Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
ACCESSION #: 9710090068
Master Builders, Inc.
23700 Chagrin Boulevard
Cleveland, Ohio 44122-5554
Phone 216/831-5500
September 29, 1997
Document Control Desk
U.S. Nuclear Regulatory Commission
Washington DC 20555
Attn. Mr. Joel Monday
RE: Final Disposition of Masterflow 713 (CMTR) and Embeco 636 (CMTR)
Grout Nonconformance
Dear Mr. Monday:
This is to provide you with a summary of the final disposition of
Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grout nonconformance reported
by Master Builders, Inc. earlier this year.
Please find attached, a letter of notification that will be mailed
to the affected nuclear utilities. It summarizes the nature of the
reported nonconformance, suspected cause, additional testing/points of
relevance, and actions to prevent recurrence.
As mentioned in the letter, the suspected cause of the
nonconformance is an incompatibility between key formulation components
and the locally available portland cement (Streetsboro, OH) used in the
above mentioned products. Further, we have determined that the specific
nonconforming behavior is observed only after the Streetsboro, OH
formulated products "ages" (shelf-life) for more than 3 months. These
problems DO NOT exist with the products produced at our Rancho Cucamonga,
CA plant from portland cement which is locally available in Southern
California.
Additionally, the matter was discussed extensively with
representatives from Entergy Operations during a NUPIC audit in March of
this year. Unfortunately, these discussions produced no additional
insights as to the exact cause of the nonconformance.
In any event, we are issuing the attached letter in an effort to
bring this issue to closure, It will be mailed to all utilities
originally notified earlier this year.
If you have any questions, or need additional information, please
contact John Dorado or myself at 216-831-5500.
Respectfully Yours,
William K. Secre
Vice President, Research & Development
Master Builders, Inc.
cc: L. M. Shydlowski, J. P. Boyer, P. Vinocur, B. Violatta, L. Yappel
B. Smith, T. Coverdale, B. Caine, C. Yerico, R. Wells, J. Dorado
nrc97final/jd
Date Page 1 of 2
Customer
Sample
Attn.
RE: Final Disposition of Masterflow 713 (CMTR) and Embeco 636 (CMTR)
Grout Nonconformance
Dear Customer,
This is to provide you with a summary of the final disposition of
Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grout nonconformance reported
by Master Builders, Inc. earlier this year.
Nature of the Observed Nonconformance
As reported by Grand Gulf Nuclear, in November 1996, the following
nonconformances were observed during their testing of Masterflow 713
(CMTR) Grout:
o foaming/frothing
o segregation
o shrinkage
o slow setting
o low compressive strength
Material was returned to the Master Builders Streetsboro, Ohio QC
Lab for testing. Our preliminary testing confirmed the nonconformances
noted by Grand Gulf Nuclear with the exception of the low strengths (1
day compressive strengths of approximately 2,900 psi were obtained from
our testing).
In addition, we have tested several bags of material, produced at
different points of the year, and have observed the same foaming/frothing
and segregation. Similar behavior was also observed for Streetsboro
produced Embeco 636 (CMTR) Grout, which is based on the same primary
formulation as Masterflow 713 (CMTR) Grout.
Suspected Cause
The suspected cause of the nonconformance is an incompatibility
between key formulation components and the locally available portland
cement (Streetsboro, OH) used in the above mentioned products. Further,
we have determined that the specific nonconforming behavior is observed
only after the Streetsboro, OH formulated products "ages" (shelf-life)
for more than 3 months. These problems DO NOT exist with the products
produced at our Rancho Cucamonga, CA plant from portland cement which is
locally available in Southern California.
Additional Testing/Points of Relevance
Testing to date, has demonstrated that any Masterflow 713 (CMTR)
Grout or Embeco 636 (CMTR) Grout that was used within 3 months of the
manufacture date is not affected by the suspected shelf-life instability
problem. Initially, testing was performed by Grand Gulf Nuclear and
subsequently retested by Master Builders on a lot of Masterflow 713
(CMTR) Grout (Lot No. 24-4844-W6) that was less than 3 months old. In
both cases, the gout performed as expected (i.e. no signs of foam/froth
or segregation). Subsequently, this material has been retested at 3, 4,
5 and 6 months of age. We found that up to 5 months, the material
performed in an acceptable manner. However, the material showed signs of
the undesirable behavior at 6 months. Testing of Embeco 636 (CMTR) Grout
produced similar results. In any event, the 3 month timeframe is a very
conservative estimate.
Page 2 of 2
In addition, we have confirmed through testing that the irregular
behavior only occurs in the unhardened state, immediately after mixing.
Therefore, material that does not exhibit this behavior (i.e.
foaming/frothing, segregation) will perform as expected in the hardened
state (i.e. conformance to the requirements of ASTM C 1107 and CRD-C621).
Furthermore, we have confirmed that the undesirable behavior occurs
only when the grout is mixed to a fluid consistency (20-30 sec. through a
flow cone). Suspect grout mixed at flowable, stiff or damp-pack
consistencies does not exhibit the behavior, and performs as intended
(i.e. no foaming, frothing, segregation; and meeting the requirements of
ASTM C 1107 and CRD-C621).
Actions to Prevent Recurrence
Since the initial report from Grand Gulf Nuclear, Master Builders
has discontinued production of Masterflow 713 (CMTR) and Embeco 636
(CMTR) Grouts at the Streetsboro, OH plant, All orders for Masterflow 713
(CMTR) and Embeco 636 (CMTR) Grouts have been and will continue to be
supplied from our Rancho Cucamonga, CA plant. Masterflow 713 (CMTR) and
Embeco 636 (CMTR) Grouts, produced at this facility, have not exhibited
the same undesirable behavior. We are continuing to monitor the shelf-
life of Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts produced at
Rancho Cucamonga, as a precautionary measure.
In terms of nuclear safety-related orders, we are shipping material
from the Rancho Cucamonga, CA plant to the Streetsboro, OH plant (being
held at and shipped from the Aurora, OH warehouse). The material is
being dedicated for safety-related use by the Streetsboro QC lab, in
accordance with Policy 10-Commercial Grade Dedication of Products, of the
Master Builders QA Manual. Furthermore, we will continue to dedicate
Rancho Cucamonga produced Masterflow 713 (CMTR) and Embeco 636 (CMTR)
Grouts in this manner, until the shelf-life issue with Streetsboro, Ohio
produced Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts is resolved.
As I mentioned, our plan is to either reformulate Masterflow 713
(CMTR) and Embeco 636 (CMTR) Grouts, or develop replacement grouts for
Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts in order to correct
and prevent recurrence of the nonconforming behavior. Until that time,
Masterflow 713 (CMTR) and Embeco 636 (CMTR) Grouts, as mentioned above,
will only produced at our Rancho Cucamonga plant, and dedicated per our
Policy 10.
I hope that this information is helpful to you. Please review the
above information, and contact me, if any additional actions need to be
taken. Unless we hear otherwise, we will consider this matter closed.
If you have any questions, or need additional information, please
contact me at your earliest convenience at 216-831-5500, extension 2240.
Sincerely,
John Dorado
Product Manager
(formerly Quality Control Manager)
Master Builders, Inc.
cc: B. Caine, G. Culton
extnotfinal/jd
Mailing List
*Final notification will be forwarded to all affected utilities,
originally notified, that DID NOT respond
o South Carolina Gas & Electric Co.
P.O. Box 88
Jenkinsville, SC 29065
Attention: Mr. Thomas Borch - Product Quality
o Bechtel Power Corporation
(R.E. Ginna Nuclear Station)
89 East Ave.
Rochester, NY 14649
Attention: Mr. Dave Fredrickson
o Rochester Gas & Electric Co.
1503 Lake Rd.
Ontario, NY 14519
Attention: Mr. Richard Biedenbach, Director, Safety & Health,
Nuclear Power
o Public Service Electric & Gas Co.
965 Chesterbrook Blvd.
Mail Code 63C-1
Wayne, PA 19087
Attention: Mr. Bill Bradley, Nuclear Quality Assurancecc: Ms.
Cathy Talbert (Buyer)
o Virginia Power Co.
Innsbrook Technical Center
5000 Dominion Blvd.
Glen Allen, VA 23060
Attention: Mr. Jeff Bailey
o Consolidated Edison of New York
4 Irving Place
Room 615 S
New York, NY 10003
Attention: Mr. Arthur Ng, Q.A. Engineer
o Southern Nuclear Operating Co.
Georgia Power Co. (re: Hatch and Vogtle plants)
P.O. Box 1295
Birmingham, AL 35201
Attention: Nuclear Engineering & Licensing Manager
and Manager - Materials Services
o Georgia Power Co. (re: Vogtle plant)
Nuclear Operations
P.O. Box 1600
Waynesboro, GA, 30830
Attention: General Manager
o Entergy Operations, Inc.
P.O. Box 31995
Jackson, MS 39286-1995
Attention: Glenn Griffen
o Consumers Power Co.
212 West Michigan Ave.
Jackson, MI 49201
Attention: Ms. Nancy Borton
o New York Power Authority
James A. Fitzpatrick Nuclear Power Plant
268 Lake Rd.
P.O. Box 41
Lycoming, NY 13093
Attention: Mr. Doug Mullens and Mr. Dan Sullivan
o Baltimore Gas & Electric Co.
Calvert Cliffs Nuclear Power Plant
1650 Calvert Cliffs Parkway
Lusby, NM 20657
Attention: Supervisor, Vendor Audits
o North Atlantic Energy Services
Seabrook Station
Box 300
Seabrook, NH 03874
Attention: B.L. Drawbridge, Executive Director, Nuclear Production
R.J. DeLoach, Executive Director, Engineering & Licensing
M.D. Harrington, Material Requirements Department
Supervisor
o American Electric Power Co.
Indiana/Michigan Power Co.
1 Riverside Plaza
Columbus, OH 43215
Attn. Manager - Nuclear Safety
Licensing & Fuels Division
o Florida Power Corporation <<<< *Sent for informational purposes
Crystal River Energy Complex only.
15760 W. Power Line St.
Crystal River, FL 34428-6708
Attention: Mr. J. O. Poston, Senior Nuclear Quality Assurance
Specialist
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