Cristiana Colloca GS/SEM – ATOP – MARCH 2009

Infrastructure Consolidation of Accelerators Injectors

(civil engineering)Cristiana Colloca GS/SEM – ATOP 5th of March 2009

CONCERNEDSurface

- Roofs, façades, floors, windows, sanitary etc. all buildings (machine and tertiary)

- Roads, parking, green areas, storage surfaces, etc.- Cleansing

Underground tunnels

NOT CONCERNEDFor all the buildings (machine and tertiary), surface and underground:

- HVAC- Heating plants and heating network- Electrical equipment- Lifting and transport equipment- Automatic doors- Kitchen equipment-...

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

THESE WORKS ARE NOT CONVERED BY THE NORMAL MAINTENACE CARRIED OUT EACH YEAR

Contents

DATA AND DETAILS IN

SITE CONSOLIDATION ON CIVIL ENGINEERING AND TECHNICAL INFRASTRUCTURE AT CERN

2008 UPDATEC. Colloca, M. Nonis, P. Pepinster

du 18.08.2008

SITE CONSOLIDATION ON CIVIL ENGINEERING AND TECHNICAL INFRASTRUCTURE AT CERN

2009 UPDATEC. Colloca, P. Pepinster

du 24.02.2009

References

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Categories of roofs repair:

1 - Sensitive equipment: roof leaks are affecting the safety of equipment and/or the running of an accelerator; critical situation; immediate intervention is required

2 - High frequency leaks: the roof is no more waterproof and leaks are detected very often; conditions will become critical if an intervention is not taken within a short time

Roofs consolidation : criteria

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Roofs consolidation - SENSITIVE

2470/SG4 Point 4 LHC/LEP

SEXP 1988 532 9 532 Steel panels 106

2285/SX2 Point 2 LHC/LEP

SEXP 1988 1800 9 1800 Bituminous flat roof 300

150 Meyrin EXPE 1958 3550  6 430 2005 3120  Asbestos panels 800156 Meyrin ASSE 1972 398 6 139 2001 259 Plastic panels 72

2675/SR6 Point 6 LHC/LEP

SSSTA 1986 1834 6 1834 Bituminous flat roof 366

887/EHN1 Prévess in EXPE 1977 14000 6 1000 Bituminous flat roof 200355 Meyrin SSSTA 1958 2082 4 486 2001 450 Bituminous flat roof 100181 Meyrin STOC 1969 2865 3 1’432 2002 1432 Bituminous flat roof 300

872/BA5 Point 5 SPS TECH 1974 1100 2 1100 Bituminous flat roof 180363 Meyrin EXPE 1975 1181 1 188 2004 993 Bituminous flat roof 197918 Prévessin BULA 1979 942 4 942 Bituminous flat roof 150

27711430

Location Function Year of Construction

TOTAL FOR INJECTORS

Area to be renovated

MaterialCost

Estimate (kCHF)

TOTAL

Total area (m2)

Total ODM 2004-2008

Renovated area (m2)

YearBuilding

~51%

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Roofs consolidation - FREQUENTBuilding Location Function Yea of

ConstructionTotal area

(m2)

Total ODM 2004-2008

Renovated area (m2)

Year Area to be renovated

MaterialCost

Estimate (kCHF)

867 Prévessin ASSE 1973 11437 20 3100 2001-2006 8337 Bituminous flat roof 1680

904 Prévessin EXPE 1976 950 18 131 2000 819 Bituminous flat roof 900

504 Meyrin HEBE 1971 1465 17 410 1996-1998 1055 Bituminous flat roof 210

866 Prévessin BULA 1973 2630 17 2630 Bituminous flat roof 540

108 Meyrin ATEL 1965 890 15 0 890 Bituminous flat roof 176

865 Prévessin BULA 1973 2202 14 481 2005 1721 Bituminous flat roof 341

864 Prévessin BULA 14 Bituminous flat roof 540

31 Meyrin BULA 1973 670 13 60 2000 610 Bituminous flat roof 120

102 Meyrin ATEL 1964 1530 12 1530 Bituminous flat roof 300

30 Meyrin BULA 12 186

5 (DEP) Meyrin BULA 12 Rain water drains 60

112 (barracks)

Meyrin BULA 10 Bituminous flat roof 60

2 Meyrin BULA 1955 1066 10 0 1066 Bituminous flat roof 211

3 Meyrin BULA 1957 1117 10 305 1998 812 Bituminous flat roof 161

54853101TOTAL FOR INJECTORS

TOTAL

~57%

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Facades consolidationCarbonatation on concrete and corroded steel, icing-deicing cycles...(spalling phenomena etc.)

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Facades consolidationBui ldin g Location Ye ar of

C onstru ction Fun ction Proble m de scription Su rface to re pair [m 2]

C ost Estim ate (kC HF) Priori ty

255 Meyrin 1960 REFR Concrete carbonatat ion and steel corrosion 900 317 1863 Point 6 SP S 1975 REFR Concrete carbonatat ion and steel corrosion 1320 465 1

30-112 Meyrin 1971 BULA Concrete carbonatat ion and steel corrosion 6300 1480 1269 Meyrin 1970 SST A Concrete carbonatat ion and steel corrosion 150 53 136 Meyrin 1969 BULA Concrete carbonatat ion and steel corrosion 936 330 1

60 Meyrin 1959 BULADeteriorated concrete façade with steel corrosion (South

façade)250 89 1

504 Meyrin 1971 HEBE Deteriorated concrete façades with steel corrosion (NW façade and balcony of SW façade)

350 123 1

132 Meyrin 1967 ST OC Concrete carbonatat ion and steel corrosion 50 18 2118 Meyrin 1985 AT EL Concrete carbonatat ion and steel corrosion 221 78 2168 Meyrin 1968 ASSE Concrete carbonatat ion and steel corrosion 700 247 2149 Meyrin 1958 ST OC Concrete carbonatat ion and steel corrosion 83 294 2215 Meyrin 1966 SST A Concrete carbonatat ion and steel corrosion 134 47 2203 Meyrin 1965 ST AT Concrete carbonatat ion and steel corrosion 700 247 2206 Meyrin 1962 SST A Concrete carbonatat ion and steel corrosion 155 55 2286 Meyrin 1970 T ECH Concrete carbonatat ion and steel corrosion 115 40 2361 Meyrin 1971 T ECH Concrete carbonatat ion and steel corrosion 221 78 2

250-258 Meyrin 1959-62 SST A-ST OC Concrete carbonatat ion, steel corrosion 200 71 2

31 Meyrin 1973 BULA T op edges of facades with spalled concrete over access zone

50 17 2

281 Meyrin 1970 T ECHDeteriorated concrete façades with steel corrosion and

spalled concret e540 190 2

287 Meyrin 1970 T ECH Deteriorated concrete façades with steel corrosion and spalled concrete (NW and SE façades) 300 90 2

102 Meyrin 1964 AT EL Concrete carbonatat ion and steel corrosion 300 106 3

226 Meyrin 1971 SST ADeteriorated concrete façade with steel corrosion

(S and E façades) 100 35 3

25 Meyrin 1975 BULADeteriorated concrete façades several cracks

(SW and SE Façades) 230 81 3

4551984

TO TALTO TAL FO R INJEC TO RS

~22%Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Windows, claddings,spalling concrete, painting etc.

Other Miscellaneous Consolidation Measures -

Buildings

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Building Location Year of Construction Function Problem-Description

Surface to repair

(m2)

Cost Estimate (kCHF)

192 Meyrin 1971 CONT Deteriorated floor and ceiling in main floor 550 95

253 Meyrin 1958 DIST Corroded external support beams of building 165 40

291 Meyrin 1969 ACCE Deteriorated wooden floor 100 16

867 Prevessin 1973 ASSE Metal cladding with corroded areas 140 30

112 Meyrin 1971 BULA Metal cladding with scaling paint, some points of corrosion along facade 571 86

185 Meyrin 1975 EXPE Inside panels (walls and ceiling) containing asbestos are unsecured   450

181 Meyrin 1969 STOC Metal cladding with unfastened panels and corroded areas 500 70

864, 865, 866 Prevessin 1973 BULA Completion of replacement window frames campaign   60

501 Meyrin   BULA Terrace repair   250

TOTAL 1097

TOTAL FOR INJECTORS 90

~8%

Other Miscellaneous Consolidation Measures -

Buildings

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Cleansing

- CERN does not comply with applicable (no mix of clear and waste water and fosses septiques (ex. SPS))

- very bad condition of the drainage equipment due to age and progressive invasion of roots penetrating the pipes

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

The estimated cost for the asbestos removal from civil engineering structures is still kept to 5 MCHF for all CERN site, not including the ancillary work such as the relocation in other buildings of the working personnel for the duration of the work.

Main works are:- Bldg 150 - PS technical galleries

Asbestos removal

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Consolidation Requests - Surface

Intervention Typology Overall cost (kCHF)

Total cost for 'Injectors’

(kCHF)

Proposed Annual Spend

for ‘Injectors’(kCHF)

Civil engineering      

Roof (sensitive equipment) 2771 1430 150

Roof (high frequency) 5490 3110 150

Facades 4551 984 500

Windows 4090 60 60

Toilets, sanitary installations 450 200 200

Other interventions 1097 30 30

Roads& Parking areas 1300 500 500

Cleansing 300 120 120

Asbestos removal 5000 4000 800

TOTAL 25049 10434 2510

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Minimal Consolidation Program 2009 for Injectors - Surface

Intervention Typology Total cost (kCHF)

Roofs (EHN1, BA5) 380

Facades (863, 867) 500

Windows (864, 865, 866) 60

Toilets, sanitary installations 50

Roads & Parking areas 100

Cleansing 50

TOTAL 1940

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Previous canalisations of leaks were done using flexible PVC membranes. These need to be changed for the stainless steel channels now used, in order to comply with current fire norms.

Underground Consolidation *- PS, SPS, Booster

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

*Contribution of Richard Francis Morton GS/SEM

A campaign of repainting of the tunnel vault is required to reduce

the amount of dust and contamination caused by water

ingress and decay of the original paint. This work may also require

some superficial repair to the concrete.

Underground Consolidation - PS, SPS, Booster

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Significant areas of tunnel floor have been contaminated by hydrocarbons and will require resurfacing.

Underground Consolidation - SPS

Additional work is required to ensure

construction joints are repaired and levelled to allow transport to pass.

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Construction of an oil separator at one or more locations underground to allow oil to be removed from the drainage system before it is pumped to surface.

Underground Consolidation - SPS

A campaign of decalcification and cleaning of the central drain is long

over due. This work is currently hampered by the lack of water

supply at regular intervals along the tunnel.

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Many of the toilets in the underground SPS complex are in a poor state of repair and require renovation.

A campaign of repair/replacement of the concrete covers to the technical gallery in the PS is required to make safe the floor.

Other Miscellaneous Consolidation Measures -

Underground

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

Intervention Typology * Total cost (kCHF)

Replacement PVC Gutters 120

Renovation of Tunnel Vault 150

Renovation of Tunnel Floor 200

Oil Interceptor T.B.A.

Drain Decalcification and Cleaning T.B.A.

PS Concrete cover renewal T.B.A.

Renovation of Underground Toilets 120

TOTAL 590

*The amount of work possible is entirely a function of access during shutdown. This may mean spreading the work over several shutdowns.

Consolidation Requests - Underground

Cristiana Colloca GS/SEM – ATOP 5th of March 2009

CERN infrastructure (surface and underground) is rapidly deteriorating, trends are negative (i.e. roofs) => overall consolidation planning on large scale is a major issue to be treated because of safety, legal, operational and economical reasons

Consolidation costs are constantly rising due to the lack of intervention (ex. Anti-carbonatation treatments)

2009 consolidation program is based on most urgent interventions known today, but depending on:• Budget (available today = 800 kCHF for all CERN (!))• Boundary conditions during the approval of the program

(accelerator operation, weather conditions, etc.)• Number of FTE assigned to perform the program

Increasing expectation for consolidation activities from CERN community, visible actions need to be done to avoid widespread feeling of frustration

Conclusions

Cristiana Colloca GS/SEM – ATOP 5th of March 2009