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'~~ ' O EBASCO SERVICES INCORPORAT''''

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* . WATERFORD STEAM ELECTRIC STATION - UNIT NO 3

d & ) A V // M_ ,

r_ss cc- MPROCEDURE FOR: Concrete Pre-Place: ment Inspection PROC. NO. QC 4.0-4

DATE: 1-25-74'

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i_ ISSUE /DATE ! PREPARED APPROVED * - RDU.RKSw

5 4.MWWA-4-A/1-25-74 J F Gregory %.

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DOCUM UNTABLE.*

AND ETURN LE

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PDR FOIA xCARDE84-455 PDR i

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'9 FREEDOM OF INFORMATK)N* '

ACT REQUESTFORM NO, E-1 (3-3-72) *.

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*.- DATER 1-25-74 EBASCO SERVICES INCORP0HAl'ED PPOC NO.bc 4.0-4

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ISSUE: . ..ATERFORD STEM 1 ELECTRIC STATIO.. - UNIT NO 3 PACE:1 0F 8-

y A. e.

1.0 PURPOSE,

This procedure is intended to be a guide for those quality controlinspection functions which are required before placement of con-crate. Statements, suggestions and instructions contained herein .

, are not intended to supplant the plans and specifications for this,

project, but rather to supplement them.

2.0 REFERDICES .f2.1 ACI Manual of Concrete Inspection

na

2.2 AC;' Journal - June,1971

: a-

$ 2.3 ACI, SP4 - Formwork for Concretees!

2.4 PCi, T-21-3 - Po us for irchitectural Concrete5:

B 2.5 Procedure QC 4.0-2e.

2.6 Specification IDU 1564.472gg 2.7 Specification IDU 1564.473

2.8 Procedure QC 4.2.1-1~ ;

ea.I 2.9 Building Code Requirements for Rainforced Concrete (ACI 318-63)4

} E 2.10 Manual of Standard Practice for Detailing Rainforced Concrete*

i Structures (ACI 315-65)5

1 -

2.11 Manual of Standard Practice for Reinforced Concrete Construction.

! 8 (CESI)- -

,

: w .

! T 2.12 CRSI Recommended P'ractice for Placing Rainforcing Bars>

. . . . . . . . ...

5 2.13 U. S. Dept. of the Interior, Bureau of Reclamation, '

"Concreto Manual," Seventh Edition.i

o.

1.

3.0 m*

, h. Before concrete is placed in a given section of the work, the I

specification requirements regarding excavation, forms,' rein-forcement, embedded fixtures, and joints must be fulfilled andthe work inspected. To keep delays at a mini ==, inspectionshould be continual through the three stages of the work, sa -

,' follows:'

.

Preliminary - When excavation has been complaced or forms built.If dimensions and stability are satisfactory, the contractor

_

may then clean the foundation, place releasing agent on the forms,and install any reinforcement and fixtures.

->

CLASSIFICATION: Concrete BY: J F Cregory APPROVED:.

. _ . - . - . - . . . . . . - ._ . ._

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DATB 1-25-74 .A EBASCO SERVICES INCORPORA*@ PROC N01*

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! . 4 ISSiJE: A . WATERFORD STEAM ELECTRIC STATION - UNIT NO 3 PAGE: 2 0F 8 *

3.0 GCIERAL (Cont'd),

Semifinal or " cleanup" - When everything is in place for

; concreting, a * detailed inspection of foundations , forms,and all equipment or parts to be embedded in the concrete.i

*$

If the installations are satisfactory, the work is ready.

for final cleanup.^ -' 's

FinalD -Iammadiately before concrete is placed. Forms and,

fixtures must imot have been displaced. Surfaces must be,.cism and, if specified, must be wetted. At this time4

! the "Preplacement Inspectors Racord" should be signedad turned over to the Quality Concrr; Concreta Supervisor.

,

g Assuming that the requirements with regard to suitabilityof materials, proportions, and werking conditions (weather,se

"e time, lighting, equipment, etc) have been met, the contractor" may than proceed with concrete pl.tcing.

h 4.0 EXCAVATION AND FOUNDATION

3,

4.1 General Surface Inspection : The inspector shan ensureuz that all surfaces upon or against which concrete will be

,

S placed shan be prepared by suitably shaping and throughly] g!

cleaning, washing and unwatering as may be indicated inj w the plas, or as the Engineer may direct, to meet the

{ various situations encossatored in the work.

.i | 4.2 Earth Surfaces - Inspection of an earth surfaces uponi

j which or against which concrete is to be placed shall confirm*

g that the surface is well compacted and free from standing1 3' water, mud or debris. Soft or yielding soil shall be removed

8 and replaced with lean concrete or with selected soils and,

i~

y compacted to the same density as surrounding area. The!g- surface of absorptive soils against wtiich concreta is to

] e be placed shan be moistened thoroughly so that moisture winj g not be drawn from the freshly placed concrets.

[ 4.3 Concrete Surfaces - The inspector shan verify that they final result is a roughened, pitted surface from which all

' < dirt, unsomd concrete, laitmca and glazed mortar havek, been removed and upon which the aggregate is partiauy

exposed. Wet sandblasting shall be done, if required by,

[ the Engineer.> '*

f

4.4|'

Banding Hatarials - Epoxy bonding compossids, approved by'

the Engineer, may be used to band new to old concrete.Where this is the case the inspector shall note the asthod

.4 of application and the type of material.,

4.5 Underwater Piecesent - All work requiring placement of' '

concrete underwater shall be designed, directed andinspected with due regard to local circumstances andpurposes. An sanderwater concrete shall be placed

iaccording to the plans or specifications and as directed,

4 ad approved by the Engineer. !.

CLASSIFICATION: . Concrete BY' J F Cremory APPROVED: |*

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. _ _ . , . - _ _ _ _ . _ . - . _ - _ . _ , . . _ . , - - _ _ . _ _ _ . . . _ . _ , , _ _ __ . . . . _ . _ _ _ . , _ _ . _ . , _ . . - --

. .-. _ . . - -- .. - . _ - _ --

~'DATER , - , c_ w .o EBASCO SERVICES INCORPOR.W PROC HO;QC 4.0-4.

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; >- ISSUE: A WATERFORD STEAM ELECTRIC STATION - UNIT NO 3 PAGE:3 OF 8. .-

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4.0 EXCAVATION AND FOINDATION (Continued) !

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4.6 If concrete is to be supported by' piles, the inspector-

1

shall check the number and location and should report-

any that deviata from plan location.-

^ -' Pile driving inspection is the subject of another procedure.s

'

5.0 PORMS,

!

j k"5.1 General Form Inspection - The inspector shan determina

that forms are built true to slopes, lines and dimensions!

g as caued for on the drawings. They shan be properlybraced and tied to maintain correct position and shapew

9 until their removal. On final results criterion both! 8*

hform material and method of construction shall be subjectto the approval of the Engineer. The safety criterion

j g - is the responsibility of the contractor.

.

i 5.2 Bracing and Rigidity - The inspector shan determine,through the concreta quality control supervisor, whether

h the Engineer must approve the contractor's fornworkg plans. If so, the inspector must ensure that these

'; a approved plans are used by the contractor in erection of the

N forms. If sliding forum or " lift" forms are used, the form3 after being raised, shan de puned tight agair.st the concretey already cast. Joints in forms should be made especially;

secure, even and tight. To avoid unsightly offsets and3 mortar leakage at horizontal construction joints, formsg should be reset so that the sheathing overlaps thei

g concrete only 1 inch or so. Ample tie bolts shan beused close to the joint to insure holding the form tight

{: ' to the concrete during concrete placement and vibration.;

' -

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y - . .

as 5.3 Forst Surfaces - Form surfaces shall be smooth, notar-'

"'

tight, and free from holes and seams which would permitEC[ mortar to escape. Where appearance o( the structure isp important, form joints shan be horizontal or vertical

miess otherwise specified or shown on the plans.: <'

Form faces for surfaces which win be exposed.at thecompletion of the project shan be made of metal, plywood-

I or sized and surfaced lumber, tsalass otherwise approved,,

- mid shall be mortar-tight and smooth., , .'

5.4 Form Ties '- Metal tie rods shan be used for supporting allforms. Provision shall be made for removal of a sectionof each rod at the surface of the concrete to a depth of'

approximately 1 inch. Form ties for vans subject to*

_ internal or extemal hydrostatic pressure and required to be{ watertight against au leaks shan be permanent snap type.

; with water seals..

@

CLASSIFICATION: Concrete BY:J F Gregory APPROVED:,

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. _ _ . - - - - _ _ _ _ .

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DATE. 1-25-74 . 's EBASCO SERVICES INCORPont''"D PROC No.QC 4.0-4.

ISSUE: A . WAT3tFORD STEAM ELECTRIC STATION - UNIT NO 3 PACE: 4 OF 8 |*

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5.0 FORMS (Continued)

! 5.5 Qianfers, finets and edging - Where refinish corners andangles exposed in the finished structure shan be formed with

*

moldings to form chanfers or finets on the finished*

concrete. Ihe standard dimensions of chamfers and finets,'s -' unless otherwise specified, shall be 3/4 ' inches by 3/4 inches. <

Care shall be exercised to insure accurate moldings. Thediagonal face of the molding shall be planned or surfacedto the sans texture as the forms to which it is attached.,

1, g@ 5.6 Vertical construction joints on faces which win be1 exposed at the completion of the project shan be trued

| E with an edging strip. Horizontal construction jointsmay also require edging strips in some locations.;

n,

3 5.6 Reusing Form Material - Forse which are to be reused shan4

au be repaired before reuse to provide smooth and mortar-g tight faces. If the forms win'be reused for concreteo which will be exposed in the completed work, holes or

k openings shall be filled with wood and sanded smooth.,u Forma shall be thoroughly cleaned of all adhering concrete

g and dire lef t from previous use and shall be retreated

t! with releasing agent before resetting. Forms which are

K badly damaged or which have had excessive repair workwi done on them shall be discarded at the direction of

h .P.he Engineer.

E-g 5.7 Releasing Agent - Forms lef t in place from a previous

placement of concrete shall be thoroughly cleaned and,h, treated with an approved nonstaining form releasing agent3 shortly before the suceeding placement. This treatment8 sha'11 be made before the placement of any reinforcing-

W steel adjacent to the forms. The inspector shall-

E .I determine that all excess releasing agent on the form'

" surt. aces, embedded items or reinforcing shall be carefullyN removed.

E 1

*

o 5.8 Cleanout Openings - All.! foreign material such as chips,

g blocks, sawdust, dried mortar, and ice shall be removed., e Foreign material is likely to accumulate in corners and' M. places difficult of access. In deep narrow forms, holes

for cleaning and inspection may be provided at the! . ,

i bottom and at joint levels of the forms. The inspector*

shall ensure that the means and material to close theseholes has been prepared and is at hand. ;,

:

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' Goncrete ' J.F CreI''7CLASSIFICATION: BY: APP!tOVED:*

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!!

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DATE- 1-25-74 .A EBASCO SERVICES INCORPORAM'

PROC MO,1.,

AISSliE: . W TERFORD STEte! ELECTRIC STATION a UNIT NO 3 PAGE: 5 0F g**

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6.0 REINFORCEMINTi

6.1 General Inspection - Reinforcement shall be checked forsize, bending, spacing, location, firmness of installation,and surface condition. Practical information with illustra-,

tions is contained in the Manual of Standard Practice for,

; -

j Reinforced Concrete Construction. CRSI and CRSI Reconsnended. , , .,

| Practice for Placing Reinforcing Bars.'

6.2 - Bar Dends and Cuts - Reinforcing steel shall be cut and> bent * to the tolerances specified in the proposed revision- .

i

ad of ACI 30166, Specification for Structural Concrete for'

| { Buildings, Section 5.41 (as published in the ACI Journal,June , 1971) . Dia:ensions for all bars and bar bends sliown

h on Ebasco Design drawings will be found on the appropriate -

sheet of Drawing B-484 (Bar Bending Schedules) . Where,

m.ad construction is being done from Field sketches, an

appropriate Bar Bending Schedule will be referenced. The -5 - inspector shall determine that all reinforcing steel isM properly bent, installed in the proper amount and in the* correct location by use of these documents. If rein ='

. forcement is to be bent at the job, the diameter of the

.

pin around which the steel is bent should not be less~

5 than the recoassended values in the Manal of StandardIE

Practice for Detailing Reinforced Concrete Structures,

% ACI 315-65 and the Manual of Standard Practice for3

Reinforced Concrete Construction. CRSI.

6.3 Restrictions on Welding or " Tacking" - Welding or tackingg. will not*be permitted on reinforcing steel. Chairs or4

; w. supports may be fabricated by welding together extrai g reinforcing material or structural steel. Embedmontsg may7 be " tacked" to extra bars whi&h are tied to the,

reinforcing systemi Any reinforcing type steel which is'

| . made into supports by welding or to which embedmen_ts are; g. ,e

y " tacked" must be installed in addition to the reinforcing'

shown on the plans.a,

af* 6.4 Surface of bars - the reinforcing shall be inspected for <

(a) loose scaly rust caused by out-of-door storage, (b) |E,; -

j objectional coatings (c) loose or weak dried mortar. The |ofollowing shall be a guide. !'

(1) some rust is not harmful to the band between concrete,

and steel and no benefit appears to be gained by removing( all of the rust. However, any rust and mill scale which

is not firmly attached should be removed to assure the*

development of good bond.'

' Rust increases the normal roughness of the steel surfaces!

and consequently 'tends to augment the holding capacityof the bar, but it may reduce the effective sectional.area of the bar.

" Bars that appear to have rusted beyond usefulness may be-

checked by cleaning and weighing them for conformancewith Federal Specificatim QQ-S-632.

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; ,,

BY: J F Gregory APPROVED:""*** *CLASSIFICATION: *

- - - - - ... -._=___ - _ . - . . .- .-

.

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DATE. 1-25-74 .A EBASCO SERVICES INCORPold EDPROC 30 Jnt I. n_/..

ISSUE: A . wATERFORD STEAM ELECTRIC STATIOS 4 UNIT NO 3 PACE: 6 0F 8*. ->*

Usually normal handling is sufficient for removal ofloose rust and scale prior to embedment of reinforcement

' s teel. Ilowever, in some instances it may be necessaryto rub with a coarsely woven sack or to use a wire brush.(Ref. United States Department of the Interior, Bureauof Reclamation, " Concrete Manual" Seventh Edition,'

Page 304)..

(2) Objectionable coatings likely to be found on partsof the reinforcing are paint, oil, grease, driedmud and loose or weak dried mortar which has beensplashed on the bars ahead of concrete being placed.

,1 ,0bjectional coatings shall be removed.

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BY:J y cm _ APPROVED:CLASSIFICATION: Concrete .

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DATE *1-25-74 Q 4.04.rN EBASCO SERVICES INCORPORF ''D.

PROC NO.

ISSUE: A . WATERFORD STEAM ELECTRIC STATION '- UNIT HO 3 PAGE: 7 0F 8'i.

, -D.*

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: 6.0 REINFORCDfENT (continued),

6.6 Continuous Inspection - As for inspection of other operations,*

the inspector should not wait until reinforcenent'has been,

wired substantially in place before checking the correctness,

, ,

j of its position, but to avoid costly mistakes he should i

j inspect it as early as possible during its placing. He;,., . , ,

should at this time check the size and spacing of bars,'

correctness of bends, clearance between bars and forms, and- security of supports and ties. Values for the judgment of :

these items will be found in the pl.ans and specifications I;'

w' or in the CRSI Roccamiended Practical for Placing Reinforcing

g Bars. . .,

,

| E 6.7 Splices - No splicing of bars shall be permitted excepti| $! where shown on the drawings. Mechanical splices (Cadwalds)] d will be inspected in accordance with Procedure QC 4.2.1-1

i~g (Reinforcing Steel Mechanical Splice Inspection), however,'

preplacement inspection for concrete should.* assure thatR these splices have indeed been made in all places where<

j 0 they are indicated on the plans and that they have beenk, accepted by the Quality Control Supervisor.!

! ug 6.8 Supporting Reinforcing - All steel reinforcement shall beg accurately located in the forms and firmly held in place

; :*, c before and during the placing of concrete, by means of) Mi built-in concrete blocks, metallic supports, spacar bars,j h wires, or other devices adequate to insure against displace-

ment during construction and to keep the steel at the properi **

h distance from the forms. Bar supports and spacers shall be!

i sufficient in number and sufficiently constructed to carryproperly the steel they support, aven when subject to

- construction loads. Supports on the gro m d shall be8, adequate to prevenc settling. There shall be no metallicg, support closer thma 2" from the grotsid.i

] Wire used in tying bars should not be smaller than 18re sage. Where wire ties are used, the twisted ends should4

be made to project away from an exterior surface.g' .,

i o' .,

( 7.0 DiBEDDED FIXTURES *,

i b 7.1 General Inspection - Anchor bolts, inserts, pipe sleeves,pipes, conduits, wiring, flashings, manhold-cover frames,'

,t instrumentis, and other embedded fixtures and mechanical.*

| equip ===t shall in general be fixed firmly in plan! location before concrett is placed. Preparation of contact,

.

surfaces depends upon whether or not bond with the concretej is desired.a habedmonta shall not be permitted to affect

the position of metal reinforcement except as shown on; .

! the pisms.

I.

*i

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. r

CLASSIFICATION: Concrete .BY: J F Cregory APPROVED:*

; . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . _ _ . _ , _ _ _ _ . _ . . _ . . . . _ _ . . . . _

,

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_ _ _ . _ _ _ _ _ , _ . . _ . , . . _ . _ _ _ _ _ , ~ . _ . - - , , _ _ _ . - . . . , , , _ _ _ _ , , , -____-___.___.____.m..,. ,.,._ -,_.,,.... m, , , ~ . .

. . _. . . - . - . - - -. . . - - - -. ._. _ _ .

i4,

DATre 1;25 74 n EBASCO SERVICES INCORPOKA"'ED PROC MQJQC 4.0-4> -

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ISSUE: "A %ATERFORD STEAM ELECTRIC STATI0h - UNIT NO 3 PACE: 8 OF n,. .

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7.0 DiBEDDED FIXTURES (continued)

| 7.2 Waterstop - Installation of waterstop in forms is ,co beaccomplished by nailing or using wire. Holes made in the4 ,

i end bulb' portion of the waterstop need not be mended. Holes.

.

through the web portion and center bulb may be made only'

i with the approval of the Quality Control Engineer and shall.. .,' be mended with cement. Waterstop shall be firmly attached

and inspected for proper embedment and location.

i 7.3 Additional Openings - Where conditions require additionalmi openings not shown on the plans, proposed openings shallj' be approved by the Engineer. All except very small

,' openings-should be protected by short diagonal bars so

E placed as to carry the stresses around the opening.% Reference 8 gives recoassendations regarding permissible !

,

;

re- openings in construction.

h'

'

,

I 8.0 EKPANSION JOINTS

8.1 General Inspection - The inspector shall ensure that !expansion and contraction joints are installed according

g. to the plans and specifications and are located correctly.

5,

..

$ 9.0 DOCUMENTATION '

i 5* 9.1 construction Documentation - A docuraent referred to as a |i

| k concrete preplacement checkout card will be provided by the !

a contractor or Construction Department. This card is

g ~ ~maintained near tha forms to provide a constant status i

g -

' Quality Control document. The placement checkout cardcheck for concrete' placement prepdrations and is not a l

*

| y; should be signed by the Concrete Quality Control Supervisor.,

F or his designee when he is satisfied that concreteplacement 'mey proceed; but' if' placement is not made withina:

M 24 hours, he must again satisfy himself that the quality

{E|control features for that placement have been maintained!

1~

and must again sign the placement checkcut card.1 < l

9.2 Quality control Documentation.- A concrete preplacement |g5;

inspection record must be prepared by the inspectors and jj signed by ,the Concrete Quality Control Supervisor. This'

, ,

} record is a quality control department document and must jbe signed by the Concrete Quality Control Supervisor or j

his designee before he or his designee signs the 1, ,

1 aforementioned preplacement checkout card provided by the 1

construction group. The concrete preplacement inspection j

record will then be routed through the Resident Engineer's*

office before going to the quality control file.

| .

i + '

! . ,

i CLASSIFICATION: Concrete BY:y , % ,_ APPROVED:,

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j C0tlCPtrE PRE p! ACE *E!!T_INSPECTIOtt 2ECORD Shatt 2 e's 3

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llos Dimensions, plan or Sketch Inspector's'

2.0 FonHS (Cont'd) Reetrks, Etc th ,Stanature Date

,

2.6 Blockouts approved for dimensions ,.

* W/ / f'' ,

'

j/2.7 Dirt and waste cleaned from inside of form .i

' /f /*'.

2.8 Cleanout openinge closed / ,// j,,

3.0 REIllFORCIfC dNian e and size of base are according Y~

3.2 Properly tied (not welded or " tacked") (.'. g

'

3.3 Clearance from forms approved g

3.4 Cover over top of reinforcing approved (3.5 Spitees are correct leastli

(.) 3.6 Indicate number of mechanical splices a( j,

- y.y ,

3.7 Indicate trade et reinforcing steel# '

Steel checked for mud, grease, o!! or3.8 loose scaly rust

* .

4.0 Dia GD G ITDtS.

4.1 Indicate sizes of waterstop required

.*

|

4.2 Waterstop properly installed 8. supported .

* ,*

r'~Notes F111 all spaces - see "NA'' where iten le not applicable i

s

f

Fe34 Page 2 (1/15/73) llav. 1-2 4-74

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_-_ - _ _ _ _ _ . _ _ - _ _ _ _ _ - _ _ __ __________ _ _ _ _ _ _ _ _ . _ - _ _ _ _ _ _

*...

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CollCRhTE FKE Pi ACIMEt47 IkSFECTIC' RE2RD|

.'

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Noe - Dimenolone, Flen or Sketch Inspector's4.0 DiBEDDED ITDt3 (Cont'd) Remarke, Etc 13 o . Signature Date

4.3 Floor drein piping

. Y'

'

4.4 Fressure Piping hAs, ye' .

. ' 'i 4.5 Electrical conduit /.k ! '-'.

4.6 Cround wire .%. !.: asg v i~

4.7 Anchor Bolte N kIV:6k,y~tt 4.g habedded Flates A ,

*

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4.9 Fipe Sleeves ,

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4.10 Construction Fiping Fenetrations . g ''

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|.4.11 Expension or contraction Joints or devices I

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