ML20127B792
| ML20127B792 | |
| Person / Time | |
|---|---|
| Site: | Waterford  |
| Issue date: | 05/31/1976 |
| From: | J.A. JONES CONSTRUCTION CO. |
| To: | |
| Shared Package | |
| ML17198A241 | List:
|
| References | |
| FOIA-84-455 W-SP-7, NUDOCS 8506220059 | |
| Download: ML20127B792 (11) | |
Text
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- - Procedure No. w-sp -
6 J. A. JONES CONSTRUCTION COMPANY -
SPECIAL PROEESS PROCEDURE i ,
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REFAIR AtID CURING OF C0!! CRETE REPA IR FOR PLACEttEtlT %9502-100 .
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J. A. JONES CONSTRUCTION COMPANY PAGE ; 0F6 SPECIAL PROCESS PROCEDURE ROCEDURE NO.
W-SP-7 TITLE: REPAIR AND CURING OF CONCRETE REPAIR FOR PLACEMENT REV. NO. 1 -
699502-10B & DATE 5/31/76 PROJECT TITLE: WATERFORD SES UNIT NO. CONTRACT NO. W3-NY-4 1.0 PURPOSE To outline methods used by J. A. Jones Construction Company and Subcontractors for repair and curing of concrete repair for Placement 499502-108.
2.0 SCOPE .
This procedure includes the requirements to be used by J. A. Jones Construction Company and their Subcontractors in the concrete repair of Placement 499502-108.
3.0 REPAIR SEQUENCE 3.1 The sequence of repair work shall be as follows:
R-1 ,
3.1.1 Epoxy Pressure Grouting Cored Holes with Cracks.
3.1.2 Repair of top surface. -
3.1.3 Waterst'op embedment.
3.1.4 Filling of holes not in crack aha.
R-1 3.1.5 Pressure grouting voids and horizontal cored hole #25 in West face.
4.0 REFERENCES
4.1 Ebasco Services, Incoroorated Specification LOU-1564.477, Section 11, latest revision, " Concrete Placement., Curing and Finishing".
4.2 ACI-503, Guide for use of epoxy compounds with concrete.
4.3 Sika Chemical Company brochure for "Sikadur Epoxy Adhesives". '
4.4 J. A. Jones Construction Company Work Procedure, W-WP-5, " Concrete Placing, Curing, Finishing and Repair."
5.0 RESPONSIBILITIES 5.1 Ebasco Services, incorporated is responsible for supplying all materials, receiving inspection, testing and documentation of such tests as required by Reference 4.1 to support 'J. A. Jones Construction Company and their Subcontractors in performing their work.
5.2 J. A.. Jones Construction Company and their Subcontractors are responsible for forming, placing aggregate, grouting and curing of cement pressure grouted area, the epoxy pressuring grouting for sealing cracks and the surface preparation and topping and finishing of top surface as required by this procedure.
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J. A. JONES CONSTRUCil0N COMPANY PAGE 2 0F 6 SPECIAL PROCESS PROCEDURE PROCEDURE NO.
w_Sp.7 <
TITLE: REPAIR AND CURING OF CONCRETE REPAIR FOR PLACEMENT REV NO. I 1 499502-10B & DATE 5/31/76
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PROJECT TITLE: I WATERFORD SES UNIT NO. 3 CONTRACT NO W3-NY-4
._ TOP SURFACE PREPARATION 6.0 PROCEDURE 6.1 J. A. Jones Construction Company Engineering shall map the surface of the entire pour delineating the areas that can be made to meet the required elevation and finish by grinding and the areas that must be chipped out to sound concrete and topped.
4.2 The areas requiring chipping and topping shall be chipped down to a minimum of one and one-half inch (It') below required elevation.
R-1 6.3 After chipping to sound concrete and prior to any topping or grinding of other area, J. A. Jones Construction Company Engineering shall notify Ebasco Engineering that the. area is ready for inspection. Any area containing
' unsound concrete shall be inspected by the Windsor Probe method, s in ver-Ifying the concrete soundness, the equivalent average 28 day compressive .
strength shall not be less than 5000 PSI and none of the equivalent com- .
I pressive strengths shall be less than 4600 PSI. ,
6.4 Areas requiring grinding only to produce. an acceptable surface shall be ground with suitable grinding machines until acceptable.
R-i 6.5 The surface of the chipped out area shall be cleaned and free from standing water, then coated with a neat coat of Sika HI-Mod' Epoxy mixed and applied per manufacturer's requirements. J. A. Jones' Quality Verification to verify and document the acceptance of epoxy material as to shelf life, mixing and application.
R-1 6.6 After neat coat of epoxy, place 4000 PSI Class AA Concrete using pea gravel as coarse aggregate to required elevation and finish as required by approved construction drawings.
6.7 After the required finish has been obtained,'c'ure per requirements of Reference 4.1 and 4.4 WATERSTOP EMBEDMENT 7.0 PROCEDURE 7.1 PREPARATION ,
7.1.1 Determine area.to be repaired. Area shall be determined by estimat' ng workable area that can be worked, based on " pot life' and required cooling time if repair requires more than one inch (l") thickness, Reference 7.3.2.
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J. A. JONES CONSTRUCTION COMPANY I PAGE 3 0F 6 SPECIAL PROCESS PROCEDURE
- W-SP-7 -
REPAlR AND CURING. OF CONCRETE REPAIR FOR PLACEMENT
- REV. NO. 1 .
499502-10B & DATE 5/31/76 PROJECT TITLE: WATERFORD SES UNIT NO.i 3 CONTRACT NO. W3-NY-4
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7.1.2 Clean area to be worked as follows:
7.1.2.1 C'ip n to sound concrete.-
7.1.2.2 Surface must be dry. ,
7..l.2.3 Remove all ' dust, laitance, gr' ease, and other foreign particle E.
7.1.3 Straighten and support waterstols as required.
7.2 Mixing. -
7.2.1 Mix Sikadur-Hi-Mod Gel two (2) parts epoxy per manufacturer's reconnenda tions. Amount to be determined b'y area to be worked.
7.2.2 Measure Colma quartzite Aggregate and mix one (1) part Sikadur-Hi-Mod Gel epoxy to one (1) part quartzite* Aggregate. Add aggregate slowly to binder while mixing.
7.2.3 Do not attempt to use after " pot life" has expired. By adding aggregate, it will add approximately five (5) minutes to " pot life".
7.3 Application. .
f.3.1 Apply prepared epoxy morta'r to embed waterstop as required per attached sketch, Appendix A.
7.3.2 Apply mortar not to exceed one Inch (l") thickness. If required mortar thickness exceeds one Inch (l"), allow preceeding layer to cool before applying second layer. Coolness can be determined when the mortar becomes hard. It should be cool, approximately one (1) hour after mixing.
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7.3.3 When more than one (1) layer is required, a neat coat of Sikadur-HI-Mod epoxy to preceeding layer before applying additional layers l
of mortar is not required.
7.4 Curing. * -
7.4.1 None required. -
NOTE .
DO NOT EXCEED ONE INCH (l") 1.AYER AS NOTED IN 7.3.2 ABOVE.
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J. A. J0NES CONSTRUCTION COMPANY 7 PAGE 4 0F 6 SPECIAL PROCESS PROCEDURE PROCEDURE NO.
W-SP-7 ,
TITLE.* REPAIR AND CURING OF CONCRETE REPAIR FOR PLACEMENT REV. NO. 1 .
499502-108 t,DATE 5/31/76 PROJECT TITLE: WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 REPAIR OF VERTICAL CORED HOLES VITHOUT CRACKS 8.0 PROCEOURE R-1 8.1 Thoroughly clean and dewater holes number 1, 2, 3, 4, 5, 6, 6, 9, 11, 12, 13, 16, 17, 20 as located on attached sketch, Appendix S.
8.2 Coat inside surface of hole and surface of area chipped out to expose reinforcing steel with Sikadur-Hi-Mod epoxy. The epoxy to be mixed and applied per manufacturer's recomendations. J. A. Jones' Quality Verification personnel is to ve'r'Ify and document epox acceptance as pertains to shelf life, mixing and appilcation.
R-1 8.3 In accordance with Reference 4.1 and 4.4, fill holes with 4000 PSI Class AA concrete using pea gravel as coarse aggregate in layers and vibrate as required to consolidate and finish to match required surface texture.
8.4 Cure as required per Reference 4.1 and 4.4. ,
PRESSURE GROUTING VOIDS AND H0R' IZONTAL CORED HOLES No. 25 IN WEST FACE.-
9.0 PROCEDURE ,
9.1 J. A. Jones to inspect and document both North and South large void has been chipped to sound concrete".'
9.2 Form both North and South void per attached sketch, Appendix C, and Pa'ragraph 9.3 below.
R-1 9.3 Completely dewater aryd clean the void space. Construct fonns in strips to allow packing of aggregate as form progresses over the void. The sectior of the form which will cover the deepest section of the void shall have a " slip pipe" Installed long enough to reach the extreme back of the vold.
Install the section of form over the deepest section of the void and extend *
" slip pipe" to reach the extreme back of the void. Pack the void around ,
e the " slip pipe" with washed aggregate until the angle of repose causes the aggregate to fall out front of void. I'nstall the bottom section of form with grout nozzle located at extreme bottom of vold. Completely fill void with aggregate (No. 4 to 1 Inch, conforming to ASTM C-33) tamp to ensure proper packing and install ' sections of form until entire void is packed.
Top section of form must provide vent at top of vold. Apply liquid port-land cement grout (4000 PSI 28-day strength by ASTM C-109) through " slip pipe" until grout is forced out through bottom grout nozzle and top vent.
When grout i s observed entering hole drilled down from top surface, fill hole with aggregate. When grout i s forced out all vent, slowly remove
" slip pipe" while under pressure. When " slip pipe" is removed, apply grout through bottom grout nozzle until grout i s forced through all vents.
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, J. A. JONES CONSTRUCTION COMPANY PAGE 5 0F6 PROCEDURE NO.
SPECIAL PROCESS PROCEDURE .
y,gp,7 REPAlR AND CURING OF CONCRETE REPAlR FOR PLACEMENT REV. h0. I TITLE
- 499502-108 & DATE 5/31/76 PROJECT TITLE: WATERFORD SES UNIT N0 3 CONTRACT NO. W3-NY-4 9.4 Cure by leaving forms in place to keep in moist condition, as required .
per Reference 4.1 and 4.4.
9.5 Form opening of horizontal cored hole as required and pack with aggregate and pressure grout per Paragraph 9.3 above. .
9.6 After curing has been completed on North and' South void, remove forms and apply waterproofing over area per J. A. Jones' Work Procedure, W-WP-II,
" Waterproofing" except that two (2) layers of waterproofing membrane shall be Installed around all edges.
EP0XY PRESSURE GROUTING CORED HOLES WITH CRACKS 10.0 PROCEDURE 10.1 All equipment required for this procedure shall' be collected and checked out. A dry run shall be performed using water for the grout, pumping against a closed valve to assure the equipment is in good working order.
Special note shall be made of the pressure gauge and relief valve to assure correct operability.
10.2 The Sikadur-Lo-Mod LV epoxy and bagged pea gravel shall be ordered, received and approved for use.
10.3 Cored holes number 7, 14, 15, 18, 19, 21, 22, 23 and 24 as located on Appendix "B" shall be cleaned of all foreign material and free of all standing water, before any other grouting operation is started. '
10.4 An expanding plug as detailed on attached sketch, Appendix "D', shall be' fabricated for each hole to be pressure grouted, and coated with wax to prevent adherence of the epoxy. Each plug shall provide a fill port and a vent. The fill port shall be provided with a quick coupling and the vent with a cap or valve for venting. The supply line between the pressure pot and quick coupling gil be provided with a sight glass for observing flow of epoxy.
10.5 The grouting operation shall begin with hole number 24 Assure that all holes are clean and dry, then pack hole number 24 with pea gravel from one of the sealed bags. When the hole has been' packed with the paa gravel, install the plug, as provided in 10.4 above.
R-l 10.6 Mix the Sikadur-Lo-Mod LV epoxy per manufacturer's recommendations. Mix only the amount that can be used in approximately 15 minutes or as directed be the Sika representative. Place the container of epoxy into one of the paint pressure pots which has been connected to the quick coupling in the plug in hole 24 Apply air pressure as directed by Sika representative
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.. J. A. JONES CONSTRUCTION COMPANY PAGE 6 0F 6 PROCEDURE NO.
CONSTRUCTION tiORK PROCEDURE W-SP-7 TITLE: REPAlR AND CURING OF CONCRETE REPAIR FOR PLACEMENT P.EV. NO j !
499502-108 & DATE: 5/31/76 -
PROJECT TITLE:
S WATERFORD SES UNIT NO. 3 CONTRACT NO. W3-NY-4 1 x '
R-1 10.6 (continted) to pressure pot and obs'erve flow of epoxy in sight glass. When the epoxy runs ,
out, switch grout supply line to other pressure pot and continue grouting l
. operation. Clean first pressure pot gro'ut supply line with Sika Equipment !
Cleaner 650 while additional epoxy is being mixed. Continue this switching and mixing operation antil epoxy is ob' served passing into one of the adjacent cored holes and at the end of this operation,' maintain pressure for an aaditional 30 minutes or until excessive grout appears In the adjacent cored holes.
10.7 Fill the hole in which the epoxy was observed flowing into with pea gravel, install the plug and start the grouting operation as described in Paragraph 10.6.
Observe the other holes and when epoxy is observed flowing into one of them, -
stop the grouting operation in the present hole and move to the hole where' epoxy was observed. Continue this observation, filling with pea gravel, and
< grouting operation until all connecting holes have been grouted, assuring that all air has been removed and epoxy is forced out the vent opening.
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- 10.8 Holes without connecting cracks shall be grouted by cleaning and filling with pea gravel and grouting as outlined in Paragraph 10.6 above.
10.9 Hole number 22 shall be grouted, as above, except when grout is observed passing i through the connecting crack into the South void on the West side. The pressure shall be relieved and the opening of the crack plugged with Sika Set Plug then ;
the pressure' resumed and g' routing continued until all air is removed and grout 1
is forced out the vent. -
- '10.10 Remove all plugs and clean plugs and equipment with Sika Equipment' Cleaner 650.
10.11 After epoxy has set and at time of filling of holes which did not contain cracks, fill the remainder of the holes using the procedure for filling cored i holes without cracks, Paragraph 8.0 above.
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., i W-SP.7 APPENDIX A
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