Nuclear Power Plants Solutions for safety, durability and sustainability

Transcription

1 Nuclear Power Plants Solutions for safety, durability and sustainability NPP 1

2 Concrete Power Durability is unarguably a primary requirement for the various types of concrete applications in nuclear power plant construction. Beyond that, emphasis will also be placed on long-term performance standards, material quality, mix optimisation, the science of chemical admixtures and advances in understanding aggregate-paste transition zones. Generally, specifications for both fresh and hardened concrete bear out durability as the main consideration as seen in the following: Fresh concrete Maximum water/cement ratios Minimum cement contents including all types of cementitious materials Minimum concrete cover to reinforcement Appropriate consistency class for perfect workmanship Hardened Concrete Minimum permeability Minimum water absorption Minimum chloride penetration In fact recent specifications, in terms of service life requirements (e.g. short <30 years, normal years, and long >100 years) have been developed, primarily through European standards. BASF has lead the way in construction chemicals since the early 1900 s. Combining revolutionary technology capabilities with a strong vision, it has innovated admixture solutions to meet the demands for highly durable concrete in the nuclear power construction industry.

3 Our leading range of concrete admixtures includes Glenium, Glenium SKY and Pozzolith, all with unique water-reducing properties that allow the use of optimised quantities of supplementary cementitious materials, such as ground granulated blastfurnace slag, pulverized fuel ash and microsilica. This enhances the durability of nuclear power plant structures through the reduction of permeability, water absorption, whilst increasing the resistance to chloride and sulphate attack. Our admixture specialties such as Tetraguard, Rheomac and Rheocrete, thanks to their action on shrinkage and corrosion inhibition, also contribute towards the durability of concrete. Beyond durability, BASF s admixtures, developed over several decades, also meets construction needs with regards to flexibility, workability and sustainability of nuclear power plants. Durability Continuous micro-structural changes from within, coupled with environmental impacts, will cause changes in the properties of concrete as it ages. To counter various agents, such as chlorides, sulphates, carbon-dioxide and moisture, impermeability of concrete is key to a long-lasting structure. The skilful use of BASF admixtures Glenium, Glenium SKY and Pozzolith enables superior water-reducing properties in concrete along with robust compatibility with various types of cement supplementary cementitious materials. Structures can now last longer with reduced permeability, water absorption and resistance to chloride and sulphate attack. Flexibility Our latest innovations have revolutionised ready-mix and pre-cast applications. With no impact on the setting times of concrete, our latest technology allows constant workability of concrete over longer periods of time (typically two hours or more). Workability Glenium, Glenium SKY and Pozzolith, in conjunction with RheoMATRIX viscosity modifying admixtures, can be used effectively to produce self-compacting concrete that eliminates the need for vibration and reduces manpower. At the same time, high quality concrete with an excellent finish can be achieved especially when combined with the use of our Rheofinish water-based release agent range. Sustainability Our admixtures Glenium, Glenium SKY, Pozzolith, or RheoMATRIX, our unique VMA, - increase the use of supplementary cementitious materials in concrete to help optimise the heat of hydration in mass concrete applications. This provides a better control of peak temperatures. NPP 3

4 Power-full Performance Additionally, the time-tested range of concrete admixtures in our portfolio caters to specific needs in the construction of nuclear power plants. Normal concrete with high durability This is primarily for concrete with a water/cement ratio in excess of Our Glenium SKY range of high performance water reducers is best suited to produce such high workability concrete with good water reduction capabilities that in turn lead to lesser impermeability in the concrete. In addition, Glenium SKY has the following benefits: Improved placement, thanks to control of rheological properties Higher strength and improved durability No segregation even at high workability Early demoulding and shorter curing cycles Better dimensional stability Compressive Strength Compressive Strength (MPa) 90 In instances where there are stringent requirements for higher and consistent workability retention (>2 hours or more) for mixes with water/cement ratios in excess of 0.40, a unique innovation from BASF Total Performance ControlTM utilising the Glenium SKY range can be used hours 18 hours 24 hours 3 days 7 days Age Glenium SKY No admixture 28 days Special concrete applications with stringent durability parameters Offering unrivalled technology with versatility in high performance areas such as low permeability/low water absorption concrete and low shrinkage applications, our Glenium or Glenium SKY formulations are effectively used for the following: High performance concrete High strength concrete Self compacting concrete With their unique nano-scale repulsion effects in concrete, Glenium or Glenium SKY are also used for faster mixing logistics at large projects under any given condition of construction. These hyperplasticisers are based on the latest generation polymer technology and include variants such as Glenium ACE for precast applications.

5 The Power of Protection Concrete structures in a nuclear power plant need to be protected from aggressive airborne contaminants such as salt-laden marine environments and atmospheric pollution. Masterseal protection systems are used to reduce the contact of chlorides and other contaminants thus reducing the risk of reinforcement corrosion leading to cracking and spalling. Our Masterseal range of protective systems includes silane-based impregnants for restricting the ingress of chlorides, atmospheric carbon dioxide and water, as well as protective coatings that give an aesthetically pleasing appearance. Installations such as nuclear power plants require numerous sensitive electronic control systems and protection of these from destruction by static discharge is a necessity. Our Mastertop range of Anti-static and Electro-static discharge floor coatings ideally meet these requirements. As in all power plants there are areas that require the use and storage of chemicals and our Ucrete chemical resistant floors and bund linings are the industry choice for this purpose. With its long history in protecting concrete from chemical and mechanical attacks, Ucrete copes well with high and aggressive chemical loads as well as with abrasion and high impact. NPP 5

6 Powerful Seals to Inevitable Joints Like all large concrete structures, nuclear power plants need to have numerous construction joints and each of these is a point of potential water ingress. BASF offers a range of Masterflex products that can create watertight joints even in the most complex and demanding designs. The range includes a reinjectable hose system for lifetime watertightness of construction joints, and expandable gaskets and water stopping injection products to guard against leakage. These are complemented by the Masterflex range of joint sealing systems including single part polyurethane materials, to polysuphides, to Elastomeric PVC Tapes for very wide joints. Overpowering Radiation Radiation safety is of paramount importance in the nuclear power industry. Floor and wall coatings have to be able to withstand exposure as well as being easily decontaminated. BASF s uniquely formulated radiation resistant flooring and coating systems for the reactor structure and other potential radiation exposure areas are available under the Mastertop range (formerly known as the Epirex series). These tried and tested products exhibit a high degree of certainty against radiation contact. 6 NPP

7 Uninterrupted Production Power Dynamic machines such as power-generating turbines need to be installed so that vibration is below the specified level and all operational loads are effectively transferred to the concrete foundation. Uninterrupted operation of such machines needs precision maintenance of their alignments and levels. Our precision grouts are designed specifically for this task by creating a complete support for the base of the machine and transferring the load to the foundation. Our Masterflow range of cementitious and epoxy-based grouts have been designed to provide the load transfer for the most demanding environments. Used worldwide for more than 70 years, Masterflow grouts are the industry standard as they offer high chemical-resistance and thermal-resistance characteristics. Empowered Impermeability Every form of environmental deterioration mechanism is a result of water and water permeability in concrete. Therefore, making concrete structures waterproof is paramount to ensure the durability of structures. The importance of stopping water penetration in reactor buildings cannot be overstated. The seamlessness of the waterproofing membrane, the ease with which it can be installed without seams and joints, even over complex dome structures, and its prolonged performance under continuous exposure to UV, are some of the key parameters in the selection of waterproofing membranes. BASF s range of Coniroof waterproofing membranes meets such demanding parameters completely. NPP 7

8 A B C D Concrete Raft/foundation Reactor Building & Turbine Buildings Reactor & Auxiliary Buildings Turbine Building, Electrical Building, Control Room & Administrative Buildings Cooling Tower, Pump House & Intake Structure Power Pack Solutions Possible Application Area Product Description A B C D Normal & Mass concrete for raft/ Foundation; Structural concrete High Performance & Self Compacting Concrete High Performance & Self Compacting Concrete GLENIUM SKY GLENIUM GLENIUM SKY High range superplasticisers - normal & retarding High range superplasticisers - normal & retarding High range superplasticisers - normal & retarding Mass self compacting concrete with low fines RHEOMATRIX Solution for Smart Dynamic Concrete Mass concrete for raft/foundation TETRAGUARD Shrinkage reducing admixture Smooth finish concrete surfaces RHEOFINISH Mould release agent To roughen construction joints RHEOFACE Concrete surface retarder Curing of vertical concrete surfaces MASTERKURE Non-film forming curing compound Construction joints Re-injectable hose Hydro-swelling injection resin Hydro-swelling gaskets Expansion joints MASTERFLEX 2-part Polysulphide sealant Watertight seal for trafficked wide joints Neoprene based pre-formed seals Sealing wide expansion / seismic joints Hypolan based sealing strips Inside coating to water retaining tank Internal Protection of concrete walls MASTERSEAL Solvent free, high build epoxy coating Protection of external concrete face Anti-carbonation coating Machine foundation grouting Cementitious Precision grout Turbine foundation grouting High performance epoxy resin grout Equipment foundation grouting MASTERFLOW Cementitious Precision grout Foundation grouting for pump/equip Chemicals resistant epoxy resin grout Walls/floors in controlled areas Radiation resistance epoxy coating Protection of flooring surfaces MASTERTOP Epoxy Floor Coating Floors subjected to abrasion High performance floor hardener Roofs/terraces/Dome/Podiums CONIROOF Spray/Liquid applied PU waterproofing Chemical resistant floor in wet area UCRETE Anti-skid PU concrete Fixing rebar/shear connectors Epoxy acrylate resin anchor Bonding agent for old to new concrete CONCRESIVE Epoxy bonding agent Cathodic protection to re-bar Zinc rich, epoxy coating THORO Structurite Single part, polymer modified cementitious Corrosion passivation treatment to re-bar Primer active primer Patch repair of structural members like beam/ Single component, fibre reinforced, high build Column repair Mortar Form and pour, volume repairs of EMACO Duel-shrinkage compensated structural members (NANOCRETE) micro-concrete Total corrosion protection treatment to concrete structure Rapid setting patching mortar Spray applied repairs to large surface areas of structure SHOTPATCH Dry-Spray, high build, Micro-concrete Total corrosion protection treatment to concrete structure RHEOCRETE Corrosion inhibitor 8 NPP