ML19326D090
| ML19326D090 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 05/25/1973 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| References | |
| PROC-730525, NUDOCS 8006060595 | |
| Download: ML19326D090 (40) | |
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UNITED STATES OF AMERICA
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ATOMIC ENERGY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING APPEAL BOARD
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In the Matter of )
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CONSUMERS POWER COMPANY ) Docket Numbers 50-329
) and 50-330 (Midland Plant, Units 1 and 2))
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APPLICANT'S REPORT ON QUALITY ASSURANCE ACTION BEING UNDERTAIEN TO ASSURE SATISFACTORY CONDITION OF WORK ALREADY PERFORIED AND MATERIALS NOW ON SITE May 25, 1973 THIS DOCUMENT CONTAINS POOR QUAUTY PAGES
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e 8006060 A
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l COIffEIPIS PREFACE PART I: PROCEDURES 1.0 Scope 2.0 Inventory and Inspection Control Procedure 3.0 Specialist Qualification and Responsibilities 4.0 Calibration and Control of Instrumentation of Test Equipment ATTACHMENT A - Field Inspection Procedure G-4:
" Control of Measuring and Testing Equipment" PART II: SUhEARY OF INSPECTIONS 1.0 Material Storage Areas 2.0 Containment Liner Plate Coating 3.0 Auxiliary Building Concrete and Waterstops
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PREFACE This report is filed to comply with Condition 1 of the Atomic Safety and Licensing Appeal Board's March 26, 1973 Memorandum and Order (ALAB-106) in the Midland proceeding (Docket No 50-329 and 50-330). It describes the quality assurance action being undertaken by the Applicant, Consumers Power Company, and its architect-engineer, Bechtel, to assure that the construction work already performed and the materials now on the Midland Plant site are in satisfactory con-dition. The report also covers inspection and calibration of instru-mentation to be used in the QA program.
The construction phase of the Midland project has been shut down for more than two years, during which time there has been a con-tinuing effort to protect the work and materials at the site. Peri-odic inspections were made during the shutdown and prior to ALAB-lC6, documentation of which has been available at the Plant site to repre-sentatives of the Commission's Directorate of Regulatory Operations.
Bechtel, in conjunction with Consumers Power, has prepared procedures for inspection, evaluation and remedial action to be under-taken in preparation for resumption of construction after the shutdown.
Those procedures are described in Part I of this report. They are being carried out by Consumers Power and Bechtel within the basic framework of their quality assurance programs. Part II of this report su=tarizes the results of the initial inspections under these procedures.
Nonconformances, if any, disclosed by additional inspections under these procedures, together with accomplished or planned resolutions of the nonconformances, will be dealt with and documented in accordance
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with the detailed procedures set forth in the Consumers Power Midland
-Project Procedures Manual' and the Bechtel Field Inspection Manual, and will be described in the monthly reports to be filed pursuant to Con-dition 4 of ALAB-106.
CONSUMERS POWER COMPANY By Stephen H. Howell Stephen H. Howell Vice President
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Sworn and subscribed to before me this 25th day of May,1973 Sylvia B. Ball Sylvia B. Ball
- Notary Public, Jackson County, Michigan My con
- mission expires May 18, 1976
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.PART I: PROCEDURES 1.0 SCOPE Condition 1 of ALAB-106 requires a report on the quality assur-i ance action being undertaken by the-applicant and/or its architect-engineer to assure that the construction work already performed and the materials now on the site are in satisfactory condition. The report is to include-inspection and calibration of instrumentation to be used in the Quality Assurance Program.
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Procedure 1.0
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2.C INVENTORY AND INSPECTION CONTROL PROCEDURE 2.1 PURPOSE To describe the inventory and inspection control procedures necessary to assure that construction work already performed and materials stored on site are in satisfactory condition.
2.2 SCOPE This procedure covers inventory and inspection control for construction work already performed and materials now at the jobsite. This procedure requires:
- a. Identification of construction work which has already been performed and materials which have been purchased, fabri-cated, and delivered to the jobsite or alternate storage areas.
- b. Evaluation of the present condition of those items identi-fled in (a) above.
2.3 PROCEDURE 2.3.1 Identification of Construction Work Already Performed The following ite=s of "Q" listed construction have been completed unless otherwise noted below.
(1) Auxiliary Building a) Foundation slab at elevation 568' .
b) East and west exterior walls north of column line D to elevation 579'.
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.c) Exterior wall at column line A to elevation 584' .
I d) East and west exterior walls south of column line G to elevation 579'. *
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e) Exterior vall at column line H to elevation 584' .
f)' West ving slab at elevation 574' .
g) Rebar installation for interior valls to eleva-tion 568' to elevation 584' is approximately 75%
complete.
h) Backfill placed at exterior valls to bottom of slab at elevation 568'.
. 1) Work slab has been placed for on-grade slabs
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, north of column D at elevation 584' .
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(2) Reactor Building #1 a) Tendon Gallery.
b) Approximately 75% of reactor building base slab forms are in place.
c) Structural support / shear steel is 50% installed; velding of support / shear steel clips, for top
framework, is 30% complete.
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i d) Rebar installation for reactor building base slab is 15% complete.
(3) Reactor Building #2 ;
1 a) Tendon Gallery floor slab.
Procedure 2.0 Page 2 1
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b) Tendon Gallery wall rebar installation is 90%
complete.
c) Work slab for reactor building base slab.
d) Structural support / shear steel is being stored on site.
(h) Site Excavation and Backfill a) Emergency service water pond excavation.
b) Structures excavation.
c) Approximately 25,000 yards Class 1 backfill is in place to north of plant structures.
2.3.2 Identification of Materials The following "Q" listed material has been delivered (in part or total) to the jobsite. Purchase Orders, construction laydown drawings, and storage records will be utilized to verify identification and quantities.
(1) Liner Plate for Units 1 & 2 a) Upper liner plate.
b) Floor liner plate.
c) Reactor cavity thickened liner plate.
(2) Anchor Bolts a) Embedded.
b) Stored.
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(3) Post-Tensioning Materials a) Trumpets.
Procedure 2.0 Page 3
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f b) Sheathing, c) Bearing plates.
(4) Auxiliary Building Pipe Tunnel (5) Miscellaneous Steel-Embedded or for Embedment a) Steam generator soleplates.
b) Reactor soleplates.
I c) Stainless steel piping, d) Reinforcing steel.
, e) Threaded rods.
(6) Miscellaneous Steel-Stored (or in-place) a) Sump liners.
b) Structural steel.
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c) Forged steel penetration (flued head).
d) Polar crane support brackets.
(7) Cadweld Splices (8) Coatings a) Liner plate coatings.
b) Auxiliary building pipe tunnel coatings.
.(9) Waterstops 233 Evaluation of Present Condition Inspection and examination of construction work completed,
-materials in storage, and accessible portions of embedded I
materials will be performed in a timely manner so as to properly evaluate the condition of the work and materials Procedure 2.0 Page 4
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.before the performance of new construction work would prevent such evaluation.
A. Concrete Work A visual inspection of structural concrete will be performed to identify deterioration, if any, due to exposure or evidence of lack of durability. Exposed l-portions of embedded items will concurrently be ex-amined.
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Concrete work shall be mapped to show visually sig-
nificant cracks, if any, areas of leaching, seepage, i and spalls, at a scale not less than 1/l+" to l' .
Random, hairline cracks less than 5' in length shall be considered insignificant for mapping purposes.
. A second map, similar to the first, shall show ex-posed portions of embedded items and by reference to an identification key, the extent of deteriora-tion or corrosion and physical appearance (ie, I
soundness of embedment, etc) shall be noted.
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Exposed portions of embedded items requiring inspec-Lion include:
- 1) Beinforcing dowels.
- 2) Anchor bolts.
- 3) Miscellaneous metal.
- 14) Waterstops.
Procedure 2.0 Page 5 l
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B. Earthwork A visual inspection of earthwork construction vill be performed to assess the degree of surface ero-sion which has occurred.
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In addition to visual inspection, tests shall be performed to determine the adequacy of earthwork i
construction. Borings, if required, vill be taken at the locations to be determined by Project Engi-neering, to determine in-site density, shear strength, and to obtain samples for mechanical analysis, moisture content and unit weight.
Undisturbed samples shall be taken and tested in ac-cordance -d ++ b chtel Specification 7220-C-210.
C. Waterst_ ,
A visual inspection of waterstop material shall be performed. Evidence of cracking, checking, physical abuse, or other deterioration due to exposure, sun-light, freeze-thav, chemical attack or other delete-rious agent, shall be noted.
D. Liner Plate Liner plate vill be examin:i to determine the condi-tion of both plate and coating (inorganic zine on one side only).
Procedure 2.0 Page 6
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(1) Plate Examination Representative samples of liner plate sections will be examined to determine the extent of corrosion and pitting in uncoated areas.
a) Surface Preparation Prepare surface by removal of accumulated rust in an area approximately 1" diameter on opposite-surfaces by wire brushing followed by abrasive polishing to achieve bright metal surface.
b) Thickness Determination Measure and record plate thickness at each of two locations on two plate edges using dial thickness gage or calipers.
c) Pitting Evaluation Measure and record deepest visually determined surface irregularity usiog pit depth dial gage at each test location.
d) Microscopic Examination Remove a panel (4" by 6" minimum size) from each of five liner plates (1/4" plate) for micro-scopic examination. Examinations of plate sur-faces and edges will be performed in the as-cut
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condition and after wire brushing to determine
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suitability for welding.
Procedure 2.0 Page 7
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Plate thickness and depth of pitting will be measured as above, and photomicrographs pre-pared to document condition.
(2) Coating Examination The condition of the inorganic zine coating will l
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be determined on representative samples of liner plate.
a) Surface Preparation
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Dust, moisture, and foreign matter will be re-moved from an area approximately 8" diameter on
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selected plates, using a clean and dry cloth, b) Thickness Determination
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Coating thickness will be determined and re-
, ported on five locations on each plate, using a magnetic film thickness gage-c) Visual Examination Visual examination of the prepared surfaces will be performed to determine extent, if any, of mud cracking, pinholing, overrpray, dry spray, and presence of inclusions. A 10K magnification may be used, if necessary.
E. Reinforcing Steel Reinforcing steel will be examined to determine ex- ,
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tent of corrosion caused by exposure to atmosphere and/or silting and water.
Procedure 2.0 Page 8 l
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(1) Embedded Reinforcing Steel
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The accessible portions of 10% of the partially
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embedded reinforcing steel will be measured to determine extent of material loss, if any.
a) Surface Preparation Remove accumulated rust on approximately 1" 1
diameter areas on opposite sides of the
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rebars by wire brushing followed by polish-ing to achieve a bright metal finish.
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b) Thickness Determination Measure and record the diameter with a cal-iper gage, on 10% of the rebars exposed to silting. Two measurements shall be taken 90 apart at the same elevation within 6" of the concrete juncture on deformed and
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undefor=ed diameters. As a control, on the same rebar, measure in a similar manner the diameters at a point above the area ex-posed to silting.
(2) Stored Reinforcing Steel Measure length and weigh two reinforcement bars of each diameter and tensile category.
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Procedure 2.0 Page 9
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F. Shop Fabricated Embedded and Buried Stainless Steel Piping (not installed)
A representative sample of piping vill be visually examined and described.
G. Anchor Bolts A representative sample of anchor bolts will be ex-amined and diametric measurements made and reported.
(1) In-Place Anchor Bolts a) Surface Pretaration Remove tape covering grease coating.
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Remove grease by. application of solvent '
and wipe surface clean with dry cloth.
b) Diameter Measurement Measure and record diameter of all anchor bolts where corrosion is present with a caliper gage.
(2) Stored Anchor Bolts a) Surface Preparation Remove grease by using solvent and wipe surface clean with diy cloth.
b) Diameter Measurement Measure and record diameters using a cal-iper gage.
Procedure 2.0 Page 10
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H. Structural Steel (uncoated)
A representative sample of structural steel vill be examined to determine extent of corrosion and depth i of pitting, if any.
(1) Surface Preparation Remove rust and loose mill scale, if any, on an area approximately 1" in diameter from flange at two locations on each member by hand wire brushing and abrasive polishing.
(2) Thickness Determination
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Measure flange thickness at two positions on each member with a caliper or plate thickness gage. Visually determine presence of pitting, i if any, and measure with pitting depth gage.
4 I. Structural Steel (coated) and Polar Crane Support Brackets A representative sa:ple of the polar crane supports, brackets, and. structural steel members coated with inorganic c.ine, vill be examined to determine ex-tent of corrosion, if any.
(1) Examination
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Visually inspect uncoated mating surfaces for
pitting and to identify areas of coating dam-
- age, if any.
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(2) Pitting Evaluation Areas of evident pitting shall be measured by a pitting depth gage and recorded.
t J. Exothermic Weld Splice Materials (Cadwelds)
(1) Remove plastic end caps and visually examine internal and external exothermic weld sleeves.
(2) Surface Preparation Remove accumulated rust, if any, in an area approximately 1" in diameter on opposite sides of the sleeve wall by wire brushing followed by abrasive polishing, to achieve a bright metal surface.
- (3) Thickness Determination f On a total of ten assemblies, measure and record wall thickness of two individual weld
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sleeves on visually rusted surfaces, if any, using a caliper gage.
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K. Post-Tensioning Materials Representative samples of post-tensioning materials, in-place and in-storage, shall be examined to de-termine extent of corrosion, if any.
l (1) Tensioning Bep ing Plates - In Place Visually inspect exposed surfaces of bearing plates to locate rusted areas, if any.
Procedure 2.0 Page 12
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a) Surface Preparation On representative areas where rusting is evident, remove rust by wire brushing followed by abrasive polishing to a bright metal surface.
b) Pitting Evaluation i
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Using pit depth sage, measure and record depth of deepest pit, if any, as deter-mined by visual examination.
(2) Tensioning Bearing Plates and Trumpets -
In Storage Examine post-tensioning materials in storage
} to determine extent of corrosion, if any.
a) Surface Preparation Remove accumulated rust, if any, approxi-mately 1" in diameter on opposite bearing plate and trumpet surfaces, by wire brush-ing and abrasive polishing to achieve a bright metal surface.
b) Thickness Determination
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Measure and record thickness of one bear- t ing plate and one trumpet wall using a dial thickness gage of ca).iper.
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(3) Lower Tendon Sheathing This sheathing is hot dip galvanized inter-
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nally and externally. Visually inspect galvanizing for indication of coating failure or dross inclusions, if any.
L. Auxiliary BuildL-q Pipe Tunnel The auxiliary building pipe tunnel will be examined to determine coating condition and extent of cor-rosion, if any.
(1) Pipe - Section Examination The surfaces of the pipe section shall be visually examined to locate rusting, if any, in veld cut-back areas.
a) Surface Preparation Rusted areas, if any, vill be prepared by removing rust, residual coatings, and
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foreign material by vire brushing fol-loved by abrasive polishing to bright metal surface. A total of five such areas shall be prepared if extensive rusting is evident.
b) Thickness Determination Measure and record plate thickness on five locations using a dial thickness gage.
Procedure 2.0 Page 14
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i c) Pitting Evaluation At each prepared test . location on each side of pipe, measure and record with a pit depth, or caliper gage, the deepest visu-ally determinable surface irregularity, if any.
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(2) Coating Inspection Procedure a) Surface Preparation Remove any dust, moisture and foreign matter on an area approximately 8" in j
diameter on both the internal red lead and external coal tar enamel primed surfaces.
b) In a total of five internal and five ex-t ternal locations, measure and record coat-ing thickness with a magnetic film thickness gage. Visually inspect coatings with the aid of a magnifying glass and describe degree of abrasions, degree of
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chalking, delamination pinholing, and
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presence of inclusions. i M. Other Materials The status of other materials shall be determined 4
by examination in a manner consistent with the aforementioned procedures.
Procedure 2.0 Page 15 l
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30 SPECIALIST QUALIFICATION AND RESPONSIBILITIES 3.1 PURPOSE To identify the qualifications and responsibilities of spe-cialists.
32 SCOPE This section covers the qualifications and responsibilities of specialists who will be performing earthwork examinations, con-crete examination and metallic, and non-metallic examination of j construction work already performed and materials now on the site.
33 QUALIFICATIONS AND RESPONSIBILITIES 3 3.1 Specialists performing examinations of construction work or of materials in storage shall satisfy one of the following requirements:
(1) Graduate of a four-year accredited engineering or science college or university, plus five years of i experience in testing or inspection (or both) of
l- equivalent manufacturing, construction and instal-lation activites. At least 'tvo years of this ex-perience should be associated with nuclear
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facilities; or if not, the individual shall
- have training sufficient to acquaint him thor-oughly with the safety aspects of a nuclear fa-
, cility.
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(2) High school graduate, plus ten years of experience in general engineering of equivalent manufacturing, construction and installation activities. Five years of this experience is required in testing or inspection (or both) of equivalent manufacturing,
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construction and installation activities. At least 4
two years of this experience should be associated
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with nuclear facilities; or if not, the individual shall have training sufficient to acquaint him thoroughly with the safety aspects of a nuclear I
facility.
3 3.2 Access Access shall be permitted to all parts of the construc-tion site to permit examinations.
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3 3.3 Responsibilities of Specialists The responsibilities of the specialists shall include, but not necessarily be limited to, the following:
a) For the purpose of this inspection t' *y will gen-erally act in the capacity of the " Responsible .
Engineer" as indicated in Bechtel Field Inspection
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Manual Procedure G-3 b) Examination of materials and construction.
c) Witnessing or veri 1Ying examinations and tests performed by others.
d) Initiation of non-conformance reports.
Procedure 3 0 Page 2
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- 3. 3 J4 Records The specialist shall assure that records of inspections are prepared and forwarded to Project Engineering.
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4.0 CALIBRATION OF INSTRUMENTATION AND TEST EQUIPMENT PROCEDURE 4.1 PURPOSE To identify the calibration procedure for controlling the ac-curacy of measuring and test equipment to be used for the '
Quality Assurance Program.
4.2 PROCEDURE Calibration of instrumentation and test equipment to be used in quality assurance relating to construction activities shall be performed in accordance with Bechtel Field Inspection Pro-cedure G-4, the current revision of which is attached hereto as Attachment A.
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Procedure 4.0 Page 1
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ATTAv M A FIELD INSPECTION PROCEDURE G-4
" CONTROL OF MEASURING AND TESTIIC EQUIPMENT"
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- l FIELD INSPECTION PEOCEDURE G-4 g
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CONTROL OF MEASURING AND 'IESTING EQUIPMENT I
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100 SCOPE This procedure establishes direction for the centrol of measuring '
and testing equipment (includes tools, instruments, gages, meters, and other devices) used to measure, gage, rest, inspect, i
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or otherwise examine items to determine compliance with '
' specifications during inspection and verification of construction
' activities.
NOTE: Permanent plant instrumentation and components are not !
I included within the secpe of this procedure. i
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2.0 DUTIES >
1 2.1 The Project Field Engineer is responsible f or: l
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l a) Notifying centractors of the requirements for control I
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of measuring and testing equipment.
"N Mcnitoring the centractors' programs for control of !
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measuring and testing equipment. t t
s ms/ I c) Assigning personnel to coordinate with Quality ,
i control Engineers and Construction Coordinators to determine the measuring and test equipment to be maintained.
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2.2 The Project Field Quality Centrol Engineer in coordination with Field Engineers and Construction Coordinators shall ,
select Ecchtel test and measuring equipment which is to be l
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used to determine final acceptance. The selection shall be determined frem a review of engineering criteria, field ,
material requisitions, and purchase orders. The equipme-'
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selected shall be posted on an equipment lisu and show the ;
assigned frequency of accuracy verification. The PFCCE will '
accumulate manufacturer's accuracy data, designate those authorized to perform accuracy verification tests, and i 7
verify that records are current. He shall assign perscnnel to operate the system for control of measuring and testing ,
equipment.
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2.3 The assigned Quality Centrol personnel shall assure that:
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[i FIELD INSPECTION PEOCEDUBE G-4 Q -
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l TITLE: CONTTOL OF MEASURING 05 !12 -l'_
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m- AND TESTING ECUIP!ENT l'AGC Of . !O -
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used by construction
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a)
Measuring and testing equipment, }
personnel shall be of the standard commercial types. ww-b)
Calibration and accuracy verification of the measuring and testing equipment is in accordance with' the tolerance for accuracy established by the g manufacturer.
c) Manufacturer s data shall be available for review.
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Methods of accuracy verification used by the authorized personnel or test facility are in
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accordance with accepted and recognized practices.
The method used shall be clearly noted in the certification report.
e)
Standards utilired in the accuracy verification methods have a known valid relationship to NationalThe standard standards, where such standards exist.
used shall be clearly noted in the certification report, f) All items of measuring and testing equipment being controlled are recorded on the Equipment List.
The Equipment List includes the project
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j g) identification number, the manuf acturer's serial number, model number, and the interval of accuracy
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verification.
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The project identification number is permanently affixed to the equipment.
The certificatien label is affixed to the equipment i) and displays the date of certification, certification expiration date, and the identification of the agency nerforming the accuracy verification.
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j) The checkout records for the withdrawal and and display assignment of equipment are maintained,the date of wit the equipment.
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Accuracy. verification of the equipment is performed on or before e::piration of the certificacion.
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Only equipment with a current certification is issued or used for inspecticn or test.
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I FIELD INSPECTION PROCEDUEE G-4
( 05 125-72
,a-[<uh TITLE: CONTEOL 07 MEASURING
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- ) AND TESTING EQUIIMENT Pact 2 or 4 NO- G-4 l
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s- 6 m) The authorized certification agency verifies the j l accuracy of the equipment to the applicable !'
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standards, and generates the associated records and
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test data.
i i NOTE: When discrepancies in the equipment are i
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found during accuracy verification the l
certification agency is required to notify
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the Materials Supervisor, who shall notify the PFCCE and the PFE. A check shall be e
made to determine what items were accepted I with the discrepant equipment and the l acceptance results evaluated. Those items i judged to be outside of specification limits j j shall be held as nonconforming and reported using Field Inspecticn Procedure G-3.
n). Recertification of any measuring device is required by those utilizing the equipment should damage occur .
I to the measuring device or variations be observed in i the inspection or testing process that would indicate ,
the devicets loss of accuracy. l L
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o) Functional cross-checks against similar equipment are 3 performed during shcrt periods of heavy usage to s noniter operation and accuracy.
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%3/ SOTE: Verificaticn on the established intervals is
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not required, with the e::ception of gauges utilized for ASME tests, if the daily checkout log indicates the measuring device has not been used since its last i
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certification and a functional check against a similar device in service indicates proper operation. If found satisfactory, the QCE
- may authorize the device
- s use and enter the I circumstance on the Maintenance Record and establish a new certification period.
2.c The Material Supervisor is responsible for accountability of equipment, assignment of prcperty numbers, maintaining the
, withdrawal / assignment record, transfer of equipment between the project and the certification agency. and forward the
{ test data records to the quality control file.
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FIELD INSPECTION PRCCEDURE G-4 l A*H 'g .. *; 3 ~' ,.
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TITLE: CONTROL OF MEP.SUFING
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ASD TESTING EQUIPMENT :
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- . 00 COCUMESTATION The following permanent records shall be maintained to indicate accuracy proper control exists ever the use of equipment and that verification is performed on a regular basis
(1)
Calibration and accuracy verification reports.
QC-G4-1 App. A (2) Maintenance Record.
Field Inspection Report, QC-Gi-1, shall be used for reporting other insMetion activities. All nonconformances QC-2NCR.
shall Le reported using the Ucnconformance Ecport, Completed fo.ms and reports shall be routed to the Quality Control Documec.'atden Coordinator for final processing.
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g, FIELD INSPECTION PROCEDURE G-4 i 7
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05 d; .' : . I ;'-j' TITLE: CC"TFOL OF MEltGUBING ~~-- ~ ~~ - 2
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R.j D.UD TESTING EQUIPMENT PACC g Of q
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APPENDIX A i s) '
FIELD INSPECTION PROCEDURE G-4 I
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\ i k INSTRUCTICNS FOR PREPARING AND PROCESSING THE ,
i MAINTENANCE RECORD QC-G4-1
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- The following instructions are provided as a guide for preparing and i
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j processing the Maintenance Reccrd, QC-G4-1, Figure 1. The numbers in uhe column marked ELOCK NO. of these instructions correspond to the i block numbers in Figure 1. The type of information required is shcwn ;
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the ENTRY INFORMATION column.
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I 7LCCK N_O. _
ENT2Y INFOTIATION -
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- 1. Enter property number assigned and permanently marked on i
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the equipment.
- 2. Enter the generic name of the item, i.e. , torque wrench, i I
s pressure gage, etc., Manufacturer's trade names are not ,
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(,j ! 3. Inter the name of the manufacturer of the item. l
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- 4. Enter the manuf acturer's model number. i
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- 5. Enter the manufacturer's serial number assigned to the I item. .
- 6. Enter name of vendor from whom the equipment was !
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! 7. Enter Purchase Order Number.
i j 8. Enter the range the equipment is capable of o,rerating j within, i.e., a pressure gauge can have a reading face graduated from 0 - 300 psi, a torque wrench nas a range of 0 - 300 foot-octnds.
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- 9. Enter sine of the equipment, i.e. a pressure gauge can have a 3 inch diameter reading face, a torque wrench a 3/8" or 1/2" square drive.
- 10. Enter the acceptance tolerance (if applicable) as shown en the manufacturer's certification. i 3, 1
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p) r g FIELD INSPECTION PRCCEEUEE G-4 JM '- -
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. e ', :, - f TITLE: INSTRUCTICS F03 PDEPARING 05 12 _1 ~ - Z' gg -
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l O s. . jp THE MAINTENANCE RECORD, I' '
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i 11. Enter maintenance tolerance (if applicable) as shown on I the nanufacturer's certification.
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- 12. Enter accuracy verification instruction number.
- 13. . Enter Instruction revision number.
10 Enter accuracy required, i.e. , percent, linear measurement in .001 of inch, psi, etc.
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- 15. Indicate if correction charts or curves are required.
- 16. Inter min. and max. of scale required to.be verified.
- 17. Enter points of values to be verified.
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- 18. Enter data pertinent to the item, i.e., date item was retired from service.
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- 19. Enter verificaticn schedule.
- 20. To be completed by the Quality control Documentation g coordinator.
s/ s l The following method of processing the Maintenance Record will be used j as recall notification to the caterial department for removing
equipment from cervice and delivery to the certification agency for
' accuracy verification.
a) The Field Engineer will set up a Maintenance Record form for each verification cycle (Slock 19) in effact.
b) The Field Engineer will' onter each item of equipment on the appropriate form. Determine this by using the verification schedule acsigned to items of measuring and testing equipment.
i Example: An Item assigned a cycle of 30 days is entered on the ,
form with 30 days displayed in 31cck 19.
- c) About one week prior to the certification expiration date the .
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Field Engineer will send a copy of the appropriate record to the material department.
d) The material department will remove from service the equipment licted on the record and prepare the itemc for shipment to the ;
appropriate agency for accuracy verification and certification.
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'. FIELD INSPECTION PEOCEDUBE G-4 !pM: D bD 'f ' .
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/ n .u , 1 TITLE: INSTRUCTICN FOR PEEFARING l 'f* 05 i, 12- i 1 - T' i i
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, THE MAI!MENANCE RECCRD, i L'
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O i W'- FI/JCK NO. ENTRY INTOR'GTION Vj l . note: If equipment has not been used since last date of Certification, a functional (cross check) test may be ,
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authorize its use and enter the circumstances in the ;
equipment records and establish a new certification e per.'.ca.
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!e) Upon return of the equipment the assigned Field Engineer will process.
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FIFLD IMSPECTION PROCEDURE G-4 #'"
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! TITLE: IUCTRUCTION FOR PREPARING d" - 05 ' 1'-
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FIELD It?SPECTIOti PROCEDU32 G-4 !/ ar:b D NCF,i_s f. k -
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. TITLE: INSTRUCTICU FOR PEEPARING i 05 1.' - 1 1 ~' ' !
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l il** -[.; TIIE MAINT2tECE RECORD, i.mc.,: o, w
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PART II: SIM'ARY OF INSPECTIONS 1.0 MATERIAL STORAGE AREAS 1.1 DATE OF INSPECTION April 27, 1973 1.2 PERSONNEL CONDUCTING INSPECTION Bruce H. Peck - Mechanical Supervisor, Consumers Power Compan'/,
Midland Plant Site.
1.3 SCOPE OF INSPECTION This general audit inspection covered the two material storage areas, one adjacent to the Plant site and the other at a Dow Chemical Company railroad siding, to verify the status of materials in storage and to see if any materials had settled l
.; into the ground following the spring thaws.
1.1+ INSPECTION METHODS l
Visual.
1.5 INSPECTION RESULTS All material under Specification C-50 and C-50A, circulating water piping, reinforcing steel and crane brackets are stored on dunnage off the ground. No materials were observed to be in contact with the ground.
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1.6 CONCLUSION
S AND RECOMENDATIONS
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1.6.1 Materials in storage in these areas are stacked in a
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satisfactory manner.
l'.6.2 The status of these materials should be monitored on a periodic basis.
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2.0 CONTAINMENT LINER PLATE COATING 2.1 DATES OF INSPECTION May 1 and May 2, 1973 2.2 PERSONIEL CONDUCTING INSPECTION J. Newcomb - Coatings Specialist, Materials and Fabrication Quality Control Services, Bechtel Incorporated, San Francisco Office.
R. Grote - Field Engineer, Bechtel Power Corporation, Midland Plant Site.
H. Hondorp - Engineer (Metallurgist), Materials and Fabrication Quality Control Services, Bechtel Associates
Professional Corporation, Ann Arbor Office.
l C. Hinson - Coating Specialist, Technical Service Department, Carboline Company, St. Louis, Missouri.
2.3 SCOPE OF INSPECTION The inspection covered those liner plates (32 of 29 +)1 now stacked
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horizontally in two laydown areas, one ad,jacent to the Plant site and the other on Dow Chemical Company property, that are accessible without unstacking. One side of the plates was coated in late 1969 and early 1970 with an inorganic zinc primer manufactured by the Carboline Company and bearing the trade name Carbozine 11.
The coated surfaces were inspected for defects such as mud cracking, overspray, weld spatter, sags and runs, dry spray and insufficient coating applications. The dry film thicknesses were measured.
Inspection 2.0 Page 1
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2.4 INSPECTION METHODS Inspection of coated surfaces for defects was visual. Measure-ments of the dry film thicknesses were made at five or more
, random locations on each plate examined, using an elcometer and a mikrotester, both of which were calibrated in the field prior to and during use.
- 25 INSPECTION RESULTS
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2.5.1 Visual Inspection
, The uncoated backside surfaces of the liner plate and structural attachments have rusted and bled onto the coated surface of the plate beneath, which will require removal (li 6ht sand blast) and re-coating. Three plates
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exhibited defects sufficient to require complete removal and replacement of the prime coating. The following defects were observed:
Mud cracking - 12 plates Overspray - 3 plates Rusting - 4 plates Weld spatter - 3 plates Dry Spray - 3 plates Sags and runs - 4 plates
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2.5.2 Thickness Measurements Dry film thicknesses exceed that required by Bechtel Specification 7220-C-50A.
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2.6 CONCLUSION
S AND RECOMMENDATIONS
, 2.6.1 The inorganic zine coating performed a partially pro-tective function during the storage period.
, 2.6.2 All coated areas of those plates examined will require
sandblasting to some extent to prepare the surface for further coating application. This may be done either by
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complete removal and replacement of the prime coating or by light blasting (sweep blasting).
2.6.3 The remaining liner plates should be examined as they ,
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are unstacked to establish the extent of required rework I
or preparation prier to re-coating.
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t 3.0 AUXILI RY BUILDING CONCRETE AND WATERSTOPS 3.1 . DATES OF INSPECTION May 8 and May 10, 1973.
3.2 PERSONNEL CONDUCTING INSPECTION F. Joyce - Supervising Civil Specialist, Quality Control, Bechtel Power Corporation, San Francisco Office.
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~ J. Dotson - Quality Assurance Engineer, Bechtel Associates Professional Corporation, Ann Arbor Office.
5 R. Grote - Civil Field Engineer, Bechtel Power Corporation, Midland Plant Site, 33 SCOPE OF INSPECTION
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The inspection covered structural concrete and waterstop material.
- for evidence of deterioration or damage. The inspection was confined to the exposed slabs and walls of the Auxiliary Building.
At the time of the inspection, the formwork had not been removed from the north, south, and portions of the east and west walls.
In addition, a small portion of the slab had not been cleaned of mud which had been washed in during recent rains.
- 3. l+ INSPECTION METHODS Visual inspection. Mapping of visually significant cracks (random, hairline cracks less than five feet in length not con-sidered visually significant; they are generally a result of localized finishing operations or minor surface drying).
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35 INSPECTION RESULTS 3.5 1 Structural concrete Several cracks were observed within the middle portion of the slab, generally running in an east-west orientation.
The cracks were narrow, by visual examination ranging
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fromhairlinetolessthan1/32inchthick. The slab t cracks generally teminated at the junction of the wall
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pours. Several cracks had a white deposit (efflorescence) within them. This discoloration would be expected as the l
slab was covered by water and silt until recently.
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The cracks observed were characteristic of typical ther=al i
- shrinkage cracks. Typical internal temperatures of = ass a
concrete, due to heat of hydration, may reach 130 F or -
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more. After this heat dissipates, the concrete contracts i 1 and themal shrinkage occurs. The resulting cracks are to l
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be expected and would not impair the structural integrity
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The exposed wall had several non-significant hairline
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cracks. The lower pertion of these cracks had deposits
- of minerals that were a result of moisture permeating through the cracks. The minerals are in solution when >
the moisture is moving through the crack but are left
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behind when the moisture evaporates at the outside sur-
-face of the crack. The source of the water is the temporary water standing behind the concrete wall, and the deposition of minerals will stop when the source of moisture is removed and waterproofing material is con-tinued upward behind the wall.
352 Watersteps No damage was observed other than locali::ed stairfing.
The waterstop matarial was still flexible, and no evidence of cracking or checking was observed.
3.6 CONCLUSION
S AND RECOB E DATIONS 3.6.1 The inspection disclosed no evidence that suggests structural inadequacy of the Auxiliary Building slab and walls.
3.6.2 The embedded waterstep material appears to be in satisfactory condition.
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