Text

FENOC-Davis-Besse Nuclear Power Station, Unit 1 Docket No. 50-346, License No. NPF-3 Submittal of Contractor Root Cause Assessment Report-Section 3
	ML12138A058
Person / Time
Site:	Davis Besse
Issue date:	05/14/2012
From:	; FirstEnergy Nuclear Operating Co
To:	; NRC/RGN-III
References
	L-12-196
	Download: ML12138A058 (91)
	v • d • e

Exhibit 11

JC8 i '~il (j;~ S~* :.

I"~~;

' ll(:ch to :.,. OI\\k *Uur.

Tot,)d.:;, Edison:

Fi.cld /O'l'lcl

[~.>1l

Exhibit 11

-, : ~.~. ~.

. "~

".f

l)~~~,gri'N~~

' Slump:,.. "

* *** ****** !,;i~y.*....

~

lO/'.!.3/70 *

~,hiei\\t 2~:~ld ii1'jI*/i.i.:i.l.

Ialedo: t.91$Or, C()t.1rany Oak. Hil):b()T, 011 ia C~2wSF 4'"

181.5 2560

4900

' C~Z-S~;"'2.

'4"

~15bo.:..:

'." *.';1.**.*14

- '0'"

- - . *:3u~0,

' 559~

(,.

': ).

.... ::.\\... :..,'"

C-2~Sf-t;

'..5i *

'. ioeo 2740

. ~5.J.O.

.4850 C-2:"SF-4.

'. 5;" /'4"

.... ': '...J

~30{)

1545

.3365.'*

5040.

c..:~ -S1'- 3 I; fl' i:j:'yO 2,~20

~3~O 4590

.'./

. i

- i'

Exhibit 11

.........-.---...--- *..---~.

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'.~~~i*:~..~~ ~ ' ::*;'......

~i: :~;~

~:~ a*

r;f

~,~

o 6.0 0 0 S 3 ' 2 '"

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.).)

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,.,. ~.

~~ *li.cl~ Gtlild~n~ ~all

/J[i Tol.:::do

!!:tlis(;=~ G~;np2'~Y Oa!*; li.n: ;;V( 1,):'.j.q

.'" ;:-'::!,t

.: :',;, ~

SU~i:lM\\Y OF U.j~ORATO.:-tY 'l£S:;:S CO;-!CRl::TE }UX DBSIG};

. ~,:~"

- - .:~.*,~:.,

.( :;.:

Date

.. :.:: '.. ~'".

July 6, lnO July 6, 1970.

ti".1e ;...ggre~t:. t~ ::e;~ (iioodvi:le Lime & Ch~r.l:. c,'i i..::)./

July 6, 1970 i~ine AggLCgc:! r.:e '.:c ; c ('V!hi tc Rock Quarry)

L~boratory Rc?ort

Xlimi>n-c

$-2201' 8':'2207; 8-220,7 : (2 pages)

.. 8:22°7:, (2 pages) 8-2207* (2 pages) '

6.;.778~

' (2 pali,'Cs).

6 M niJ9 6-'/789(2 r>ages) 6~7891 (2 pages) 6-78~i (2 pages) 10/2'3/70 Augus t. 27, 1970 Au~u~t 27, 1970

. Conc.:ete Xi:" Jl.!.,ign C-2-Sl;-'-2

. Prcaziu8 ~~8t of Co~c~cto

. Sept. ' 10,1970.... Concret3 1'i:':<. Desig>l C-2-SF~2 Oce. 2., 1970 Oct *. 22. 1970 COnC'l:Bt(~ Nix D<ls:"&n C-2-S~'-3

. :. ',. ~ ~'.>,:.. '".::....

Conccct~ Xix nesii~n C-2-S~-J and C-2-SF-L, and C-2-Sr-'-4

,, ~

t o-**:,.: * '.:.<..~:-.: :

July 6, 1970 Coa::,+sC;! Af;g l~e gd ::,~ f(; ;, :: (Vl';}oG vii..:!.e

\\:~. ::

Lime 6.: C:.crr:ica 1 C:>.)

July 6, ].970

. July 13, 1970 S6undn~8U of Vi~~ AE ; rcgntB

(\\olbOdvil::'~ i.iri.<: 6< C;; ",:,~ cuI Co.).'

July 28. 1970 Concret. Nix DBaign C-2-SP

Exhibit 11

.......... P,o~i<<.n'

., JOHN F. GISl~60N. P..E. :.;.

.'... : heeuli""'Yle,, ",osldonl*

." NOAAlAN *t.,HENNIN

..:..' Vice;.P,eBld.;'1 [I>9ln.o,""9

..', A:U£RT C: ;. H()~lEl\\ ; ' *.A.I.; C*~.

. : *.* VIC. *P'.tild.1I1' Ch.ml*.,;,,*.

.. OLINTON R.' IUf.

.'.citt.ry*T'.....'tr '.'. -:'-.'

Exhibit 11 the" 'aggregate wi 11 ', be ~' reportedwhen comp1 ete,d.

,Very truly yours, TWIN,CITY TESTING AND ENGmEERING1.ABORATORY. INC, '

.*t*..*. '

Exhibit 11 aggragf,t8fo'r laborat.ory and '

.....;';..*;:...::..~..*.'.~'.'~'.'.:.~:::...'....., /. ','::. :

. ENGINEERS AND CHEMISTS 662 Cromwell Avenuo ~ SI,Paul, Minn. 55114.

.,. REPORT OF:

FINE AGGRE'GAre TEST

'.: " 1-0LEDO-EDISON Po\\~&R & LIGHt "

<'TOLE'no, OHIO '

Fegles ConstI;l!ction Company 2HO..' Nicollet Avenue.

.. t-Hnne.apolis.}!innasota 55404

.. Attn(*:. }1r,John 'Ellison

. DATE:

FURNISHED BY.

COPIES Toi July 6, 1970

\\-Ihite Rock ' Qua~ry "~.

CruahedLimeatone - Manufactured Sand.

.....;'f. :...:;:..

1'} ~\\:~~t;:::::;; ~~; /

5 ~: ti\\"n~5iS : ~~O(IU\\l..J~,~

. *.:~:....>.!~i:.r:.~ ~:...:I

. ' ~ ' ; : *

.~ :. ';'.f!.

......;-\\

~> ' ~~<::( ',. "<",, ~. "..;.

.' '4t200 '_. ",., I ' ~

" ' * ~ ~~l 100~

.' 97.'

75*::.**.* *

' 54;'..

36

20. _

2:18

-: : - ~..:...,

LIIDllI:WIIIICnl ~,gJ~~i,~~~f.~i~'~.*F.r~~,~v, :~r;f'f*. 2~06) **.*

."..'~..~ :.">~.'..~ : i~.:~iS'~.~::..(*: ~. :.~.~ '.~' :-~ '.,, ~, A r: ;. 'i':'".'

t, '

*,4.. ',: '~ ~~,i-

~. ~<:. t..........

~r()(9ahliCJ~II.1:tllr.',~ :,; ~::, <,. {/:~,,\\'. >.. **,i.*..i.~ * ;.t..~:'.,

i~iU:AEI$*~)~I~TIIOrIlJ% ~.**/;:. t.**. >~\\l:*.~* :* ~ ** *. **... I

. ~.....

The ~b~~esllmplei8. tQo <f1neto me$t. sp~~:i.ficationsfO~finEl aggre8~te

or()~D*

portland 'cement conctete " Tharefore;tnG.u8o.of this sand is not raco.,'.

,Sample ;was ' submitted to the ;l.~borai:ory : arid. received her.e on june 18. r j

. e:NGIN~E~S A~O> ~~EMISTS.'.

662Cro~~eIlA~~nuo"St;PQ :~I,Mlnn, 55114

"..*....... OF:,

'. *......... COA~SEAGGREGAtE..TEST J.v~,......J-EDISOR' P,OIVER&LIGHT'.

.DAiE:

July 6. 1970

,...... *. FURNI~HEci BVIWoo(ivillc Lilne &

"'~OPIIESTOI '.

I~oodvillc, Ohio '

nn'aal)OJ'1S. Minnesota ' 55404

.* :JonnEl1:i.son *:*.*...

" Crushed LimBs tone p~ojEbf: :

.'.SPECIF,icAri '

:~i~i~~ ;*

7i"" '~::-:~"..""~

". ~

.None : *.

..()~ 2%

. None.

',;: ~;: ;\\(0;4%

..O~3%

~ar1lICI61((~ip@lfIc-9raijltY, u",d&r 2~ ;O)."

.. ~ ; ~ '<<~ <:?l\\~..... ";

' ::e~~:. \\ ' ",

. ". ~~~:

N~o#rin

ij

:;1;!';:*~iij<p.~,

N'............. ~~::

"~;.j:~~i~!;;I'~o,. % ~~~),~t.4 il~~~gCf '.*',29. 4X

".,.,.,~.' __.'.' " :.;. ' :;' 2~~9 i{6~ ".

2.68

. ~':," : "

,:).':,.,.,.:",;;:l.i<

,,'. '..,l;~ ;:

1.3 *

. !<s:

' A~O%'{/ ~QXcombin&tionof 8~mpi~~." 1. " ~n42frespact1v61Y meot8. the 11;2I,~,~q~'r '

. des:tgn!lti,on;:cioo.rs& 8SsresatG. Sample2me~ts ~ the 3/411-114 size dellignation; *,Tl:1e ** ~

. qualitYroqu~toments : aEi* s~6Wn,. The,ab,oye.iaamples !w&re suhmittod to thelahor.to*y':~,

l.ved hera on>:June18. :1~70'

~.

" ::'~~:..

Exhibit 11

.~~ i-

'",. --~~: '

'*****3 : ~,' 2.-::-H-~;

-6~77~r77*~;6~~~- -~~

*t;;*fT*\\st44~~;:~~~

0";-'5. *:

o-:

,l~*R}ti

..'. <:*cti*V* tE$*[tr&,ANDENGINEER~NG

L.Or~A*rORV.1NC~U~ :*:'.,: '.;'."

ENGINE~R'SAN~CHEM'STS OF: '...* CONCRETE: ~f[X. D~st~N

.: :4'"'.... l:o.I,I\\,I~*C.jJ.J..,;). lJ.'j POWER *&LIGHl'.

OATEi July 6, 1970 Cond~te..*.

(6i, Diam~tet' 55404 '

. ;~".'

c., :

f"URNISHEoav, Nicholson

. COPIESTOI C~2~SF 4000l>S!...

Foundation ' l~alh

over:jiu*Thick.'

It/t'.;;.,114 *.

.' 4i'.>

~a~~6X:** ;.

~

<tYP,&l P~ttland Cement (ASTMC1S l1anufacturedSand fu~ishe4 :by. wu.nn,n:'.L

'. i.~s'i:e,rnuildei:8 Pouo11th Ty.

..' 2~. l1ByR,.* :Af:A ~urnish~d by Mas ter '.

. ; '. ~~..:.

..:'j ': :.

Y\\ t!fi,~~tt:~::*..

Exhibit 11 ENGINEERS ANO CHEMISTS

,..*. ':REPORT 01'"

. --~;,

. 662 CromwollAvenuo-St. Paul, Minn. 55114 CONCRETE NIX DESIGN '

OATE:

PAGE:

(6" Diame.ter X 12" high cylinders) - Continlled

_.f **

";.';>(.:, :.......*.........:.,

2520.'

2600 *.

2560 '*'.

1:ohax:eportcd later July 6, 2

.~

,: ~*.*,.~_*~~~~:w~;~;.;~e::.i:: :~\\~~~m~V~~ ~!~c~iril~ and should )~ adjuste.d

'. i~~ ~'t~ 'en8thap* ec1m~n8werecuredin: ' 1abQratory.Sir 'in the.molds. for : th~ ;*

<l *** 'l..*...* * '....****

~h~.: : htii~i.a~ttetRp~fa~~~.ewa~

. appi'ox1matel;y73°F and *t.he. relative ' humid~;y:,.**

.' 28.(iaY:*',B.pe¢imens:w,replaced il\\th~ lahQr$~ory foS room.3 ~2day8 of '; age V~:*i

,.. m~o\\lln: o£ \\~if ;;E,,'~ill'~~~t. t~~e ~~ded,H,r~~n.ai'

tbe apeeified 4<r.o.~~n$' ;

-~ ~":..

I I i

\\ i I

ENGINE!;RS AND CHEMISTS 662 Cromwoll Avonue* St. Paul, Minn. 5511" REPOR'r Of': SOUNDNESS TEST OF FINE AGGREGA-re

'tOLEDO";'I::D~SONPO:\\'ER "LIGHT TOLEDO, OHIO DATE:

July 13.1970 FeglesConstruction Company 2110 Nicollet Avenue

'NinnaspoUs. Minnesota 55404 FURNISHED COPIIl:S TOI BY, Hoodville Lime &

\\o.'oodv1l1e. Ohio

Attn:

Mr. John Ellison No.

8-2207

.: ;. ~ -,.

"e IDENTIFICATIONI

',' Mamifilctured SandOrushed Limescone ASTM Designation C88-63 (5 cyCle) '

SodiulliSulfat8

. ~'.

. '. ~

,," 'I"~' F,.~(on

',,' Be.oro Test '

, I~,ari"),

Yo$t Fr.ctlon '.

"Aftor1:lIrt, '

' 11I'.msl 98 6

2 3

2 6

2

!n,the calculation of ' the wdghted average 108s, the siaes smaller than a shall 'be assumed to have no,1089.

The soundness loss of' thin material meets,', ', '

spac1.ficatioris * ',This report i,sanaddendulll to ours of July 6. i970.Saaipla wae ",

submitted, to the laboratory and received here on June 18. 1970.

Exhibit 11 ENGINEERS AND CHEMISTS

'.. 662.. ~romwoll Avenuo* ** SI; Paul; Minn. 5511. 4

,'~.

. ~E~¥RTO.f" :' *. SOUNDNESS TEST OF COARSE AGGREGATE

.' :- ' TOLEDO-EDISON PQlo/ER &' LIGHT

. 'tOtEDO. OHrO '

QATE:.

Ju~y 13, 1970

. F'gles

. Con~truction Company

.,..UANISHE08V: ~~odville Lime & * "'II'lIw".",.,,,,*,*.,,I,).*i.*i:'~1 21'10 Nicollet Avsnue W)odvi lle." Ohio COPIES TOr

'Minneapolis,.Minnesota. 55404

". Mr. john Ellison

~...

i..

40% 1 1/2",:",3/4" and. 60%. 3/4"-114 Crushed Litr,estone

.ASTM Designation ' Ce~-~3.. (5eycle)

' So4~um

' SU1h:te T,it Ft.lltlon,.**

Aft., Ten '

. '. Igjemll..

Exhibit 11

-;;i~. (;lrY. *;EST. * !\\.~~~~~ilE~i~~6(18RA~6RV.I~C. * * *

.. ~. "'.'.

ENGiNEER~ AN[)* CHEMISTS **

662 C(omwoH AV~n\\io

Sl~ Paul,Mlnn. 55114

. REPORT OF:

CO~CRETE MIX DESIGN POWER & LIGHT OATE:

.July 28, 1970.

FURNISHED BYI Nicholson Concrete.

Millnesota. 55404.

. Hi'~. John Ellison 8-2207

~:

. COPIES TOt

. C.,.2-SF *

' 4000 psi

Foundation Walls ovar. 12'~ Thick 11/2".-114..

' 4".. /.

' 3%-6~'

",.: :",.::. '. ~ '....

'.' <~pe I Portland Cement (ASTM C1SO) 7~;~:"

l1anufactiured Sand furnished. byWoU*1~VJ'Jo.L.~

..'.;" i>.'.

t;m~T~1f!~.~Jj ~~ :rr~;~i

'. *. Cru8he~1 Limeatone.furniShed by WOII)C1'r, l,:l; l~ '~"'~'.!I',,!I: ~~I:}'~

..~.

l~~ii~~rBUi~der~ Pozzol1th Type200::'N..*..

.... 2~MBV.l.tAEA furnished by

Ma~tar Builders\\,jol:Op~,n.y(:

'. 564(1 '

1, : Typ~:ioO';N Pozzo~i.~h.

.'. '16.9 ounces

. t.~,YR* AEA '** *

.. ' :*....,'~'i46l/unc.s~

1/'},.";":3/41'),

.. 630a.

14"~(j4) '. '.......,

.., '94511

,'I\\:gg:r:eluu;4' '.... Total '.,>.

15750 '

'. * *. ~:.5 *.$::- : ~ats'.

5 ~9L8al/sk

.~~~.~.l

**;:~Q~~"i:d

of: ~: ils tic Conc't'G ta..'

..**. id.<S:, pcf..'

~~~~!.!:...2.!:~~:2.!.. (6 11

D1~~~tnXJ,2 11 'hish,~~~i~(tetil)

. '.:... :.:.*..-"......:..*~.,: ;.....,..

';"?~.:

DATE:

- ~

. PAGE:

/ : : '

2520 2600 "

2560,.

. ':.~...

O:.!;~~h/ !\\l0jlgh"**.:.,.".v.w..' aboveal:e' on an oven dry baSis lUldahould be adj us tad Ul':; i:l~llI:tElga

' t'e~ ~at ' tbG.time of batching. '

. " s#cmgth 8P~cl~en8wete

. cured~n 'laborato):ya1rin thellloldsfor The 8m'b:ient temperature.wasapprodtJlately730F and the relative humid!

.:~""ft"I"vil :"'1i*t!;

'28 ~~~ '~pecitJlens ' ~are plac;ed in tho l8.b.ora;~ory fog room. at 2 days of ~ge.,*

",.~;'""

<:~~:',:;. '.;;.......,.. ",

....-,._-..._.i~f ~~K 'AEA : wiii~a~.to : b~ ** yar1~dt~~intain.the *specified air

'*\\:,:*[,z*~.;':**

",1

\\

I

Exhibit 11 662 Cr~J1\\wlJlI A"(JfI~o *51, Poul, Minn*.5511".

.. ' RI{ff;().~'r OF:. '.

' CONCIUn'E'}UXDESicN

... *TOLEPO,::' EDISON.* pmmR A.:.~D :. LIGllT ~

tortpo;>O'RIO August: 27, l?io

.DATE:

Fegl(is *Cons truc tion Company

,211(fNicollet Avenue Jl'URNISHED BVI Nicholson

~inneapolis, Ninnes6ta

". Att~ ;: Mr,:.John Eliison

. ~: ".,

COPIES TOI '

C';'2-. SF~2

': 400() pst Foulld~ tiot\\Walls ov'r

. 12".:Thick.....

1~'1.~#4.....

.'4" :' >*'

'..30} :',,: 6' 1.

f. ": ~.I~ '

HedU$aTypeH> porti.a~d Cement (ASTM e150).'.

MaX\\ufa~tux:ed Sa*nd. furn.by Woodville Lime *

6t * """III."!"~"',

C~i.ujbedLimestc)nozzoHth 'Type '200-N..': i'

2. ~\\1R.t\\EA > furn:~ : b{~8ter
. Bui l~e~s Comp8i\\y"'?i; ",,:t.:.
~ :'.
~ 1~~e, eer )~. 121. Jhig~: cYli~4ers) 411..
.*.*5.5
. ;< 145; o *......"
",.~.
5 3/4"
5.1 l45.8 1340
'* 1260 1300
Exhibit 11 662 Cromwoll Avenuo. St._Paul. Minn. 5511"
,Op, CONCRETE mx DESIGN 1760 1720
,1740
- 3580
' 3680 3630,
\\
an oven~~~ b~~i~ ~nd : sho~ld be - adj~8ted iimi:i' of bat~hirig.
in the
ENGINEERS ANOCt-iEMISTS 662 CromwGII Avonua.*St. Paul, Minn. 55114
REPORT OF:
!.REEZIl'G 1£51 OF CQ.~~
TOLEDO *-: I::DISON P01~~R AND LIGtiT DATE:
August 27,
. TOLEDO., OHIO FURNISHED BYI f~ *li; Construction Company
. Nicollet Ave.nue COPIES TO, espolis. *Hinnesota Mr. John Ellison
'1
06 '
N"~H' ';'I' C
' Ul9b-~G ENGINEERS AND ' CHEMISTS
,662 Cromwoll Avonuo ~, St. Paul; Minn. 55114
, ",' ~f~6~T OF:
r.Ol\\C:RETE MIX DES!C[
TOr;i.DO-ED!SO~POHER AND LIGHT
!f',tBDO. OH!0 '
DATE:
September 10 1 1970','
Fegl,es Construction Company TOI ' 2110' NicoUetAvonue FtJRNISHED BYI N:i.cholson
, Hi:;.neapolis. Hinnesota Ac'tn,:Mr., John 'Ellison COPIES TO:
C.,.2-SF-2 '
4000 ' 'si p
FoundstionWalls over 12l1 thi;ck 1~1I.;{f4 ' " ','
4 11 3%': '6%
,, ' i'feduB8Type rtPortlandCement (ASTM elSO),
"Manufactured Sand,iurn. by Woodvi.lle Lime & Chemica',l,; C9.'
, Crushed Limestop;efurn. by Woodvj.lle Lime & Chemic~,l ::~~~,
, 1~Ma~ter BufldElx:s, POZZ9UthType200-N ",,,"
' i ~ : MllVRAEAfu~n.byMaster Builder8, CompaI1Y
',,~,,~~;N, PO~+~ith ','",::'"
.:.' : '.~.
~....
,I..*.*..
" ',' 56' 4Ji,'
,',:,:,,"J,,"
If
'..~:.~:.::::
. l~; 90\\ihd' ~s '.*.'"
3.0. ounces*
{
m~f "i:.......
~55(j#,.-
". j6;O :gala "
6.0';sal/sk
.',,'. 4*ii,.. :.>...:.:.........::.. '.::."'..
~. O '~'s~lyd "~:'" <".
5 i. 51.', :: ':;','.-:,
i45.9:' p~(,.'
5.1 t45,8 l340
'l260
"_l300 Exhibit 11
\\
53/4"
\\
\\
\\,,
\\
\\
I
Exhibit 11
,,'.. * -,-*<."!...:/.:,*i " \\f..2 :;f.
""" ' "<,,. ~""~_\\lr.I"'~. :.: Ca1~t:~:tE'S~f9. *..XND* *Et~G;N~*~~ir~G :
ENGIr'i~E~S ANO.*: d~E~r~T~;
.1760.;
1720
..... 1140
.:' ~.,:.
an ovendrybas'i8 *..~nd til!le. ~fbatqhhg!
OATE:
.'. PAGJ;.:
1520 1570 1545 '
. 3320 3410 3365
.. ~~;g :
'. 5040
Exhibit 11
l&

S"nNG. ANOE~'~G, ~N..............
ENGINEERS AND CHEMISTS '
'. 662 Cromwell Avenue - St. Paul, Minn. 55114
. R;kporn OF:.
CONCRETE MIX DBSIGN'
.... ' trotto'a-EDISON POWER &-LiGHT '
. To'tEno OHIO'
. DATE: '
/ ' Faglas Construction Company
, 21tO. Nicoilet Avenue FURNISHED BVI N;;.c:holson Concrete
~po1is; Minnosoto 55404 John Ellison
. COPIES TO:
C~2-SF-3..
4000,psi,
FouridationWdUs
.'. over: 12" Thick.
'* 1%"-#4 '
6".:
3%
w 6'7..
C~2-SF-4 4000 psi
~,~
" Foundation wai'i$,.' *.',
.".... '. ovtr *12" Thick '.'
. l~" ~1i4. '
511..
31. -
6%
', Type tP,ortlaodqement.(AS1:MC150) **
"..... Manufactured *Sand: furn.by Woodvill$
., QC. ::II.!O~!I!JJ.~tI.""':
. Crushed ' Ijimeston:e. fu,rn.bY Woodvilh Lim~ ' &:,,,-n,.{I!Uhli;. *.~I;,";
. 1.,Mas tel'. j~uilde rs.' r.o2.Zolitn '):ypc. 200~N *..
. 2.MBVR' AEAf,ut:[l. by l-iasterBullders :colnlHInV
'.* ". 588(1.***
,17
6 ounces
4~Oounees~ :,
". 1(.46~
620/1.'
m~g.;~ * ~S;,':@(~*...
, 5.S <gal/sk.... '"
511.*., '.. '..
'. 6;25sxlyd.'.
5.7~
'. 144~8pcf 196().
20liO 2000
Exhibit 11 ENGINEERS AND CHEMISTS 662Cromwo!J Avonu.o-St. Paul, Minn. 55114.
CONCRETE MIX DESIG'N OAT,":
PAGE; October 2.
2 (6
1
/ Diamater x 12" hiBh Cylinders) (cont ~)
,'...~..
(psi)
(PB'~??.
.~~;,.,'..
2600 2640 2620 3450.
.. 3330 *
.. 3390 To b~ ~eportQd ' bt~1:
2770 2710 2740
. 3470.
3550 3510.. '.
~eightssho~n
abOYaa~e. on8~~ven drybasls
.. " ih the~ggregatesat t'he' time :of' bard-,ing.
and should be adjusted for the
..,::~. :~;..
..1 * '...
':",~"
.~* ':¢:C:!il1Pl.r.E.~.>~.~.*~s.~~G8:~a~,f;t~~~:~.1~~~: *.* :.:;ea*~~i6~i;~~!t;*~.~;t~~n~i~h~nr~~:t'~~!d~u!L~i ty c. '..
28
day ; ~p~.¢~trien8were ' pl<ice4i6the ' l'aliol;'storyfogroom at 2 dL1Y80f. age~*, ;.
Ii\\,.il'~:"':>;;" ;":;'; ;*.* '*;'*.. ~f&v4\\{<ill~hl, ~~~e "
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Exhibit 11 DATI[: Oct<;lber
22, 1~70
...URN/SHED BY: Nt cnolsoll
. CO,.,ES TO:
Exhibit 11
.~:\\:i';~':~I~.~~~;15~i~oj~~f~I,J~t1~i:Ry.:~iff':l
00rr OP
662~~;~="',..:;* :
DATE: October 22.197~,~ }/
'6 ";1891 PAGE: 2 (6" D1a.neter x 12"' HlghCyliRders), (Continued)
'.;.f'.-:'"
2600.
2640.*
262().**.
3450
....* 3330 ~'.
..339("'"
'4530 465o.
' 4~90 2770.
211.0 2740
.3470.
.3550 3510.
4890
.4810.
4850
.:.~
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' ight~,;" ~~~~ab6ve~re on the overidry b88harid '8hould be. II(ljU8ted
_,..,.'!...,.*",......"....~
. tu~e ' Jlf : th~
. 8gsr8gateat thet;ime of batchln'g. *
...... ". ~...-.:.\\/. ::.,,:.. "
~.'.
.tr.eogth' spec1l1len. were cured in laboratory ' air 1nther,lo1d8f~tthe*
~*:;:,:~):; ),;;
t,..'th. :~aalbtent, te~p.rature,was appro:ximate 1y 1'3,0. " and thl1re1.tlv.h~.n(d,iJt)Ji;
28. :<Jay.*pec1mens,t!e;e piace~ " In the.. l.bor~tory fog room :'.~ -:;t: ~.,. ~!t5;ii
".*..':. j, r~,}' ;,..* **..,.,***..> y:9*,~I~~ *~* 1;}~:: ~0?}i~r':~?, ml,.~I..~h.,~~~lfl'd..i * *..
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E)(hibit 12: NCR - Interim Field Report, W2C and Temp.
© 2012. Performance Improvement International-Appendix VIII-13
-I SHEEt!
1 OF 1
STARTUP SYSTEM: NO,_ N.A, NAME_--:.N;:,:.,.:.:Ao.:...__________..*_.____
QC ~~~LNON CONFORM. HOl.D TAd NO.. _,_N_,_A_,______
SUBJECT:
Shield Building Slipform Concrete lfix Design C2-SF-4 l--__c_o.n._trae.t 7749 -;18 PROBLEM:
Water cement ratio of mix design C2-SF-4 was exceeded for 48 cu.yds of concrete placed at el. 583 1 -6" in the containment shield building walls.
Minimum temperature was below the specified requirement of 70 degress F. as per attached reports.
Attachments:
Concrete cylinder test reports for cylinder Nos.
170, 171,.,172 and 17~.
. I
. APPARENT CAUSE: ENOR'0 CONSTR. S. U. TEST PROC. OPER. ERROR
-"-'-"~"-' REFERR-ED TO:--ENGR'O-- COi\\fSTR--:--STARTUP~----'-""~-;~~-"'---""- -, '---;-'.
SOLUTION OR SUGGESTED ACTION:
nle attached cylinder strength reports and mix plant inspectio~
report indicate acceptable strengths were attained.
Request Engineering -approve this deviation from specification require-.
ments on the basis of acceptable 28 day cyl:i.nder strengths. Code requirements in way of lot" temperatures for the placement area Were not: violated.
REPLY REQUESTED OF H. l,. \\.Jahl BY DATE 6/18/71
,//59.h /._=
(USE FIELD REPORT REPLY FORM) REPLY-RECEIvEDDATE AUTI-lORIZATION TO PROCEED WITHOUT A WRITTEN REPLY 1___
A r/
=nIST1UBUTION:--=- ---
\\i~:.~~~'FE - FILE P~EP~RED ~~~~j'~/
3 - ENGR 10 S~gned/Date.(..,". >.c,*.;:.f.;~~r.:r.ag'... of 9
\\
n.r:;CHTEL P&I DIVISION Revised 61'70 STARTUP FOnM 47
I I".
I RE-:t:ORT NO.,
1 Exhibit 12 FILE NO.OSl.). CC-1.8
~7"'>6f7 SHEET 1
OF 1, j
Power Station
.' OWNER........;::T;.:;;E;.;;.C.;;.o_M.--:C..;:;E;;;;.I_____
PLANT DavisMBesse Nuclear/,
UNIT I
, ~
~~------
STARTUP SYSTEM:
NO.
N.A.* NANE
...;;N,;..;,."""A~._________________
,_ -"'qc Np..
1.2220". NONCONFORM.
HOLD TAG NO.
...;;N~'.:;,;;A.:....__________*.:.....
SUBJECT:
~s~h~ie~l~d~B~u~i~ld~i~n~g~s~Ii~p~f~o;.:;;rm~C.;;.o~n~c;.:;;r~e~t.;;.e__~~___________________
Mix Design C-2-SF-4 Contract 7749-18 Co..>.1Jl1ENT:
(SOLUTION OR CORRECTION ACTION TAKEN)
Engineering. has reviewed the Interim Field report and its attachments.
x:elat1ng to an excess of liater.in concrete mix CM2"SF-4.
All concrete breaks are considerable higher than the 4000 psi specified No other harmful effects have been noted in the subject concrete.
Consequently, Engineering approves the structure as it 1s constructed.
f *.......:
9 IMPORTANT:
THE FOLLOtnNG ITENS l-rJST BE FILLED OUT:
DISTRIBUTION:
1 - QC/PFE 2 - QAE 3 - FILE BECHTEL P&I DIVISION FIELD CHM~GE NOTICE REQUIRED FIELD CHANGE NOTICE ISSUED AS BUILD DRAWING CHANGE REQUIRED Page 2 of 9
....1(....>1...... "'-'11
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PITT,S8L.I~t:~. T~~?'T)NG oLfr.80~~;rORY Exhibit 12
~. I:!HMILI~Hr.O HlOI*
PITTSOURGH. PA.
Ordor No, cr...*sebo
,<:., Ooto __AJ..*~_-';"'p;f,_&_.7_1_._
REPORi REPORT OF 'TEST ON* CO~C~ET::,CYlINOeRS Ii: _
6".DIAMETER BY*12" LENGTH i
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'l'olcdo Edison Compn'!.y, c:_-..:.:;:*-.:.::*;..I..:.'.,... **_;_,_:=?----
__~--:-___________ __.:-;.;;
Davis* Besse. NllCle..'u Power Plant,
-_ Y.
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Concrete Class. C-Z -..S:?{ P.S.I. /1000 AreQ 28.27 Sq. In
hr Slump Air %
Concroto Dote Tested Age Total Load Compo St.
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Nicholson CO~CRETE & Si....PPLY CO.
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Project Identification:
'l'olcdo Edison Comm!.!!,J...Y_-.,.;-~_______________________
Dnvis..nesse Nuc'lenr Power Plant Contractor: in:
£e-~.6..,
BOlch Plont:
NicHolson LocQt~nofConcre~ P~ceme~~__~~~1~,~.I~£~~~2~_~__~~_~__________~__~___~
D?-to Cost
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PiTTS,S,U;-',(jf.!H TE:S7;NG LAZO~A70r-\\Y
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I Exhibit 12 d UT!,,'1t.I,HI!:O,Int'lll
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Tomp. °F_.__.,;;t~~<J'_..;..._____._.__ Weather..(. ~,C)""
't:-r~.:..H:,:I1::.:m~(d'~i:':'~Y~;::===7-
'por!eocl To:
Bechtal.CorpofaUon nf' / f'H1 ojcet IdcntHlcotion:
Toledo Edison Compant.-
,,,,!:::":-=~,......____________?-~
.... ~_~'.,..'.,..',.""""",,,::--+-_
___U~~_~~~\\~Uh1tP~~r~S~1~~7~T~O~N______________________-+_!~~;~:'~v~.. ~~~:~:~~~~,;~;.~r.~~~'-+__
B I
1C*
~ '.... 'f.".Jt."~!>>
IOstrl.'ctlon Maneger:
ec.lto oroorntlon Efch Plant:
Nicholson CONCRE1'E & SUl'?LY co,
? ?LA~T.1NS?T.;CiIOX
,~
f/~
I~CU:'1tC Closs C- (f:rttuJ No', Cu. Yds,
~JJC: No. Lo(!o$__.!;.~=-_~ Mix Z X £.., J'

..--~-----------~~~~----~--~-------~------------------------------~-..--------~--~.--

Q~(lntith~$ per Cu. Yd.
DESIGN BronC: or Sourco
lO, Lbs. (S.S.D.)
A':'lQ., i..!,t. (S.S.O.)
h'_ A~h, Lbt.
o~-:lr, Coo!s. (Total)
/~/
3/'./11.iJ;;7;~
~~"";f /L;//At"All AGGR::GA':'l! G~AOA'j'IO~.. %?A5S!X~
1/2" 3/1,'1 2"
TM l
I 10 To
... :¢ N'i FiMf t:.,an 200 t<:ash Z,~
Met'l Finer than 200 i.G
/V'/
~y_~~o~S~___________-4~~~~_'~~~~__-4____~I~.O~______~C~Lvm~s~____~______-+____~--~__--O~v.~2~5------
Q.t!l & Li!:mif!)
/)
0<' Co?
O.S Cod 8. Li!'lnito 0.25 50f~ f ra~mcnt s I
.;l,U
"(I"~t vlt~
"'f1.'(a~,~';--l!-i.." \\
PI~~Sf?<::;FGH ~J"ESrlNGl L!AS~ATORY
....-'"** ', ~.'
II." 4~,
Exhibit 12
.:~~t!"e ~a
[9TAhtlSK!.O IOhl a:
~~
~
PITTSBURGH. FA.
Order No._ CL*8800
~~~
l'~
"'t A "U'tU...L..""UcfION '0 CI.'tNT~. "ur. ""I'ILIC AlfD OUIIBU.VU. AU 11(1'011,..
Roport No., / t::E:
<>>.,.;'-c
,,<< ~\\.~
Alltl.u....nf'D "'. tHI: CONI"IOJ;;HT'Al.,..no,.r.,,1"., 0" C"'t&.'tT~. ""0 I.UTUOJU%4'ffOH o (".sA"Il(',~
FOil "U'I-ICATION at'....U.....T** c."..c~un'o..!\\ Oil u."Ae,.. '"0M 011 IUOAII"'"
OUII !'OllTe,. nt.UlYCD rCNt"!'O DUll WlttYTlN "",.NOVAI..
/-ctf.. 71..
REPORT Date
~
REPORT OF tEST ON CONCRETE. CYLINDERS 1; 6" DIAMETER B'l' 12" LEHGiH
.;z -OCinA Reported To Bechtel Corporation
~l"),.f'f' 1'***:*... (......
Proioct Identification: ---.Toledo Edison Company niwis-llesse Nuclear Power Plant 11;V'.',.~.!;lw~~.;...7a Controdor: in:
Lf'*'lr/{:....'/
Batch Plont:
Nicholsofi Location o( Concreto Placement Afr-~L1>Y4
w42, e
Date Cast ~2..C - 'lL Concrflte Class (:P..6L-.t(u/ P.S.I. ~u Are" 28.27 Sq: In.
C~lInder Slvmp Air %
Concrete Dote Tost~d Ago Total Load Compo St.
dent.
Inches Temp. (> F.
OOY5 Lbs.
P.S.I.
/'
LY$
-;)"""
4:l.
6.; V G"-:r
-'7'
,,/S~<doa
~,*.vtf~
';-5 Z
/<-~£x:'tt1
<,,<'/7 l-:. ?~
7P
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7<?z.ZJ 7-?(
00 7v,?'(:
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...4'L/J ~".(../ (/{/~r'?< 'tLP:?
/
'EMARKS: -9/. ~
I 12"< $>. rO
\\ ~4 r2. C. f?S tID
.tf;1S,'i'r.t-'~~. 95' "cc:l2. 0.
e/...2. f~ 10
. ~\\
. '?I~TI)/G lA90~ATORY J,.{/'-"'....
~
~":.. :. :.;
Page 9 of 9
Exhibit 13: NCR -Interim Field Report (Wrong Mix)
© 2012. Performance Improvement International -
Appendix VIII-14
1
~\\
(~
I OW'NER TECo - eEl PLANT DaviR~Bessc Power 'Station UNIT""""";"'--

~~,~~----------

S'l'AR 'l'U~. SYSTEM: NO. __N_,A_'_NAME,_~_N_,_A_.---'-r---------
QCNO~) NON CONFORM, I~OLD TAG NO:_
.. --:.N~,..!;!A.!-.__
SUBJECT:
______C_o_n_cr_e_t_e~,~p_l_a_ce_m_e_n_t__C_on__tr_a_c_t__
7_74_9_-_l_8~________~_____._________

~---------------------

PROBLEM:
Faglas Power Services, Inc., placed 6 yds. of C 1..3 concrete i.n pour 112 at elevation 215 1.. 6H
Fly ash 't>1as not uged in the batch.
The batch plant operator apparently did not change the batch plant mix design punch card before producing the aforementioned concrete.
APPARENT CAUSE: ENGR'0 CONSTR.
S. U. TEST PROC. OPER. ERROR REFERRED TO:
ENGR'G CONSTR. STARTUP SOLUTION OR SUGGESTED ACTION:
The Field recommends that Engineering approve thi.s concrete as placed.
The mix design is approved for use in Qwlisted structures, the batch did not contain fly ash and is designed for the 4000 PSI strength requirements.
The concrete batch ticket was checked and reveals acceptable quantities of all materials Here used to produce the concrete in question. '
~----------------------------------------~--.-----------------------------
REPLY REQUESTED OF
11.
l~. Hahl BY DATE 6[18/71 (USE FIELD REPORT REFLY FORM) REPLY RECEIVED DATE AUTHORIZATION TO PROCEED WITHOUT A WRITTEN REPLY----------

;;;J DISTRIBUTION:

1 - AC/PFE - FILE PREPARED BY "BECHTEL /
2 - QAE
/
/.
Signed/Date
.. '-"- "-'-' :/~,
3 - ENGR!G BECHTEL P&l DIVISION Revised 6/70 STARTUP Fofi~e47 of 4
".t~o'!***.~
REPORT NO 3 Exhibit 13 f("
~)
?"'FIL~NO:P513, (':C-IQ, 6-; '7 - 3C)'~1 (
SHEET~ OF -L UNIT _____
Ol-."NER IECo-CEI PLANTpavis-Besse Nuclear
,Power Station
"'--' STARTUP S,,{STEH:
NO.
N.* A.
NAME N. A;
,.:Z/l, :l ()
_/~
QC NO.
1.-;..~
NONCONFOlUf.
HOLD TAG NO*.....;,N,;.;..,;.;.A..;,..________-
.. _""",.-.1'0.
SUBJECT~ Concrete Placement Contract 7749-1a-6 jas OF C-1-3 concrete mix was placed in the shield building pour No. 2 @elev. 215 1-6".
FiY ash was not used in the mix.
co~mNT:
(SOLUTION OR CORRECTIqN ACTION TAKEN)
Pittsburg. Testing Reports Nos *. 275, 276, 277 &278 on Concrete Cylinde C~mpreBsive Strength indicate that the concrete inadvertently placed
. -in the shield building meets the specified minimum strength of 4000 psi with.considerable margin.
No other concrete defects are discernible.
Consequently, Engineering.approves'the concrete as'it has.been placed
. :l.n the structure.
No remedial action is required.
IMPORTANT:
THE FOLLOWING ITEMS HOST BE FILLED OUT:
FIELD CHANGE NOTICE REQUIRED YES_ N0.JL.
NUMBER.___
FIELD CHANGE NorrCE ISSUED AS BUILD DRAWING GHANGE REQUIRED' YES_ NO.,L DISTRIBUTION:
1 - QC/PFE
.~.
2 QAE 3 - FILE PREPARED;;
BB?Ji~4~.~//'
Signed/Date -c.. /.~~
!psep tI P'. 1-1c{;e.a )'
July 14, 1971 BECHTEL P&I DIVISION Revised 6/70 STA-~TUP FORM 48 Page 2 of 4
Exhibit 13; o 0
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,I Page 3 of 4
Exhibit 13
,.l
11 C),*~~ <
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't. \\......
-" I 1....:'l
_~""..........----.--~-----
L.
,.. "::').
'1l~~,+~AJA~"~~h::JWISon j'-
CONORETE and SUPPl Y CO, t';
Ml.tt.,,,G J,O'WRESS aU$lt'£G5 Of'TtC&
~
P,O.. OOX 2'01' 'STATION' B 22o, "'t..'Eu::>t. Sf tC'lt..EDO. Ot-tlO 434>>04 PHONE ;:49*2G(\\:
t DAVIS-BESSE PLANT I
,rj I
~~~~/~~~~6~
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=~o~L~=-/~~~________
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Page 4 of 4,:'
i'
Exhibit 14: NCR 57 - Wrong Cement Type Appendix VIII-iS
© 2012. Performance Improvement International
Exhibit 14 Page 2 of 7
Exh ibit 14 Page 3 of 7
Exhibit 14 Page 4 of
Exhibit 14
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Page 5 of 7
Exhibit 14 Page 6 of
Exhibit 14 Page 7 o f 7
Exhibit 15: Slip Form Time Quantities Analysis Appendix VIII-16
© 2012. Performance Improvement International
j' Exhibit 15 t:.'/M
/J~.&¢ F~~'t f/l/".
jt,;1Til~
J),4/t
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./.8/CIU:Q
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EX~15
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Page 4 of 4
Exhibit 16: Rebar Cover Spacing (FEN DC Document - Not Included as an Attachment to this Report)
Appendix VIII*17
© 2012. Performance Improvement International
Exhibit 17: Spec C-29 Reinforcing Steel
© 2012. Performance Improvement International -
Appendix VIII-18
Exhibit 17
*.."'rl Ind 1....1...1.._1 Spcdf'ic.lti,,,,r. Nn.
7141)f<!9 I lti'hmn Job Nil,
'IN!)
Q*List Ntl, I.Z:30 THE TOLEDO EDISON CUMPANY Rl!CEIVEf."
AND AUG! 9 191f THE CLEVELM";O H..ECTHIC IlLUMINATli\\G COZlII' \\r{MEClr. l:.1,"'. lhV.
1M Vls*nfSSE NUCUA!\\ rlOWUl. STATION t--_____* _______.
p r. ('" 3~ I ',: r,'.
n ~, ~,J' L f J ',,'
IJAVIS~ BESSE MAsnf( fllt COpy UNIT NO. I CONS1IWCTJUN
...nm~~tl \\914 lIAli ton 'rlll7..
fllED~.
tl' '.
r J'"
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PREVIOuS ISSUE liS fiE n. VrJJD£fJ FURNISHING, DETAILING. [-,ABRKATING, A,<:f)-t)t:"'1::1'\\1frlttN(-j': -~___
REiNl"URClNG STEfL
"~.
J... ",.* -
o eeCHTEl. CDMPANY GAITHERSBURG. MARYLAND Bv Nu.
Date Revisions 3':~J*70 A
l"~\\lI.'J f,)f CH~'111,\\ 1 lr\\w.,1 "m\\ Bid 0
S-17*70 l!.sll\\.'d for Detailing :1I111 ~I akrial Pur,-h:lsI.'
I ()'30*7(1 1
I"ut'd rr'rJ..:sn*;ll'lh'lion S. Adtkmhl!:l.\\
f;,\\ i,,*tI fUi 1\\,i(knllulll *l
~
E'/I 71 I
\\
Page 1 of 8
Exhibit 17 SJl~'dI1l:;ltioli No.
771t9-C-?9 INDIVIDUAL PACE Rt:Vl $1 O~ WD~X mum'l'
....-----..... ~-........--------.... --~........... ---.....-....,-
Lat'CH;lt lndh'idll<ll
!,.!"IliE..._~':!~':.1l51"u:11 }~o~_"
'I'aole of Contents 3
1 o
2 3
4 I,
Documentation DisldJRltion Requin'!lllcnts 4
. '\\
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o i i 91 Page 2 of
Exhibit 17 TECIINICA L SPECtFICATI()~S TABLE OF CO~TENTS I.()
CENEHAL 2.0 AU8REVIATIO:--lS 3.0 CODES Al'D STAl"lHI{OS 4.0 MATEnlAL S.O TESTS 2
6.0 INSl'ECfJ()~
2
,'I')
7.0 DETAiL J)}~A\\"'I~GS 3
.')
3 8.0 SIIOI' ERRORS 3
( ~',
,~..
9.0 HANDLING. SIUI'PIKG AND STORAGE OF ~IATElU,~LS 10.0 QUALITY CO~TROL REQUmEME~TS 2
.').
JJ.O MEASURE~fENT AND PA\\,~1ENT 4
3 i
Page 3 of 8
Exhibit 17
,*.'Wtl 111.\\ IOOU1oltbl Ui~'i>inn TECHNICAL Sl'EC1FICAT10NS FOR FURNtSIlING. I>ET..\\tUNG, FABRIC'ATll'\\G ANI) OELIVElHNG REJ:~FORCING STEEL 1.0 (a:NI:H,\\L
'I'll\\' WORK ind\\ltk.. Ilw fUl'IIl>.lIillt Qf :111 1',1:",1. labor. malcr;;ll... IUIII*; aud I.'qniplllt'1l1 and lhe pl.'rfOrlll:llll:c of <III op,'r:llinll:i ;IIHi iuddt'nlah :1I~~~'SS.1'Y to Mlai!. hlmish. fabricate. deliver.
unlo3l1 lind :>Ion: rl'inror..'lIw sl~'d.lInl Wlf': m....r.h fabrj,:,,IS-sp<2'cifwtlltc/dn or as showtl 011 the d~s.i!!n dmwint',s and il\\ this ('\\)I\\l! ;'0:\\.
2.0 AlJUHi!VIATIONS The ahht~'vialion:s, Ii~t\\.'d hdow. wht.'11 us~'~1 ill these SPCd1icillillll~, shull haw tbe following llwlIllings and shull rd'~'r 10 IIw Jat~st edition ill dfi.'d on thl! link of the Contmet.
At'I* AIll~rk:1Il C\\)IWf(!t(' Ins1itule ASTM
Am~'I'h:an Society 1'01' Tl.'!tting "lid Materials
(
.~~
AIS) - Amt'rican Jr')!l and St{'l'lln::;titulc 3.0 COPES AND STANDARDS EXI.'~*pl as olherwi£c specilil'd or shown in the finnl design drawings, the detailing. fabrlc\\\\tion, llIld tagging of all ft'inron:ing steel sh.-.U be in accordance with the "Manulll of Standard Praclk'c fOT Detailing Reinforced COncrl'h~ Stnlctures" (Ael Standard 31 ?).
4.0 MATERIAL 4.1 All material sbaU be new ltlld unused would reduct! or destroy bond. Reinf&r'M11l1r.IIJ'T~!!tmm"S"T!!tttrmiTfrcf01n~iOii'5'r}
bl.'nding shall not be us('d.
4.2 Reinforcing. bars shall conform to the *',standard Specifications for Deformed Bmet Steel il:lrs for Concrete Reinfort'emcllt" (ASTM A 61 S). Reinforcing bars shall be Grade 60 unless 11Otl'd otherwise on the dmwings.
Page 1 of Page 4 of ?
4
Exhibit 17 1"l"W lln.IIIIJIl,frilll Uivislon 4.3 WcJdNJ witt.' fahrk for (,'Oi\\,rdl' rt'infoTCclllent shalt conform '0 "SI'Ccifications for Wdt.l~'d Sk~') Wire Fahrk fl)r Concr",!e ncinforn'lI1c-nt" (i\\STM A 185).
5.0 TESTS 5.1 The' CO:-:TH M-rOR sh:lll ftlrni,dl tlw rl'quit'~il numbl't of twtifi{'d ('opi~s of nil ~1iI1 12 TC":.1 Rl'I'Mh '" lilt' n":r*,xtin' parlk~ hskll Oil Form ED (.OSS t:(~\\*l*ting th~ chl'mk'll ulld I,hy,it'al pmp'*rfi,*... vI' ill,' rt.:'illf(lrcin),'! sll'cL a~ dl!s~'tibcd ill lhe rd('rl,'lwc~l Sjll'(:iI'k:lIh'r1!-. ;1Ilt! :o;tar\\l.l;uds.
radl dd!\\Try ~h~\\11 b~' jekllliriNI hy its applicllbk Mill Test Rq'Nl.
5.2 The CO~::\\TIUJCnON ~L\\N,\\(;H~ may. t'or Ilh~ Imrp()<;t' or IIwkin!! dwrnical ;1I1:11:,~js c1l1?d,:;: and phrsi.:a! l'nllwrtr l,*~h. ;11 his (11'1 iOlJ. ~'kd famllllll ~;JlJlJlJ~'sof tilt' swcJ 12 deliverc,} 10 pefi'm III U~('f'S il'sls ;1$ ((.II\\~\\l:s;
a.
N(!. II h;lr lii;t.\\' ;lIId ~nmll~'r.. (l,W raullom di:mll'WI' size ~ampJc from e:lI'lI 50 tous of bill d\\'liwrnl 1'01' "'mi.>n and ht'nu {l'St<,;.
'.0
b.
No. 14 ~md No. 18 bar sites -- OIW ::;tmple for t~adl h(lr sizt.* from ('"eh 100 tOilS (If bar dcliwfl'" fur tcnsi,)11 h'st only.
5.3 The OWNFRS' Indl'tl;.'li(\\.;ut Testinl! lahcwah.lry wm [\\\\,I'f(,11II tlw \\I~I~r\\ le!;t!; :1IIc) if tlll' tl!:;t Slllllpl!.' I)at doc:, not liIt!d lilt;' minimum strenglh n'(luir~l1lcnts ~I" cI~!filll'd in ASTM
--- ----Aft; 615... second flllt-.~ite sampk fl\\ml the ~IIl1C Itt'"t wtHbt-t:tken.lIIdf(t>1~I""IS~ilfu\\,-ttpescll"'e(rtl.--f~--li---------+
the 'olter test result meets thl' minimum l"Otrl'lIgth requirements, relillll~ frolll (he!>e two tests will be combined with Ilw mill lensile lest rC5uIt unci lIVCtllIWU. If the uVl'flIgcd l'esuU is found to meet the mininml\\\\ strength requirement, the heat will he nCCcllh't1.
1n the cvC'nt that the nvcralwu r~sult of <111 three tests does not meet the minimum strcngHl requirements, the heat will hI' r~*j-.;'t'tcd.
o o
S.4 The method of testing will conform to th~ ASTM A 615 requirements.
S.S The CONTR/\\CTOR shall furnish :;ufl1cicnt bars with elIcit shipment to satisfy the testins nCl'ds of P.amgmph 5.~.
6.0 INSPECfION The WOnK ~lmn include r~,..*I!i\\'in!! in:i>pl'ctioll lit thl' johsilc by t h~' CONTHACrOR. The re
,:cj\\'ing inspe~*tioll shall dch'rlllinc Ihat the r.:quin:mcnts !,f ASTM*Afll 5 IlIm: been met. that adc(jlHltc dl)l'U!lIl.'llhltioll 0l'1 r~ttllir~d b~' jl:lraf'nlph 10.3,1 :ICt'ompany Ihe cl\\:livcry. ami Ihat WI!.I!ing: l'onl(lrlll~ 10 l'ar;lgJaph 7.3 :md the,>hOI) d\\'tllil dr:\\\\Vlnt\\~*
I'llge l of 4 Page 5 of 8 4
Exhibit 17 I'",,*.., alII' Imlu'lrilli Spl!cifkatl...... 1'\\11.
77*19-C-29 Oivi~lun
(
7.0 DETAIL DR,\\WINGS 7.1 Th~ OWNE RS will furnish prints of thl.' dl'sit:fI dr.lwillgs whi..:ll will ~i'H' nll inform;ltion J rr<lllill'd fur Ihe !>hop d,'l.dling ('I' th~~ rCin/i.'crillg Sll'l'l.
1.,:!
For al'lwo\\':\\1 and Ilbtrj\\lutkJ/l of n!infNdll~ sh'd dl'taiJ 1";IWill~S, s£'c Scc(ioll V, paral!raph 37.0, atllkndmn mllnhN ::!.
All n'lnli:m:itlJ,!,kt'! :.hollfd be 1,11~I:J. T:.Ig~ <;h~)llid tw mJt!\\* llf,Il!rabl~ mlll~..bl lmd I sn;lrheti ill a II.Tihk Ill; IIln.:r. n.)1 k5S than on!.' t.lg I'~r h IIIdIt*, ;l1(~ldICd br wirt'. J Idt'llHfk;llioll lap :-.ll(>ul..1,>how 111.: gr;,ut', Ill(' 1lJ:l!k: ~lf Sill'. Ihl~ kll/.!Ih of the bars, lind!
hf~a( !HlI'lll';:f:; Of rd""'rt:n':-l' thl'U'lo.
n.
Chl'micaJ AIl:lI)'sis Page 6 of 8
..0
o.
c 8.0 9.0 SHoP f.IWOl\\S Milh'ri.d hllpt(l()~'I)Y dL'lailt'd or \\\\'I()[I~h' I:ll>rica{('d. \\0 Ihal illl pladll)! in Ih~ rlt'1d lICC:CSSit(ltcs
~'xtl'l\\ wcr", sh;11I be 1\\1(> r~sl1on~jhililr of tilt' CO~TRACrOR. Th~ CONTHACTOR shall pay flw ('Ill irl' cost (If r~l)I;u.:O:I\\\$,l\\t 01",)( J'idd.::om:ctions, indudillg,In shipping ('u~rs*
HANDLING. SIIII'PIl':G AND STORAGE OF ltATERIALS 10.0 QUALITY CONT1H1L REQUIRDIEt-:TS Sc(' par:!gr::ph 6.0 uf this sp\\.'Cification.
AU mah'ri:t)s sh:111 be-sl()t,~d lIt lhe jobsitc in a maimer IhRt will I,rotc.;' Ihem (rom !.lein, contaminated hy :my di'lctNjulls materials !'>lId1:1S grc;J$~" oil alld Illud, Also see Section XII 0 the Conh\\ld Doc.:um~lIl.
10.1 Sec Section xn of the Contmc' Document.
lO.2 ShOll 1Ilsp~!l~Uon 10.3 Quulity Control \$ocumentation Rt:'1uired 10.3.1 The CONTRACTOR shall furnish certified cOllies to the CONSTRUCTION MANAGE'~ (.If the.' Mill Tt's( Report. containing the following propt'rtics. for each IIl'ot ddi\\'('r~'d to Ihe jobsitc.
I 2 3
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11.0 MEASIJHF~In';T A;>.:n J'A Y~IENT JL I The LIIIIII~ SUIll I','j,".' f',lt tl!l~ l'ompkte WORK ftll lilt! Shkltl Hllilding shall indude Ow rdnlQtdll!! sll'd <'1'~'.. i1'kd Iwr.:in Tlw uilit prict's hid in 1):lI;ll'.I;,pll :!.2 alld ~.J of (he l'wpm;!1 :;haJl h... U~"J 1"'1 ;Idlli\\i(lll~ III N (h-It:I;nn'i fWI1I IIw Lumll Sum bid in Ih~lll:;
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11.2 Net dHlnt!~s in Llu:lIltiti\\*:> l'haU b~' ~'ilklll;h.*LI 1111 IIll.' Ihl.'l)rdic.:!l1 lellgUu; t)f the bms liS d~'I;!ill'd, :lIld m tlw tlw,H\\'ti<':11,\\'\\'i!-~htl> as riven in 11Il' **Slallthm.l Sp{'cificutiolls for Dl..'rornwd Billet SI"~'1 Ii.us for C(1na~'h' J<dlll'()r~\\'wtlt {i\\STM i\\ (15).
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Exhibit 17
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FOR QUALITY ASSURANCE USE
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(AI MR. H. W. WAHL (0) M. B. STEPHENS
[l)f,OflR Page 8 of 8 PHOJECT ENGINEf:R CONHrlllICTION MANAGER Ot.:CHlEl Gor\\1PANY P.O. BOX 449 190 51'IADY GROVE ROAD GAITHERSBURG, MD. 20760 POBT CUNl'ON. OHIO 434!i2 i;: Iha mqUlred Cf:r1l11!1d C'OPICS shall be fUfllIshed IIjWI1 or,lriot to the ilrnv~Lof the matfui<lJ.i!lJh£ljphsl\\lh..____._-..___-----.-
10 CHUIIIUI corilS
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THE TOLEDO EDISON COMPANY JOB 1\\10. 7749 AND E:OPT. ITEM NO.
L nlE CLtVELAND ELECTRIC ILI.UMINATING COMPANY DAVIS*OESS£: UNIT NO.1 COr-JSTRUCiION QUf.\\LI'fY /\\SSUHANCE DOCUMENTATION DISTRIOUTION REQUIREMENTS
CONSTRUCTION DOCUMENT NO. 7749*18
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Exhibit 18: Wall Plumb Measurements Appendix VIII-19
© 2012. Performance Improvement International
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© 2012. Performance Improvement International Appendix VIII-20
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Page 2 of 2
Exhibit 20: Slip-Form Records Summary Appendix VIII-21
© 2012. Performance Improvement International
Exhibit 20 Page 1 of 3 Davis-Besse Containment Shield Building Records Davis-Besse Containment Shield Building Construction Data taken from slip form record Date Shift Outside Temp Deck Elevation Footage jacked Shift Concrete Total Concrete Comments 01/25171 1
31 4'0" 0
108 108 1 6 cy batch rejected 81/4 slump 01/25171 2
37 5'8" 1'8" 132 240 01/26171 3
38 8'8' 3'0" 108 348 1 6 cy batch rejected 7 slump 01/26171 1
29 10'8" 2'0" 42 390 Pour stopped at 10 am due to high winds 02101171 1
5
?
02/01171 2
9 14'10' 3'0' Weather cold 02/01171 3
0 17'8' 2'10' 108 02/02171 1
-2 19'8" 2'8" 108 86?
02/02171 2
12 2'10" 102 968 6 cu yd dumped on 2nd shift because to tower crane down time 02/02171 3
16 24'9" 3'0" 114 1092 02103171 1
19 28'8" 3'11 "
162 02/03171 2
22 31 '11" 3'8" 132 02/03171 3
21 34'2" 2'8" 90 02104171 1
37'6" 3'4" 192 02/04171 2
32 38'6" 1'0" 66 Pour stopped at 583'6" at el. Waterstop inserted and key way poured Pour apparently.tOJ!ped. Maybe due to cold Weatherl 04/26171 1
43'4" 3'9" 150 1314 Date?
04126171 2
47'5" 4'1" 144 1458 04/26171 3
51'0" 3'7" 126 2084 The concrete below the moving forms after being finished was sprayed with clean seal #12 by Drace Co.
04/27171 1
55'0" 4'0" 138 2222 Engineering on 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shifts The concrete below moving form cured with Brace's clear seal #12 04/27171 2
4'3' 170 2504 04/29171 1
68'7" 5'1" 168 2672 04/29171 2
73'6" 4'11" 156 2822 04/29171 3
77'0" 5'6" 144 2972 Concrete below moving form cured with Graces's clear seal #12 04/30171 1
94'4" 4'9" 210 3710 04130171 2
99'8" 4'11 "
198 3906 Page 1 I
Exhibit 20 Page 2 of 3 Davis-Besse Containment Shield Building Records 05/01171 3
103'11" 5'5" 156 4064 Construction joint water cured and water cut before starting next pour. Concrete below moving form cured with Graces's Clear Seal
12 05/03171 1
108'6" 5'5" 216 4280 05/03171 2
113'2" 4'8" 192 4472 05/04171 3
117'6" 4'4" 192 4464 4 story poles checked on 5-1-71 by taping up from B.M. eI549'0" on inside wall pole near yoke #1 1/16" short
-pole near yoike #21: 1/16" short;
-pole near yoke #41: 3/16" short
- pole near yoke #61: 1/16" short 05/04171 1
122'6" 4'6" 198 4862 05/04171 2
126'6" 4'6" 204 5066 05/05171 3
130'3" 3'9" 180 5246 Concrete below moving form cured with Grace's clear seal #12 05/06171 1
140 4'11" 216 6092 05/06171 2
153'3" 4'10" 234 6314 05/07171 3
158'4" 5'1" 207 65??
Concrete below moving from cured with Grace's clear seal #12 05/07171 1
163'4" 5'0" 234 6776 05/07/71 2
167'10" 4'6" 204 6980 05/08171 3
171'10" 4'0" 204 7184 Concrete below moving form cured with Grace's clear seal #12 Construction joint water cured and water cut before starting the next pour 05/10171 1
176'9" 4'11" 215 74??
05/10171 2
183'3" 4'6" 198 7598 05/11171 3
185'10' 4'7" 204 7802 4 story poles checked on 5-8-71 by taping up from B.M. el. 549'0" on inside wall:
Story pole near yoke #1 0'01/8"short Story pole near yoke #21 0'01/8" short Story pole near yoke #41 0' 01/4" short Story pole near yoke #61 0")1.." short 05/11171 1
189'5" 3'7" 180 7982 05/11171 2
193'4" 4'4" 184 8162 05/12171 3
197'10" 4'4" 210 8372 6 cy of concrete was sent back to the batch plant due to time factor (governed by the spec) due to a break down in the tower crane.
Concrete below moving form cured with Grace's clearseal #12 05/12171 1
4'4" 192 8564 05/12171 2
205'11" 3'9' 174 8738 Page 2
Exhibit 20 Page 3 of 3 Davis-Besse Containment Shield Building Records 3-'
05/13171 210'4" 05113171 214'5" 05/13171 2
218'3" 05/14171 3
222'6" 05/14171 !
1 226'10" 05/14/77 2
230'9" 05/15171 3
234'2" 05/17171 1
238'8" 05/17171 2
242'6*
05/18171 3
246'9" 05118171 1
250'4" 05/18171 2
253'0"
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256' 61/2*
05/19171 1
256' 61/2" I
4'5" 198 8932 Concrete belowrOOving form cured with Graces Clear seal #12 4'1" 180 9116 3'10" 174 9290
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180 9857 4 Story poles checked on 5-15-71 by taping up B.M. el. 549'0" on inside wall; Story pole near yoke #1 - 0' 0 1/8" short Story pole near yoke #21 - 0' 03/16" short 3'5" 181.5 10038.5 Story pole near yoke #41 - 0' 0 3/16" short Story pole near yoke #61 - 0' 05/16" short On 5114171 2nd shift truck #82 ticket OB02764 delivered 02764 delivered 6cuyds of concrete with Type II cement instead of Type I cement.
Concrete below moving form cured with Braces Clear Seal #12.
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66 10230.5 10,386.5 10578.5 10726.6 10854.5 10962.5 11028.5 Concrete below moving form cured with Graces Clear Seal #12 iOn 5-18-71. about 9:30 pm the concrete mix was noted as being sticky and not as consistent amix as it should be. The slump was 3". The problem appeared to be the cement - to try to correct the problem the mix was changed to type II cement at about 11 :30 pm 5-18-71.
Concrete cured with Graces Clearseal #12 before moving form.
Concrete struck off @256'0 Y:t & 256'6 Y2" water stop and keyway place and water is being piped to the top of the shield wall for curin the concrete for required time.
Concrete below moving form cured with Graces Clearseal #12 n
gl Page 3
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Exhibit 21: Guide for Preparation
© 2012. Performance Improvement International-Appendix VIII-22
Exhibit 21 TECHNICAL GUIDELINES Prepared by the International Concrete Repair Institute September 2004 Guide for the Preparation of Concrete Surfaces for Repair Using Hydrodemolition Methods Guideline No. 03737
__ © 2004 International Concrete Repair Institute All rights reserved.
International Concrete Repair Institute 3166 S. River Road, Suite 132, Des Plaines, IL 60018 Phone: 847-827-0830 Fax: 847-827-0832 Web: www.icri.org E-mail: info@icri.org 925 Page 1 of 16
926 Exhibit 21 CONCRETE REPAIR MANUAL About ICRI Guidelines The International Concrete Repair Institute (ICRI) was founded to improve the durability of concrete repair and enhance its value/or structure owners. The identification, development, and promotion of the most promising methods and materials is a primary vehicle for accelerating advances in repair technology.
Working through a variety offorums. ICR! members have the opportunity to address these issues and to directly contribute to improving the practice of concrete repair.
A principal component of this effort is to make carefully selected information on important repair subjects readily accessible /0 decision makers. During the past several decades, much has been reported in Technical Activities Committee Rick Edelson, Chair David Akers Paul Carter Bruce Collins William " Bud" Earley Garth Fallis Tim Gillespie Fred Goodwin Scott Greenhaus Robert Johnson Kevin Michols Allen Roth Joe Solomon Synopsis This guideline is intended to provide an introduction to hydrodemolition for concrete removal and surface preparation, the benefits and limitations of using hydrodemolition,
and an understanding of other aspects to be addressed when incorporating hydrodemolition into a repair project. This guideline provides a description of the equipment, applications, safety procedures, and methods of water control and cleanup.
literature on concrete repair methods and materials as they have been developed and refined. Neverthe less, it has been difficult to find critically reviewed information on the state of the art condensed into easy-to-use f ormats.
To that end. ICRI guidelines are prepared by sanctioned task groups and approved by the ICR!
Technical Activities Commillee. Each guideline is designed to address a specific area of practice recognized as essential to the achievement of durable repairs. All ICRI guideline documents are subject to continual review by the membership and may be revised as approved by the Technical Activities Commillee.
Producers of this Guideline Subcommittee Members Pat Winkler, Chair Don Caple Bruce Collins Eric Edelson Ken Lozen Bob Nittinger Steve Toms Contributors Scott Greenhaus Rick Toman Mike Woodward Keywords Bond, bonding surface, bruising, chipping hammer, coating, concrete, delamination,
deterioration, full depth repair, hand lance, high-pressure water, hydrodemolition, impact removal, mechanical removal, micro-fracture, post-tensioning, rebar, reinforced concrete, reinforcing steel, robot, rotomill, safety, sound concrete, surface preparation, surface profi Ie, surface repair, tendon, vibration, wastewater, and water jet.
This document is intended as a voluntary guideline for the owner, design professional, and concrete repair contractor. It is not intended to relieve the professional engineer or designer of any responsibility for the specification ofconcrete repair methods, materials, or practices. While we believe the information contained herein represents the proper means to achieve quality results, the International Concrete Repair Institute must disclaim any liability or responsibility to those who may choose to rely on all or any part of this guideline.
Page 2 of 16
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOLITION METHODS Hydrodemolition has been used on the following Purpose types of structures:
This guideline is intended to provide owners, design professionals, contractors, and other interested parties with a detailed description of the hydrodemoIition process; a list ofthe benefits and limitations of using hydrodemolition for concrete removal and surface preparation; and an understanding of other aspects to be addressed when incorporating hydrodemolition into a repair project. The guideline provides a description of the equipment, applications, safety procedures, and methods of water control and cleanup. This guideline is not intended as an operating manual for hydrodemolition equipment as that information is specific to each equipment manufacturer.
The scope of this guideline includes the use of hydrodemol ition for the removal of deteriorated and sound concrete in preparation for a concrete surface repair. In addition, the use of hydrodemolition for the removal of coatings is discussed.
While the procedures outlined herein have been found to work on many projects, the requirements for each project will vary due to many different factors. Each project should be evaluated individually to ascertain the applica bi lity and cost-effectiveness of the procedures descri bed herein. Other methods of surface preparation are discussed in fCR! Technical Guideline No. 03732, "Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays."
Introduction Hydrodemolition is a concrete removal technique which utilizes high-pressure water to remove deteriorated and sound concrete. This process provides an excellent bonding surface for repair material. First developed in Europe in the 1970s, this technology has become widely accepted for concrete removal and surface preparation throughout Europe and North America.
Hydrodemolition can be used for horizontal, vertical, and overhead concrete removals and surface preparation on reinforced and non reinforced structures. ft is effective in removing concrete from around embedded metal elements such as reinforcing steel, expansion joints, anchorages, conduits, shear connectors, and shear studs. Hydrodemolition can be used for localized removals where deterioration is confined to small areas and for large area removals in preparation for a bonded overlay. This technology can also be Fig. I: Damage created by chipping ham me r
Bridge decks and substructures
Parking structures
Dams and spillways
Water treatment facilities
Tunnels and aqueducts
Nuclear power plants
Piers and docks
Stadiums
Warehouses
Retaining walls The Effects of Mechanical 1m act Techni ues Mechanical methods such as chipping hammers, rotomills, scabblers, and scarifiers remove concrete by impacting the surface. These procedures crush (bruise) the surface, fracture and split the coarse aggregate, and create micro-fractures in the substrate (Fig. I and 2). As a result, the ability of the fractured substrate to provide a dura ble
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used to remove existing coatings from concrete.
Fig. 2: Damage created by rOlomilling Page 3 of 16
928 Exhibit 21 CONCRETE REPAIR MANUAL bond with the repair material is compromised, requiring a second step of surface preparation to remove the damaged region.
Furthermore, impact methods may damage the reinforcing steel and embedded items such as
,. ;:?~<!,uJS ~~e.ar ~t;I ~. ~n.d.~o.n!1~st~~s~ ~I!d. }P!l~~i ~ ll.
joint hardware. Impact methods transmit vibrations *
through the reinforcing steel, which may cause :.
further cracking, delamination, and loss of bond :
between the reinforcing steel and the existing :
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mechanical impact will travel through the structure, disturbing the occupants. During repair of thin slabs and precast tees, chipping hammers may shatter the substrate resulting in unanticipated ful!
depth repairs.
For a discussion on surface bruising and the mechanics ofconcrete removal by impact methods, refer to [CR[ Technical Guideline No. 03732, "Selecting and SpecifYing Concrete Surfuce Preparation for Sealers, Coatings and Polymer Overlays."
Hydrodemolition Benefits and Limitations The benefits of hydro demolition can be placed into two groups: structural benefits that improve the quality of the repair, and environmental benefits that improve the quality of the work place.
Hydrodemolition also has limitations, which need to be considered.
Structural Benefits o
A rough, irregular surface profile is created to provide an excellent mechanical bond for
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o Exposed aggregates are not fractured or split; o Lower strength and deteriorated concrete is
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o Reinforcement is cleaned, eliminating the need for a second step of surface preparation; and o
Reinforcing and other embedded metal elements are undamaged.
."". b*u; i~g ~~;c"ret~ ;;';;~v*arth;~~t~;j~t i~ drr~ct~ci at the surface, causing high-speed erosion of the cement, sand, and aggregate. The water jet does not cut normal weight aggregate which remains intact and embedded as part ofthe rough, irregular surface profile (Fig. 3). The aggregate interlocks
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Fig. J: SUI/ace prepared by hydrodemolition has a rough irregular profile with protruding aggregate and is excellent for creating a mechanical bond mechanical bond and composite action between the substrate and the repair material.
The rough, irregular surface profi Ie provided by hydrodemolition can result in bond strengths that equal or exceed the tensile strength of the existing concrete. The concrete surface profile can exceed CSP-9 (very rough) as defined in ICRJ Technical Guideline No. 03732.
Rotomills and scarifiers remove concrete to a uniform depth and may leave deteriorated concrete below the specified depth. Alterna tively, the water jet moves in a consistent pattern over the surface and will remove unsound concrete even if it i below the specified depth.
..since the"wa'tirletdoesnO'tc;eate"mecl1anical*

impact, vibration is not transmitted into the structure :
from the hydrodemolition operation. Delami- :
nation beyond the repair area caused by vibration :
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During hydrodemolition, sand and cement particles mix with the water jet. The abrasive action oftheses particles is usually sufficient to clean uncoated reinforcing bar and embedded metal items without damaging them. Corrosion material is removed from the reinforcing bar and metal items, allowing for easy inspection and identifi cation ofcross-sectional area loss. The reinforcing bar is cleaned without any loss ofdeformations.
Cleaning ofthe entire reinforcing bar, however, will not occur ifthe reinforcing bar has not been completely exposed during hydrodemolition.
Environmental Benefits
Minimizes disruptions to users of occupied space by significantly reducing transmitted sound through the structure; o Increased speed of concrete removal can reduce construction time;
Minimizes dust; and Page 4 of 16
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOLITION METHODS
Robotic units reduce labor and minimize injuries as compared to chipping hammers.
Concrete removal by hydrodemolition can take place inside an occupied structure, such as a hotel, apartment building, office building or hospital with minimal noise disruption to the occupants.
Hydrodemolition can quickly remove concrete.
As such, project duration can be reduced, mini mizing the impact on the users of the structure.
During demolition, cleanup, and final wash down, the concrete debris and repair surface remain wet, minimizing dust in the work area. Since hydro demolition cleans the reinforcing steel, the need to sandblast is eliminated unless additional concrete removal is required using chipping hammers. As such, silica dust in the work area is reduced, thereby providing a safer work environment.
The use of chipping hammers and other impact methods are labor intensive and physically demanding, which can cause injury to the employee.
Robotic hydrodemolition equipment reduces the use of these tools and the possibility of injury.
Limitations
The hydrodemolition process consumes a significant amount of water (6 to 100 gpm
[25 to 380 Ipm]). A potable water source must be available. The cost of the water should be considered;
Wastewater containing sand and cement fines (slurry) must be collected, treated, and returned to the environment. Wastewater disposal may require a permit;
Projects requiring total demolition can be done faster and more economically with crushers and similar equipment;
Water can leak through cracks in the concrete and damage occupied space below the repair area. Hydrodemolition should not be used over occupied areas due to the risk of blow-through (unanticipated full-depth removal);
Repair areas of varying strength will result in non-uniform removal. Areas of high strength may need to be removed using hand lances or chipping hammers;
The water jet is blocked by reinforcing steel resulting in concrete shadows under the reinforcing bar that may need to be removed using hand lances or chipping hammers;
Since the water jet ofa robotic unit is contained in a metal shroud, some robots are unable to completely remove concrete up to a vertical surface such as a curb, wall or column. The remaining concrete may have to be removed using hand lances or chipping hammers;
The water jet will remove the sheathing from post-tensioning tendons and may drive water into the tendon;
The hydrodemolition robot may be too large to access small or confined areas of the structure;
The water jet can damage coatings on reinforcing steel and other embedded items;
The water jet can introduce water into electrical system components, especially if embedded in the concrete and already deteriorated or not properly sealed; and
If cleanup is not properly performed in a timely manner, further surface preparation may be required.
The Hydrodemolition System The hydrodemolition system consists ofa support trailer or vehicle, high-pressure pump(s), a robotic unit to perform the demolition, and high-pressure hoses to connect the pump(s) to the robot. Hand lances are also available to remove concrete in areas inaccessible to the robot.
Support Trailer Hydrodemolition units are typically transported on 40 to 50 ft trailers (Fig. 4). The robot may tlf" \\~.l cr I'UII'I)'
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Fig. 4: Hydrodemolition support trailer. A self contained unit transports pumps, robot, hoses, and spare parts be transported on the same trailer or separately on a smaller trailer. The support trailer usually contains a supply ofspare parts, tools, maintenance area, fuel and water storage, supply water hoses, and filters. These units are designed to be self-sufficient on the job site with adequate spare parts to perform routine maintenance and repairs.
Page 5 of 16
930 Exhibit 21 CONCRETE REPAIR MANUAL High Pressure Pumps The high-pressure pumps used forhydrodemolition are capable of generating pressures from 10,000 psi to 40,000 psi (70 to 275 MPa) with flow rates from 6 to 100 gpm (25 to 380 Ipm).
The pumps are driven by a dies el or electric motor, typically operating between 100 and 700 horsepower. The engine size will vary based on the flow and pressure rating of the pump. The pumps operate most efficiently at their design pressure and flow. High-pressure hoses connect the pumps to the robot. The pumps may be located a significant distance (500 ft [150 m])
from the actual removal area. However, due to a drop in pressure and flow through the high pressure hoses, the pumps should be located as close as possible to the removal area, typically within 300 ft (100 m).
Robotic Removal Unit Horizontal Surfaces The force created by the high-pressure pump(s) is controlled using a robotic removal unit (Fig. 5).
The robot is a diesel or electric powered, self propelled, wheeled or tracked vehicle. It is used to uniform Iy move and advance the water jet over the surface during concrete removal.
(
Fig. 6: Nozzle is mounted on a traverse beam RO!3li on Osclllallun Fig. 7: Rotating or oscillating nozzles Fig. 5: Typical hydrodemolition robot The water jet is mounted on a trolley that traverses over the removal area along a cross feed or traverse beam (Fig. 6) perpendicular to the advance of the robot. The water-jet nozzle may either oscillate or rotate (Fig. 7). The oscillating nozzle is angled forward in the direction of the traverse. Rotating nozzles are angled from the center, creating a cone effect while rotating (Fig. 8 and 9).
The nozzle assembly is enclosed within a steel shroud with rubber seals around the perimeter to contain the debris during demolition (Fig. 10).
15 "
Fig. 8: Rotating nozzles are angledfrom center IIt"II 1*1\\...."1\\* ~\\ 0".
I<liUH I tlll ",I I'"
\\I\\.-l~t.l " '1/1..
It 1'1 Fig. 9: Rotation ofthe angled nozzle creates a water cone Page 6 of 16
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOLITION METHODS Fig. 10: Nozzle is enclosed within a steel shroud The rotation/oscillation ofthe nozzle com bined with the traverse and advance of the robot provide a uniform and continuous motion of the water jet over the removal area (Fig. II). Each of these functions is fully adjustable. The depth of concrete removal is determined by the length of time the water jet is directed at the removal area.
Fig. 11: The water jet traverses back andforth perpen dicular to the forward advance ofthe robot Adjusting the followin g parameters will increase or decrease the depth ofremoval:
a. Total traverse time (time of each traverse x number of traverses); and
b. Distance of the advance.
Once these parameters are set, the robot will reproduce the settings in a programmed sequence to provide consistent removal of the concrete. For example, during deep removal to expose the reinforcing bar 3 to 4 in. (75 to 100 mm), the traverse speed may be 8 seconds (the time required for the water jet to move from one side of the traverse beam to the other) and the water jet may traverse 3 times before the robot advances forward 1to 2 in. (25 to 50 mm). On the other hand, for light scarification 1/4 to 112 in. (6 to 13 mm) or coating removal, the traverse speed may be 3 seconds and the water jet may traverse only one time before the robot advances 2 to 4 in. (50 to 100 mm).
The depth 0 f concrete removal is controlled at the robot. Since the pumps are designed to operate at a specific pressure and flow rate, it is unusual to reduce the pressure (and subsequently the flow rate) to adjust the depth of removal.
Narrow areas may be removed by adjusting sensors that limit the movement of the water jet along the traverse beam. The traverse and advance functions limit the removal to a rectangular area along the advance path of the robot. Because the water jet is contained within a steel shroud, most robots are unable to remove concrete within 3 to 6 in. (75 to 150 mm) of vertical surfaces.
Specialized Robotic Equipment Vertical and Overhead Surfaces Various types of robotic equipment are available to perform removals on walls, soffits, substructures, beams, columns, and tunnels. These robots are often built on wheeled or tracked vehicles and have the ability to lift the traverse beam into the vertical or overhead position. The primary functions of traverse and advance are utilized in order to provide uniform concrete removal during vertical and overhead repairs.
As an alternative to the robot, the water jet may also be attached to a frame that allows the jet to move in a two dimensional "X-Y" plane. The X-Y movement of traverse and advance are present in these units to provide uniform concrete removal.
The X-Y frames can be lifted and positioned over the removal area using a crane, backhoe, all terrain forklift or other similar equipment.
Hand Lance Hand lances operate at pressures of 10,000 to 40,000 psi (70 to 275 MPa) while delivering approximately 2 to 12 gpm (8 to 45 Ipm) ofwater.
Hand lances are not as fast or as precise for concrete removal as a programmed robot and are slower than chipping hammers. Hand lances are effective in performing light scarification and coating removals. It should be noted that the water jets on hand lances may not be shrouded, increasing the risk of debris becoming airborne.
Hand lances can be used for removal of:
Concrete shadows below reinforcing bar;
Concrete adjacent to walls, columns, curbs, and in tight and confined areas not accessible to the robotic equipment; and
Coatings.
Page 7 of 16
932 Exhibit 2'1 CONCR ETE REPAIR MA UAL f t Hydrodemolition involves the use of potentially dangerous specialized equipment. At all times, the mannfacturer's instmctions for the safe operation of the equipment and personal protective equipment should be followed, as well as all oeal,state, and federalregl.llations, Hydrodemolition units should bc supervised and operated b.qualified persOlmel celiified by the equipme t manufacturer, Hydrodemolition employs high-velocity vater Jets to demolish concrete and perform surface preparation, Even though the waterjet is shrouded on robotic units, debris can be propelled from beneath the shroud with sufficient velocity to cause serious injury Serious injury or death can also occur if struck by the water jet. Hand lances are typically noi shrouded and care must be exercised to avoid injury when using ihese tools.
Workers. equipment operators. and any indi viduals entering the work area are required to wear hard hats. safety glasses, hearing protection.
safety shoes, gloves, long pants and long-sleeve shirts, and must be trained in the proper use of personal protective equipment. When using a hand lance. the operator should wear a full-face shield. rain suit. and metatarsal and shin guards.
Additional protective clothing may also be required for use vvith hand lances. Everyone involved with the hydrodemolition operation should receive specific training outlining the dangers associated with the use of high-pressure water.
Prior to starting demolition, an inspection of the area should be performed including the area under the work area. All barricades, partitions, shielding, and shoring must be installed and warning signs posted to prevent unauthorized entry into the work area, The area below the work area must be closed off and cle3Tly marked "Danger-Do Not Enter," Electrical conduits or other electrical equipment in thp wDrk area should be deenergized to avoid electrical shock.
Special precautions are required for post tensioned structures as referred to in the section "Considerations for Hydrodemolition Use."
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~@ W@HTIQ Scarification Scali fication is perfOTIlled to remove the surface concrete a d provide a rough profile (Fig. 12 and 13). Scariiication is often used in preparation for Fig 12: Scarified surface with 1 in. aggregate a concrete overlay. If the surface was previously rotomilled, the minimum removal depth using hydrodemolition should equal the size of the coarse aggregate to remove all concrete micro fractures and damaged or crushed aggregate.
Scarification may not remove all unsound concrete due to the rapid rate at which the waterjet moves over the surface. It may be necessary to resurvey the scarified surface and identify delami nated or deteriorated areas for further removal.
I?m'llia [lapin Remoua~
Partial depth removal is commonly required if chloride contamination has reached the top mat of reinforcing steel or deterioration, delamination or spaDing occurs within the top mat of reinforcing steel. Partial depul concrete removal can expose the top mat of reinforcing steel and provide clearance,typically a minim um of 314m (19 mm),
below the bottom reinforcing bar of the top mat (Flg. 14 and 15). Determin'ng t 1e rei 1forcing bar size and co c 'ete cover are c Hira! to determine the ;'equired removal dept!.
Concrete removall sing hand lances 0. chipping harnrners may be required to remove shadows uncleI' tJ':e rCLi!forcing bar, previously repaired areas
.?aga a of 16
PREPARAT!mJ OFCONCRETE SURFACES -OR REPAIR USING HYDRODEMOLITION METHODS Fig. 14.* PartiAl depth removal Fig 15: Partial depth removal on a retaining wall or high areas resulting from variations in the strength of the concrete. In addition, concrete removal may be necessary adjacent to vertical surfaces such as curbs, walls and columns. Saw cutting of the perimeter of the repair area, if required, should be performed after hydro demolition to prevent damage to the saw cut. This will require additional concrete removill along the repair perimeter with hand lances or chipping hammers. If the saw cut is made first, the area outside the saw cut should be protected using a steel plate. The steel plate will allow the water jet to slightly over i lID the saw Cllt 'Nithout damaging the surface outside [he saw cut wi1iJe completely removing the concrete within the repair area.
full e~!~~i Hemo1Ja~
Hydrodemo lilian can be used for full depth removal where delamination has occurred in the lo'.',;er mat of reinforcing or chloride contami nation exists throughout the entire thickness of the slab. Fuil depth removal can be performed along expansion joints and other areas where there is a high concentration of reinforcing steel that may be damaged if Co:wentional removal metl.ods are used. Other structural elements such as shear connectors, shear studs, and steel beam flanges can be exposed without damage.
During full depth removal, the removal rate slows as the depth increases because the water jet stream dissipates as it moves away from the nozz e and the water jet must push more water and debris from its path prior to conta.c ting he surface to be removed.
Full depth removal is often necessary on waffle or pan joist slab systems (Fig. 16).
Fig. J6: Full depth removal-waffle slab Coating Removal Hydrodemolition can be used for the removal of epoxy, urethane, hot applied membrane, and other coatings from concrete surfaces (Fig. 17).
When performing coating removal, a multiple jet nozzle is used. The multiple jets allow the water to penetrate the coating without damaging the concrete. However, if the concrete below the coating is deteriorated, it may be removed along with the coating.
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. "'" '. ~
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Fig 17: Coating removal using a spinning, multi-nozzle pIa head Page 9 of 16
934 Exhibit 21 CONCRETE REPAIR MANUAL The Hydrodemolition Process Concrete removal by hydrodemolition is impacted by the following factors:
Size and density of the aggregate; Concrete strength; Uniformity of concrete strength; Extent of cracking; Deterioration and delamination; Surface hardeners; Previous repairs w ith dissimilar strength material; and Size and spacing of reinforcing steel or other embedded items.
In sound concrete, the variation in the depth of removal will generally equal the size of the coarse aggregate (Fig. 18). For example, if the coarse aggregate is 1 in. (25 mm), D = I in.
(25 mm) and the specified depth of removal is 2 in. (50 mm), the range of removal will be 2 in.
(50mm) +/- D/2(l l2 in.or 13 mm), or 1-1/2 in.
(38 mm) to 2-1/2 in. (63 mm).
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If the strength of the concrete increases or a high-strength repair area is encountered during hydrodemol ition, the removal depth will decrease (Fig. 19). The decrease in depth may not be immediately detected by the operator, resulting in an area ofshallow removal (Fig. 20). To obtain the required depth in higher strength concrete, the total traverse time is increased and the advance of the robot is decreased. If the high strength repair area is large enough, it may be possible to set up the hydrodemolition robot over the area and remove to the specified depth. This Fig. 18: The depth ofremoval depe nds on the size ofthe course aggregate During hydrodemolition, a high-pressure water jet is uniformly moved over the surface and, provided the concrete is sound and the strength does not change significantly, the removal depth will remain consistent. Depth variations occur when the concrete strength changes, cracking or delamination is present, the concrete is deteriorated or the surface has been previously repaired using a different type and strength of material. In comparison, rotomi II ing or dry-m illing equipment can be set to a specific depth and the milling drum will mill the surface to that depth regardless of any variations in the concrete strength, quality or level ofdeterioration.
Fig. 19: High-strength concrete is removed at a slower rate than normal concrete, which can result in a non uniform removal Page lO of l6
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOLITION METHODS Fig. 20: High-strength repair area within the hydro demolition area procedure can be problematic for two reasons.
First, if the water jet overruns the high-strength repair area, it may result in a blow-through or full depth removal at the perimeter ofthe high-strength repair area. Second, since the water jet must be slowed significantly, it may cause excessive removal below the high-strength area once it is removed and the softer base concrete is exposed.
For these reasons, it is often preferable to use chipping hammers in high-strength repair areas.
The opposite effect is encountered if the concrete strength decreases or there is cracking, deterioration or delaminations (Fig. 21). Concrete that is deteriorated, low strength or delaminated is removed faster than the surrounding sound concrete by the water jet. For example, if the average removal depth is 2 in. (50 mm) and there is a delamination that is 2 in. (50 mm) deep, the actual removal within the delaminated area could be 3 to 4 in. (75 to 100 mm) deep. For this reason, removal in an area that is seriously deteriorated and delaminated may not be consistent.
This effect is often described as "selective removal ofdeteriorated concrete." While the water jet is traversing and advancing uniformly over the surface, it is removing unsound, delaminated, deteriorated, cracked, and low strength concrete selectively below the specified removal depth.
Selective removal is not without I imitations.
For example, ifthe robot is traversing and advancing rapid Iy as during scarification, it may not remove deeper delaminations.
Size and spacing ofthe reinforcing steel will also influence the removal depth. The reinforcing steel blocks the water jet and shields the concrete below, creating concrete "shadows" (Fig. 22 and 23). Removal ofconcrete shadows becomes more difficult as the reinforcing bar size increases and M('fOO
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If.,""'" I k1.IIU1UJ",,," \\ t!..
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Fig. 2J: Delaminated or deteriorated concrete is removed at a/aster rate leading to non-uniform removal is most difficult at reinforcing bar intersections.
Increasing the specified depth of removal. will minimize the amount of shadowing.
Pointing the water jet under the reinforcing bar can reduce concrete shadows. This can be accomplished by using a rotating or oscillating nozzle (refer to Fig. 7-9). Rotating nozzles are typically angled 10° and 30° from center. The nozzle rotates between 100 and 1800 rpm, creating a demolition cone that will undercut both the transverse and parallel reinforcing bar provided the specified removal depth is greater than the Page 11 o f 1 6
936 Exhibit 21 CONCRETE REPAIR MANUAL Fig. 22: Reinforcing steel blocks the water jet leaving a concrete "shadow" under the reinforcing. Increasing the removal depth will decrease the amount ofshadowing depth of the reinforcing bar. Similarly, the oscil lating nozzle moves rrom side to side as it traverses, directing the water jet at an angle to the surface, cutting under the reinforcing bar. The nozzle is angled forward as it traverses left, and at the end ofthe traverse, fI ips to face forward as it traverses right. To minimize concrete shadows, the required depth ofremoval should be at least 3/4 in. (19 mm) below a #5 reinforcing bar. Larger reinforcing bars will require a greater removal depth to minimize shadowing. While this additional Fig. 23: "Shadow" under the rebar (note tie wire undamaged and in excellent condition) removal may result in the removal of sound concrete, it will minimize the need for concrete removal under the reinforcing bar with chipping hammers or hand lances.
Considerations for Hydrodemolition Use Issues that should be considered when evalu ating the use of hydrodemolition for a repair project include:
Limited quantity of repair: Mobilization and set up of the hydrodemolition equipment can be expensive. If there are only minor repairs or a limited quantity of repairs, the mobilization cost may make the process uneconomical.
Increase in repair quantity: The traverse and advance function of the hydrodemolition robot results in removal areas that are rectangular. The removal areas may have to be "squared up" in order for the hydrodemolition equipment to efficiently remove the concrete. "Squaring up" the repair areas may lead to an increase in the removal quantity and the cost of the project.
Reinforcing bar size and concrete cover:
Partial-depth removal normally requires clearance below the bottom reinforcing bar of the top mat of reinforcing. The size and quantity of the reinforcing bar and the concrete cover over the reinforcing bar should be determined in order to specify the correct removal depth to achieve the required clearance.
Potentialfor full-depth blow-throughs: Hydro demolition of severely deteriorated structures may result in full-depth blow-throughs. Blow throughs may take place where full depth slab cracks occur, especially ifdeterioration is evident on the slab underside. Shielding may be required Page 12 of 16
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOllTlON METHODS to protect the area below from damage. Shoring below the blow-through may be damaged or destroyed. When the water jet is in the open air, as will happen when the water jet blows through the deck, it is extremely noisy (may exceed 130 db) and dangerous. Sound resistant partitions should be installed to contain the noise within the structure ifblow-throughs are expected.
Extent of previous repairs: Repair materials may have a different compressive strength than the original concrete. Since the hydrodemolition jet is set to move at a uniform rate, the presence of dissimilar strengths of material will result in a variation in the depth of removal. Higher strength areas may require further concrete removals using chipping hammers or hand lances to achieve the specified depth of removal. Lower strength areas may result in deeper removals and possibly full depth blow-throughs.
Occupied areas adjacent to or under the repair area: Occupied spaces such as stores or offices may occur in the structure. It may not be practical to perform hydrodemolition adjacent to or over these areas. Water from the hydrodemolition may leak to the occupied level below. As such, the repair area should be protected to prevent water from entering the occupied area.
Shoring requirements: During structural repairs, concrete may be removed from around the top reinforcing. An analysis of the structural capacity of the remaining slab section should be made by a qualified engineer to determine if shoring wi.11 be required. The weight of the hydrodemolition robot should be considered when determining shoring requirements.
Equipment location: The hydrodemolition equipment is transported on a trailer. Ifpossible, the pumps should be located within 300 ft of the repair area. A suitable location next to the structure must be selected. Pump units that are powered by diesels engines should not be located next to the air intake of adjacent buildings. In congested metropolitan areas, the pumps may be removed from the trailer and placed within the structure. Diesel powered pumps will need to be located close to an exhaust shaft and the exhaust from the pumps piped to this location. A fuel tank will also have to be placed in the pump area and provisions made to fill the tank as required.
Although electric pumps may be used inside the structure eliminating the fueling and exhaust concerns, they have a substantial power requirement and will need an electrical service installed. Due to the weight of the pumps, they may need to be placed on the slab on ground or in a shored area of the structure. Temporary shoring may be needed to move the pumps into the structure.
Available water sources: Pumps used for hydrodemolition require a steady supply ofclean water at a sufficient volume to perform the work.
Generally, local municipal water is used for hydrodemol ition. Sources close to the work area, such as a nearby fire hydrant or water line feeding the structure, should be adequate. Specific water requirements will vary, depending on the hydro demolition unit used for the project and the method of cleanup. Cleanup performed using a fire hose operating at 100 to 200 gpm (380 Ipm to 760 Ipm) will use substantially more water than an 8000 to I O,OOO-psi (55 to 70 MPa) water blaster operating at 8 to 12 gpm (30 to 45 lpm).
In remote areas, water can be drawn from wells, fresh water lakes, rivers, or streams. This water must be pre-fi Itered to remove any suspended solids to avoid damage to the high-pressure pumps. Recycled water has been used for hydro demolition, however, it can add substantially to the cost of the project due to collection and filtration of the water and the added wear to the equipment caused by dissolved minerals in the recycled water. When available, potable water is used. Water may have to be trucked into remote locations.
Post-tensioned structures: The use of hydro demolition on post-tensioned structures has potentially severe risks and must be carefully evaluated to maintain a safe working environment, maintain structural integrity, and to preserve the long-term durability of the structure. Sudden release of anchorages can result in dangerous explosive energy and flying debris capable of causing damage to equipment and serious injury or death to workers. Tendons should be de-tensioned prior to removing concrete from around anchorages to prevent the sudden release of the anchorages and loss ofpre-stress forces. The loss of pre-stress forces may result in the loss of structural integrity and result in the need for shoring. Careful eval uation must also be exercised when removing concrete around post-tensioning tendons. Removal ofconcrete around tendons can result in a change of tendon profile, which may also result in the loss of prestressing force and structural integrity.
The wires or strands ofpost-tensioning tendons are usually undamaged during hydrodemolition, however the sheathing and protective grease wi II be removed from unbonded tendons. In bonded post-tensioning tendons, the water jet may penetrate the duct and remove the grout inside. Tn either case, the hydrodemolition water may enter the Page 13 of 16
938 Exhibit 21 CONCRETE REPAIR MANUAL tendon at the edge of the repair area and can be driven into the tendon outside the work area.
Water remaining in the tendon can cause future corrosion affecting the long-term durability ofthe post-tensioning system. Each tendon must be carefully examined and any water that has entered the tendon removed. Both the grease and the protective sheathing must be restored.
Tt may not be possible to remove moisture that has entered the post-tensioning system during the hydrodemolition process. In addition, verification of the presence of moisture is difficult and may not be possible. Refer to JCRI Technical Guideline No. 03736, "Guide for the Evaluation ofUn bonded Post-Tensioned Concrete Structures,"
for suggested procedures to detect water in post tensioning tendons. Long term monitoring for future corrosion may also be prudent.
Conduit and embedded metal items: Embedded aluminum and steel conduit will not be damaged by hydrodemolition if they are in good condition.
However, deteriorated portions ofaluminum and steel conduit will be damaged and water will enter the conduit system. PVC conduit will be damaged during hydrodemolition. As a safety precaution, all conduits should be deenergized during demolition. Other metal items within the removal area such as shear connectors, shear studs, and anchorages will not be damaged by hydrodemolition.
Noise limitations: Hydrodemol ition does not produce sound that is transmitted throu g h a structure, however, the noise from the hydro demolition unit in the work area is sufficiently loud to be objectionable to the public. Further more, noise can be excessive during full-depth repairs or blow-throughs. Sound reducing partition walls that separate the public from the work area may be required. Acoustical studies indicate that the sound waves created by hydrodemolition are low frequency and are best controlled using dense material such as sheet rock or concrete board.
There are a variety of sound deadening materials suppl ied by various vendors that have proven effective in controlling noise. Partition walls should be protected from moisture. If properly sealed at the base, a water resistant sound reducing partition wall will also assist in containing the water within the work area.
Protection of lighting, sprinklers, and other services: Light fixtures, fire protection systems, and other services may be damaged by airborne debris from the hydrodemolition or clean up operation. Iffull depth removal or blow-throughs are anticipated, light fixtures may need to be removed and stored and temporary lighting installed.
Sprinkler heads may need to be protected. Mist and high humidity in the work area could damage electrical panels and other services. Items remaining in the work area should be protected.
Temperature: When the temperature falls below freezing, the structure must be heated or the hydrodemolition stopped to prevent water from freezing in the work area.
Test Area A test area should be designated to establish the operating parameters and to demonstrate that the equipment, personnel, and methods of operation are capable of producing satisfactory concrete removal results. The test should include sound and deteriorated concrete areas, each a minimum of 50 ft2 (5 m2). First the robot is set to remove sound concrete to the specified depth. Once the operating parameters have been determined, the equipment is moved to the deteriorated area and a second test is performed using the same operating parameters. If satisfactory results are achieved, the quality and depth of removal will become the standard for the project. lfhand lances are to be used to perform concrete removals, they should also be demonstrated to show satisfactory results.
It is noted that the hydrodemolition robot will move the water jet over the surface in a constant motion and if the concrete is of uniform strength, the removal depth wiJi be consistent. However, since concrete is seldom uniform, there will be variations in the removal depth on the project.
Other factors affecting the removal depth include the extent and depth ofdeterioration, the size and quantity of reinforcing bar, the concrete cover over the reinforcing bar, and the presence of surface hardeners. As the equipment is used, nozzles will wear, changing the force created by the water jet. As such, the hydrodemolition equipment operator must monitor the depth and quality of removal and adjust the parameters of the robot to provide consistent removal through out the project.
Wastewater Control Controlling the wastewater has often been viewed as one of the more difficult tasks associated with the use of hydrodemolition. However, with pre planning and proper installation of a wastewater control system, the water can be properly managed (Fig. 24). Hydrodemolition wastewater should be Page 14 of 16
PREPARATION OF CONCRETE SURFACES FOR REPAIR USING HYDRODEMOLITION METHODS W,:jILT rrl)m
\\\\ \\'f),. " Il:"
rnul"C lcr P\\lmp rII R c,-~ II\\ ' fI n,)~ Or <\\(,Id
\\ h'IR)!.
-: ~'1;. :.
Fig. 24: Typical wastewater handling system discharged to the storm or sanitary sewer or to the ground for absorption and/or evaporation under permit from the controlling authority.
Discharge into an existing storm or sanitary line may occur in the structure or to a nearby storm or sanitary line accessed through a manhole. A 4-in. (100 mm) connection should be adequate.
Wastewater may not be discharged directly to a wetland, stream, river or lake.
Hydrodemolition wastewater contains suspended particles and typically has a pH of lIto 12.5. The wastewater is initially placed in settling tanks or ponds to reduce the suspended solids. The partic les are heavy and settle out quickly as the water is allowed to stand. This can also be accomplished by allowing the water to pass through a series of berms that are lined with fi Iter fabric or hay bales.
The controlling authorities for discharge have varying requirements for the level of suspended solids and the range of pH for discharge into their system. Typically the water should be clear and the pH range between 5 and 10. Ponding the water will clarify it, however, the pH of the wastewater may have to be reduced prior to discharge. This can be accomplished by the introduction of acid, CO2 or other pH reducing materials into the wastewater. Adding f10cculants can assist in reducing suspended solids. A location for settling ponds or tanks and pH reducing equipment should be determined.
The cost to discharge wastewater ranges from the cost of a discharge permit to charges for the actual water consumed and discharged. The cost ofwater consumed is generally that ofcommercial water usage within the community. The controlling authority may require monitoring and testing of the wastewater. Local ord inance requirements must be reviewed and met prior to discharge, including the obtaining of proper permits.
Water containment and collection systems will vary depending on the structure. Where possible, it is best to take advantage of gravity to move the water to the treatment area. In many structures, the slab on ground can be used to collect and treat the water. The water may be allowed to flow through the structure to the lowest level or through the existing drains, which have been disconnectedjust below the underside of the first supported level. All slab-on-ground drains should be plugged and water should not be allowed to enter the drainage system prior to treatment. Once the water is clear and the pH adjusted, it can be pumped directly to the discharge point. Additional treatment capacity may be necessary ifrainwater cannot be separated from the wastewater.
Floor slabs and decks are commonly crowned or sloped to provide drainage. Since water will run to the low area, a simple method of water control involves the use of hay bales or aggregate dams, which can be set up along curb lines or the perimeter of the work area. As the water ponds in front of the hay bales or aggregate dams, the suspended solids will settle out. In areas where the drains are plugged, the water is forced to pass through the hay bales or aggregate dams. Retention ponds can be built at the end of the structure and the water directed or pumped to these ponds.
Settl ing tanks can also be used and the water pumped from the structure to the tanks.
Debris Cleanup and Disposal Hydrodemolition debris consists of wet sand, aggregate, chips or chunks ofconcrete, and slurry water. Slurry contains cement particles and ranges from muddy water to a thick paste. Removal of the debris should occur as soon as possible to prevent the debris from sol idifying and adhering to the surface, making cleanup more difficult.
Tools used for cleanup include: fire hoses, pressure washers, compressed air, sweepers, skid steer loaders, vacuum trucks, and manual labor.
The types of cleanup will vary based on the type of removal performed as follows:
I. Above the reinforcing bar-any removal depth above the top reinforcing bar ofthe top mat of reinforcing and the reinforcing bar remains supported by the concrete;
2. Below the rein/orcing bar-any removal depth below the top mat of reinforcing bar in which the top reinforcing bar mat becomes unsupported by the original concrete; and Page 15 of 16
940 Exhibit 21 CONCRETE REPAIR MANUAL
3. Full-depLh removal.
During above the reinforcing bar clean up, equipment such as skid steer loaders, sweepers, and vacuum trucks may be driven over the surface to assist with the cleanup (providing they meet the weight requirements of the structure). The debris can be swept, pressure washed or air blown into piles where it is picked up by a loader. A vacuum truck may be used to vacuum the debris from the surface. In all cases, the surface must be pressure washed to remove any remaining cement slurry.
Ifthe removal is below the reinforcing bar and the reinforcing bar is unsupported, it is difficult and possibly unsafe to drive equipment into the removal area. The debris can be removed by washing with a fire hose (large water consumption),
pressure washing or blowing it onto the adjacent original surface where it can be picked up with a loader. A pressure washer operating at 8000 to 10,000 psi (55 to 70 MPa) and 8 to 12 gpm (30 to 451pm) is effective. Vacuuming has proven very effective in removing debris from around the reinforcing steel, however, the surface will require pressure washing to remove the cement slurry and paste.
Duringfull-depth removal, the debris simply falls to the floor below where it can be picked up with a loader.
The debris, which consists of wet sand, aggregate, chips or chunks of concrete, and slurry is placed in dumpsters or hauled away in trucks and may be recycled or placed in a landfi II in accordance with the requirements of the controlling authority.
Removal Depth Measurements Following hydrodemolition, the surface profi Ie is very rough and three depth measurements are possible (Fig. 25):
I. Minimum removal-original surface to the shallowest removal point.
2. Maximum removal-original surface to the deepest removal point.
3. Average depth of removal-The difference between the minimum and maximum removal at the same location.
Measuring the depth of removal can be accomplished using:
I. A straight-edge placed on the original surface;
2. A string-line pulled over the removal area; and
3. A surveyor's level.
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Fig: 25: Measuring depLh ofremoval using a straight edge The most common practice of measuring the depth of removal is to place a straightedge on top of the original surface and extend it over the removal area. Measurements are taken from the bottom ofthe straightedge to determine the depth of removal. This quick and simple technique can only be used during the removal process and is not applicable for final measurements in large removal areas.
A string line may be pulled over the removal area and measurements taken below the string.
However, this method could provide incorrect results if slopes or crowns occur in the original surface. Surveying equipment may be used and is very accurate; however, to account for slopes, pitches and crowns in the original surface, a detailed survey must be made of the original surface prior to removal and measurements taken at the same locations after removal for comparison and determination of the actual removal depth.
Summary Effective concrete removal and proper surface preparation are key elements to a successful repair project. A surface prepared using hydrodemolition is rough, irregular, and is excellent in creating a mechanical bond with the repair material.
Hydrodemolition eliminates micro-fractures and damage to reinforcing steel, minimizes transmitted noise and dust, and cleans the reinforcing steel.
The use of hydro demolition may not be appro priate for every structure and a careful review of the benefits and limitations ofthe process relative to each structure should be undertaken. Proper safety procedures must be observed at all times when using hydrodemolition.
Page 16 of 16
Exhibit 22: ACI 546R-04
© 2012. Performance Improvement International Appendix VIII-23

ML12138A058

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