 20 samples. Seller to reject the entire lot/batch, if three or more samples do not meet the bulk density and particle size distribution acceptance criteria. Seller should notify Company if there is a lot/batch rejection.
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.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 15 of 43 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.
Table 2. Airalon 3000 55-gal drum acceptance criteria Reference Test Original lot Acceptance criteria*
ASTM C494, C260, or C233 Infrared analysis**
Attachment C Essentially similar to Attachment C 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.
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.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 16 of 43
- 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/pumper sits for >30 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.
6.2.1 Scales Requirements Scales used for weight measurements shall be calibrated and traceable to National Institute of Standards and Technology. All weighing operations of assemblies and materials shall be conducted on digital certified scales with a minimum accuracy of 0.5 lb.
6.2.2 Plaster or Mortar Mixers The Multiquips Whiteman WM70S-H8 (8-hp Honda engine) and the Whiteman WM70PE (1.5-hp electric motor) mixers with a 7 ft3 capacity have been used previously for Packcrete mixing. The WM70PE machine mixes 7 ft3 of material running at a slow rotation speed with the mixer vanes measuring between 19-27 rpm. The motor speed controller was set to a value of 28-38 rpm. Other models of plaster/mortar mixers may be used if the rotation speed and mix times are qualified in accordance with the requirements in Sect. 7 and approved by the Company. The maximum batch size that mixes well in the WM70PE mixer is approximately 2.7 ft3 using 22.5 lb of vermiculite. The electric motor bogs down with larger loads. The Whiteman WM90PE (3-hp electric motor) mixer with a 9 ft3 capacity is recommended to mix larger volumes. Blastcrete Equipment Co. has the D3522MP (mixer pump) that can mix batches up to 5 ft3 and dump them into a hopper and start mixing another batch. The hopper feeds a peristaltic pump that pumps the material to the end of the 2 diameter hose. No labor is required to move the mixed Packcrete using the mixer pump. Other mixers models may be used by the Seller if qualified in accordance with the requirements in Sect. 7 and approved by the Company.
6.2.3 Low Profile Platform Vibrator The VIBCO Low Profile Platform Vibrator (24-in. wide x 36-in. long) with the SCR-1000 adjustable eccentric vibrator, or a Company-approved equal, must be selected based upon the maximum estimated wet cast weight (EWCW). The vibration force and duration must be controllable for the container size and weight in accordance with the requirements in Sect. 7.3.1.6. Other models may be used by the Seller if qualified in accordance with the requirements in Sect. 7 and approved by the Company. Verify that the Low Profile Platform Vibrator selected has the capacity to generate the forces required in Sect. 7.3.1.6 and to cast the specific Type-B shipping package.
If other vibration equipment is used for a SSP, Sect. 6.2.3 and 7.3.1.6 must document all changes in the SSP casting using the PLQ equipment specification.
6.2.4 Table Vibrator A standard table vibrator from VIBCO with at least a 6-by 12-in. table top and an electric motor vibrator producing up to 100 lb of force should be used. This vibrator is required to vibrate small 4.5-gal or sample pipes cast during production when the table in 6.2.3 will be loaded with the shipping package.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 17 of 43 6.2.5 Time Clocks The Company recommends the use of two different types of time clocks. The first is a digital 24-h clock with the date that identifies the processes. The start time and date shall become a part of the unique identifier [e.g., alpha prefix (B, BQ, M, P, or SA) plus a 10-digit number for the start date and time of the process using a 24-h format (1021131415 is used for October 21, 2013, at 2:15 p.m.)] for the qualification, mixing, and baking processes.
The second type of time clock is a magnetic digital timer that measures both the mixer and vibration cycle times.
One timer should be used to measure each operation. The magnet lets the operators connect it to the mixer housing or other steel support.
6.2.6 Furnace with Temperature Recorded and Controller The furnace shall be a vented gas-fired or a forced convection fresh air circulating electric furnace with the heat zone verified with thermocouples to 500 +/- 25F at the baking location of the containers in the furnace.
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 +/- 20F.
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 PRELIMINARY LOT QUALIFICATION Packcrete PLQ requires using documented and approved equipment, equipment settings, operating procedures, containers, and raw materials that have passed third party inspections in Sect. 5.4. Packcrete properties are influenced by the raw materials (Sect. 5), equipment (Sect. 6), and process controls. The Packcrete PLQ is shown in Fig. 2.
This section provides the PLQ requirements for establishing a mix setup for casting the 4.5-gal pail, 30-gal drum, SSSP, and SSP. Section 7.5 establishes a process setup and adjusts the mixing and casting process if required to obtain the required wet and baked densities. Once the process setup is established, the Seller may cast a set of PLQ castings in a 30-gal drum and a set of six sample pipes. When the densities are acceptable, the 30-gal drum and sample pipes are sent for additional testing that is performed as defined in Sect. 9.
The PLQ options 1 and or 2 and sub-options are selected by the Seller based upon the Packcrete casting experience they have with the PLQ and SSP equipment specifications. It is recommended that new Sellers start with option 1 until they are confident to move to option 2. Before a Seller will be approved to cast a SSP by the Company confirmation samples must be cast and tested from a simulated specific shipping package (SSSP).
Once the PLQ setup is Company approved, the Seller shall follow Form A to produce a Form B (Attachment E) for each Packcrete batch and next follow the shipping package specific casting specification and cast a simulated shipping package. For FLQ the SSPES will reference this equipment specification for many mixing, casting, curing, baking, and testing operations. The difference between PLQ and FLQ is that the samples for testing come from a 30-gal drum or a SSSP. Depending upon the casting results and where the forms are used, the casting forms in Attachment E could be for approval as part of a certification data package.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 18 of 43 7.1 PROCESSING SETUP REQUIREMENTS The Packcrete processing setup requirements ensure that the Seller is following Company approved procedures, using acceptable raw materials, and that fabricated hardware has passed all inspections. Each castings serial number shall be traceable to the lots of materials used in the mixing process. All changes shall be documented in the Sellers procedures and approved by the Company. Final lot qualification (FLQ) will occur in the SSPES.
FLQs are possible using the six cast pipes and samples cut and tested from the SSSP. Tested samples must pass the testing requirements described in Sect. 9. Additional production sample set testing is defined in Sect. 8.2.
Fig. 2. Packcrete preliminary lot qualification.
7.1.1 Setup Verification It is recommended that new casting setups begin by using the nominal setup and casting the 4.5-gal pails documented on Form A (Attachment E) and identified by the SACN. Mixers and vibration tables must be qualified following this specification using the proper adjustments of rpm (frequency) (Sect. 7.3.1.5), and force settings based on the wet cast weight estimate (Sect. 7.3.1.6). Once confident in the SACN, the Seller may apply the manufacturing process to the 30-gal drum to gain more casting experience.
7.1.2 Preliminary Lot Qualifications (PLQs)
Following a SACN, and casting the 30-gal drum requires Forms A, B, D, E, and F for PLQ castings per Sect. 7.5.
The Seller is responsible for the PLQ baked Packcrete to have a density of 22.4 +/- 3 lb/ft3 and has the option to adjust the mixing recipe amounts in accordance with Sect. 7.1.4 or 7.1.5 and requalify the mixing, casting, vibration, curing, and baking processes to bring the baked density to the nominal values. Process changes made to processing times, adjustments to process equipment settings, or dry weight percent within a lot of raw materials require a new Form A to be approved by the Company.
7.1.3 Final Lot Qualifications The FLQ processes and testing are in this and the SSP equipment specification. FLQ is used to mitigate the risk of rejecting the baked Packcrete in the containers body and lid during production. FLQ requires material property testing confirmation using sample pipes and SSSP castings baked Packcrete to have a density of 22.4 +/- 3 lb/ft3.
FLQ is only completed after the Company has reviewed the FLQ testing results in comparison to acceptance criteria documented in RP-802282-0002, and the Form A SACN is signed by either the STR or TR or both. Once
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 19 of 43 the Company has approved the SACN, it may be used for production parts. Equipment replacement of like-for-like process equipment does not need to be re-qualified.
7.1.4 Change ControlHardware or Process Settings for Mixing, Vibrating, Curing, and Baking Any hardware change to the mixing or vibrating hardware shall be documented on a new Form A and reapproved by the Company. Each vibration force setting, time duration, temperature, and mixing recipe variable for the process qualification (PQ) shall be recorded on Forms C, D, E, and SSP and shall be repeated during production and documented on Forms D, E, and SSP. The Seller is responsible to follow this specification to generate a process that meets the baked density acceptance range. Hardware settings for the mixer rpm and mixing time for each additive are fixed using Form A.
7.1.5 Mixing Recipe Amounts and Adjustments This section defines the amounts of materials needed to mix Packcrete. To mix Packcrete, the first step in the mixing operation is to add water and Airalon 3000 to the mixing bin and mix until the mixture is saturated with tiny bubbles as shown in Fig. 3. The second step is to add Portland cement to the mixture and mix until a sloppy wet bubbly cement mixture is achieved. The third step is to add vermiculite to the mixture and mix until the vermiculite is fully coated with the wet cement mixture. The fourth step is to stop the mixer and verify the vermiculite is fully coated, as shown in Fig. 4. Mixing beyond the point when the vermiculite is fully coated will lead to higher wet and baked densities. The fifth step is to perform the ASTM C860, Sect. 6.2, Ball-In-Hand Test, to verify that the proper amount of water is in the mixture.
The Packcrete recipe in this section is based on the maximum weight of vermiculite that the WM70PE mixer can mix without bogging down or stopping. The vermiculite dry weight percent of 37.5% should be used as a starting recipe for the 4.5-gal sample casting to generate a recommended wet density range of 53.9 +/- 2.4 lb/ft3 (51.5 to 56.3 lb/ft3) that should yield a required baked density range of 22.4 +/- 1 lb/ft3 (21.4 to 23.4 lb/ft3). The 4.5-gal samples are smaller volumes; therefore, the density target range is different from the FLQ and production process ranges (i.e., recommended wet density range of 53.9 +/- 5.6 lb/ft3 and a recommended baked density range of 22.4 +/- 3 lb/ft3). The wet density will vary from batch to batch. If an adjustment to the average wet density recipe is needed, it must be made with written Company approval following Form A by adjusting the vermiculite dry weight percent between 35.5 and 39.5%, which should change the average wet density by about +/-1 lb/ft3. Higher vermiculite dry weight percent results in lower amounts of Portland cement and lower densities.
Note:AEAAiralon.
Fig. 3. Mixing Packcrete.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 20 of 43 Fig. 4. Mixing Packcrete, continued.
Table 3 provides the nominal recipe for a large batch (2.7 ft3) and a small batch (1.8 ft3). Table 4 provides the maximum adjustments needed to increase and decrease the wet density by ~1 lb/ft3. Each value in the tables is calculated by the equations in this section. The vermiculite dry weight percent also determines the Portland cement dry weight percent, and each dry weight requires its own amount of water to pass the ASTM C860, Sect. 6.2, Ball-In-Hand Test. In Table 4, adjustments in the amount of Portland cement and water in pounds were needed to increase or decrease the wet density of the starting mixture, with the vermiculite and Airalon 3000 remaining fixed. Adjusting the wet density from 52.9 to 55.0 lb/ft3 requires the addition of 6.42 lb of Portland cement and 3.85 lb (6.42 lb x 0.6) of water. The amount of water needed for the casting was based upon passing the ASTM C860, Sect. 6.2, Ball-In-Hand Test, during development. If the Ball-In-Hand Test fails, the water content must be adjusted accordingly.
The Tables 3 and 4 values are calculated using these equations:
For 22.5 lb of vermiculite and a nominal vermiculite dry weight percent of 37.5%, the amount of cement is calculated on a dry weight percent as follows:
Cement = verm x (1/%V - 1) = verm x (1/0.375 - 1) = verm x 1.6667 Cement = 22.5 x 1.6667 = 37.5 lb The water mass is calculated by the following equation.
Water = verm x 3.11 + cement x 0.6 Water = 22.5 x 3.11 + 37.5 x 0.6 = 92.48 lb The Airalon 3000 is measured by a graduated cylinder and is calculated using the following equation:
Airalon = verm / 0.375 (lb/ml) = 22.5 lb / 0.375 (lb/ml) = 60 ml
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 21 of 43 Table 3. Nominal recipe for a large batch and a small batch at wet density of 53.9 lb/ft3 Material Target wet density Airalon 3000 Vermiculite Vermiculite a Portland cement Water Volume Units lb/ft3 ml dry wt %
lb lb lb ft3 Tolerance
+/-2.4
+/-2
+/-0.1
+/-0.1
+/-0.3 Average large mixer load 53.9 60 37.5%
22.5 37.5 92.48
~2.7 Average small mixer load 53.9 40 37.5%
15.0 25.0 61.65
~1.8 a All mixer load sizes must be qualified before use. Use the vermiculite weight ratio to calculate the Airalon 3000, Portland cement, and water weights.
If the Packcrete setup described in Sect. 7.1.1 generates a wet density that is too high, the Seller may increase the amount of vermiculite to 39.5% weight percent to reduce the wet density. If the Packcrete wet density is too low, the Seller may reduce the amount of vermiculite to 35.5% weight percent to increase the wet density. Once changes have occurred in the Packcrete recipe, a new Form A shall be generated and new LQ testing shall be performed, as described per Sect. 7.1.2.
Table 4. Extreme recipes for a large Packcrete batch at wet densities of 52.9 and 55.0 lb/ft3 Material Target wet density Airalon 3000 Vermiculite Vermiculite a Portland cement Water Volume Units lb/ft3 ml Dry wt %
lb lb lb ft3 Tolerance
+/-2.4
+/-2
+/-0.1
+/-0.1
+/-0.3 Lower density mixer load 52.9 60 39.5%
22.5 34.46 90.65
~2.7 Higher density mixer load 55.0 60 35.5%
22.5 40.88 94.50
~2.7 a All mixer load sizes must be qualified before use. Use the vermiculite weight ratio to calculate the Airalon 3000, Portland cement, and water weights.
7.2 SETUP APPROVAL CONTROL NUMBER (FORM A) FOR PROCESS QUALIFICATION The purpose of the Packcrete setup process is to define and control the required mixer recipe material weights, mixer rotation speed, and mix times to properly mix and cast Packcrete. Form A (Attachment E) identifies the SACN that defines these recipe and mixing settings. The Seller shall create a new Form A for any unique vermiculite weight % or process setup change as defined in Sect. 7.1. The first time through the PLQ process, use the nominal recipe found in Table 3. If needed, the Packcrete recipe may be modified following the requirements in Sect. 7.1.5 up to the limits found in Table 4.
7.2.1.1 Using Form A, record the SACN.
7.2.1.2 Record the vermiculite wt %, mix volume (estimated), water weight, Airalon 3000, Portland cement, and vermiculite in accordance with Sect. 7.1.5. This defines the nominal recipe. Adjustments require written Company approval using Form A.
7.2.1.3 Record the serial number, manufacturer, and model number of the water filter in accordance with Sect. 5.5.
7.2.1.4 Record the mixer serial number, manufacturer, model number, speed control setting, and blade rotation speed in accordance with Sect. 6.2.2.
7.2.1.5 Record the vibration equipment serial number, manufacturer, model number, vibration speed setting, and vibration time in accordance with Sects. 6.2.3 and 7.3.1.6.
7.2.1.6 Use the Form A setup on a practice casting, such as the 4.5-gal pail or 30-gal drum, and document the results using the forms in Appendix E. The Seller may also proceed to preliminary lot qualifying of raw materials by
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 22 of 43 casting a set of six sample pipes per Sect. 9. Set up the casting following the requirements in Sect. 7.3 and perform casting following the requirements in Sect. 7.4.
7.2.1.7 Provide Form A that defines the mixing setup with the casting Forms C, D, E, and F (Appendix E) or form(s) in the SSPES that control the mixing, vibration casting, furnace, and baking to the Company as proof that baked density was within the acceptable limits. The Company TR and/or STR shall sign and concur with either wet ink or pdf electronic signatures on Form A for approval once the PLQ testing results have been confirmed to be acceptable. If needed go to the shipping container specification to cast a simulated shipping container used to cut testing samples for PQ.
7.2.1.8 FLQ and Company approval are required before any container production may start. Confirmatory testing results of a set of six sample pipes and testing samples cut from a SSSP cut and tested following Sect. 9.
7.3 PROCESSING PREPARATION FOR SAMPLES AND PARTS The purpose of processing samples and parts is to create and document a controlled Packcrete casting that follows an approved mixing setup defined on Form A. The same processes are used for casting samples and parts, with the vibration force being adjusted for EWCW of the container and on partial fillings of containers being vibrated for 10 s and turned off and vibrated for 1 min after filling is completed. These and other processing forms data are recorded on Forms C, D, and E or form(s) in the SSPES (for the SSSP).
7.3.1 SetupMixing, Vibration Casting, and Curing Samples and Parts The active mixing setup approved settings for that casting are on Form A (Attachment E) and identified by the SACN shall be followed for that container size. The Packcrete setup approval process is documented in Sect. 7.2 prior to proceeding to the PLQ process of casting the 30-gal drum documented in Sect. 7.5. The 4.5-gal pail Form C and 30-gal drum Form D have also been used to train and become familiar with Packcrete processing.
A concrete curing vibrator such as McMaster-Carr 7693T18, may be used to vibrate the Packcrete after pouring in a casting that is too large to move or use a vibration table to minimize large air bubbles. Additional vibrators and methods may be used to obtain acceptable Packcrete density in a simulated casting. Specific models of vibrators shall only be used if their use and applicable settings are qualified per the SSPES and documented in approved procedures.
Each unique EWCW of a sample or part shall have the vibration table force set as shown in Sect. 7.3.1.6 for the VIBCO SCR-1000. For a different VIBCO vibration motors use, contact the Company for the proper settings.
For samples, document the casting information on the proper Forms C, D, and E (Attachment E) or form(s) in the SSPES. Follow the SSPES for casting in shipping containers. For optional samples, use Forms C, D, and E or form(s) in the SSPES to record casting data. Adjustments shall be made to the casting vibration force settings based on the EWCW of the sample. The Seller shall complete the following steps:
7.3.1.1 Ensure that the mixer specified on Form A for SACN is properly cleaned in accordance with Sect. 6.1, and inspect its working surfaces for residues or foreign materials (e.g., oil, grease, or non-Packcrete material affixed to the surfaces) and excess waste material; clean if required.
7.3.1.2 Verify that the mixer blades are operating within the qualified mixer rotation speed range for the qualified mixing times. Determining total mixing rotations requires both the mixer speed and the time that the mixer runs at that rotation speed. The total number of rotations of the mixer blades shall be controlled by settings on Form A by SACN for each mix time and recipe ingredient. The mixer rotation speed and/or mix times may be modified to obtain the total number of mixer blade rotations. For the WM70PE mixer, see Sect. 6.2.2. Other mixer rotation speeds and times shall be qualified as needed.
7.3.1.3 Ensure that the mixer can transfer the Packcrete from the mixer into the container on the vibration table. If not, adjust the locations. Hand loading is also acceptable.
7.3.1.4 Verify that the force counter weights of the vibration table are set to generate a vibration of ~2.1 times the wet cast weight estimate per Sect. 7.3.1.6. Record this setting on the casting form. The speed setting is specified on Form A for the SACN.
7.3.1.5 Verify that the vibration setting on the table speed is set as specified on Form A for the SACN. The vibration casting frequency for SCR-1000, or a Company-approved equal, shall be held fixed at 80% of 4000 rpm speed, generating ~53 Hz (3200 vpm) to properly cast Packcrete (Sect. 6.2.3). Ensure that the speed setting
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 23 of 43 is fixed and not free to change. Higher vibration forces (Sect. 7.3.1.6), frequency, and durations result in higher wet and baked densities.
7.3.1.6 Vibration force is defined by the manufacturer and shown in Attachment D for the VIBCO SCR-1000. (The table in Attachment D was used to select a force at a setting and to create an equation that defines the forces between the settings.) Verify that the force eccentric counter weights of the vibration table (shown in Fig. 5) are set in accordance with Table 5 or the equations in the section generated from the force settings in Attachment D. The vibration intensity (vibration force / wet cast weight estimate) must be around 2.1+/-.6 times the EWCW.
Since the EWCW is ~38 lb for the 4.5-gal metal pail, 74 lb for the 30-gal drum EWCW is ~255 lb with a vibration force of 532 lb, the PQ for each size casting must have the unique vibration force modified for that casting. To generate force settings between the table values, use the following equation to estimate the vibration force at a set value:
For the VIBCO SCR1000 VForce = 33.9xSet No.2 + 449.6xSet No. - 380 lbf VForce = 33.9x1.12 + 449.6x1.1 - 380 = 74 lbf (Set No.@ 1.1)
Use a 2.1 vibration intensity force multiplier for the EWCWs and round to the nearest tenth for loads less than 500 lb. If the EWCW is between 500 to 730 lb, the maximum vibration force setting of SCR-1000 is 6, and the vibration force is 1100 lb. For containers over 730 lb, a different vibration source must be developed.
For the VIBCO SCR-1000 Set No. = 6.63 (150612 285xEWCW).5 / 67.8 Set No. = 6.63 (150612 285x38).5 / 67.8 Set No. = 1.1 (EWCW@38 lb)
Table 5. Vibration settings Casting SCR-1000 Set No. a Vibration force b (lb)
Estimated wet cast weight c (lb)
Vibration intensity 4.5-gal metal pail 1.1 74 38 1.94 30-gal metal drum 2.5 532 255 2.09 a Vibration force setting numbers for the VIBCO SCR-1000 are shown in Attachment D.
For other vibration motors, document the changes in the specific shipping package equipment specification and contact the Company for force settings and approval.
b Recommended vibration force settings for the VIBCO SCR-1000 shown in Attachment D.
Vibrate for 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.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 24 of 43 Fig. 5. VIBCO SCR1000 default eccentric counter weight set at 3 (675 lb).
7.3.1.7 Inspect the inner surfaces of the empty container. Ensure that it is free of oil, grease, free liquids, and waste material; clean as needed per Sect. 6.1.
7.3.1.8 Prepare the Packcrete raw materials by performing the following actions:
7.3.1.8.1 Transfer the SACN from Form A to Form B.
7.3.1.8.2 Transfer the required measurement amounts from Form A to Form B.
7.3.1.8.3 Record the water chlorine measurement on Form B each day.
7.3.1.8.4 Verify that the mixing area has acceptable environmental setup per Sect. 6.3.1.
7.3.1.8.5 Verify that the mixing area has acceptable mixing water per Sect. 6.3.2.
7.3.1.8.6 Verify that the curing area has acceptable environmental setup per Sect. 6.3.3.
7.3.1.8.7 Verify that the bags of materials were stored properly and are not damaged per Sect. 6.3.4.
7.4 PROCESSMIXING AND VIBRATION CASTING, CURING, AND BAKING FOR SAMPLES AND PARTS The active mixing setup approval settings on Form A (Attachment E) identified by the SACN from Sect. 7.2 shall be followed once approved. Mixers and vibration table speed setting are qualified following Form A for the rpm or frequency (Sect. 7.3.1.5). The vibration force (Sect. 7.3.1.6) must be calculated for each unique casting size.
Record the vibration force setting on casting Forms C, D, and E (Attachment E) or form(s) in the SSPES for each casting. Place a check on the casting form next to the setting once the vibration motor is set. For optional samples Forms C, D, and E or form(s) in the SSPES are used to record casting data. Adjustments shall be made to the casting vibration force settings based on the wet cast weight estimate.
7.4.1 ProcessMixing and Vibration Casting for Samples and Parts The Seller shall complete the following steps:
7.4.1.1 Weigh and record the container weight clean and empty on Forms C, D, and E (Attachment E) or form(s) in the SSPES.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 25 of 43 7.4.1.2 Weigh and record the container weight filled with water on Forms C and D or form(s) in the SSPES.
For Form E, the filled with water weight is replaced with a calculated volume and wet cast weight estimate.
Record the container volume.
7.4.1.3 Record the MCN, SACN, Vermiculite wt. %, Water Filter replacement date and weather is current on Form B.
7.4.1.4 Verify that the mixer speed rpm is set according to SACN.
7.4.1.5 On Form B, record daily mix waters chlorine value and check that it is acceptable.
7.4.1.6 Weigh and record the mixing waters temperature on Form B and the air temperature.
7.4.1.7 Inspect material bags for visible damage; discard damaged bags (such as water damage) and check that they are acceptable.
7.4.1.8 Weigh and record the Portland cement and vermiculite to the recipe on Form A for the SACN using a certified scale and record on Form B.
7.4.1.9 Measure the amount of Airalon 3000 shown in the recipe on Form A for the SACN in a graduated cylinder and record on Form B.
7.4.1.10 Add water and Airalon 3000 to the mixer and mix for at least 1 min, add Portland cement to the mixer and mix for at least 1 min, and add vermiculite to the mixer and mix for 50-70 s in accordance with the SACN recorded on Form A. For each mix, record the MCN and the SACN on a unique mixing Form B.
7.4.1.11 Ensure that the mixture is uniform and thoroughly mixed with minimal visible dry material and free liquids remaining in the mixer. If required, adjust the mix times until the mixture is uniform and modify the SACN and send it for Company approval.
7.4.1.12 If the mix looks too dry or wet, perform the ASTM C860, Sect. 6.2, Ball-In-Hand Test. If the test fails, adjust the water content accordingly, record any changes to be applied on the next mixer batch, generate a new Form A to request approval for a new SACN, and discard the mixer load. Contact the Company to approve the new Form A and new SACN.
7.4.1.13 Record the vibration table force setting on the casting Forms C, D, and E or form(s) in the SSPES in accordance with Table 5 in Sect. 7.3.1.6 if applicable. If other vibration sources are used document them in SACN (Form A).
7.4.1.14 Set the vibration speed setting on the table (SCR-1000 @ 80%) per Sect. 7.3.1.5 and record it on Forms C, D, and E or form(s) in the SSPES. Ensure that the speed setting is fixed and not free to change.
7.4.1.15 Start and stop the vibration table based on the vibration cycle time. For partial castings, vibrate the container 10 s and stop. Once the casting is full, vibrate for 1 min and record the vibration setting, vibration force, and vibration intensity on Forms C, D, and E or form(s) in the SSPES.
7.4.1.16 While the casting is wet, scrape the casting opening, clean the container, and measure and record the actual wet cast weight on Forms C, D, and E or form(s) in the SSPES.
7.4.1.17 Calculate the wet density, record the wet density on Forms C, D, and E or form(s) in the SSPES and verify that the wet density is within the acceptable limits on the casting forms. Section 7.1.5 defines the recommended wet density range. If the wet density is not within the acceptable limits, it is recommended to discard the container load, adjust the vermiculite dry weight percent and water weight as defined in Sect. 7.1.5, obtain written Company approval by repeating the SACN Form A, and repeat steps starting with Sect. 7.4.1.1. If the adjustment limits are met and the wet density is still out of specification, contact the Company.
7.4.2 ProcessCuring for Samples and Parts The Seller shall complete the following steps:
7.4.2.1 If the curing area has an acceptable environment as defined in Sect. 6.3 and the cast wet density is acceptable, move to curing area.
7.4.2.2 Cover the casting with plastic and initial cure for 4-30 h.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 26 of 43 7.4.2.3 For sample pipes, after initial curing and before baking, the plug in the sample pipe will need to be removed.
Scrape both ends of the casting to a flatness of 0.02 in. The flush cast side needs to be finished to a depth of 0.3 +/- 0.05 in. and the plug side needs to finished to a height of 4.5 +/- 0.05 in. from the fill hole end. This flatness can be obtained by using a drill press and large flat bottom bit made from sheet metal and welded to a small rod. The bit should just fit inside the sample pipe, and as the drill bit turns, the sample pipe is slid in a small circle, scraping the bottom of the casting flat. Remove the scraped Packcrete shavings from the sample pipe before baking.
7.4.2.4 After scraping, clean the parts, cover them with plastic, and store in the curing area until fully cured.
7.4.2.5 Cure at least 7 days before baking based upon the estimated BCN MCN and record cure time on Forms C, D, E, and SSP.
7.4.2.6 Weigh and record the before baking weight on Forms C, D, and E or form(s) in the SSPES.
7.4.3 ProcessBaking for Samples and Parts The Seller shall complete the following steps.
7.4.3.1 Using a large vented furnace separate the castings as much as possible to ensure proper airflow and radiation heat transfer for each casting.
7.4.3.2 Place the cured castings into the furnace.
7.4.3.3 Record the BCN on Forms C through E for all casting parts in the furnace.
7.4.3.4 For parts, on Form F, record the number of each casting loaded into the furnace. Calculate the sub-total volume of each casting type and the total volume of the furnace load for the BQCN.
7.4.3.5 Calculate and record the actual cure time on Forms C, D, and E or form(s) in the SSPES for all casting parts before the furnace is started. Assure the cure time is over 7 days.
7.4.3.6 Set the initial furnace set point temperature to 200°F.
7.4.3.7 Hold the temperature at 200°F for 4 h and record date and times on Form F.
7.4.3.8 Increase the furnace set point temperature to 275°F.
7.4.3.9 Hold the temperature at 275°F for 1 h and record date and times on Form F.
7.4.3.10 Increase the furnace set point temperature to 350°F.
7.4.3.11 Hold the temperature at 350°F for 1 h and record date and times on Form F.
7.4.3.12 Increase the furnace set point temperature to 425°F.
7.4.3.13 Hold the temperature for at 425°F 1 h and record date and times on Form F.
7.4.3.14 Increase the furnace set point temperature to 500°F.
7.4.3.15 Hold the temperature at 500°F steady state and record date and times on Form F.
7.4.3.15.1 For baking small samples, a qualified baking time of at least 40 h has been shown to be successful. Record the 500°F bake time on Form F. Optionally, the samples may be placed in the furnace with simulated shipping package specific parts following Form F.
7.4.3.15.2 Record the 500°F baking time on Form F for the volume of castings in the furnace by placing a bottom center thermocouple (BCT) to measure the temperature of the bottom center of the simulated shipping package specific parts inner liner for the current furnace loading located at the coolest location in the furnace (near the door edge seals). For the 30-gal drum, place the BCT in the center of the casting, 6-in. deep. Record the minimum 500°F holding time when the BCT temperature is >425°F and no increase in the BCT over 2°F in 6 h of baking. This minimum 500°F baking time shall be recorded along with the furnace cubic foot casting volume to qualify the unique furnace load with the BQCN plus the volume in cubic feet.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 27 of 43 7.4.3.15.3 A qualified baking time at 500°F shall be used for simulated shipping package specific parts, and samples of equal or less casting volume identified by the BQCN and recorded on Form F. The BCT is not required.
7.4.3.16 After the minimum baking time is met for 500°F, turn off the furnace and let the castings slowly cool down with the door closed for at least 8 h.
7.4.3.17 Remove castings and allow cooling in air until they reach ambient temperature.
7.4.3.18 Weigh and record the after baking weights on Forms C, D, and E or form(s) in the SSPES.
7.4.3.19 Calculate and record the baked density on Forms C, D, and E or form(s) in the SSPES using the equation at the bottom of the form.
7.4.3.20 Verify that the baked density is within the recommended acceptable limits at the bottom of the form.
7.4.3.20.1 For an SACN casting with the acceptable baked density, submit completed Forms A, B, C, and F for 4.5-gal pail sample to the Company for approval with the PLQ testing results. If approved, go to Sect. 7.6.
7.4.3.20.2 For an unacceptable baked density and this is the first failure, go to Sect. 7.4.1 and repeat this process.
7.4.3.20.3 For an unacceptable baked density and multiple failures have occurred, go to Sect. 7.1.4 or 7.1.5 and adjust the weight percent of vermiculite in the mixture and repeat the SACN casting in Sect. 7.4.1.
7.4.3.20.4 For an unacceptable baked density and multiple failures have occurred and the vermiculite weight percent is at the acceptable bounds shown in Sect. 7.1.5, contact the Company for guidance.
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 while the 30-gal drum needs Forms A, B, D, and F (Attachment E) 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 PACKCRETE PIPE SAMPLES FOR PRELIMINARY AND FINAL LOT QUALIFICATION 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.
- 8. PACKCRETE PLQ AND PRODUCTION TEST SAMPLES The purpose of this section is to describe exception(s) to the processing steps described in detail in Sect. 7 for each type of sample if additional Packcrete testing samples are needed. Each unique vibration casting process is addressed.
In addition to its unique casting control form [Forms C, D, and E or form(s) in the SSPES], Forms A, B, and F are needed for each sample and each type of sample to ensure that vibration force is adjusted to generate a vibration intensity approximately 2.1 times the estimated wet weight as required in Sect. 7.3.1.6. This ensures that the samples for the 4.5-gal pail, 30-gal drum, sample pipes, SSSP are set to the proper force setting.
Each Packcrete sample shall be marked and tracked from its origin.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 28 of 43 8.1 PACKCRETE 4.5-GAL PAILS Form C defines the data required to vibration cast the 4.5-gal pails according to the requirements in Sect. 7.5 and is used to gain casting experience.
8.2 PACKCRETE PRODUCTION SAMPLING SET The production sampling set shall consist of a 30-gal drum (Sect. 8.5) or SSSP casting following the SSPES and six pipes (Sect. 8.7). This sample set shall be tested in accordance with Sects. 9.2-9.6. The results should be sent to the Company. The 30-gal drum may only be used to replace the SSSP casting in the production sampling set once equivalences has been demonstrated with test results.
8.3 PACKCRETE 30-GAL SAMPLE DRUM Each 30-gal sample drum manufacturing method shall follow the requirements in Sects. 7.3 and 7.4. Mark and record the Packcrete 30-gal sample drum information on Form D (Attachment E).
8.4 PACKCRETE BRICK SAMPLES PER ASTM C862 Packcrete bricks (9 x 4.5 x 2.5 in.) manufactured for tests that comply with the requirements of ASTM C862 shall be cut from a 30-gal casting that meets the requirements of both Sect. 7 and ASTM C862, note 7.
8.5 PACKCRETE SAMPLE PIPES Each pipe sample manufacturing method shall be qualified as defined in Sect. 7. Mark and record the unique pipe sample information on Form E (Attachment E). A watertight plug should be inserted into one end 4.8-in. deep from the fill hole. The Packcrete shall be cast into the pipe sample flush and scraped following the instructions in Sect. 7.4.2.3.1. The EWCW of a single pipe sample is ~7.5 lb.
- 9. PACKCRETE FINAL LOT QUALIFICATION PROPERTIES LIMITS Chemical and mechanical properties shall be evaluated to document and qualify the lot of raw materials for use in producing Packcrete. Some of these values are defined in Sects. 5-7, and others are not. This section defines additional testing and references RP-802282-0002 for the acceptance ranges and as specified in the SSPES. The PLQ test samples may be taken from a 30-gal drum. FLQ test samples may be taken from a SSSP and a set of six sample pipes. Additional material test sample production is defined in Sect. 8 when directed by the Company.
A 30-gal drum (preliminary) or SSSP (final) and a six pipe sample set are used for this testing.
9.1 WET AND BAKED DENSITIES The casting specification uses the wet density as a manufacturing guide to help control the baked density; therefore, the wet density is not important to the safety of the shipping package. The baked density for each casting shall be within the acceptable range of 22.4 +/- 3 lb/ft3, as defined in Sect. 7. The density of the containers will be tested by the Seller for 100% of the castings in accordance with Company-approved procedures.
9.2 DYNAMIC IMPACT CRUSH STRENGTH Determination of the dynamic impact crush strength involves a set of high-speed compression impact tests performed by the Company using cast sample pipes, as defined in Sect. 8.5 and is not required for acceptance of the packages. The supplier is responsible for producing the pipes and sending the pipes to the Company for testing. A total of six sample pipes are needed for these tests. These tests shall be tested at each temperature in accordance with Instructions for Operating 20K-Pound MTS High-Rate Load Frame and Thermotron Test Chamber and Performance of High-Rate Impact Tests, from Y/DW-2345. The acceptable bounding values are listed in RP-802282-0002.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 29 of 43 9.3 CHEMICAL COMPOSITIONS OF THE CONSTITUENTS Three samples taken from a 30-gal drum (preliminary) or SSSP (final) are needed for verifying the chemical composition. Each sample shall be oven dried at 45°C. Oxide analysis X-ray fluorescence spectrometry samples shall be fused at 1000°C with Li2B4O7/LiBO2. X-ray fluorescence oxide analysis shall meet the precision and accuracy requirements for rapid methods per ASTM C114-11b requirements. The Packcrete chemical composition acceptable bounding values are listed in RP-802282-0002.
9.4 THERMAL CONDUCTIVITY Three samples cut from a 30-gal drum (preliminary) or SSSP (final) casting with an acceptable baked density are needed for verifying the thermal conductivity. The thermal conductivity of the samples is measured following ASTM C1113. The thermal conductivity is measured at 20, 100, 200, 300, 400, 500, 600, 700, and 800°C. The three test values shall be averaged at each temperature. These averaged values shall be between the acceptable values listed in RP-802282-0002.
9.5 SPECIFIC HEAT CAPACITY Three samples cut from a 30-gal drum (preliminary) or SSSP (final) casting with an acceptable baked density are needed for verifying the specific heat capacity. The specific heat capacity shall be tested from 35 to 995°C and in 10°C increments following ASTM E1269 requirements. The three test values shall be averaged at each temperature. These values shall be between the acceptable values listed in RP-802282-0002.
9.6 LINEAR THERMAL COEFFICIENT OF EXPANSION Three samples cut from a 30-gal drum (preliminary) or SSSP (final) casting with an acceptable baked density are needed for verifying the linear thermal coefficient of expansion. The linear thermal coefficient of expansion shall be tested following ASTM E228 requirements at a temperature range of 170 to 290°C at 10°C increments.
The average of the three tests values from 40 to 150°C shall be between the acceptable values listed in RP-802282-0002.
9.7 ELASTIC MODULUS The elastic modulus for Packcrete is derived from dynamic impact strength testing results defined in Sect. 9.2, and this property has been found to not be important to the safety of the shipping package. No samples or testing is required for the elastic modulus verification. The average test values shall be between the acceptable values listed in RP-802282-0002.
9.8 POISSONS RATIO Uncompressed (elastic) and compressed (plastic) Poissons ratio in the past has been assumed based upon similar types of material and the state of the material. The exact value is not important to the safety of the shipping package. No samples or testing is required for the Poissons ratio verification. Further explanation is found in RP-802282-0002.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 30 of 43 ATTACHMENTS ATTACHMENT A: SUBMITTAL CHECK LIST
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 31 of 43
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 32 of 43 SUBMITTAL SCHEDULE FORMAT SUBMITTAL PURPOSE AA After Award PTM Prior to Mobilization CD Compact Disk FI For Information AI After Issue PTS Prior to Shipment DVD Digital Video Disk FA For Action AIT After Inspection/Test PTT Prior to Test EM E-Mail AM After Mobilization PTW Prior to Weld EN Electronic (Native)
AP After Proposal/Bid Q
As Required EP Electronic (PDF)
ATS At Time of Shipment (Separately)
R As Requested O
Original B
Before Balance of Payment WP With Proposal/Bid P
Prints/Photocopies NTP Notice to Proceed PH Photographs PTC Prior to Construction/Commencing Work S
Sample PTD Prior to Delivery X
X-rays PTF Prior to Fabrication PTFA Prior to Final Acceptance/At Completion PTL Prior to Lift Packcrete Casting Submittal Check List Item No.
Reference Requirement Description Schedule Format a No. of Copies Submittal Purpose 3.8 Manufacturing Plan PTF EP 1
FA 3.9.1 Excel Submittal Checklist Q
EM, EN AR FI 3.9.1 Approval Data documents for Packcrete processes procedures for weighing, mixing, pouring, vibrating, curing, and baking.
PTF EP 1
FA 3.9.2a Raw Material Test Reports and Third Party Test Laboratory Certificate of Conformance (COC)
PTF EP 1
FA 3.9.2a Copy of mixing materials COC PTF EP 1
FA 3.9.2a Certification Data Package PTD EP 1
FA 3.9.2a Approved Procedures used PTF EP 1
FA 4
Quality Assurance Plan WP EP 1
FA 4.7 Training and Qualification of Personnel PTF EP 1
- 6.
Written Plan for cleaning, equipment, work, and storage environments PTF EP 1
FA 7.2 Mixing Setup Control Number (SACN) Process Verification (Form A)
PTF EP 1
FA 7.5 Setup Approval Process Verification4.5-gal Pail or 30-gal Drum PTF EP 1
FA, FI 7.6 Lot Qualification Castings PTF EP 1
FA, FI 9.3 Chemical Compositions of the Constituents PTF EP 1
FI 9.4 Thermal Conductivity PTF EP 1
FA 9.5 Specific Heat Capacity PTF EP 1
FA 9.6 Linear Thermal Coefficient of Expansion PTF EP 1
FA 9.7 Elastic Modulus PTF EP 1
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 33 of 43 Packcrete Casting Submittal Check List Item No.
Reference Requirement Description Schedule Format a No. of Copies Submittal Purpose Att. E Form A Packcrete Setup Approval PTF EP 1
FA, FI Att. E Form B Packcrete Mixing for Samples and Parts PTD EP 1
FA, FI Att. E Form C Packcrete Sample 4.5-Gal Pail Vibration Casting Control PTD EP 1
FA, FI Att. E Form D Packcrete Sample 30-Gal Drum Vibration Casting Control PTD EP 1
FA, FI Att. E Form E Packcrete Sample Pipes Vibration Casting Control PTD EP 1
FA, FI Att. E Form F Packcrete Furnace and Baking PTD EP 1
FA, FI a The Certification Data Package must also have one printed hard copy of the entire certification data.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 34 of 43 ATTACHMENT B: REQUEST FOR WAIVER/DEVIATION SAMPLE FORMS See the STR for updated forms.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 35 of 43 Attachment C: Airalon 3000 Infrared Analysis
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 36 of 43 ATTACHMENT D: VIBCO VIBRATION FORCE SETTINGS
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 37 of 43 ATTACHMENT E: PACKCRETE PROCESSING FORMS 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 M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 38 of 43 Form A Packcrete Setup Approval Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Casters company name (Sellers name)
Setup Approval Control Number (SACN) a SA __ __ __ __ __ __ __ __ __ __
Check control mix times Water and Airalonat least 1 min, Portland cementat least 1 min more, vermiculite50-70 s more.
Equipment Manufacturer Model No.
Serial No.
Operator Witness Mixer Vibration table Measurement Comments Measure Units Operator Witness Vermiculite (wt %)
Estimated mix volume ft3 Mixer speed control setting rpm Mixer blade rotation speed b Measured rpm
[1200 / time_____ (s)]
rpm Vibration speed setting c 80% (4000 rpm, 53 Hz)
Vibration time once full 1 min min Water weight lb Airalon 3000 (AEA)
Material Test Report No.
ml Type III Portland cement Material Test Report No.
lb Vermiculite, Type 1, Grade 3 Material Test Report No.
lb Company TR approver d Date Company STR approver d Date a SA alpha prefix plus a 10-digit control number is used to document the starting date and time of the setup approval using a 24-h format (i.e., SA1021081515 is used for October 21, 2008, at 3:15 p.m.).
b Measure the time required to rotate the mixer blades 20 times and calculate the measured rpm [1200 / time (s)].
c The vibration speed setting follow Sect. 7.3.1.5 and the force setting must follow Sect. 7.3.1.6 based upon the castings wet weight.
d Written Company approval is required to execute this form. Either wet ink or pdf electronic signatures are acceptable from the technical representative (TR) or subcontract technical representative (STR) after the Lot Qualification testing is successfully completed.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 39 of 43 Form B Packcrete Mixing For Samples and Parts Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Casters company name (Sellers name)
Y-12 observers present Mix Control Number (MCN) a M __ __ __ __ __ __ __ __ __ __
Setup Approval Control Number (SACN) b SA __ __ __ __ __ __ __ __ __ __
Part Serial Number / s Packaging name Water Filter c Replacement Date (mm/dd/yy)
Pass Fail Check control mix times Water and Airalonat least 1 min, Portland cementat least 1 min more, vermiculite50-70 s more.
Measurement Comment Measure Units Operator Witness Vermiculite (wt %)
Estimated mix volume ft3 Mixer speed setting rpm Daily mix water chlorine c Pass Fail ppm Water temperature d
°F Water weight d lb Air temperature
°F Airalon 3000 (AEA) ml Verify cement bag quality e Pass Fail Type III Portland cement lb Verify vermiculite bag quality e Pass Fail Vermiculite, Type 1, Grade 3 lb Wet density Target 53.9 +/- 5.6 lb/ft3 (48.3-59.5 lb/ft3) lb/ft3 a M, P, or SA alpha prefix plus a 10-digit control number is used to document the starting date and time of the Mixing process using a 24-h format (i.e., M1021081515 is used for October 21, 2008, at 3:15 p.m.).
b SACNSetup Approval Control Number is obtained from Form A and indicates the date and time that the setup approval was started.
c Potable water that has been filtered through at least a 20-micron filter and has chlorine content <4 mg/l (4 ppm, 0.0004%
by mass). Record the date the filter shall be replaced and check the box to document its maintained.
d Record the water weight and temperature within 10 min from completion of the weighing process.
e Record the bags quality. A damaged bag that appears to have been wet or to have been torn open and is leaking prior to shift start shall not be used.
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 40 of 43 Form C Packcrete Sample 4.5-Gal Pail Vibration Casting Control Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Casters company name (Sellers name)
Y-12 observers present Mix Control Number (MCN) a M __ __ __ __ __ __ __ __ __ __
Serial Number Measurement Comment Measure Units Operator Witness Clean and empty Estimated 2.96 lb lb Filled with water b Estimated 42.46 lb lb Water temperature b
°F Container volume Estimated 0.634 ft3 ft3 Vibration table force setting c
- 1.1, 74 lbf lbf Wet cast weight Estimated 38 lb lb Vibration intensity ~ 2.1 Force / Wet Weight Vibration table speed setting c 80%
Full vibration time 1 min min Wet cast weight Target 36.69-39.73 lb lb Wet density d Target 53.9 +/- 2.4 lb/ft3 lb/ft3 Measured wet density (51.5 to 56.3 lb/ft3) acceptance Accept Reject d Scrape the top and weigh lb Cure time (at least 7 days)
BCN - MCN days Before baking weight lb Baking Control Number (BCN) a After baking weight lb Baked density e Target 22.4 +/- 1 lb/ft3 lb/ft3 Density Wet Density Baked Measured baked density (21.4 - 23.4 lb/ft3) acceptance Accept Reject d a M, or B alpha prefix plus a 10-digit control number is used to document the starting date and time of the process using a 24 h format (i.e., M1021081515 or B1021081515 is used for October 21, 2008, at 3:15 p.m.).
b Record the water weight and temperature within 10 min from completion of the weighing process.
c Document the vibration force (Sect. 7.3.1.6), frequency (Sect. 7.3.1.5) settings and duration are set.
d The recommended wet density of 51.5-56.3 lb/ft3 and baked density of 21.4-23.4 lb/ft3 is to ensure castings on Form F have a baked density within 19.4-25.4 lb/ft3. The Seller may waive these recommendations and proceed at risk. 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
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 41 of 43 Form D Packcrete Sample 30-Gal Drum Vibration Casting Control Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Casters company name (Sellers name)
Y-12 observers present Serial Number Measurement Comment Measure Units Operator Witness Clean and empty Estimated 28 lb lb Filled with water b Estimated 288 lb lb Water temperature b
°F Container volume Estimated 4.2 ft3 ft3 Wet cast weight Estimated 255 lb lb Vibration table force setting c
- 2.5, 532 lbf lbf Vibration intensity ~ 2.1 Force / Est. Wet Wgt.
Vibration table speed setting c 80%
Operation Mix Control Number (MCN) a Vibration duration e Time Operator Witness Pour Start 1 e 10 s
Pour Start 1 e 10 s
Pour Start 1 e 10 s
Full vibration time 1
min Wet cast weight Target 224-284 lb lb Wet density e Target 53.9 +/- 5.6 lb/ft3 lb/ft3 Measured wet density (48.3 - 59.5 lb/ft3) acceptance Accept Reject d Scrape the top and weigh lb Cure time (at least 7 days)
BCN - MCN days Before baking weight lb Baking Control Number (BCN) a After baking weight lb Baked density e Target 22.4 +/- 3 lb/ft3 lb/ft3 Density Wet Density Baked Measured baked density (19.4 - 25.4 lb/ft3) acceptance Accept Reject d a M alpha prefix plus a 10-digit control number is used to document the starting date and time of the process using a 24 h format (i.e., M1021081515 is used for October 21, 2008, at 3:15 p.m.).
b Record the water weight and temperature within 10 min from completion of the weighing process.
c Document the vibration force (Sect. 7.3.1.6), frequency (Sect. 7.3.1.5) settings and duration are set.
d The recommended wet density of 48.3-59.5 lb/ft3 and baked density of 19.4-25.4 lb/ft3 is to ensure castings.
e For partial casts, vibrate the drum 10 s and stop. Once full, vibrate for 1 min.
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
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 42 of 43 Form E Packcrete Sample Pipes Vibration Casting Control Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Casters company name (Sellers name)
Y-12 observers present Mix Control Number (MCN) a M __ __ __ __ __ __ __ __ __ __
Serial Number b Measurement Comment Measure Units Operator Witness Empty container weight lb Container volume Estimate ft3 Wet cast weight Estimate ft3 Vibration table force setting c lb Vibration intensity ~ 2.1 Force / Wet Weight Vibration table speed setting c 80%
Full vibration time c 1 min min Baked measurement
___-P1 ___-P2 ___-P3 ___-P4 ___-P5 ___-P6 Operator Witness Label sample b Before Baking d Internal diameter (ID) (in.) d Clean and empty (lb) d Wet cast (lb) d After baking (lb) d Baked internal height (BIH)
(in.) d Volume (ft3) d Wet density (lb/ft3)
Baked density (lb/ft3) d Density Wet Density Baked Cure time (at least 7 days)
BCN - MCN days Baking Control Number (BCN) a B __ __ __ __ __ __ __ __ __ __
a M, or B alpha prefix plus a 10-digit control number is used to document the starting date and time of the process using a 24-h format (i.e., M1021081515 or B1021081515 is used for October 21, 2008, at 3:15 p.m.).
b A record Serial Number plus a unique pipe number is assigned to each casting.
c Document the vibration force (Sect. 7.3.1.6), frequency (Sect. 7.3.1.5) settings and duration are set.
d Use these weights to calculate the wet density and baked density as shown below, then contact the Company for disposition.
Volume = 2200.16 BIH ID 2
ft3 Wet density =
Volume
)
(
pty CleanAndEm WetCast lb/ft3 Baked density =
Volume
)
(
pty CleanAndEm g
AfterBakin lb/ft3
SPC M801794-0003 000 01, Packcrete Preliminary Lot Qualification Page 43 of 43 Form F Packcrete Furnace and Baking Specification Number Revision Issue date (mm/dd/yy)
Revision date (mm/dd/yy)
Baking company name (Bakers name)
Casters company name (Sellers Name)
Baking Control Number (BCN) a B __ __ __ __ __ __ __ __ __ __
Bake Qualification Control Number-Vol (BQCN-Vol) a BQ __ __ __ __ __ __ __ __ __ __ - __ __ __
Furnace Serial Number Bake start date (mm/dd/yy)
Bake start time (24-h format)
Computer data file name b Measurement Pass Fail Operator Witness Baking process control Furnace (check or NA)
Start time Start date Stop time Stop date Operator Witness Baking Cycle 1 200°F for 4 h Baking Cycle 2 275°F for 1 h Baking Cycle 3 350°F for 1 h Baking Cycle 4 425°F for 1 h Time BCT temperature >425°F c Time at least 6 h, BCT < 2°F increase Part baked Estimated volume (ft3)
Number in furnace Subtotal (ft3)
Operator Witness Samples 4.5-gallon pail 0.63 30-gallon drum 4.20 4NPS pipes 0.03 Total volume (ft3)
Comments a B and BQ are alpha prefix plus a 10-digit control number is used to document the start date and the time of baking and process qualification using a 24-h format (i.e., B1021081515 is used for October 21, 2008, at 3:15 p.m.). For the BQCN-Vol, the -Vol represents the maximum total oven casting volume in cubic feet that is qualified (i.e., BQ1021081515-150 is qualified for a casting load of 150 ft3).
b The sample baking cycle time and temperature data could be presented both in a digital and graphical form. For example, an Excel file showing the original data and time verses temperature plots shall be acceptable.
c BCTbottom center thermocouple. Calculate the baked density as shown on Form F following this furnace heating cycle phase.
Record the 500°F holding time when the core temperature is >425°F and no increase in the BCT over 2°F in 6 h of baking.