ML20087M984

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Forwards Addl Info Re .Errata Sheet,Stress Tabulations for Remaining Stages of Const,Stress & Deflection Tabulation for Remaining Unsymmetrical Const Conditions Encl.Related Correspondence
ML20087M984
Person / Time
Site: Midland
Issue date: 03/27/1984
From: Mooney J
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To: Harrison J
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
CSC-7533, NUDOCS 8404020257
Download: ML20087M984 (50)
v • d • e


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wy Executwe Man.sger Midl.,nd Project Office h)

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, iMANC General Offices: 1945 West Pamall Road, Jackson, MI 49201 e (517) 788-0774 March 27, 1984 Mr John J Harrison, Chief Midland Project Section U S Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER GWO 7020 ADDITIONAL INFORMATION TO JANUARY 4-6, 1984 NRC AUDIT QUESTIONS File: 0485.16.1 UFI: 42*05*22*04 Serial: CSC-7533 0460.2 12*16 00211(S)

REFERENCE:

J A Mooney to J J Harrison letter dated February 8, 1984, CSC-7292 Enclosed find the following three items of additional information to the referenced letter:

1.

Errata sheet for subject letter attachment (Attachment 1) 2.

Stress tabulations for remaining stages of construction after CT 1/12

[ supplement to question response 3 of referenced letter].

(Attachment 2) 3.

Stress and deflection tabulation for remaining unsymmetrical construction conditions after CT 1/12 [ supplement to question response 8 of referenced letter].

(Attachment 3)

In addition, we are also enclosing Construction Technology Laboratories report, dated 3/6/84, evaluating crack conditions in slabs at elevation 674'6" and 704'0" in comparison to slab at elevation 685'0" (Attachment 4).

This is in response to NRC inquiries raised at February 2, 1984 Stone and Webster public meeting.

/RHW/klw Attachments CC RJCook, Midland Resident Inspector DSHood, USNRC JGKeppler, Regional Administrator, Region III l

OC0384-00011A-CN01 8404020257 840327 PDR ADOCK 05000

9 2

i CONSUMERS POWER COMPANY Midl.tud Units 1 and 2 Docket No 50-329/50-330 Letter Serial CSC-7533 Dated March 27, 1984 At the request of the Commission and pursuant to the Atomic Energy Act of 1954, and the Energy Reorganization Act of 1974, as amended and the Commis-sion's Rules and Regulations thereunder, Consumers Power Company submits Additional Information to January 4-6, 1984 NRC Audit Questions, J A Mooney to J J Harrison letter Serial CSC-7533, dated March 27, 1984.

CONSUMERS POWER COMPANY By 60 W U

JA' fooney Executive Manager 9

1 Sworn and subscribed before me this df day of M a d 1984.

~ HAM

~2 Totar'jf Public My Commission Expires'

,23 f, / f M l

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OC0384-00011A-CN01 l

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3 OM/0L SERVICE LIST Mr Frank J Kelley Atomic Safety & Licensing Attorney General of the Appeal Board State of Michigan U S Nuclear Regulatory Commission Ms Carole Steinberg Washington, DC 20555 Assistant Attorney General Environmental Protection Division Mr C R Stephens (3) 720 Law Building Chief, Docketing & Services Lansing, MI 48913 U S Nuclear Regulatory Commission Office of the Secretary Washington, DC 20555 Mr Myron M Cherry, Esq Suite 3700 Ms Mary Sinclair Three First National Plaza 5711 Summerset Street Chicago, IL 60602 Midland, MI 48640 Mr Wendell H Marshall Mr William D Paton, Esq RFD 10 Counsel for the NRC Staff Midland, MI 48640 U S Nuclear Regulatory Commission Washington, DC 20555 Mr Charles Bechhoefer, Esq Atomic Safety & Licensing Atomic Safety & Licensing Board Panel Board Panel U S Nuclear Regulatory Commission U S Nuclear Regulatory Commission East-West Towers, Room E-413 Washington, DC 20555 Bethesda, MD 20014 Ms Barbara Stamaris Dr Frederick P Cowan 5795 North River Road 6152 N Verde Trail Rt 3 Apt B-125 Freeland, MI 48623 Boca Raton, FL 33433 Dr Jerry Harbour Mr Fred C Williams Atomic Safety & Licensing Isham, Lincoln & Beale Board Panel 1120 Connecticut Ave, NW, Suite 840 U S Nuclear Regulatory Commission Washingten. DC 20036 East-West Towers, Room E-454 Bethesda, MD 20014 Mr James E Brunner, Esq Consumers Power Company Mr M I Miller, Esq 212 West Michigan Avenue Isham, Lincoln & Beale Jackson, MI 49201 Three First National Plaza 52nd Floor Mr D F Judd Chicago, IL 60602 Babcock & Wilcox PO Box 1260 Mr John Demeester, Esq Lynchburg, VA 24505 Dow Chemical Building Michigan Division Mr Steve Gadler, Esq Midland MI 48640 2120 Carter Avenue St Paul, MN 55108 Ms Lynne Bernabei Government Accountability Project Mr P Robert Brown 1901 Q Street, NW Clark, Klein & Beaumont Washington, DC 20009 1600 First Federal Bldg Woodward Ave Detroit, MI 48226 3/14/84 OC0384-000llA-CN01

4 BCC JWCook, P-26-336B SHHowell, M-1180B TABuczwinski, Midland-207 LGraber, LIS JNLeech, P-24-506 DFLewis, Bechtel FJLevandoski, B&W GALow, P-12-237A DASonsners, P-14-106 PPSteptoe, IL&B, Chicago DJVandeWalle, P-24-614B BJWalraven, P-24-517 RAWells, Midland FCWilliams, IL&B, Washington, DC DTPerry, Midland NRC Correspondence File, P-24-517 UFI, P-24-511 CMS-Midland RC DMBudzik, P-24-517A RJErhardt, P-14-113A LSGibson, P-24-618A P-24-505 (Last)

OC0384-00011A-CN01 m

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ATTACHMENT 1 l

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l TA BLE 3- +

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C24%TRdlit04 REoAR corJcas TE

()= a *)zw ')sa

'sw ("*)2 e

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(22 0)

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(EE. E/,ais) j TOTAL g, 3 f

(,- s o.4)

CHAM 65.

3

- Si

-58

-13

- 16

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TOTAL (o)

CHAdr.dk

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(exc. cry,1)

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woTE.: @ STRESS DISTRi&OTion F0K THE. ExtSTlWe C.OnDITIOM 15 A4 UPPER 50udD SeLuise64 l

AwD uAs REnkt onTMMED u5)MG T44E. LONG TERM 50ll SPRiu65 SelondM 14 FIGURE 5 4 i

@ AVERA6E TEMSILE STRESS,

@ VALUES in ( ) ARE IN K/I'T i

@ avaa4se suera sraess.

@ exisTius sTaesses inctuos r nasrRess te4n.

rABLE 35

  • ^ * * * " ^ ~ * ' ' ' " ' *^" G . = t 2-d LO C AT I o N3

( FtG l-G AREA 4) 60T ELT. # 13 4, C,R P 2 3 So DIFFEREMTtAL DEFLECTioH au Mii_LS 7E NSIO N Ca/4 PPE SS /OA/

CONSTRUCT lon REoAR concesrE

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O O

O O

(ExisTI>J G)

{

TOYA'

(,- z i.z )

'2.

66 69 Ig IS SG SZ 4

(531)

(EAC E/w8) i TOTAL (1c.8)

CHA M i

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(JACK:. E/

TOTAL g4 i

(. l) cuAAGai 4

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( z 3.o)

(EXC.c.Tl/st) 5.S (o. z )

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-(A Mo

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( z3.zj

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@ AVERA6E TEystLE STREbs.

@ val.Ues IN ( ) ARE IN K/PT

@ avaa4se sueAR sraess.

@ exisTine stresses inctuos niasraes Lean.

4

TA BLE 3G G X :::: Sl' d' L O C-. AT 1 O M EAST e PA - R ' LIM E W Au.

( fig l - (. A n.A 5) top ELT 4 2 6RP 23 Su 1

DiFFEREMTiAL DEFLECTIOM 84 MILLS 76 N S / O N CO M P P 6 SS /0/V c AsTRLICTIOR i

REonR concesrElST'

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( g g,i) l (e s C E/ws)

TOTAL

~

(-4c.8)

CHA46E 5

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TOTAL 602) i CHA64&

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(EXC.cT/st)

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CHA46E (JAcacCT g)

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@ AVERA6E TEM 51LE STRESS.

@ VALUES in ( ) ARE in K/PT

@ AVERAGE SHEAR STRESS.

@ EAl5Tl46 STRESSES lHCLUDE P'RASTRESS LSAD.

1 1

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t TABLE 37 l

l i

L O C_. A T t o N }

EAM E PA - k LINE m L L.

G x 2: Si d C l^ta N-AREA 5)

BOT E LT # (4-l GRP 23 SkX l

DSFFEREMTIAL DEFLECTioM 84 t41LLS 76 N51 O N Co M P 4'6 SS /oA/

i ConsTRLICT804 p>E o AR concesrf

(), e (^),w (6.), ('d (Ah (ad,y z

Stress 5 trn As d trRuss srqAnd MmMARKS srAs,as g

est (oS'%

PSI (s i.) */W CH Akn(pe.

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o o

o o

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TOTAL 1

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woTE: @ STRESS DISTRinuTioM FOR THE. ExtSTlWe CO@lTION 15 A4 UPPER 500dD SM.0TM j

AHD aAs EEEu caTAIMED USIMG THE. LONG TERM SOIL SPRIN65 540ltlN 84 FIGURE 5-6 i

@ AVERA6E TEM 5tLE STRESS.

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@ AVERAGE SHEAR STRESS.

@ EAISTING STRESSES INCLUDE PRESTRE55 LSAD.

i

e T A B L E 8-I CALCU L ATED STRESSE5 FOR UM5YMMETRICAL COkl5TR. AMALY$15. (STAGE 11 FIG.8-1)

TE A15 t O h!

CoM PRE 5510td REBAR COuCRETE STRA M

$7gg DESC R n PT iO h!

sranss srREss R. E M AR K b

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(t)

WALLEELoW EL.Gl4*-o ed (et.LINE 1.s BETWEEN (.0L.UMES 61.H(Ili)

' ' 6)

SLAS AT EL. 659'-o BETWEiaM CCL.LtMES_ 6 1.H

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(-92.e%)

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2) AVERA6E SHEAR STRESS.

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ATTACl! MENT 2 I-I i

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Oc0384-000llA-CN01

AUIILIARY BUILDING UNDERPINNING -

STRESSgS STRAINS, AND DgFLECTIONS DURING CONSTRUCTION The attached Tables 3-8 through 3-16 and Figures 3-15 through 3-25 supplement similar tables and figures given in Attachment 3 of Consumers Power Company's response to the January 4 through 6, 1984 NRC audit questions (Reference 1).

Tables 3-8 through 3-16 show stress, strain, and different!61 deflection values. In addition, the difterential deflection values are shown graphically in Figures 3-15 through 3-20.

The differential deflection values have been calculated for the following temporary underpinning construction stages:

1.

Existing condition (load combination 1) - Figure 3-1 (see Reference 1. Attachment 3) 2.

Following excavation for E/W 8 (load combination 2) - Figure 3-2 (see Reference 1. Attachment 3) 3.

Following jacking of E/W 8 (load combination 3) - Figure 3-3 (see Reference 1, Attachment 3) 4 Following excavation of CT 1/12 (load combination 4) - Figure 3-4 (see Reference 1. Attachment 3) 5.

Following jacking of CT 1/12 (load combination 5) - Figure 3-5 (see Reference 1. Attachment 3) 6.

Following excavation of E/W 5 and CT 3/10 7.

Following jacking of CT 3/10 (load combination 7) - Figure 3-21 8.

Following jacking of E/W 5 (load combination 8) - Figure 3-22 9.

Following excavation of CT 5/8

10. Following excavation of E/W 2 (load combination 10) - Figure 3-23
11. Folicwing jacking of CT 5/8
12. Following jacking of CT 2/11
13. Following excavation of CT 13/15
14. Following jacking of CT 13/15
15. Following excavation of CT 14
16. Following jacking of E/W 2 (load combination 16) - Figure 3-24
17. Following jacking of CT 14
18. Following excavation of balance of soll
19. Following jacking of CT 6/7 0361y 1

1

l l

For calculating stresses, strains, and deflections, the assumptions described in Reference 1 have been used. Differential deflections have i

been calculated using different models for different stages.

Construction stages 6 and 7 have been analyzed using the weightless model l

shown in Figure 3-8 (Reference 1).

Stages 9 through 12 have been analyzed using the weightless model shown in Figure 3-25, and stages 13 through 19 have been analyzed using another weightless model shown in Figure 3-26.

The stress and strain values for construction stages 7, 8, 10, and 16 have been analyzed. These stages represent the maximum and minimum values of the predicted differential deflections (Al and A ) f0F 2

temporary construction stages 6 through 19 as shown in Figures 3-15 through 3-20.

The changes la stress and strain values as shown in Tables 3-9 through 3-16 correspond to the changes from the previous construction stages, as included in the table. For example, the change in stress and strain in stage 10 is the change between stsge 8 and 10.

Conclusion As stated in Attachment 3, Reference 1, the maximum tensile stress occurs following excavation of E/W 8 and is lower than the allowable. The tensile stresses and strains are lower in all subsequent stages.

Reference 1.

Auxiliary Building Underpinning Response to January 4 through 6, 1984, NRC audit questions; CPCo Letter to NRC, Serial CSC-1292, J.A. Mooney to J.J. Harrison, 2/8/84 0361y 2

l-

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TA B L E 9 L OC A'1~1Q N

~ SLA8 @. El. 659 '- o "

BETWEE N Col. LtWE $ $ H (ris, g.g y DIFFERENT As. DE FL.ECTIO N IN MILA.S TEN 5 ton COMPR E 55 to N W4hW N"MA R"#

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(JAcu cr)(3)

TOTAL 45 g J

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@ Avee A4 e Te nsi us. srRe.ss.

v^t v e s in ( ) Age in w/rv-

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EXISTIN 4 STitESS INct.upc5 PRE $75tE66 M

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NOTE *.(.h STRESS Dl5TRIBUTWM FOR TH E En tSTING: C.ON D I TIO N 15 AN UPPSR SOUND SotuTioM i

Ano 'HAS BErd onT Aisaa usiNA THE Lonc,reRM Soit seminAs, see Fie. 34

@ AVE 12AG E TE M Sl 'E STR E. 55.

VALUES ta ( ) ARE 1H W/PT-l

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L5) EXsSriN4 STstE55 INc. copes PRES 7 mess W

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TABLs it Loc Ario n

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DEFLECTION IN MILLS TEN 5foN COMPR E SSloN g,,7,,,

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Au c>

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@ AVE 1EAAE W R $>l LE. STR s. SS.

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@ AvseAAE 6 HEAR $~r RE SS,

EglSTIN4 STitE55 INc.t.upes PRESTRess M

1 Taste 3 - 12 l

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TOP, ELT "9, dRP 23,

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DEFLECTION IN Mit4s TEN 5foN COMPR E 551o N CosNTaar,Tsof8 RagAn CONCRETE 6TA&E5 (O'\\g (O'}jw ( ')3 E

( *}3W R EMA RKS

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(- 12.1) rorAu

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( 11.4) t o.r 3 u 4

2.7 6

NOTE.* h STRESS DISTRl8uTtON FOR TH E EntSTIN4 CONDI TION l$ AN UFPast SoVND SOLUTeQM AND FIAS BEEN OBT AINED OSING THE. LON4 T ERM SIL S PRIM 45, SEc Fio,. 5-6

@ AveeA4E:

T"E M St WE. STR E. SS.

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$~T RE SS.

E/ssriN4 STit E55 INc.e voEs PRESTREM M

i Taste 3 - 13 L oc ATio N

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BOTTOM ELT "l34 GRP 23, 5xx i

i DIF FE RE NTsA a.

DE FLECTIO N IN Mit Ls TENSION COMPR E 5510 N l

cosfirmer.reose r es ST at a.i n s"$$

Srgaig R EMA RKS GTAaES O')2s ( '}Jw ( '}3 E d*}3W l a)2E (A WSI

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O AUXILIARY BUILDING UNDERPINNING. SOIL SPRINGS UNDER AUXILIARY BUILDING /,' 6 & nn / 9 ////V / / / / / \\ m ~ X) l R K = iso xc Y a e -z \\ / // /, n=sw w// ///: 5A i ,/ \\ M .. -,, a~ 6 , c,,... l g l ~ INSTANTANEDUS S0IL SUBGRADE M0001.(( FOR DEFLECTION ANALY5is i

y _ O AUXILIARY BUILDING UNDERPINNING- ~ SOIL SPRINGS UNDER AUXILIARY BUILDING // 7 sc : So i<.ct" o ,7 9 ~,,,,, f f O C C r ~O / l<,:.150 WLF U / e e l f 7I' ~ i % _, _1,_ # 8 8 E)

l. '

~ l T NS'TANTANEOUS SOIL SUBGRADE MODULil l FOR DEFLECTION ANALYSIS 1 l

9 l ATTACHMENT 3 l OC0384-00011A-CN01

g TABLE B '2 CALCULATED STRESSES FOR UM5YMMETRICAL ( OMSTR AMALY515. (STAGE 21 FIG. 8-2) TE td Sl o d CoM PRESSIOM REAR COumETE STRAW STRAIM DEbC RI PT lO h! sraess STRESS R E M ARK b _ _ _' c/d P5i

  • 10 id/id KSI x lo i WALL BEtow EL.G,l4'-O ou (.eL.Llue 5.5 BETWEEd COL.LiblES G L H(Ns) bb*b )e WALLEELoW EL.G,14'-0 ou COL. LIME 7.8 BETWEEnl COL.Llues 6 L H(7T)

U 7 (s) 228 SLAB AT EL. 659'-O BETWEEM CCL. LIMES 6LH ( 5:16. l-3) "I (. 1 (~# EPA WALLS TOP -38 - 11 l AREA 4 ( FLG. L-6 BOT 8.1 i8 (~ E PA WALLS TOP -67 -6 AREA 5 ~' ~ P l G.1 -6 bot -1o -6 FLOOR SLAB AT EL.685'-o 12 7 3 5' i A R E A 6 / 5:16. 1-6 l) AVERA6E TENStLE STRESS. 4

2) AVERA6E SHEAR ST R ESS.

j 4 s

1 T A B L E 8-3A CALCU LATED STRESSES FOR 045YMMETRICAL COMSTR AMALY515. (STAGE 32 FIG.8-3A) TE h3 SI O d CoM f'RESSIOhl REBAR STR As hi STRAlkJ DES C RIPT lO h! sraess stress R E M ARK b K5i[ id% d P5l x IO id/id / x WALL RElow EL.G, tie'-o 04 toL.uun s.5 l BETWERM COL.LlWES G L H(Ni) ~ (9 i WALL &EtaW EL.Gl4*-0 #4 COL. LIME 7.8 2o& BETWEEbl COL.LiHES G L H (7.'f) (9 i SLAB AT EL. GST'-O BETWEEM 33 CGL, LIMES GEH ( F IG. 8 -3) i I-*"#*) EPA WALLS -9 i A R E. A 4 ( $"/#") 4 plG. I -- 6 BOT 8.8 2o E PA WALLS (-'9*'It) I -M - 3' AREA 5 i F IG.1 -6 bot _ g, - i9 FLOOR SLAB AT EL. 685'-o 88 AREA 6 / Fl6. 1-6 l ) AVERA6E TEMstLE STRESS.

2) AVERA6E SHEAR STRESS.

t i

TABLE 8-4 CALCULATED STRESSE5 FOR UM5YMMETRICAL COMSTR. AMALY515. (STAGE 43 FIG.8-4) ~ TEikiSI O d COM PRE.SSIOM REBAR COumETE g7gg,g STRAlk] DESC R n PT \\ O h! sraass STRESS R E t4 AR K S __ _ _' o/d 10 W/ed id i P51 4 K bl x wat aELOW EL.f.44*-0 *H (oL.uME 5.5 7'o BETWEBM COL.LlMES G L H(7.'_n') (2) 4 WALL &EloW EL.Gl4'-0 44 (OL. LIME 7.8 '6I BETMEEN COL. LIMES 6 L H (7_'f) (q. SLAB AT EL. 659'-o SErwsted COL.LtME5 6LH ( F lG. 8 -3) l EPA WALLS (-2.1.8 %) 1 ~ AREA 4 "M

pis, g.- 6 BOT 3. z.

3 ) E PA WALLS ~' l AREA 5 ~ (19.1 g) 5: 1 G. I - 6 bot g g, FLOOR SLAB AT EL.685'-o 18 I So AREA 6 / Fl6. 1-6

1) AVERA6E TENSILE STRESS.
2) AVERA6E SHEAR ST R ESS.

I I

i T A B L E. 8-3 CALCU LATED STRESSE5 FOR UM5YMMETRICAL C.Ok1STR AMALYSIS. (STAGE 3'2 FIG. 8-3) I re usich! COM PRESSIOM N AR COumETE STRAIM STRAlW DESC R1 PT 1O hl Sraess R E M AR K S STRESS K <s 1 x iO sea /ed P5l M 10 ed/od i WALL BELOW EL.f. V-0 ou Col.LINE 5.5 BETWEEM COL.LlWES G L H($Id l WALL &ELOW EL.Gl4'-o en COL. LIME 7.8 SETWEEM COL. LINES 6 L H (7_'t) i SLAB AT EL.Gst*-o BErwseal CCL.LtMES GEH ( 5: 56. 8 - 3) (~ '

  • )

I EPA WALLS TOP -33 -9 AREA 4 FtG. I-6 (.362 %d bot g.7 q.o E PA WALLS (~ "" TOP -46 -13 AREA 5 l (-3 l'8 K#t} s:IG.1-6 BOT n -61 FLOOR SLAB AT E L. 685'- o ARE.A 6 [ FIG. 1-6 i l) AVERAGE TENSILE STRESS.

2) AVERA6E SHEAR STRESS.

i i

an. J a p 9 e I 4 e ATTACHMENT 4 J i OC0384-00011A-CN01 ~ ' w-+=- pr -,g-o

a h s on of the PORTLAND CEMENT ASSOCIATION COGrQCGCQEC2 QCChftCICgg ECbCfCQCf0C# 5420 0 : Mard Pcal Skcoe. m.r c;s 60077 4321 e Phone 312'965-7503 1 March 6, 1984 Dr. Thiru R. Thi.ruvengadam Section Head - Civil Engineering Midland Design Production Consumers Power' Company 1945 Parnell Road Jacks.on. Michigan 49201 Evaluation of Cracking in Slabs at Elevation 674 ft-6 in., 685 ft-0 in. and 704 ft-0 in.

Dear Thiru:

On January 6, 1984 A. E. Fiorato and R. G. Oesterle of Construction Technology Laboratories (CTL) inspected cracks in the Auxiliary Building at the Midland Nuclear Power Plant. These cracks were located in the Control Tower floor at Eleva-tion 685 ft-0 in. A description of the site visit, analysis of observations, evaluation of the structural effects of observed cracking, and results of an engineering evaluation of conditions that led to cracking are presented in two previous reports by CTL dated January 10 and January 30, 1984. This letter is intended to clarify some concerns discussed during a recent site visit by W. G. Corley of CTL regarding the findings in the report of January 30, 1984. The January 30 report states that evidence did not strongly support the prob-ability that cracking was caused by settlement of the EPA walls. Rather, results of calculations suggested that shrinkage of concrete was the primary cause of the observed cracking. As part of the evaluation reported on January 30, 1984, a comparison was made between observed cracking at Elevation 685 ft-O in, and at Elevation 704 ft-0 in. If cracking in the floor slab at Elevation 685 ft-0 in, was caused by differential settlement. similar cracking should be expected in the roof slab at Elevation */04 ft-O in. However, field observations indicated similar cracking did not occur in the roof slab. Calculations made for the January 30, 1984 report show that the sum or measured crack widths along the floor at Elevation 685 ft-0 in, was comparable to expected shortening of the slab 9

constinction technologg laboratories Dr. Thiru R. Thiruvengadam Page 2 March 6, 1984 due to shrinkage strains. Therefore, it is our opinion that the primary cause of cracking in the slab at Elevation 685 ft-0 in, was restrained volume changes due to drying shrinkage of the concrete. Thi's conclusion has apparently led..to a concern about the, observed low amount of shrinkage cracking in.the roof slab at Elevation 704 ft-0 in. as well as a difference in crack,ing in the floor slab at Elevation 674 ft-6 in. In the following portions of this report, some of the reasons why the amount of shrinkage cracking observed at Elevations 685-ft-O in, would not be expected at Elevations 704 ft-O in and 674 ft-6 in. are discussed. PARAMETERS AFFECTING SHRINKAGE CRACKING ~ Shrinkage is defined as the reduction in volume of concrete independent of external lead. Shrinkage is primarily related to the loss of water during the drying process. The amount of shrinkage and resulting cracking expected in a particular concrete depends on a number of parameters. Constituents of the concrete mix and the environment in which the concrete is placed both have significant influence. The resulting cracking pattern is affected by restraints imposed on the volume changes and the amount of reinforcement present within the concrete. The following sections of this letter compare parameters affecting the roof slab at Elevation 704 ft-O in, with those affecting the floor slab at Elevation 685 ft-0 in. Also,.the parameters affecting the floor slab at Elevat. ion 674 ft-6 in. are compared with those affecting the floor at Elevation 685 ft-0.in. The comparisons indicate why different cracking patterns should be expected in each slab. ROOF SLAB AT ELEVATION 704 FT-O IN. Both the roof slab at Elevation 704 ft-0 in and the floor slab l at Elevation 6.85 ft-O in. are relatively thick concrete slabs containing reinforcing bars and cast on metal decking supported by structutal steel teams. However, there are significant differences in the constituents of the concrete, exposure to environment during casting and curing, restraint of volume l change, and amount of reinforcing steel in these slabs. Figures 1 through 4 show relevant parameters for the two slabs. l l l l j

construction technology laboentotics Dr. Thiru R. Thiruvengadam Page 3 March 6, 1984 Concrete Mix The class of concrete used in the roof was D-2 having constitu-ents listed in Table 9.7 of Specification 7220-C-230(Q), Rev. 25. Concrete for the slab at Elevation 685 ft-O in, was Class C-1. Class D-2 is a higher strength concrete with a lower water-to-cement ratio and has different proportions of coarse and fine aggregates than Class C-1. Calculations indicate that, for equivalent casting and curing conditions, shrinkage volume changes in Class D-2 concrete are expected to be only 50% of volume changes in Class C-1 concrete. Therefore, with equiva-lent restraint and reinforcement, significantly less cracking would be expected in the roof slab than in the slab at Elevation 685 ft-0 in. Exposure to Environment Shrinkage is closely associated with drying of concrete. There-fore environmental conditions that increase drying also increase both the rate and total amount of shrinkage. Conditions that influence drying include temperature, relative humidity, expo-sure to high winds, and' volume-to-surface ratio. The slab at Elevation 704 ft-0 in, was placed in two castings on October 13 ' and 24, 1977. The slab at Elevation 685 ft-O in, was placed in two castings on June 14 and 17, 1977. mid-October are usually significantly differentWeather conditions during than those during mid-June. Available records of weather conditions during the time of casting of each floor and for several days after do not indicate any high winds or significant precipitation. As an indication of temperatures, the average of the recorded daily high and low temperatures'from the day of the first casting to 28 days after the second casting was calculated. This average temperature was 71*F with a range of 40*F to 98*F for the slab at Eleva-tion 685 ft-O in. The average temperature was 46*F with a range of 14*F to 70*F for the slab at Elevation 704 ft-0 in. Drying and subsequent shrinkage strains increase with increased temperature. Therefore, the slab at Elevation.685 ft-O in. i would be expected to have higher shrinkage volume changes due to differences in ambient temperature. The volume-to-surface ratio of the concrete also has a signifi-cant effect on the rate of drying. An increase in this ratio, which is essentially the effective thickness of the concrete, decreases the rate of drying. The slab at Elevation 704 ft-O in. d ~

4 construction technology labofetoties Dr. Thiru R. Thiruvengadam Page 4 March 6, 1984 is nominally 21 in. thick as compared to the 15-in. thickness I of the slab at Elevation 685 ft-0 in. With this difference in thickness combined with the ef,fect of difference classes of concrete, total calculated shrinkage volume change after 6-1/2 years in the slab at Elevation 704 ft-0 in. is only 36% of that for' the slab at Elevation 685 ft-0 in. Restraint s Unrestrained shrinkage volume changes do not cause stresses er cracking in concrete. Stresses and the potential for cracking result from constraints that oppose movement of the concrete as it shrinks. Stiffer constraints induce higher stresses and higher probability of cracking. Slabs in the Control Tower are restrained from shrinkage in the plane of the slab by internal reinforcement, by the steel framing system under the slabs and by the surrounding walls. As shown in Fig. 1 and 2 for Elevation 685 ft-O in., shrinkage movement in the east-west direction is restrained by two layers of No. 6 bars at 18 in. on center and by six W18x60 steel beams spaced at approximately 6 ft-6 in, The beams are continuously connected between the north-south walls from Column Line 5.3 to 7.8. The internal reinforcement and external beams are con-straints that contribute to the. potential for the observed cracks in the north-south direction. i As shown in Fig. 3 the steel. framing system at Elevation i 704 ft-O in. consists primarily of beams in the north-south j direction. Ther,e is no continuous external structural steel that would restrain the slab in the east-west direction. The only. steel restraint in this direction would be produced by the internal reinforcement. Figure 4 shows~that shrinkage in the east-west direction is restrained by two layers of No. 8 bars at 9 in. on center..The combined stiffness of external' beams and internal reinforcement for the slab at Elevation 685 ft-0 in. is 35% greater than the stiffness of the internal; reinforcement-at Elevation 704 ft-OHin. As shown in Section'A of' Fig. 4, the roof slab'is restrained by walls that support the edge of_the slab from below. However,- Section A in Fig. 2 shows that the slab at Elevation 685 ft-0 in. is restrained by walls that extend above the slab in addition to walls that support the edge or slab from below. The edge restraint on the slab at Elevation 685 ft-O in. is essentially . - - = _, -. ..~.--

conittuction technology laboratotic Dr.'Thiru R. Thiruvengadam Page 5 March 6, 1984 twice as stiff as the restraint on the roof slab. Therefore, because of differences of in'-plane restraint from internal reinforcement, steel framing systems, and surrounding walls, less north-south cracking would be expected in the roof slab than in the slab at Elevation 685 ft-0 in. Beams in the north-south direction under the roof slab could have restrained the slab in this direction, thereby increasing the probability of east-west cracks. However, as shown in Fig. 4, large construction openings were left in the north-east and north-west corners during casting. These openings extend 25 ft in the east-west direction. The openings relieved a large portion of the roof slab restraint in the north-south direction. This would significantly de~ crease the probability of east-west cracking in the roof slab, particularly in the region of the openings. The potential for east-west. shrinkage cracking in the slab at Elevation 685 ft-0 in. is significantly reduced by the openings along the south edge. Both slabs are also restrained from out-of-plane movement. Since both slabs were cast on metal decking that remained in-place, loss of moisture occurs only f rom the top nurf ace. This results in dif ferential shrinkage through the s3ab thick-ness. That is, higher shrinkage strains occur at the top surface than at the bottom. The dif f erential shrinkage produces a curvature that tends to curl the slab downward. This downward out-of-plane movement is opposed by the steel beams below the slab. The estraint by the steel beams results in negative bending in the slab in the region directly above the beams. Negative bending causes tensile stresses in the top surface of the slab that increase the probability of cracks occurring near the supporting beams. It should also be noted that negative bending from ^ gravity loading on the slabs acts in the same direction. The roof slab at Elevation 704 ft-0 in. is supported in the north-south direction by twelve W36x300 beams at spacings ranging from 5 ft-6 in. to 8 ft-0 in. The slab at Elevation 685 ft-0 in. is supported in the north-south direction by four W36x300 beams at center spacings of 17 ft-6 in, to 20 ft-0 in. Calculations indicate that the roof slab at Elevation. 704 f t-0 in, would have a lower probability of cracking f rom negative bending than would the slab at Elevation 685 ft-0 in. This is true f or - -. - ~ r m we+

l construction technologJ aboratories l Dr. Thiru R. Thiruvengadam Page 6 March 6, 1984 negative bending resulting from either the curling effect associated with differential shrinkage or from equivalent gravity load on the slabs. Also, if cracking did occur in the roof slab at Elevation 704 ft-0 in., the width of the crack at the top surface due to curvature in the slabs would be smaller bec'ause of the significantly shorter spans. Reinforcement Reinforcing bars embedded in uncracked concrete have low stresses. The uncracked concrete carries most of the stress. If the concrete cracks, stresses are transferred to the rein-forcement the reinforcing bars then become active by spanning the cracks. The resulting width,and spacing of cracks are highly dependent on the amount of reinforcement'present in the concrete. A larger amount of reinforcement produces more closely spaced cracks with smaller crack widths. The amount of reinforcement present in the roof slab at Eleva-tion 704 ft-0 in. is significantly larger than the reinforcement at Elevation 685 ft-0 in. The amount of reinforcement in the top layers of the slab at Elevation 704 ft-O in. is approximately four times the reinforcement in the slab at Elevation 685 ft-0 in. Therefore, if the slab at Elevation 704 ft-0 in. cracked, a pattern of smaller more distributed cracks would be expected as compared to the slab at Elevation 685 ft-0 in. Summary for Slab at Elevation 704 ft-O in. Because of the differences in concrete mixes, environmental exposure conditions during and following casting, restraint to the slab by the surrounding structure, and the amount of rain-forcement within the. slab concrete, significantly less cracking from drying shrinkage would be expected in the roof slab at Elevation 704 ft-O in, as compared to the slab at Eleva-tion 685 ft-0 in. Considering the parameters affecting the slab at Elevation 704 ft-O in., the observed low amount of shrinkage cracking in the areas uncovered for. inspection of this slab i-s reasonable. ~ \\ FLOOR SLAB AT ELEVATION 674 FT-6.IN. As stated in a previous report by CTL dated January 30, 1984, an inspection of the floor at Elevation 674 ft-6 in. did not indicate cracking similar to that observed at Elevation 695.ft-0 in. Cracking in the floor at Elevation 674 ft-6 in. is generally a crazed pattern (closely spaced and narrow) i 6

l construction technology laboratories Dr.*Thiru R. Thiruvengadam Page 7 March 6, 1984 throughout the surface of the slab. However, within the crack mapping being done under Specification 7220-C-198(Q), five relatively long, distinct cracks running in the north-south direction have been identified in Submittal 7220-C-198-394-1. The crack widths are noted as either hairline or 0.005 in. Four of these five cracks are located in regions above the W36x300 floor beams. The difference between observed cracking patterns in floors at Elevations 674 ft-6 in, and 685 ft-0-in. is not as great as the difference between the slabs at Elevations 704 ft-0 in. and 685 ft-0 in. Because the crack pattern at Elevation 674 ft-6 in. tends to mask any more distinct cracking patterns, it is dif-ficult to state which slab has exhibited more shrinkage. It is not the primary concern of the following discussion to state which slab would be expected to exhibit larger shrinkage volume changes. The main point is that significantly different cracking patterns would not be unexpected in the two slabs. Both the slab at Elevation 674 ft-6 in. and the slab at Elevation 685 ft-0 in, are nominally 15 in. thick reinforced concrete slabs supported by structural steel beams.

However, there are differences in the constituents of the concrete, exposure to environment during and after casting and curing, restraint to volume change, and amount of reinforcing steel in the slabs.

Figures 1, 2, 5 and 6 show the relevant parameters for the two slabs. Concrete Mix The class of concrete indicated on the drawings and in concrete pour cards was Class C-1 for both slabs. Reports of concrete cylinder tests, though, indicate that the east half of the slab at Elevation 674 ft-6 in was cast with Class D-1 concrete. Class D-1 is a higher strength concrete with a lower water-to-ratio and contain slightly different proportions of cement coarse and fine aggregates than Class C-1. Calculations indicate that, for equivalent casting and curing conditions, shrinkage volume changes in Class D-1 concrete are expected to be 90% of volume changes in Class C-1 concrete. Also, Class D-1 concrete will be stronger than C-1 at equivalent ages. There-fore, a somewhat different cracking pattern in the eart half of the slab at Elevation 674 ft-6 in could be expected because of the different concrete classes. e v-w

construction technology laborotories 1 Dr. Thir.u R. Thiruvengadam Page 8 i March 6, 1984 Exposure to Environment one difference in exposure is related to the forming systems used. The slab at Elevation 685 ft-0 in, was cast on metal decking that remained in-place. Therefore, drying only occurs from the top surface. The slab at Elevation 674 ft-6 in, was cast on plywood forms that were later removed. This allowed the slab at Elevation 674 ft-6 in, to dry from two surfaces. This difference in exposure has two effects. One effect is that, for equivalent casting and curing conditions, total cal-culated shrinkage volume changes after 6-1/2 years are approxi-mately 65% larger in the slab at Elevation 674 ft-6 in. This effect would produce larger cracks in the floor at Elevation 674 ft-6 in. With drying from both the top and bottom surfaces, there should not be any significant di~fferential shrinkage between the bottom and top surfaces. Therefore, the curling effect and resulting negative moments at the beam locations should not be significant. This would decrease the probability of cracking over the beams in the slab at Elevation 674 ft-0 in. Also, the widths of cracks at the top surface of the slab at Elevation 685 ft-0 in, may be accentuated by the rotations associated with the curling effect. This accentuation would not occur in the slab at Elevation 674 ft-6 in. Therefore, if what would be equivalent average crack widths did occur in the slabs, a larger crack would be measured in the top surface of the slab at Elevation 685 ft-O in. Another difference in exposure is related to the surface finish on the slab. The slab at Elevation 685 ft-0 in, has a wood float finish which " opens" the concrete surface and allows drying. The slab at Elevation 674 ft-O in. has a steel trowel finish. A steel trowel finish produces a dense, tight surface that inhibits drying. The differences in finish have two effects on shrinkage ' cracks. The first effect is that the top surface of the steel trowel finished slab drys'more rapidly than the concrete a short distance below the surface. This produces differential shrink-age strains over a shallow depth and can result in a finely distributed, craz,ed pattern of shrinkage cracks as observed in the floor at Elevation 674 ft-6 in. This crazed pattern tendst to mask any more distinct shrinkage cracking. p e w = v

e coatttvetion technology laboratoric Dt.*Thiru R. Thiruvengadam i Page 9 March 6, 1984 The second effect of the steel troweled finish is that, with drying below the surface inhibited, the shrinkage strains take a longer time to develop. As concrete ages, there is a simu-ltaneous increase in tensile strength and shrinkage strains. With more moisture retained in the concrete, tensile strength develops faster.while shrinkage develops more slowly. This effect decreases the probability of shrinkage cracks through the thickness of the concrete. Also, if restraint of shrinkage movements is due to surrounding concrete structures, having shrinkage occurring over a longer time allows more creep strain l to develop in the surrounding structure. Creep strain in the surrounding concrete would relieve some of the restraint. The net effect of a slower rate of shrinkage in the slab at Fleva-tion 674 6 in. is to decrease the probability of cracking. A third difference in exposure is related to the environmental -conditions. The slab at Elevation 674 ft-6 i n was placed in s two castings on May 3 and 17, 1977. The slab at Elevatloa 685 ft-O in. was placed on June 14 and 17. 1977. Weather conditions during early May can be significantly different than those during mid-June. Available records of weather conditions d9hing the time of casting do not indicate any high winds or significant precipi-tation for either sla.b. As an indication of temperatures, the average of the recorded daily high and low temperatures from the day of the first casting to 28 days after the second casting was calculated. This average temperature was 71*F with a range of 40*F to 98'F for the slab at Elevation 685 ft-0 in. The average temperature was 63*F with a gange of 26*F to 97'F for the slab at Elevation 674 ft-6 in. Drying and subsequent shrinkage strains increase with temperature. Therefore, the slab at Elevation 685 ft-0 in, would be expected to have higher shrinkage volume changes. Restraint Slabs in the Control Tower are restrained from shrinkage in the plane of the slab by internal reinforcement, by the steel framing system under the slabs, and by the surrounding walls. The restraint from the surrounding walls is nominally the same for both slabs. However, the combination of internal and external steel in the east-west direction is significantly different. O -y r r. - m ,en.

C conittuction tahnolopj laboratoriu Dr. Thiru R. Thiruvengadam Page 10 March 6, 1984 As shown in Figs. 1 and 2, the slab at Elevation 685 ft-0 in. is restrained in the east-west direction by two layers of No. 6 bars at 18 in. on center and by six W18x60 steel bearas spaced at approximately 6 ft-6 in. As shown in Fig. 5, the west bay of,the floor at Elevation 674 ft-6 in. contains only two W21x82 beams connected to the west wall along Column Line 5.3. The beams are located relatively close to the east-west walls at Column Lines H and Kc. There is no continuously connected restraint within the center 30-f t wide region betweer.1 the north-south walls from Column Line 5.3 to 7.8. Figure 6 shows that shrinkage in the east-west direction is also rentrained by two layers of No. 6 bars at 12 in, on center. The combined stif fness of external beams and internaE reinforce-ment for the slab at Elevation 685 (t-0 in, is appror:imately 50% greater than the combined stiffness at Elevation 674 ft-0 3.no The effect of this difference in restraint is to incr;aase the probability of north-south cracking in the slab at El'.evation 685 ft-0 in. as compared to the slab at Elevation 6741 f t-6 in. Tne potential east-west shrinkage cracking in both shabs is significantly reduced by the openingt along the south edge of the slabs. Reinforcement As stated previously in this report, if concrete cracks, the resulting width and spacing.of cracks are highly dependent on the amount of reinforcement present. A larger amount of reinforcement pr.oduces, more finely spaced cracks with smaller crack widths. Reinforcement in the east-west direction of the slab.at Elevation 674 ft-6 in. is about 50% greater than that at Elevation 685 ft-0 in. In addition, there is a significant 3 amount of reinforcement added around numerous openings in the floor at Elevation 674 ft-6 in. Also, there are two layers of seven No. 11 bars in a 4-ft strip along the south edge of' the floor at Elevation 674 ft-6 in. With this larger anomat of rein; forcement, a pattern of smaller, more distributed cracks would be expected in the floor at Elevation 674 ft-6 in., as j compared to the slab at Elevation 685 ft-0 in. Summarv for Slab at Elevation 685 ft-0 in. Because of the differences in forming systems, surf ace finishes, l environmental conditions during and following casting, restraint l e e

construction technology laborotories Dr. Thiru R. Thiruvengadam Page 11 March 6 1984 of the slabs by the steel framing, and the amount of reinforce-ment within the concrete, si'nificantly different cracking from g 1 drying shrinkage would.be expected in the floor slab at Eleva-tion 674 ft-6 in, as compared to the slab at Elevation 685 ft-0 in. Considering the various parameters affecting the slab at Elevation 674 ft-6 in., the smaller widths and more closely spaced cracks in this slab are reasonable. Sincerely. Ab Ralph G. Oesterle. Manager i Analytical Design Section RO/rr l Copy to-W. E. Kunze G. Murray W. G. Corley E. Lhar A. E. Fiorato M. A. Sozen H. G. Russell Central Files F. Villalta CR4873/4320 J. Darby CR2546/4310 CR5110/4321 i i 4 I 4 e 0 _c.- ~~

e e N b h 6.6 7.8 47 '- 6" 47 '- 6" ~j' = 1 l ~ n W18 x 60 Wl8 x 60 W l8 x 60 Wl8 x 60 Wl8 x 60 00 00 DO DO DO 8 8 W 8 T DO O DO 0 00 00 'O 00 ( = -c 1 w w w w n m vc. m m DO t .. _B DO k DO 3 DO E 00 .) (__. 00 DO DO DO DO ) 7 ~ \\ W18x6D Wl8 x 60 Wl8 x 60 ' Wl8 4 60 Wi8 x 60 n 9 $ R $ 3 = k x B x o Fig. 1 Plan of Structural Steel Praming at Elevation 685 ft-0 in. -n m y ,,r. .n-4

e N Ik 5.3 6.6 7.8 i l i I h i l bC East-West Reinforcement No. 6618" Top 8 Bottom f.s :: s a f 1 f I \\ l s_ 'A" % North -South Reinforcement 3 tJo 6 6 !2" Top 6 Scticm l k /-' A sn, 7 a x A l x1 FRba /ii t A *- Plan G Elev. 685'-O" ..,..w) s~.1. :q. .a. Notes DM.'s I YT.5M 47 Concrete : Class C-1

u. y $. :u..q;:1l: s.2.:;f:;-)

", j '_. 3" r .:r:. Average Temperature During 28 days Af ter ~'fi.[f ' f-NDecking Ccsting : 71*F p[{3,j.:! ] .. :.:.. : r @.'.'i..l:. { '{ ;.;It . *.;*;;.- G ~. :.. n* } 9, :.. '.:'c 'N.(%. 26.' _ 3'- O "__, Section A-A Fig. 2 Internal Reinforce..ent, Openings and Concrete Information for Slab at Elevation 685 f t-0 in. l l 9}}

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