ML102920346

Email - from: Williams, Charles R. (Charles.Williams@Pgnmail.Com) to: Lake, Louis; Thomas, George; Nausdj@Ornl.Gov Dated Tuesday, November 24, 2009 7:16 Am Subject: Refute 3.3 for Review Attachments: Fm 3.3.ppt; PTL Test Cement 04011974.pdf

ML102920346
Person / Time
Site:	Crystal River
Issue date:	11/24/2009
From:	Williams C Progress Energy Co
To:	Lake L, Naus D, George Thomas NRC/RGN-II, Oak Ridge
References
FOIA/PA-2010-0116
Download: ML102920346 (27)

Text

Franke, Mark

/

Franke. Mark

/

From:

Sent:

To:

Subject:

Attachments:

Williams, Charles R. [Charles._Williams@pgnmail.com],

Tuesday, November 24, 2009 7:16 AM Lake, Louis; Thomas, George; nausdj@ornl.gov efute 3.3 for Review-. -

(

M 3.3.ppt; PTL Test Cement 040 1 94.pdf; mi"cert 04021974.pdf; all strengt-i-able.pdf; 7 and 28 day strength.pdf; all strenl(r ph.pdf; Erlin Hime Petro repo 976.pdf; Core Bore #5 Final CTL Petrographic W t 059169 C856 (2).pdf

_~70~

Mr Lake, I am resending due to difficulty with opening/reading the previous attachments. Again, this is prelim. Call me with questions. It looks like I will need to send each one as separate emails to keep from mixing documents.

Thank you, Charles Williams 919-516-7417 1

pl(q3

3.3 Inadequate Cement Materials D

May identify additional perspective on this issue as RCA related efforts proceeds

==

Description:==

Cement that fails to meet specifications can contribute to failure.

1.

Slow reacting cement can slow strength gain.

2.

Fast reacting cement can cause rapid loss of workability and early set --- constructability

3.

High C3A cement can support failure when exposed to Sulaftes

4.

Low Alkali cement may be specified when ASR is suspected Data to be Collected and Analyzed:

(1) Mill certificates of cement used.

(2) Records of trial-mix from laboratory (3) Original cement test records.

(4) Petrographic analysis Verified Refuting Evidence:

Verified Supporting Evidence:

All documents reviewed conclude cement meets all requirements. See attached sheet.

11/23/2009 11/23/009PII

-ld~

oU "

tid

.ihu 1

3.3 Inadequate Cement Materials, Cont. (R)

Verified Refuting Evidence:

1.

"Tests of Cement" dated 4/1/1974 and 4/22/1974 by PTL concludes that the cement meets all specifications and ASTM standards within acceptable standard deviation. (Exhibit 1)

2.

Test found that the cement was slightly finer and faster settling than specified. However, it was concluded that the variation was acceptable. (Exhibit 1)

3.

"Mill Certificate" dated 4/2/1974 from "General Portland Inc." meets all applicable ASTM standards.

(Exhibit 2)

4.

Original test records show satisfactory variation and strength level. (Exhibit 3)

5.

Original Petrograpgy report by Bernard Erlin dated 5/10/1976 concluded the there was no evidence that the aggregates had been either chemically or physically unsound. (Exhibit 4)

6.

Current CTL Petrography Report dated 11/2/2009 found no irregularities with the cement. (Exhibit 5)

Reviewed by: Dr. Avi Mor, 352-795-6486, ext 1030 - P11 CR3 Team Office 11/13/2009 P11 Propriet~ry ~nd Confidenti~l 200g Do nut ielease [LI d tl1;~d party without

-pe~R~ef~.

2

FOR Floric i---t 1b.U.H..

i_..I i,,

LABO.RAIO.RY S(

.ESTA1*S RHrO P001 PiT.1ýSEURGH, PA.

OF F41. 1

IM ' ZI?'i]L 3/4

...o, DER NO. T, nY Q7A I I Ay1

()9 2

1 z A: A,1MUTUAL rROTECTION TO CL;ENTS.

THC MICILIC ANOrOURSCLVrS.

ALL REPORTS 91CCCC

-33 ARE SUDMITTEO AS THE CONrI nNrjAI.

rI'IOPrE3rTY Or

CLINT13, ANO AUTHORIZATION FOR PUL LICATION Or CZTATCMrNTr,.

CONI.LII!IONS OR ZXTRACTS FROM OR RECAROINO LAORATORY NO.N OUR REPORTS IS RSCRVFO Pr.NCNG 'OUR WRITTEN APPROVAL.

TESTS OF CEME'14T A

-C AT

, E April 22,1974 1?

417j~e4

?

.. ""a',?6 1o.,

Powur Corocration.

Power.

io..."

, f,.

" /'

Crystal :',iver Florida Power Plant Jobu PROJECT Silo 19,

Tampa, Fla., Sampled by PTIM3/18/74, FROM [I'eceived iarch 22.1974 10 Samo es 340A thiru 340J BRAND Fla.

BIN NO.

19 CONTAININo 20,000 BARRELS SPECIFICATION ASTM C150-72TYPE II RESULTS OBTAINED PHYSICAl-TESTS w '"

r

-?

SAMPLE NO.

TIME OF SETTING SOUNDNESS AUTOCLAVE EXPANSIONý Cooipressive STRENGTH AVE. 3 SPEC*.-P.S.I.

AIR CONTENT BY VOL.

SPECIFIC SURFACE (BLAINE)

SQ. CRIGM.

INITIAL HRS.-MIN.

FINAL HRS.-MIN.

3 DaY 7 Day 28 Dav 340A 0.0(0 1:00 4:00 2290 3230 5320 7.3 4n1 7 2.40 -*

0 00:

55 3: 5T0h1 22-,L 1290 5390 R - l 40.4.6i

.. 4 0_3

. 0 - -- -

()..- O r, l.! 0 4 ! 1 2l1Ot(f )

3 3 05 3 1 0 7.1 4In 1 I.

_A D-.l -- *

)00 0,55 4-0(1.........

3..

327 5310

7. 3 4017

-2.0-E-O.06 g.50 I:5-1.;

3990 3210 5160 r q A017

_340-3" 0.06 0:45 29100 2290 26 5180 *

7.

&00Q 0 -

0.06

- 0:50 4:0A5 2220 mn7-1

_.525.0 7]

3q5

_e, 0-IL--

I

.n0r,

-5o.-(

.4

".50.

5 211o 3210 5320 6.$

400_2 3.40-n -06.0..6

0.

-;s 6 !Z,.

_Z3_60, 1 -330 5200 r.3 40-0-2 14n -.

n0n7 1.55 A

-4"35

' 2.30 130 5220.

r, 446 14 Project Specs.

1 flr.Min.

13200U in.

5200U,!in, 5.0t.lin.

4000 1,na SPEC. REQ.

n -45.in,.

8frs.

1000Nin.j 18002,in.

3500Mmin. 12.diax. t.

2 0.0,i. rn 1in_

j u

Hii 7JxiTiij.m C H EMICAL ANA L, Y S I S

, 3 A +

SI 02 AL 203 Fe2 03 Mo O S 03 Loss an Ign.

Insol. Res.

C3 S C3 S C3 A 340-A 22.46 4.53 2.85 1.12 2.52 1.84 0.40 47.6 54.8

7. 340-B-2-44 3A 4.-

1 no i nqI 2_416

.1-0.48 4c).4 55.8 6.4 340-_C-

_22*2 17 2.93 1.09 2.54 1,81 0.41 48.5 55.1 6.6 340 -D.._

2.2.32

4.

2-P

)

1 -i67 2-6N 1-L n.-4n.0 49.5 56 -1 6...8 P O-E 22.144 4.SO 2.,f2.

1._7 2 61 1.8n.-

7-1 40-F 22.52 4.33 2.93 1.06 2.46 1.76 0.42 49.5 56.0 6.5

$40-G Q

22.54 4.40 3.04 1.12 2.54 1.83 0.41 47.2 53.8 6.

340-H 22.56 4.36 3.04 1.09 2.49 1.76 0.40.47,-

54,4 6.5 30-ýI1 22.32 4.55 2.85'

'1 08 2.48 1.78

0. 4 3 9.5

56.

7.3 340-9.30, 435 2_.97 1.0

?252 1.7; n,.&5 502 56f.7 r.15 II 13' 14 42peciri d

ei ns 4 2.,i'in.

58.0i'tax.

'Ec. REQ.

b"..

5.0Nax-. 3.0Mlx 3.0:lax O.75,inx 8,(..,*

.MA (c£a r r.Id,,U I

PAC ;i( 2 )

MATERIAL DOES r7, DOES NOT C

COMPL.Y WITH SPECIFICATIONS.

gE(;/mb 3-Florida Power Corp.

A-1-3 1-Mr.

Bennett Brown 1-Mr. C. Ifiatt 2-PTL, Tampu PITTSBURGH TESTING LABORATORY R.EClcm trcIncr, " loifiagr, Cement & Qodicrut4e LJepartrnI

PITTSB" RGH TESTING LAB(.ATORY

.*ESTABLI-IMED 1001 850 POPLAR STREET, PITTSBURGH, PA. 15220 AS A MUTUAL PROTECTION TO CLIENTS., TH PUBLIC AND OURSELVES ALL REPORTS ARC SUeMITTEO AS THE CONFIDENTIAL PROPiRTY Oc CLIrENTS, AND AUTHORIZATION FOR PUGLICATION OF STATEMENTS. CONCLUSIONS OR EXTRACTS FROM OR REGAROING OUR REPORTS IS RCSERVEO PENOING OUR WRITTEN APPROVAL.

1LEASE REPLY TO7 0,

0.

BOX 1046

'ITTSBUROH, PA. 15230 743837

ý-7732 AREA CODE 412 TELEPHONE 922-4000 REPORT LABORATORY No.

ORDER No.

TJ CLIENTS No.

PAGE,2 OF 2 April 22, 1974 A

Sample No.

340-A 340-13 340-C 340-1) 340 -E 340 -F 340 -G 340-11 340-1 340-J Chlorides %

0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 REiiARKS:

Vicat initial setting time is slightly below 1 Hour Mlinimum Project Specification, but above minimum ASTN 8.equirement, and tests are well within standard deviation for this test.

Similarly, Blaine Surface is slightly over Project Specif-

ication, but within standard deviation limits.

We recommend the cement be released for use on the Project based on the above results.

Two of the samples did not achieve 5200 P.S.I. Project Requirements by a slight amount.

0 A-1-4

, k:

I'r1 General Portland Inc. U-9 MILL TEST CERTIFICATE Consignee:

Mr. Edwin Froats, Quality Engineer FLORIDA POWER CORPORATION P. 0. Box 276 Crystal River, Fla.

32629 Copy:

Wdst Coast Concrete, Inc.

1500 South Street Leesburg, Fla.

32748 Date Shipped ----------------

SEALS TOP8 336-47 050CUOU No.- ------ B- -I-T-M ----

8-3§53 -- a5 M ONS ---------- 686.925.7.----..

Type................

1I1........................

Shipped from -------- 19-Q 2

Destination:

DATA SHOWNBELOW IS TYPICAL OF CEMENT CURRENTLY BEING SHIPPED PHYSICAL TESTS Specific Surface Wagner ---------------------- SQ. CM./GM.

Blaine --

... k109 ----------- SQ. CM./GM.

Soundness, Expansion -.....

Time of Setting, Gillmore Initial 2

Hrs 0

Min.

Final ------- ------ Hrs..

10 Min.

Compressive Strength I Day PSI 3 Days ---------- 230--------------

PSI 7 Days PSI Air Entrainment T-1 --------

CHEMICAL COMPOSITION Silicon Dioxide (SiO )

2.6 --- ---------

Aluminum Oxide (A 3,O) 4.6 Ferric Oxide (FeO3).......2.7 Magnesium Oxide (MgO) 1.1 Sulfur Trioxide (SO,)

2.5 Loss on Ignition-------------1.1---------.

Insoluble Residue Alkalis (% NaO + 0.658 KO) 0.-7.

Tricalcium Silicate Dicilcium Silicate...........

.2...

Tricalcium Aluminate J. 5 -------------

Tetracalcium Alumina Ferrite 8

f~N This cement meets or exceeds all applicable A.S.T.M.

Copies Date of Report

.4/2/74.......

and/or Federal Specifications.

P.

0.

Bo IEF cHrMIST P. 0. Box 1002, Tampa, Florida 33601

'Mills at Tampa and Miami, Florida A-1-5

RC3 analysis Concrete Strength Over Time Pour Number 2.

2, 3

4 5

6 7

8 9'

10 11 12 13' 14 15 16:

17 18 19 20 21 22.

23 24 25' 26 27, 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43' 44 45 46' 47:

48 49.

50 51 52 53 54.

55.

56 7 days 28 days 90 days 1926 5390 6650 7070

DM-5 5130 5260 6810 6730 6950 7010 1927 5660 6830 7160 DM-5 5390 5525 7020 6925 7380 7270 1932 5200 6540 6920 DM-5 5390 5295 6280 6410 7200 7060 1934 4620 6210 7040 DM-5 5360 4990 6210 6210 6830 6935 2064 4010 5090 5870 727550-2 4010 4010 5150 5120 6080 5975 2065 3960 5570 6070 727550-2 4010 3985 5480 5525 5660 5865 2066 4420 5470 5590 727550-2 4390 4405 5770 5620 6150 5870 2071 4100 5360 6130 1727550-2 4070 4085 5550 5455 6210 6170 2072 3910 5040 6460 727550-2 4090 4000 5750 5395 6540 6500 2073 4090 5130 5910 727550-2 4390 4240 5570 5350 6280 6095

'2074 3870 5320 5850 727550-2 3960 3915 5520

.5420 6010 5930 2075 727550-2

ý2076 727550-2 Ratios

' Current 7/28 days 90/28 days 78%

104%

80%

105%i 83%

110%

80%

112%

78%

117%

72%

106%

78%

104%

75%

113%

74%

120%

79%.

114%

72%

109%

'2117 4420 727550-2 4600 4510 2118 4490 727550-2 4070 4280 2119 4320 727550-2 4260 4290 4240 727550-2 4460 4350 2121 4490 727550-2 4240 4365 2122 4350

,727550-2 4170 4260 2123 4420 727550-2 4240 4330 2124 4250 727550-2 4350 4300 2157 4690 DM-5 4760 4725 2158 4240 DM-5 4240 4240 2166 4690

,DM-5 4260 4475 2167 4810

,DM-5 4690 4750 2171 4880 DM-5 4930 4905 2172 4510 DM-S 4490 4500 2181 4900 4810 4855 5840 5570 5705 5820 5780 5800 5590 5750 5670 5570 5700 5635 5430 5320 5375 5710 5640 5675 5660 5640 5650 6170 5780 5975 6300 6190 6245 6150 5980 6065 6720 6230 6475 6330 6600 6465 6030 6000 6015 6120 6080 6100 6240 6190 6215 6070 6050 6240 6050 6170 6050 6130 6230 6880 6400 6010 5870 6050 6010 6230 6000 6280 6760 6230 6600 6060 6145 6110 6180 6640 5940 6030 6115 6520 6415 6560 6695 6580 6680 6650 79%

106%

74%

106%

76%

108%

77%

110%

81%

124%

75%

105%

77%

107%

72%

102%

76%

104%

70%

106%

69%

101%

73%

104%

82%

109%

74%

110%

78%

107%

6560 6760 6630 6600 6560 6670 6690 6650 6650 page 1 of 3 11/19/2009 2:46 PM Break Test Summary.xlsx

RC3 analysis Concrete Strength Over Time Number 57 58!

59:

60 61 62 63 64 65 66; 67 68 69 70 71 72 522 73 522 74 522 75 522 76 528 77 528 78 528 79 528 80 634 81 634 82 634 83 634 84 634 85 634 86 641 87 641 88 641 89 641 90 641 91 641 92:

641 93, 641 94 666 95 666 96 666 97 666 98 666 990 666 100 666 101 666 102 685 103 685 104 685 105 685 106 695 107 695 108 695 109:

695 110 700 111 700 112 700 113 700 2182

ý2196

ý2197 2219 2220

,2225

'727550-2 2226 727550-2 1926 1926 1927 1927 1932 1932 1934 1934 2064 2064 2065 2065 2066 2066 2071 2071 2072 2072 2073 2073 2074 2074 2117 2117 2118 2118 2119 2119 2120 2120 2157 7 days 28 days 90 days 5020 5410 7290 5040 5030 5360 5385 7470 7380 3780 5480 7320 3890 3835 5480 5480 7340 7330 4070 5910 7260 4120 4095 5340 5625 7090 7175 3640 5550 6070 3640 3640 5480 5515 6260 6165 3750 5540 3890 3820 5410 5475 5940 5940 4550 5470 6540 4560 4555 5750 5610 6460 6500 4490 5680 7220 4140 4315 6230 5955 7010 7115 Current 7/28 days 90/28 days 93%,

137%

70%

134%

73%

128%

66%

112%

70%

108%

81%

116%

72%

119%

5390 5130 6650 6810 5660 6830 5390 5393 7020 6828 5200 6540 5390 6280 4620 6210 5360 5143 6210 6310 4010 5090 4010 5150 3960 5570 4010 5480 4420 5470 4390 4133 5770 5422 4100 5360 4070 5550 3910 5040 4090 5750 4090 5130 4390 5570 3870 5320 3960 4060 5520 5405 4420 5840 4600 5570 4490 5820 4070 5780 4320 5590 4240 5570 4460 4358 5700 5703 4690 6300 7070 6950 7160 7380 6920 7200 7040 6830 5870 6080 6070 5660 5590 6150 6130 6210 6460 6540 5910 6280 5850 6010 6070 6050 6240 6050 6170 6050 6130 6230 6280 6760 6230 6600 6560 6760 6630 6600 6560 6670 6690 7140 79%

105%

6998 81%

111%

5903 76%

109%

6174 75%

114%

6124 76%

107%

2157 4760 6190 2158 4240 6150 2158 4240 4483 5980 6155 2166 4690 6720 2166 4260 6230 2167 4810 6330 2167 4690 4613 6600 6470 2171 4880 6030 2171 4930 6000 2172 4510 6120 2172 4490 4703 6080 6058 6468 73%

105%

6650 71%

103%

6630 78%

109%

page 2 of 3 11/19/2009 2:46 PM Break Test Summaryxlsx

I RC3 analysis Concrete Strength Over Time 114' 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135!

136, 137 138 139 140 141 142

143, 144' 145 146' 147.

148, 149 150 151 152 153 154 155 156 157 158' 159 160' 161 162' 163

164, Number 712 712 712 712 722 722 722

...722 737 737 737 737 743 743 743 743 7 days 2181 4900 2181 4810 2182 5020 2182 5040 4943 2196 3780 2196 3890 2197 4070 2197 4120 3965 2219 3640 2219 3640 2220 3750 2220 3890 3730 2225 4550 2225 4560 2226 4490 2226 4140 4435 28 days 90 days 6240 6650 6190 6650 5410 7290 5360 5800 7470 7015 5480 7320 5480 7340 5910 7260 5340 5553 7090 7253 5550 6070 5480 6260 5540 5410 5410 5495 5940 5920 5470 6540 5750 6460 5680 7220 6230 5783 7010 6808 Current 7/28 days 90/28 days 85%

121%

71%

131%

68%

108%

77%

-118%

7900 7380 7393 6900 7530 7650 5990 6800 6830 6370 8220 8030 7520 6600 6610 6100 7 days 28 days 90 days Current Ratios average:

4436 4446 5837 5850 6491 6504 7095 7393 76%

111%

'Std:

473 459 464 440 494 470 705

1. DIV/O!

5%

8%

Max:

Min:

5660 5525 7020".

69251 3640 3640 5040 5120 7470 7380 5410 5865 8220 7393 5990 7393 93%

66%

137%

101%

page 3 of 3 11/19/2009 2:46 PM Break Test Summary.xlsx

II U

8 8000 750%

7000~

6500 5500 5000.

4500 m

0 **

S a 50 S

• 0 S

0 0

• • 0 0

0.

0 S

S 0

S a 0

0 a

a.

.*a as ~

0 a.

8 8

8 8

88 8

8

-r a +/-

0

-~

0 a

S *

+

87 days Fc 28 days Fc

• 90 days Fc Current

++

+

÷R 4

CR3 - Concrete Strength 11/19/2009 2:43 PM Break Test Summar'y.xisx

'C E

83%

7500

8.

78%

78%

78%

S 0 75%74%

7 0 0 0

.7 0

0 6500 93%

90%

85%

81%

82%

81,%

81%

79%

070 77 78%

t 76%77*

76%

74% 76%

75%

76%

73%

74% 0 0

725*

• S70%

69%

00Q 79%

0 72%,-

70%

• 70%

0 66%

76%

0 76%

75%

71V 78%

0 77* 80%

70%

-7*

0l 68%

0 5500 5000 8

60%6 50%

40%

30%

8*

4 4 8

a a

8 4500 4

-. 4 4

~

8 0

8 0

4 4

4, 4

• 8 4~*

8 e

• 7days Fc 28 days Fc

• Ratio 7/28 day Fc CR3 - Concrete Strength 11/19/2009 2:42 PM Break Test Summary.xlsx

ATTAC I M iNT C

.,2 ERLIN, HIME ASSOCIATES MATERIALS AND CONCRETE CONSULTANTS jI11 S1%iZtIE DOULEVARD (3121 272.7730

.h ILLINOIS 60062 PETROGRAPHIC STUDIES OF CONCRETE FOR CONSTRUCTION ENGINEERING CONSULTANTS

SUMMARY

,:AND DISCUSSION

• The specimen represented air-entrained concrete.

made with crushed fossiliferous coarse aggre-gate andsiliceous fine aggregate and a low water-cement ratio paste.

There was no evidence that the aggregates had been either chemically or physically unsound.

The specimen was from an area where fractures had existed for a period of time and where moisture had been present.

That was demon-strated by secondary deposits on fracture surfaces.

The specimen was relatively small.

Larger specimens fr.om different areas of the struc-ture would be desirable for examination in order to obtain a better representation of the concrete.

INTRODUCTION Reported herein are the results of petrographic studies of a concrete fragment submitted by J. Artuso of Con-struction Engineering Consultants.

The specimen is from the dome of the containment structure of the Florida Power Corporation, Crystal River, UnitIII.

Requested by Mr. Artuso were petrographic studies for evaluating the specimen, and particularly for evidence of features that would cause volume instability.

C-12

ERLIN, HIME ASSOCIATES -

MATERIALS ANO CONCRETE CONSULTANTS

STUDIES, Specimen -

The specimen was an elongated fragment having nominal lateral dimensions of 5 inches, and a maximum thickness of about 3/4 inch.

All *surfaces were fracture surfices except for a shallow channel about 3/32 inch wide and 1/8 inch deep.

The channel appears to be the terminal area of a saw cut.

Petrographic Studies - Coarse aggregate of the specimen was a buff to light brown, fine-grained, fossiliferous limestone having a maximum nominal size of 3/4 inch.

The fine aggregate was a siliceous sand composed prin-cipally of quartz.

The aggregates were not particaiarly well graded, as evidenced by deficiencies of the finer sizes of the coarse aggregate and the coarser sizes of the fine aggregate.

There was no evidence that the aggregates had been chemically or physically unsound.

Particular attention was directed to alkali-silica reactivity with respect to the coarse aggregate because a similar type of aggregate does contain a highly reactive variety of chert.

Neither the chert nor the product of the reaction of the chert with alkalies (alkali-silica gel) was present.,

Paste of the specirhen was medium dark grey, firm, and contained abundant residual and relict cement. The quality of the paste reflects a low watei -cement ratio.

Air occurred as small, discrete, spherical voids that bccasionally were very slightly distorted, and as coarser irregularly shaped voids.

The spherical voids are characteristic of entrained air voids; the irregularly shaped voids,: of entrapped air.

The air content, of':the specimen is estimated to be 51/2 percent and the parameters of the air-void system are judged to be effective-for protecting critically saturated concrete exposed to cyclic freezing.

On one of the lateral surfaces were secondary deposits composed of tufts of fine acicular-ttrfingit'i (3CaO-A1203"3CaSO

'31H 2 0),

and calcite (aCO).ingte was also present as tufts in some air void-justgbelow the fracture-surface.

The fragment was not uniformly thick; it tapered to a knife-like edge.

Along that edge, were fine fractures SC-13

ERLIN, HIME ASSOCIATES MATERIALS AND CONCRETE CONSULTANTS oriented subparallel to the long axis of the fragment.

The fractures transected coarse aggregate particles.

On those fracture s-urfaces were secondary deposits similar to those described above.

The secondary compounds demonstrate that the fragment was from an area where fractures present for a period of time had been exposed to moisture.

May 10, 1976 Erlin, Hime Associates, Inc.

by Bernard Erlin, President Petrographer c-14

0 0

DIRECT TENSILE STRENGTH TEST RESULTS AREA SO.

IN.

NOMINAL DIAMETER IN.

TOTAL LOAD LBS.

CORE P..S.I.

REMARKS COR IN.

,,S I

Granite aggregate

-8.19 3 1/4 3400 415 concrete 5000 p.s.i.

value 8.14 3 1/4 3200 390 Crystal River Cores Average 400 p.s.i.

N Pour XVI 10.69 3 3/4 2500 230 All Coarse

___aggregate soft M Pour XVIII

'10.69 3 3/4 4600 430 Hard Coarse aggregate excecz.

two soft pieces L Pour XV

-10.69 3 3/4 5400 505 All hard coarse

_aggregate L Pour 9B 10.69 3 3/4 5400 485 Most coarse aggregate hard P Pour XIII 10.69 3 3/4 5400 505 All hard coarse aggregate Pour XII 10.63 3 3/4 3800 All small soft coarse aggregate' Average 420 p.s.i.

0 H*

lNote:

The Granite Aggregate concrete cores fractured surfaces indicated all coarse aggregate was hard and dense and several pieces of the CA pulled out of the Matrix, indicating greater tensile strength than the Matrix.

There was no pull out of the Crystal River coarse aggregate -

all fractured at the fractured surface.

rt 03 Ft

ATTACHMENT E Preliminary Report of Crystal River Coarse Aggregate Q

Sieve

1 3/4 1/2 3/8 4

8 Pan Wgt. Ret.

0 1.0 15.8 28.4 35.8 36.3 37.3

% Passing 100 97 58 24 ASTM Spec

1. 67 100 90-100 4

3 20-55 0-10 0-5 C-117 C-131 C-123 C-29 C-142 C-235 C-188 C-1 27 Test 200 Wash Loss Los Angeles Abrasion Lightweight Pieces in Aggregate Unit Weight of Aggregate Friable Particles Soft Particles Soundness (Sodium Sulphate)

Specific Gravity and Absorption Result ASTM Specification 1.3% (Primarily 1% Max*

dust of fracture) 42 %

50% Max 0.2%

0.5% Max 85.68 lbs/cu. ft.

No Spec Later 5.0% Max Later 5.0% Max Later 12.0% Max Later No Spec

• This limit may be increased to 1.5% if the material finer than a No.

200 consists essential of dust from fracture

.C-16

Copy No. 1 Report for Progress Energy CTLGroup Project No. 059169 Petrographic Examination of Concrete Half Core from Delaminated Containment Wall, Crystal River, Florida November 2, 2009 Submitted by:

Derek Brown COA #4731 5400 Old Orchard Road Skokie, Illinois 60077-1030 (847) 965-7500 9030 Red Branch Road, Suite 110 Columbia, Maryland 21045 www.CTLGroup.com

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Building Knowledge. Delivering Results, www.CTt..Group.com REPORT OF PETROGRAPHIC EXAMINATION Date: November 2, 2009 CTLGroup Project No.: 059169 Petrographic Examination of Concrete Half Core from Delaminated Containment Wall, Crystal River, Florida One saw cut half concrete core labeled Core #5 (Figs. 1 and 2) was received on October 27, 2009 from Mr. Jerzy Zemajtis, Project Manager, CTLGroup on behalf of Mr. Paul Fagan of Progress Energy, Crystal River, Florida. According to Mr. Zemajtis, the core represents the outer portion of concrete from a containment wall and the core is fractured at its inner surface at a delamination that was found to be present when access was gained to the wall interior. The delamination is approximately at a depth of 200 mm (8.0 in.) where horizontal post tensioning ducts are present.

Petrographic examination (ASTM C856-04) of the core was requested in order to determine, if possible, if the delamination is a recent feature, or alternatively if it occurred at some earlier time in the age of the structure.

FINDINGS AND CONCLUSIONS The following findings result from the petrographic examination.

Based on the general appearance, and both the physical and microstructural properties, the fracture at the point of delamination is most likely a fairly recent event. However, it is not possible to be completely definitive about the time frame since an older fracture, if subsequently well protected from air and moisture ingress, may also have similar characteristics.

The fracture surface passes through, not around the aggregates particles, is moderately hard, and does not exhibit loose surface debris. There is an absence of significant microcracking in the general vicinity of the fracture, and only limited evidence of surface deposits (slight efflorescence).

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Progress Energy Page 2 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 Carbonation to any significant depth from the fracture surface into the outer concrete is not observed (Fig. 3). Incipient carbonation is exhibited in thin section at the immediate fracture surface (Fig. 6a). However, an older delamination surface that was not exposed to air due to the depth of outer concrete, and other possible wall coverings, may also have such an absence of carbonation.

The cement hydration adjacent to the fracture is well advanced and comparable to that of the body of the core (Figs. 6b and 6c). This suggests that there was no moisture ingress to the fracture surface, over a period of time long enough, to change the general degree of hydration.

This is supported by an absence of secondary deposits within air voids adjacent to the fracture surface.

Additional Comments The concrete represented by Core #5 is well consolidated and free of any cracks or excessive microcracks (Fig. 4). The concrete consists of crushed carbonate rock coarse aggregate and natural sand fine aggregate, well distributed in a portland cement paste. No evidence is exhibited of any deleterious chemical reactions involving the cement paste and / or aggregates.

The concrete could be considered marginally air entrained based on an approximate volume of 1 to 2% of small, spherical entrained air voids in the hardened cement paste (Fig. 5).

Based on the physical properties and microstructure of the hydrated cement paste, and the tight aggregate to paste bond, lack of major cracks and microcracks, and absence of a materials-related distress mechanism, the concrete is considered to be in good condition.

Further details of the petrographic examination are given in the following image and data sheets.

METHODS OF TEST Petrographic examination of the provided sample was performed in accordance with ASTM C 856-04, "Standard Practice for Petrographic Examination of Hardened Concrete." The core was visually inspected and photographed as received. The core half was ground (lapped) on the saw cut surface to produce a smooth, flat, semi-polished surface. Lapped and freshly broken surfaces of the concrete were examined using a stereomicroscope at magnifications up to 45X.

Progress Energy Page 3 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 For thin-section study, small rectangular blocks were cut from the core inner surface fracture region and within the body of the core. One side of each block was lapped to produce a smooth, flat surface. The blocks were cleaned and dried, and the prepared surfaces mounted on separate ground glass microscope slides with epoxy resin. After the epoxy hardened, the thickness of the mounted blocks was reduced to approximately 20 am (0.0008 in.). The resulting thin sections were examined using a polarized-light (petrographic) microscope at magnifications up to 400X to study aggregate and paste mineralogy and microstructure.

Estimated water-cement ratio (w/c), when reported, is based on observed concrete and paste properties including, but not limited to: 1) relative amounts of residual (unhydrated and partially hydrated) portland cement clinker particles, 2) amount and size of calcium hydroxide crystals,

3) paste hardness, color, and luster, 4) paste-aggregate bond, and 5) relative absorbency of paste as indicated by the readiness of a freshly fractured surface to absorb applied water droplets. These techniques have been widely used by industry professionals to estimate w/c.

Depth and pattern of paste carbonation was initially~determined by application of a pH indicator solution (phenolphthalein) to freshly cut and original fractured concrete surfaces. The solution imparts a deep magenta stain to high pH, non-carbonated paste. Carbonated paste does not change color. The extent of paste carbonation was confirmed in thin-section.

Derek Brown Senior Microscopist Microscopy Group DB/DB Notes: 1. Results refer specifically to the sample submitted.

2.

This report may not be reproduced except in its entirety.

3.

The sample will be retained for 30 days, after which it will be discarded unless we hear otherwise from you.

Progress Energy Crystal River CTLGroup Project No. 059169 Page 4 of 10 November 2, 2009 1a. Curved surface. Outer end Is to the left.

lb. Saw cut surface. Outer end Is to the left Fig. 1 Side views of Core #5, as received for examination.

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Progress Energy Crystal River CTLGroup Project No. 059169 Page 5 of 10 November 2, 2009 2a. Inner end.

2b. Outer end.

Fig. 2 End views of Core #5, as received for examination.

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Progress Energy Crystal River CTLGroup Project No. 059169 Page 6 of 10 November 2, 2009 3a. Saw cut side. Outer surface is to the left.

3b. Fractured inner end.

Fig. 3 Views of the portions of Core #5 treated with phenolthalein, a pH Indicator. All the pink regions exhibited denote the limits of where the indicator was applied. No colorless, low pH (carbonated) regions were observed at the fractured end regions.

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Progress Energy Crystal River CTLGroup Project No. 059169 Page 7 of 10 November 2, 2009 Fig. 4 View of the lapped surface of a portion of Core #5 showing the general appearance of the concrete.

Fig. 5 View of the concrete hardened air-void system of Core #5 illustrating the moderate quantity of both coarse and fine air voids.

Scale Is millimeter increments.

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Progress Energy Page 8 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 6a. Crossed-polarized light view of the paste adjacent to the inner fractured surface. Only incipient carbonation is indicated by the speckled high birefringence colors in the paste. Carbonate fines are arrowed yellow. Width of view is approximately 0.5 mm.

6b. Plane-polarized light view of the paste adjacent to the inner fractured surface (same field of view as 6a.).

A low to moderate number of unhydrated and partially hydrated cement particles (arrowed red) are exhibited by the paste. The amount is comparable to that in the body of the core in Fig.

6c. below. Width of view is approximately 0.5 mm.

6c. Plane-polarized light view of the paste in the body of the core. A low to moderate number of unhydrated and partially hydrated cement particles (arrowed red) are exhibited by the paste. The amount is comparable to that near the fracture surface in Fig.

6b. above Width of view is approximately 0.5 mm.

Fig. 6 Transmitted light photomicrographs of the thin sections of Core #5 illustrating significant features.

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Progress Energy Page 9 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 PETROGRAPHIC EXAMINATION OF HARDENED CONCRETE, ASTM C 856 STRUCTURE: Containment wall DATE RECEIVED: October 27, 2009 LOCATION: Crystal River EXAMINED BY: Derek Brown SAMPLE Client Identification: Core #5.

CTLGroup Identification: 2452601.

Dimensions: Core diameter = 95 mm (3.75 in.). Core length = approximately 197 mm (7.75 in.); partial wall thickness.

Top End: Even, slightly rough formed surface.

Bottom End: Uneven and rough, fractured core end.

Cracks, Joints, Large Voids: Text.

Reinforcement: None observed in the core supplied.

AGGREGATES Coarse: Crushed rock composed of carbonate rock type.

Fine: Natural quartz sand.

Gradation & Top Size: Visually appears evenly graded to an observed top size of 18 mm (0.75 in.).

Shape, Texture, Distribution: Coarse-Sub rounded to angular, slightly irregular to rough, evenly distributed. Fine-Rounded to sub angular, slightly smooth to somewhat rough, evenly distributed PASTE Color: Medium gray, uniform coloration throughout the length of the core.

Hardness: Moderately hard at the outer surface and in the body of the core. At the fracture surface the paste is also moderately hard.

Luster: Subvitreous.

Paste-Aggregate Bond: Tight. Freshly fractured surfaces pass through aggregate particles.

Air Content: Estimated 2 to 4% total. Approximately 1 to 2% of the total air is larger entrapped air voids of up to 3 mm (0.12 in.) in size, plus a few large voids of 4 to 10 mm (0.16 AudidingJ Knm-At*Jp. W wlnelng Rnmulm w\\wvv.',',;;,! ('_Ct :*:*

Progress Energy Page 10 of 10 Crystal River November 2, 2009 CTLGroup Project No. 059169 to 0.4 in.). Somewhat uneven distribution of voids. Marginally air entrained based on the very low volume of moderate to small sized spherical air voids in the hardened cement paste.

Depth of Carbonation: 4 to 5 mm (0.16 to 0.20 in.) as measured from the outer surface.

Negligible when measured from the inner fractured core surface.

Calcium Hydroxide*: Estimated 6 to 12% of small to medium sized crystals evenly distributed throughout the paste, and around aggregate to paste interfaces. Estimation of the volume is difficult due to the presence of calcite fines in the cement paste.

Residual Portland Cement Clinker Particles*: Estimated 4 to 8%. Some large cement particles, particularly belite clusters, of up to 0.15 mm in size suggest a portland cement as produced more than 30 years ago.

Supplementary Cementitious Materials*: None observed by the core supplied.

Secondary Deposits: None observed either in the body of the core and or near the fracture surface.

MICROCRACKING: A small number of medium length (5 to 10 mm), randomly orientated microcracks are evenly distribu ted throughout the body of the core. At the fractured end of the core there was no observed increase in microcracking relative to the body of the core.

ESTIMATED WATER-CEMENT RATIO: Moderate to moderately high (0.50 to 0.60) but estimation may be biased upwards due to the well advanced degree of hydration / apparent old age of the concrete.

MISCELLANEOUS:

1. Water droplets applied to freshly fractured surfaces were somewhat slowly absorbed by the hardened cement 'paste.

2. Some small areas of the inner fractured surface of the core, as received, exhibit a thin white haze of efflorescence-like substance suggesting leaching of lime in solution from within the core, or alternatively, moisture on or flowing past the fractured surface at the delamination position within the wall.

3. A moderate volume of fine calcite particles is present within the hardened cement paste, most likely from coarse aggregate crusher fines.

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