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NRC INSPECTION MANUAL RII

INSPECTION PROCEDURE 88132

STRUCTURAL CONCRETE ACTIVITIES

PROGRAM APPLICABILITY: 2630

88132-01 INSPECTION OBJECTIVES

01.01 To determine whether the technical requirements detailed or referenced in the

Construction Authorization Request (CAR); the U.S. Nuclear Regulatory Commission,

Safety Evaluation Report (SER); and the approved Mixed-Oxide Project Quality Assurance

(QA) Plan (MPQAP), associated with structural concrete construction and quality control

(QC) for Seismic Category I (SC-I) and SC-II structures, have been adequately addressed

in the licensee and/or contractor construction specifications, drawings, and work

procedures, and whether the established system of management controls is adequate.

01.02 To determine whether QA plans, instructions, and procedures for structural

concrete construction activities have been established in the facility QA manual.

01.03 To determine, by direct observation and independent evaluation, whether work and

inspection performance relative to structural concrete construction activities are being

accomplished in accordance with design specifications, drawings, and procedures.

01.04 To determine whether the licensee system for preparing, reviewing, and

maintaining records relative to structural concrete construction activities is functioning

properly, and to determine whether the records reflect work accomplishment consistent

with specifications and procedures.

01.05 To determine, by direct observation of work activities and review of records,

whether inadequacies in work activities, associated with structural concrete construction

activities, indicate any potentially generic problems, management control inadequacies, or

other weaknesses that could have safety significance.

88132-02 INSPECTION REQUIREMENTS

02.01 For each onsite organization with QA or QC responsibilities regarding structural

concrete construction activities, the inspector should refer to the appropriate 

Mixed-Oxide Fuel Fabrication Facility QA inspection procedures. If there are multiple

contractors with QA/QC responsibilities in this area, inspect a sample, using engineering

judgment, regarding the safety significance and the complexity of each work activity.
88132 - 2 - Issue Date: 10/25/06

02.02 Review the construction specifications related to structural concrete construction

and ascertain whether the specified technical requirements conform to the commitments

contained in the CAR. Review concrete construction procedures and verify that they

specify provisions for adequate on-site engineering direction, are appropriate and adequate

related to procurement and use of materials, specify adequate control of hold points, and

provide adequate controls for design changes and incorporation of design changes into

as-built drawings. Determine whether appropriate and adequate procedures in the

following areas are compatible with the QA program, and prescribe adequate methods to

meet the construction specifications, where applicable:

a. Qualification of materials (cement , water, aggregate, and admixtures).

b. Concrete mix design.

c. Concrete batch plant.

d. Preplacement activities (concrete forms, rebar and splices, embedded items,

cleanliness, and inspection).

e. In-process testing of plastic concrete (slump, entrained air, temperature, unit

weight, and cast cylinders).

f. Concrete placement activities and inspection of concrete placement activities.

g. Post-placement activities (adequate curing and identification and repair of defects).

h. Evaluation and review of concrete test results.

i. Engineering direction.

j. Qualifications of QC personnel.

02.03 By direct observation of concrete work activities for SC-I and SC-II structures

(including the Emergency Generator Building and other civil structural systems described

in Chapter 11 of the CAR), ascertain whether the following applicable structural concrete

construction activities are being controlled and accomplished in accordance with the

requirements of the documents reviewed in 02.02, above:

a. Qualification of materials - Review the qualification testing for the materials

(cement , water, aggregate, and admixtures) selected for use in the concrete.

Review the qualification tests for other hardware associated with structural

concrete, such as reinforcing steel, rebar splices, curing compounds, embedded

items, etc.

b. Concrete mix design - Review the concrete mix designs, supporting material

qualifications, and testing to be used in SC-I AND SC-II structures. If more than

three concrete mix designs are used, review a sample of the highest strength or

most-used mixes, and the associated material qualifications. Rereview may be

necessary if significant mix changes are made during construction, or if sources

of concrete materials are changed.

c. Concrete batch plant. Verify the following:

1. Batch plant has been inspected and certified to National Ready Mixed

Concrete Association standards. Scales and meters are calibrated at

necessary frequency and to specified tolerances. Mixer-efficiency tests are

being performed in accordance with American Society for Testing and

Materials (ASTM) C-94, at proper interval. Batch plant is inspected to verify
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equipment performs properly - rotation speed, timing, and blade wear are not

excessive. There should be no contamination of materials or concrete mix.

Batch records are generated, controlled, and indicate placement location,

mix, volume, date, time, and special instructions.

2. Materials are properly qualified and traceable to approved sources. Storage

and handling of materials are controlled:

- Cement (and fly ash, if used) are protected from moisture;

- Aggregate is not subject to excessive segregation of sizes or contamination

from debris, dirt, other materials, or mixing with other sizes of aggregates;

- Admixtures are prevented from freezing; and

- There are provisions for production of concrete in hot weather (replacing

water with ice in concrete mix) and cold weather (heating mix water).

3. Batch water-quality requirements are met and water is adjusted to account

for moisture-content of aggregates. Aggregate moisture-content tests are

representative of actual stockpile conditions and are taken periodically,

during daily concrete production.

4. Concrete transporting equipment is suitable and in an acceptable condition.

d. Preplacement activities (concrete forms, rebar and splices, embedded items,

cleanliness, and inspection). Verify the following items have been implemented:

1. Reinforcing steel and embedments, such as anchor bolts, waterstops, or

embedded plates, are installed in accordance with specifications, codes,

drawings, and procedures. Reinforcing steel size, spacing, lap and

mechanical splices, and embedments, are located properly within the forms,

are secured and clean (i.e., free from oil, paint, weak dried mortar, dried

mud, loose rust, etc.) and have proper clearances. The areas where

embedded plates with anchors such as Nelson studs are to be set in

concrete should have sufficient concrete to provide bond and should not be

excessively congested with reinforcing steel. Reinforcing steel bending is

properly performed and controlled. Piping or conduit embedments in or

through concrete should be capped or plugged before to concrete

placement.

2. Mechanical Rebar Splices. Verify the following:

- Process (e.g., cadweld or bar-lock couplers) and crews are qualified.

- Each splice is defined by materials used, location, crew, type of splice, and

heat number (if applicable).

- Sampling and testing are performed at proper frequency and acceptance

criteria are defined.

- Inspections are performed during and after splicing by qualified inspection
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personnel.

3. Preplacement planning and training have been completed, as required, to

ensure good-quality construction, and to protect against unplanned

construction joints.

4. The placement has been cleaned and joint preparation is as specified in the

construction specification. Locations of construction joints are as shown on

the drawings. Forms are secure, leak-proof, and free from water, ice, or

snow. 

5. The QC pre-placement inspection should be completed before any concrete

is placed. Records should document that all preplacement inspections have

been completed.

6. The equipment to deliver concrete to the actual placement location is

suitable and in an acceptable condition - conveyors, lines, pumps, buckets,

etc. Ensure that there are enough concrete vibrators on hand, with extras

on standby, for consolidating concrete. Sufficient access available to

placement location for vibrator operators, concrete placement equipment,

inspection personnel, and other craftsman. Adequate preparations for

curing, protection from rain, and hot or cold weather protection are

completed before the start of concrete placement activities.

e. In-process testing of plastic concrete. The following items should be verified in the

review of the testing program conducted during concrete placement:

1. Concrete is sampled at the proper frequency for determination of

temperature, slump, air content, and unit weight. 

2. Taking of a sample and testing techniques conform to the procedures

specified in applicable ASTM standards. Samples for pumped concrete are

required to be obtained from the end of pump line, at point of placement. 

3. Test specimens (cylinders), for concrete strength testing are sampled at the

required location and frequency. Cylinders are molded, handled, and cured

in accordance with specified requirements. Curing boxes are available to

properly store and cure cylinders for the first 24 hours, per the requirements

of ASTM C-31.

4. Testing apparatuses in the onsite laboratory used to perform testing on

materials and plastic concrete are being calibrated at the required frequency.

 Observed testing conforms to the procedures specified in the ASTM

standards.

5. Personnel performing sampling and testing are trained and qualified.

6. Concrete-testing personnel have authority to reject concrete batches not

meeting specification requirements.
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f. Concrete placement activities. The following items should be verified during

observation of concrete placement activities:

1. Concrete batch tickets are reviewed for verification of proper mix, placement

location, and amount of water, if any, withheld from the batch. The quantity

of withheld water, also referred to as retempering water, is determined based

on the maximum water-cement ratio. Time limit (normal maximum of 1.5

hours) between mixing and delivery has not been exceeded, and the total

number of revolutions of the truck mixer does not exceed 300. (See ASTM

C-94.)

2. Specification temperature limits have been met.

3. Addition of superwater-reducing (super plasticizers) admixturers to concrete

batches are controlled. When admixtures or withheld water are added after

concrete is discharged from batch plant, remixing in the truck for a minimum

of an additional 30 revolutions of the truck mixer is required to conform to

ASTM C94, on uniformity of mix. After addition of super plasticizers or

withheld water and remixing, slump tests should be performed to confirm the

slump is within specification limits.

4. Placement drop distances do not exceed specification requirements and do

not result in segregation.

5. Vibrators are approved, tested for frequency, and are used properly by

trained individuals.

6. Special attention is given to areas of high reinforcing or embedment steel

congestion, to preclude areas of voids or honeycombing.

7. Inspections during placement are performed as required and by qualified

personnel.

8. Records are produced, reviewed, and indicate mix, location, time placed,

water additions, and temperature of the concrete mix and ambient conditions.

Records reflect the results of inspections, the actual field conditions, testing

frequency requirements, and that data calculations are checked.

g. Post-placement activities (adequate curing and identification and repair of defects)

1. Verify that curing is performed in accordance with specifications and

procedures with regard to the method, materials, duration, temperature

(concrete and ambient). Verify that inspections (during curing and after form

removal) are performed and documented in QC records.

2. Verify that concrete placements are inspected after form removal to identify

any defects in concrete. Examples of defects are voids (honey comb), cold

joints, excessive cracking, delaminations, excessive entrapped air voids

(bugholes), or evidence of form-related defects such as sand streaking or
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inadequate bracing. All identified defects require documentation, evaluation,

and repair, in accordance with the licensee’s QA program. 

h. Evaluation and review of concrete test results

Verify that the final inspection results after form removal, test results, and other

information related to the placement (including deficiencies, defects, etc.) have

been reviewed before acceptance of the placement, and that the as-built

documentation is complete. Verify test results are evaluated at an appropriate level

and evaluation includes trending analysis. All non-conforming conditions identified

during concrete construction activities require documentation, evaluation, and

repair, in accordance with the licensee’s QA program. 

i. Engineering direction. 

Verify that engineering direction is available, onsite, to monitor structural concrete

construction activities. The onsite engineering staff should be supplemented by an

experienced structural engineer to approve design changes, monitor and review QC

test results, and identify changed conditions. The onsite engineering staff should

be involved in disposition of nonconformance reports, and preparation of field

change requests, for approval by the design-engineering organization. 

j. Qualifications of QC personnel

Verify that personnel qualifications (education and experience) of testing and

inspection personnel have been verified by the employing organization. Personnel

qualifications must be supported by documentation. Conduct informal interviews

with QC inspection personnel to determine how well the QC inspectors know the

requirements of their work activity. Also, obtain a sense of the degree of the

adversarial or intimidating relationship QC inspection personnel have with the

construction forces. Any perceived lack of management support should be

identified and discussed with Regional management. Ascertain whether a sufficient

number of adequately qualified QC personnel are at the construction site,

commensurate with the work in progress, and adequately performing their assigned

duties through the established organizational structure.

02.04 Special Considerations - The following items should be incorporated in the inspection

of concrete placements when appropriate (refer to American Concrete Institute standards

for additional guidance):

a. Hot and Cold Weather - Provisions for maintaining concrete temperature within

specification must be provided. Hot - - cold weather conditions must be defined,

to avoid confusion.

b. Pumping Concrete - Slump and air-content losses must be monitored to ensure

placement and adequate consolidation. Samples for pumped concrete are required

to be obtained from end of pump line, at point of placement.

c. Large Placements - Planning sessions must assure consideration of all
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contingencies, [e.g., adverse weather, loss of power, concrete production delays

(batch plant breakdowns)].

02.05 Determine whether the licensee has an established audit program (including plans,

procedures, and schedule) covering the SC-I and SC-II work control functions, in the area

of structural concrete construction activities. An audit program should review by examination

of objective evidence that construction personnel who perform structural concrete

construction work are qualified to perform their assigned work.

02.06 Review the documentation generated for structural concrete construction activities.

Determine whether the licensee/contractor system for documenting safety-related work is

functioning properly. The record-keeping activities should reflect the actual conditions

encountered in the field and provide adequate documentation of work and inspections.

Determine whether records are being maintained, reviewed, and approved, as specified.

This is important in activities such as review of concrete strength. A comparison of the

actual concrete strength can help in determining the reason for low strengths relatively early

in the construction phase, before the completion of extensive concrete work. Records

should include sufficient detail to document that: (1) rebar installation met requirements; (2)

the concrete strength meets design requirements; (3) curing was adequate; and (4) repairs,

if necessary... completed in accordance with design requirements. Records should be

legible, complete, reviewed by QC and/or engineering personnel, and readily retrievable.

Review a sample of the following records:

a. Receipt Inspection and Material Certification. 

Applicable for materials purchased from offsite suppliers, such as cement, concrete

aggregate (sand and gravel), concrete admixtures, and reinforcing steel, splices,

and other components. Records confirm that required material characteristics,

performance tests, nondestructive test, and other specification requirements were

met.

b. Installation Inspection.

1. Records confirm that concrete production, concrete placement, and

installation of components were performed as specified.

2. Records confirm that the required inspections (including concrete form

removal) were performed and acceptance criteria defined.

3. Records indicate specified concrete strength was obtained.

c. Nonconformance/Deviation Record - Records include current status of these items.

Nonconformance reports include the status of corrective action or resolution e.g.,

if adequate corrective action were taken when concrete vibration was determined

to be inadequate, or concrete strength-test results were not within acceptance

criteria.

d. Training/Qualification Records of Craft, QA, and QC Personnel - Records establish

that QA/QC personnel are adequately qualified to perform their assigned duties and
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responsibilities and that craft personnel have been trained in their assigned tasks.

Records are complete and current and show which activities inspectors are

qualified to perform.

e. QA Audits - Records establish that the required audits were performed and that

deficiencies identified during audits were corrected, and that corrective action was

such that repetition of the deficiency, or similar deficiencies, would be precluded.

88132-03 INSPECTION GUIDANCE

General Guidance. 

Applicable portions of the CAR, the SER, and approved MOX Project QA Plan should be

reviewed to determine licensee commitments regarding construction and inspection

requirements, before performing this inspection. The inspector should then use these

documents during the review of the construction specifications, drawings, work procedures,

and QA implementing procedures. Structural concrete construction activities should also

be reviewed to ascertain they are consistent with standard industry practices.

The American Concrete Institute "Manual of Concrete Inspection" is a good reference,

which should be used during the conduct of this inspection. However, the licensee's

specific documents, which include specifications, drawings, and procedures, specify and

control the construction and inspection processes.

Because of the difficulty in performing remedial work and inspections on completed

concrete structures, the first use of safety-related concrete should receive special emphasis.

In most cases these first use safety-related activities will be associated with large basemat

structural concrete foundation placements. Periodic observation of concrete placements,

as required in Section 02, above, will provide assurance that conformance to applicable

requirements is being accomplished.

Selection of placements to be observed should provide for diversification of placement type

and importance to safety. Placement types to be selected should therefore include:

- Basemats;

- Building walls (early and late placements, which contain numerous openings, are

heavily reinforced, and contain numerous embedded items (pipe sleeves, embed

plates, conduit, waterstops, etc.);

- Roof slabs; and

- Columns, shear walls, beams, and slabs.

Before any concrete placement, a specific technical review of concrete-mix designs and

supporting material qualifications should be performed. The inspectors should also verify

that the batch plant has been inspected and certified before placement of any safety-related

concrete. QA/QC inspection and construction procedures should be reviewed and
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compared with the requirements of the applicable codes and construction specifications.

The technical adequacy of implementing construction and QC procedures must be

determined. For these reasons, this inspection procedure should be performed by an

inspector who is able to evaluate civil engineering activities. The inspector should use

judgment in determining sample selection during inspection activities. Sample selection

should reflect the importance of the activity to safety. The inspectors at various stages of

completion, should observe work and independently verify critical activities, such as rebar

placement, cleanliness of concrete forms, and dimensions etc. and the inspectors should

also observe testing activities performed in the onsite testing laboratory.

The licensee is responsible for implementing or having implemented, the approved QA

program and the commitments described in the CAR . The inspector must determine if this

program is implemented in an adequate and timely manner for the work that is important-tosafety. QA/QC procedures must provide for effective inspections which will ensure that

work is performed in accordance with specification requirements. Laboratory and fieldtesting procedures must provide for verification of correct material usage and correct

selection of reference standards. The afore, testing procedures should include a prohibition

against contractor QC personnel from making a discretionary selection of inspection and

testing parameters. Qualified personnel should review test results and determine if results

are acceptable. Construction procedures must reference the required inspection hold

points and must also address the QA/QC department stop-work authority.

Specific information about the licensee's plans and schedules for performing

comprehensive audits and on-going surveillance of concrete construction activities should

be reviewed during this inspection. Information should be obtained concerning audit

procedures, schedules, scope, and auditor qualifications. Licensee onsite QA staffing and

surveillance plans should ensure that QC activities are sufficiently monitored and evaluated.

QA audits should identify procedural inadequacies and the root-cause of repetitive

nonconforming conditions. Inspections should require verification of specified controls and

should not be accomplished merely by surveillance. Evaluations should result in an

indication that all quality-related construction and inspections will be adequately performed

by qualified personnel and will be based on appropriate criteria and further, that the results

of inspections will be transmitted to responsible QA and management personnel. 

Findings from this inspection activity should address each element as being satisfactory,

unresolved and/or requiring resolution, or in violation and requiring correction. When

significant inadequacies are identified in specifications or procedures indicating weakness

within the preparing organization, the inspector should inform cognizant regional

management. The issue should be addressed at the appropriate level of licensee

management.

Some general guidelines to determine how the project is actually being run, regarding to

design-construction interfaces, construction discipline interfaces, and the control exercised

by the licensee, are listed below. The list is not intended to be all-inclusive but to provide

some highlights regarding this subject.

1. Check design documents (specifications, drawings, etc.) for evidence of

coordination with other disciplines and designers, suppliers, and contractors which

address items such as embedded piping, and electrical, mechanical, and major-
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equipment supports.

2. Examine how well the design office is permanently represented at the site and if the

representatives spend time out in the work areas. Determine how often design

engineers come on site and actually follow-up at the work site, as part of their

design is being constructed, and determine the methods of interchange between

designer, constructors, inspectors, and managers. Determine how well the

licensee's engineering function is represented by other than permanent personnel.

3. Determine whether field engineering and construction personnel are reviewing

drawings, specifications, etc., released for construction, for errors or omissions, and

inconsistencies with other documents or instructions. Determine the licensee's real

role in this process.

4. Check field-construction progress and release of engineering design drawings,

including the revisions or changes, to determine if the design and the construction

efforts are synchronized; (i.e, after design drawings are released for construction,

design engineering should not make last-minute changes and revisions just before

concrete placements are made, without close coordination with construction).

5. Determine how construction workers and QA/QC personnel view training and how

well training is completed and used at the site.

6. Look at the dynamics of the work force, including the turnover rate, the attitudes in

work crews, and relations between construction personnel and QA/QC personnel.

Look for changes in the organization of the field construction forces, or QA and QC

personnel organization.

7. Look at the controls and coordination exercised when a new work activity begins.

Check the controls used to ensure that all embedded items, including reinforcing,

are, in fact, in place, before concrete placement.

8. Determine whether the construction labor forces also perform their own checks of

work as it is completed, or if they rely solely on QA/QC.

9. Look at how the QA/QC inspectors perform their inspection and check-offs. Is it

done sequentially as work is being done? For example, during reinforcing steel

placement, do they wait until 2 weeks of reinforcing steel placement have been

made, and then, on the day before concrete placement, identify bars placed on day

number 4, in the sequence, as being out of tolerance.

10. Look at the level (experience, training, and number) of supervision during concreteplacement activities.

03.01 Specific Guidance

Note: The numbering of the guidance below refers to specific subsections of 02, above.

02.01 The inspector should review the appropriate version of Subpart 2.5, “Quality
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Assurance Requirements for Installation, Inspection, and Testing of Structural Concrete,

Structural Steel, Soils, and Foundations for Nuclear Power Plants”, of ASME NQA-1.

Specific attention should be given to the QA program needs that may result from distribution

of design and construction responsibilities. Examples of these needs may be: provisions

for adequate onsite engineering direction; appropriate and adequate procedures related to

procurement and use of materials; and adequate control of hold points.

02.02 The construction specification must translate design requirements into details

sufficient to define the technical requirements for concrete construction activities. The

specifications should provide for control of design changes and the issuance of design

change notices. The review of procedures, specifications, and drawings should ensure that

concrete construction and inspection activities are controlled and performed in accordance

with applicable requirements. QA/QC procedures should specify acceptance-testing

requirements and should specify the personnel and interface responsibilities required to

define, control, and resolve field problems or design problems that are evidenced during

construction. QA/QC procedures must provide for effective inspections that will assure that

work is performed in accordance with specification requirements. The procedures should

require verification of specified controls and should not be accomplished merely by

surveillance. Laboratory and field-testing procedures must provide for verification of correct

material usage, correct selection of reference standards, and should prohibit discretionary

selection of inspection and testing parameters. Construction procedures must reference

the required inspection hold points and must also address the QA department authority to

stop work.

02.03a. Qualification of Materials 

Chemical and physical tests for all materials used must indicate that specifications

have been met. Testing needs to be performed at the required frequencies. Tests

results may be provided by the manufacturers via certified materials test reports,

or may be performed at an independent or in the onsite testing laboratory. Test

results should be reviewed for the following materials: 

1. Concrete-mix materials (cement, fly ash, sand, aggregate, water, admixtures,

etc.) and all constituents used in other cement-like materials, such as gunite,

grout, dry pack or manufactured materials such as epoxy;

2. Reinforcing steel;

3. Reinforcing splicing materials;

4. Waterproof membranes, water stops, joint materials and sealants;

5. Embedded mechanical items such as piping, conduit, mechanical and

electrical penetrations (sleeves), sumps, drains, and grating material, etc;

6. Off-the-shelf anchorage components and embedments (bolts, hangers,

inserts, etc.), and embedded structural steel items (shear connectors,

embedded plates, etc.);
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7. Materials used during construction such as for construction joint preparation,

form-release agents, and curing compounds; and

8. Other structural concrete materials that may be used.

0203b. Concrete-Mix Design

A concrete-mix design must be completed for each type/strength of

concrete mix to be used in SC-I and SC-II structures. The mix design

must be completed using the qualified materials (see 02.03a, above),

sufficiently in advance of the planned concrete-placement start dates,

to demonstrate that the concrete mix will satisfy the job requirements for

slump, air entrainment, strength and any other specified parameters.

Test cylinders need to be molded, cured and tested to demonstrate that

the required design requirements will be achieved within the specified

time period (e.g., 7, 28, or 90 days). It is not an acceptable practice to

attempt to base the final concrete design strength on incomplete test

results (e.g., estimating the 28-day strength, based on results of test

cylinders tested at ages of 7 and 14 days). If the sources of materials

used in the concrete are changed, new mix designs need to be

qualified, before placement into SC-1 and SC-2 structures.

02.03c1 Concrete batch plants providing concrete for use at nuclear facilities

must be certified under the NRMCA program. This certification

provides evidence that a registered professional engineer has reviewed

the facility and has seen evidence that certain necessary capabilities

exist to produce quality concrete. Any other batch-plant certification

should include the inspection attributes, listed in the NRMCA checklist,

which are used to inspect the facility before any recommendation for

certification. As part of the certification process, concrete uniformity

testing must be performed in accordance with ASTM C-94, at periodic

intervals. Verify that the batch plant scales have been calibrated

through their full range of use on the project. Water meters and

admixture dispensers also require calibration. During observation of

concrete batching operations, verify that the scales rezero after each

batch. 

02.03c2 Materials need to be properly stored at the batch plant. Non conforming

or unqualified materials are required to be segregated from qualified

materials. Storage of cement and admixtures require control so that

shelf life is controlled and older materials are used before recently

received materials. Cement and flyash are required to be protected

from moisture. Generally, cement should be used within 180 days of

manufacture. Admixtures must be used within the shelf life specified by

the vendor. Admixtures need to be protected from freezing. An

adequate supply of all materials needs to be available at the batch

plant, to complete the placement, with sufficient reserves of materials

to make up for concrete batches that may be rejected because of

noncompliance with specification requirements.
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02.03c3 In regard to water quality, potable water is generally suitable for making

concrete. However testing (chemical analysis) of the water should be

performed to verify that it does not contain impurities that may be

detrimental to the concrete or reinforcing steel. Also concrete should

be batched using the site water and compared to concrete batched

using distilled water. In this test, the normally accepted standard is that

the site water is deemed acceptable if samples batched from site water

do not result in a reduction in strength of more than 10 percent less

than samples batched using distilled water. The moisture content

determination of aggregates is an important test to accurately calculate

the total water in each batch of concrete. Fine and coarse-aggregatemoisture-content testing needs to be performed periodically, throughout

daily concrete production. Frequency of testing will be determined

based on weather conditions and variations in the moisture content.

02.03c4 Trucks used to transport concrete from the batch plant to the job site

need to be inspected to ensure that they are clean and free from

dirt/debris and/or water which could become mixed with, and

contaminate, the concrete. Truck mixers need to be certified in

accordance with NRCMA standards. The certification process also

requires concrete uniformity testing in accordance with ASTM C-94, at

periodic intervals, if mixing of the concrete is performed in the trucks,

or water or other ingredients are added to the concrete batch after the

concrete is discharged from the batch plant. Verify that the drum

revolution counters are operable and reset after each batch is

discharged.

02.03d1 Storage of reinforcing steel should be examined to verify that storage

conditions are adequate to ensure that rebar will not become

contaminated with materials such as mud, excessive rust, grease, oil,

etc., which could affect the bonding of the rebar and concrete.

Completed reinforcement placement should be checked for size,

spacing, splice locations, bending, proper clearances from face of forms

or excavated surfaces (i. e., verify rebar will have minimum required

cover, in addition to the correct “d” distance), and anchorage.

Reinforcing steel needs to be free from oil, grease, paint, loose rust,

dried mud, weak mortar, etc. The steel needs to be firmly held within

the forms (usually tie wire is used), to prevent the rebar from being

displaced by movement of the plastic concrete, or by other construction

activities, such as concrete vibration, or by movement of construction

personnel in the form areas. Particular attention needs to be directed

to installation of column ties, stirrups, and dowels. Verify that other

hardware items to be embedded in the concrete placement are clean,

properly located, and firmly anchored.

02.03d2 For splices, review the mechanical splicing instructions issued by the

vendor. This document usually specifies the proper performance of all
88132 - 14 - Issue Date: 10/25/06

mechanical splicing operations. Ascertain whether it is being used.

1. Cadwelding

When Cadwelding operations are being performed, verify that specified

materials (sleeves, powder, packing) are properly stored, and that

Cadwelding fixtures are in good condition. The reinforcing steel to be

Cadwelded should be cleaned shortly before Cadwelding, to remove all

nonadherent rust. The reinforcing steel ends should be aligned and

butted within the tolerances specified, using the spacers provided with

the cadweld kits. 

Observe the placement of sleeves and the use of a marking system to

ensure centering. When the firing is completed and packing removed,

examine the sleeve and reinforcing steel to ensure that metal is

showing at the vent (no slag at the tap hole), and each end of the

sleeve shows proper fill (allowable void area not exceeded).

Ascertain whether each Cadweld sleeve is identified. By interviews with

two Cadwelding inspectors, ascertain whether they are familiar with the

details of Cadwelding requirements; also determine whether inspection

of Cadwelding conforms to the specified frequency, whether inspection

(QC) records are being maintained, and whether records are traceable

to installation location, and identification of the cadwelder (craftsman).

2. Other types of mechanical splices, (e.g., Bar-Lock splices, if used)

Verify that the NRC has approved use of the type splice. Review the

CAR, SER, and manufacturer’s instructions to determine specific

installation and testing requirements. Review the laboratory test data

used to qualify the splices and verify that the licensee’s installation

procedures will result in an installed configuration that will reflect the

laboratory testing conditions. Typical inspection parameters for all

types of mechanical splices require cleanliness of the ends of the rebar

to be spliced, verification of adequate embedment of the rebar ends,

within the splicing sleeve, and verification that the sleeve is centered

over the ends of both bars to be spliced. Identification of each splice

and the craftsman/crew who completed the splice is also generally

required. All craftsmen are required to be trained. All splices require

inspection and acceptance by qualified QA/QC inspectors. A testing

program will normally be specified to ensure the splices fabricated at

the job site meet design requirements. 

02.03d4 The area where concrete is to be placed needs to be clean and free of

debris. Materials such as sawdust, wood, dried mortar, tie wire, and

other debris need to be removed from the forms before placement of

concrete. Access ports are usually provided in the forms to permit

cleaning and inspection. Water jets and/or compressed air should be

used for cleaning. Forms must be well secured and braced so they will
Issue Date: 10/25/06 - 15 - 88132

not be displaced by the fresh concrete or concrete-placement activities.

The permitted rate of rise of the fresh concrete need to be specified, to

avoid excessive loads on the forms, caused by hydraulic forces from

the fresh concrete. Otherwise, there could be form failures (blow-outs)

resulting in injuries to construction personal and/or damage to safetyrelated structures or components. 

02.03d5 Inspection personnel must inspect pre-placements within a timeframe

that represents the actual conditions before the placement. Quality

control pre-placement inspections must not be unnecessarily rushed by

advancing concrete work, especially during large slab or basemat

placements. When possible, verify the actual as-built condition of

reinforcing steel, with respect to the engineering drawings. If deviations

exist, verify that proper engineering evaluations have been performed.

Records need to document that all pre-placement construction and

inspection activities have been completed. Concrete surfaces (joints)

on which additional concrete is to be placed should be roughened, and

all loose materials removed to ensure good bonding of the new

concrete to existing concrete. 

 

The joints should be kept damp for a specified period, usually 12 to 24 hours, before

concrete placement. There should be no standing water in the forms.

02.03d6 In addition to having adequate equipment available to complete the

concrete placement, extra equipment, such as vibrators, concrete

trucks, and concrete pumps need to be available. Enough personnel

need to be available, to fill in; and to keep concrete placement

personnel from becoming fatigued by long work hours, which could lead

to errors and substandard construction. Necessary equipment needs

to be available to form construction joints on short notice, in case of an

unforeseen stoppage of the concrete placement. Equipment needs to

be available to protect the new concrete from all weather conditions,

including rain, heat and cold. 

 02.03f1 The practice of withholding water at the batch plant and then tempering

at the point of placement should take into account the results of air

content and slump measurements taken at the point of placement.

Efficient radio communications between the batch plant and field QC

testing personnel will minimize the need for water tempering at the point

of placement and thus result in more uniform batching. Check time (90

minutes max) of concrete receipt for truck transported, centrally mixed

concrete, and number of truck-mixer revolutions (300 max). Also,

verify the amount (quantity should be documented) of water added, if

permitted, and re mixing (minimum 30 revolutions). 

02.03f4 Concrete should not strike forms or bounce against reinforcing bars

causing segregation of aggregates from the mix.

02.03f5 There should be a sufficient number of vibrator operators and,
88132 - 16 - Issue Date: 10/25/06

preferably, some spare vibrators, that should be checked for proper

operation, before starting to place concrete. Vibrators less than (3

inches) diameter are generally designed to operate at about 7000-8000

vibrations per minute, when immersed in concrete. Large vibrators,

used in heavy-section concrete placement, operate at about 6000

vibrations per minute. Vibrators less than (3 inches) in diameter can be

operated by one man; (4 inches) or larger vibrators are two-man tools.

Proper vibrator operation involves duration of vibration, distance

between vibrator insertions, and depth of insertions. The vibrators

should be handled and operated vertically and never "cast" away from

the operator horizontally and then retrieved. Concrete should be placed

horizontally, in about (12 inch) layers, and never allowed to pile much

higher in one area of the form than another. The vibrator should

penetrate through the new concrete well into the previously placed

layer, to avoid any "layer-cake" effect. Occasional contact of a vibrator

with the forms is permissible, and with the reinforcement is desirable.

Form vibration is generally not desirable, and care should be taken that

reinforcement is not displaced by vibrators, or by people walking on the

steel. Vibrators should not be used to move concrete laterally. Any

excess water in the forms should be removed and not permitted to mix

with the concrete. 

02.03g1 The concrete needs to be protected from damage and properly cured.

Proper curing requires keeping the surface of the concrete moist, and,

in cold weather, warm, so that hydration of the cement continues until

the concrete achieves design strength. Curing can be accomplished

using moisture (water sprays, etc.) or by use of a curing compound.

However curing compounds should not be used on construction joints

unless they are removed prior to the next placement. Curing

compounds used on construction joints may act as a bond breaker and

result in successive placements not achieving good bond. Minimum

curing times should be specified in the construction records. Formation

of ice (freezing of the curing water) on surfaces of the concrete during

the curing period should not be permitted. Forms need to remain in

place for the period specified in the procedures. The time to remove

the concrete forms is often based on achieving a minimum concrete

strength. 

02.03g2 Defective areas in concrete should be repaired as soon as possible

after the forms are removed. Design engineering approval should be

obtained for all concrete repair methods. It is not acceptable to repair

concrete defects by merely plastering over them with mortar. Concrete

defects need to be cut to a depth to expose sound concrete and filled

with concrete of the same strength as that in the structure. Repair of

defects are usually classified as cosmetic if they are shallow surface

defects, and structural if they extend to a depth below the outer layer of

rebar. Locations of concrete defects and repair methods need to be

documented in licensee inspection records. Note that areas repaired

are required to be protected from the elements and cured to achieve
Issue Date: 10/25/06 - 17 - 88132

adequate design strength. 

02.03h This portion of the inspection may require subsequent followup, to

determine that final inspection, evaluation, and acceptance are being

controlled and accomplished in accordance with QA/QC requirements.

Final inspection procedures should include verifying embed locations

and identification of any defects and required repairs. Review the

results of compressive strength determinations. Verify that results are

being evaluated in accordance with ACI 214, “Recommended Practice

for Evaluation of Compression Test Results of Field Concrete”. During

this portion of the inspection, also review the results of strength tests on

mechanical reinforcing steel splices.

Records should be verified to show that mix specified was delivered

and placed. Structural drawings or specifications will indicate the

design concrete strength. Evaluate the licensee's trending analysis of

nonconforming items and determine if generic items are being identified

and corrected.

02.03j Particular attention should be directed toward the qualification of

personnel and their work performance. In the past, at some projects,

there was a tendency for some organizations to hire untrained

personnel residing near the site who had no prior work experience in

concrete materials testing or inspection, train them, and certify them.

Although the individuals were trained and certified, in some instances

inexperience of personnel and the lack of depth of knowledge was been

found to be detrimental to an effective QA/QC program. Changing of

personnel between different jobs and turnover of personnel can also

result in problems.

In determining the adequacy of QA/QC staffing; the effectiveness of

their activities must be considered. Insufficient or unqualified

personnel, or inadequate management, may result in inadequate

inspections of concrete-construction activities. Capabilities and

effectiveness, rather than only the number of personnel, are the

principal criteria to be used.

02.04a During periods when concrete is to be placed or cold weather is

expected during the curing time, provisions must be made to keep the

concrete above [40EFahrenheit (F)], preferably in the range of [(50 to

60EF)]. If concrete is being mixed or transported in weather below

(40EF), the ingredients may be pre-warmed so that the temperature of

the concrete after placement is elevated to account for losses. Heating

the water is the most effective and most easily controlled technique, but

the aggregate must not be frozen. The water should not be so hot as

to cause "flash set" of the cement during mixing; that is, the

temperature of the mortar should not exceed (100EF). If hotter water

is required to warm the aggregate, the water and aggregate may be

mixed before addition of cement. If the aggregate is heated, close
88132 - 18 - Issue Date: 10/25/06

control must be exercised, and the aggregate must be frequently

checked for variations in moisture content caused by local variations in

heating. Direct fired heaters may produce carbon dioxide, in the

exhaust fumes, forming calcium carbonate on the surface of fresh

concrete. Also, use of chemicals should not be permitted to accelerate

the concrete set times in cold weather.

Where the ambient temperature during concreting rises much above

(70EF), consideration must be given to the effect of high temperatures

on the concrete. Although concrete cured at temperatures up to

(100EF) gives higher early strength, with little degradation of long-term

strength, high temperatures during mixing, transportation, and

placement can be seriously detrimental. The most obvious effect is that

the concrete requires more water for work ability or the use of additives.

A less obvious effect is the need for special attention to curing, because

the higher temperature increases water evaporation from the concrete.

Exposure to strong summer sun can raise the temperature of ingredients, equipment, forms, etc., far above the air temperature. If this

occurs, provisions should be made for appropriate shades or screens,

and the equipment, forms, and metallic embedments, etc., should be

wetted just before concrete placement. If the ambient temperature is

high enough so that the bulk temperature of freshly mixed concrete

exceeds (80EF or 90EF), consideration should be given to some method

of cooling the ingredients, such as chilling the water, or using ice. If ice

is used, it must be crushed or flaked so that all the ice is melted by the

time mixing is completed.

03.02 Prevalent Errors and Recent Concerns

a. This section is included to provide background, for inspectors, on past structural

concrete problems that have been identified and on certain areas that should be

more closely scrutinized, so as to give NRC early information on potential problems.

The following are potential problems identified as concrete-related violations at

previous projects. (Note - These are not listed in order of their perceived

importance to safety.)

1. Inadequate QA/QC records documenting concrete work activities.

2. Improper use of vibrators.

3. Exceeding allowable time to place concrete.

4. Improper sampling of aggregates.

5. Improper curing of concrete test cylinders.

6. Exceeding allowable concrete temperatures.
Issue Date: 10/25/06 - 19 - 88132

7. Materials improperly certified.

8. Concrete cylinder compression test records exceed allowable coefficient of

variation.

9. Improper splicing practices (reinforcement cleaning, alignment, gage marks,

thread damage, and inadequate swagging force, etc.).

10. Inadequate concrete curing.

11. Samples of concrete not taken where and when required.

12. Excessive doses of concrete admixtures.

13. Inadequate cleanliness of placement.

14. Omission of reinforcing steel, incorrect spacing of reinforcing steel, and/or

improper anchorage (failure to firmly tie the rebar) of the steel.

15. QC inspections not done conscientiously.

16. Excessive drop of concrete.

17. Batch plants improperly qualified.

18. Improper repair of concrete defects.

19 Intentional violation of work procedures by craft personnel to avoid rejection

of their work, or to simplify their work. Examples included melting of tie wire

into ends of completed cadwelds, unauthorized addition of water to concrete,

and covering concrete defects (honeycomb) with mortar to prevent detection

by QA/QC inspectors 

20 Construction personnel and supervision intimidation of QA/QC inspectors. 

03.03 Background Information. This information is to be used as reference material,

however, the site specifications govern. The information may be valuable in

discussions about the adequacy of the specifications.

88132-04 RESOURCE ESTIMATE

This inspection procedure is expected to take, on the average, 24 to 32 hours for each

review of licensee/contractor activities. This procedure should be performed every 3

months. During the first year of placement of SC-I and SC-II concrete, select at least two

placements. Thereafter, select at least two placements per year. Regional Management

should use inspector observations regarding the relative complexity of required SC-I

concrete work activities and observed competency of licensee and contractor personnel.
88132 - 20 - Issue Date: 10/25/06

88132-05 REFERENCES

Duke, Cogema, Stone and Webster, “Mixed-Oxide Fuel Fabrication Facility, MOX Project

Quality Assurance Plan (MPQAP)”, Docket Number 070-03098, under US Department of

Energy Contract DE-AC02-99-CH10888, latest revision accepted by NRC.

Duke, Cogema, Stone and Webster, “Mixed-Oxide Fuel Fabrication Facility Construction

Authorization Request”, latest revision accepted by NRC.

Code of Federal Regulations 10 CFR Part 50, Appendix B, “Quality Assurance Criteria for

Nuclear Power Plants and Fuel Reprocessing Plants”.

Code of Federal Regulations 10 CFR Part 70, “Domestic Licensing of Special Nuclear

Material.”

Code of Federal regulations 10 CFR Part 21, “Reporting Defects and Noncompliance.”

U.S. Nuclear Regulatory Commission Regulatory Guide 1.28, “Quality Assurance Program

Requirements (Design and Construction)”, Revision 3.

American Concrete Institute (ACI)

ACI 116 “Cement and Concrete Terminology.”

ACI 117 “Standard Specification for Tolerances for Concrete Construction and

Materials.”

ACI 211.1 “Recommended Practice for Selecting Proportions for Normal and

Heavyweight Concrete.”

ACI 212.1 “Admixtures for Concrete.”

ACI 212.2 “Guide for Use of Admixtures in Concrete.”

ACI 212.4 “Guide for Use of High-Range Water-Reducing Admixtures

(Superplasticizers) in Concrete.”

ACI 214 “Evaluation of Strength Test Results of Concrete.”

ACI 221 “Guide for Use of Normal Weight and Heavyweight Aggregates in Concrete.”

ACI 301 “Specifications for Structural Concrete.”

ACI 304 “Guide for Measuring, Mixing, and Placing Concrete.”

ACI 304.2 “Placing Concrete by Pumping Methods.”

ACI 305 “Hot Weather Concreting.”
Issue Date: 10/25/06 - 21 - 88132

ACI 306 “Cold Weather Concreting.”

ACI 308 “Guide to Curing Concrete.”

ACI 309 “Guide for Consolidation of Concrete.”

ACI 311 “Recommended Practice for Concrete Inspection.”

ACI 311.1 “ACI Manual of Concrete Inspection.”

ACI 311.4 “Guide for Concrete Inspection.”

ACI 311.5 “Guide for Concrete Plant Inspection and Testing of Ready Mixed Concrete.”

ACI 315 “Details and Detailing of Concrete Reinforcement.”

ACI 318 “Building Code Requirements for Structural Concrete.”

ACI 347 “Guide to Formwork for Concrete.”

ACI 349 “Code Requirements for Nuclear Safety-Related Concrete Structures.”

ACI 359 “Code for Concrete Reactor Vessels and Containments, Section III, Division

2."

ACI 503 “Use of Epoxy Compounds With Concrete”

ACI 503.4 “Standard Specification for Repairing Concrete With Epoxy Mortar.”

ACI 504 “Guide to Sealing Joint in Concrete Structures.”

ACI 530-02 “Building Code Requirements for Concrete Masonry Structures.”

American Society of Mechanical Engineers (ASME)

ASME NQA-1 “Quality Assurance Requirements for Nuclear Facility Applications.”

ASME NQA-2 “Quality Assurance Requirements for Nuclear Power Plants.”

American Welding Society (AWS)

AWS D1.1 “Structural Welding Code.”

AWS D1.4 “Structural Welding Code - Reinforcing Steel.”

American Society for Testing and Materials

ASTM A-615 “Deformed Billet-Steel Bars for Concrete Reinforcement.”
88132 - 22 - Issue Date: 10/25/06

ASTM A-706 “Standard Specification for Low-Alloy Steel Deformed Bars for Concrete

Reinforcement”.

ASTM C-29 “Test for Unit Weight of Aggregate.”

ASTM C-31 “Making and Curing Concrete Compressive and Flexural Strength Test

Specimens in the Field.”

ASTM C-33 “Standard Specification for Concrete Aggregates.”

ASTM C-39 “Test for Compressive Strength of Molded Concrete Cylinders.”

ASTM C-94 “Standard Specification for Ready Mixed Concrete.”

ASTM C-109 “Standard Method of Test for Compressive Strength of Hydraulic

Cement Mortar (Using 2-in. Cube Specimen).”

ASTM C-117 “Test for Materials Finer Than No. 200 Sieve in Mineral Aggregates by

Washing.”

ASTM C-127 “Test for Specific Gravity and Absorption of Coarse Aggregate.”

ASTM C-128 “Test for Specific Gravity and Absorption of Fine Aggregate.”

ASTM C-136 “Test for Sieve or Screen Analysis of Fine and Coarse Aggregates.”

ASTM C-143 “Test for Slump of Portland Cement Concrete.”

ASTM C-150 “Specification for Portland Cement.”

ASTM C-171 ‘Specification for Sheet Materials for Curing Concrete.”

ASTM C-172 “Sampling Fresh Concrete.”

ASTM C-173 “Test for Air Content of Freshly Mixed Concrete by the Volumetric

Method.”

ASTM C-192 “Making and Curing Concrete Test Specimens in the Laboratory.”

ASTM C-231 “Test for Air Content of Freshly Mixed Concrete by the Pressure

Method.”

ASTM C-260 “Standard Specifications for Air Entraining Admixtures for Concrete.”

ASTM C-309 “Specification for Liquid Membrane - Forming Compounds for Curing

Concrete.”

ASTM C-494 “Standard Specification for Chemical Admixture for Concrete.”
Issue Date: 10/25/06 - 23 - 88132

ASTM C-566 “Standard Method of Test for Total Moisture Content of Aggregate by

Drying>’

ASTM C-642 “Test for Specific Gravity, Absorption, and Voids in Hardened

Concrete.”

ASTM D-512 “Test for Chloride Ion in Industrial Water and Industrial Waste Water.”

ASTM D-1888 “Tests for Particulate and Dissolved Matter in Water.”

U. S. Army Corps of Engineers, Handbook for Concrete and Cement, Published by US

Army Corps of Engineers Waterways Experiment Station, Vicksburg, Miss.

NRC Publications

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.28, “Quality Assurance Program

Requirements (Design and Construction)”. (Rev. 3)

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.29, “Seismic Design

Classification”.

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.38, “Quality Assurance

Requirements for Packing, Shipping, Receiving, Storage, and Handling of Items for

Water-Cooled Nuclear Power Plants”.

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.94, “Quality Assurance

Requirements for Installation, Inspection, and Testing of Structural Concrete and Structural

Steel During the Construction Phase of Nuclear Power Plants”.

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.136,” Materials, Construction,

and Testing of Concrete Containments”.

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.142, “Safety-Related Concrete

Structures for Nuclear Power Plants (Other Than Reactor Vessels and Containments)”.

U.S. Nuclear Regulatory Commission, Regulatory Guide 1.199, “Anchoring Components

and Structural Supports in Concrete.”

National Ready Mixed Concrete Association (NRMCA)

NRMCA, “Concrete Plant Standards of the Concrete Plant Manufacturers Bureau.”

NRMCA, “Truck Mixer and Agitator Standards of the Truck Mixer Manufacturers Bureau.”

Others

Concrete Manual, published by the Bureau of Reclamation.

Publications of the Portland Cement Association.
88132 - 24 - Issue Date: 10/25/06

For information and standards for studs (proprietary name: Nelson Studs), which are used

to secure embedded item such as pipe sleeves and plates, to concrete structures, refer to

Chapter 8, “Stud Welding”, Volume 2 of the Welding Handbook, Seventh Edition, published

by the American Welding Society.

END
Issue Date: 10/25/06 88132, Att 1 Att 1-1

ATTACHMENT 1

Revision History for IP 88132

CommitmentTrackingNumber

Issue Date Description of Change Training

Needed

TrainingCompletionDate

Comment Resolution Accession Number

10/25/06CN 06-031 06-NMSS

IP 88132 is a newly issued procedure. Issued for MOX inspection program toimprove effectiveness and efficiency byincorporating and consolidatinginspection requirements involvingstructural concrete inspection activities.

None N/A