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. Structural Soundness for Turbine-Generator Foundation Affected by

Alkali-Silica Reaction and Its Maintenance Plans

Takeo Takakura1), Hirotaka Masuda2), Yasuyuki Murazumi3), Katsuki Takiguchi4),

Yoshihiro Masuda5), Isoharu Nishiguchi6)

1) Civil Engineering Section, Mitsubishi Heavy Industries, LTD. Takasago Machinery Works, Japan.
2) Civil and Architectural Engineering Department, Shikoku Electric Power Company, LTD, Japan.
3) Nuclear Facilities Design Department, Nuclear Facilities Division, Taisei Corporation, Japan.
4) Professor, Department of Mechanical and Environmental Informatics, Graduate School of Information Science and
Engineering, Tokyo Institute of Technology, Japan.
5) Professor, Department of Architecture and Civil Engineering, Utsunomiya University, Japan.
6) Professor, Department of System Design Engineering, Kanagawa Institute of Technology, Japan.

1. ABSTRACT
Ikata No.1 nuclear power station is the PWR Plant with 566 MW capacity is constructed by Shikoku Electric Power
Company. LTD. The Turbine Generator foundation (herein after TG foundation) of Unit 1 which is referred in this paper
is the reinforced concrete structure to support turbine and generator which are located inside of the turbine building.
This turbine generator has commenced the commercial operation in 1977. An abnormal setting condition and movement
which were different with the turbine generator installation value were confirmed between generator, rotor and their
bearings during the first annual inspection in 1979.
Alkali-silica reaction (herein after ASR) cracks were observed on TG foundation and had been confirmed by the
various test result such as core sampling test. It was confirmed that, the TG foundation had been expanded in the
longitudinal direction due to the affect of ASR, and the maximum expanded rate was about 1000 micro.
The TG foundation has confirmed that it have sufficient bearing capacity to the design seismic load even now, by the
analysis based on the previous literature and investigations what were fulfilled to verify TG foundation soundness.
The various monitoring tests for comprehension of TG foundation condition such as the development of ASR and
keeping structure soundness have been executed. This paper reports the current TG foundation condition concluded
by the previous results of various monitoring. Also, it reports the present monitoring items and the extra monitoring
items that were added by recent examinations.

2．INTRODUCTION
ARS is phenomenon which is indicated by the abnormal expansion and/or cracks on concrete due to alkali-silica gel
swelling by water absorption. The alkali-silica gel would be arisen due to the reaction between highly alkaline
aqueous solution and coarse aggregate which has contained one kind of silica mineral substance.
Regularly monitoring of TG foundation for exterior cracks observations, deformation measurement due to expansion
caused by the ASR, strain measurement of reinforcement were executed in due course since 1981. Also, conducted
the test and/or investigation by core sampling specimen has been executed in the suitable period. According to these
monitoring results, the expansion of TG foundation affected by the ASR tends to subside in recent 10 years. The
maximum longitudinal expansion rate due to the affect of ASR reached about 0.1% (1000 micro) of TG foundation
total length1) which is 50m. The development of ASR would be judged as rested. On the other hand, TG foundation
has developed internal stress due to the ASR. The TG foundation is affected by ASR, however it was verified and
have sufficient structural soundness to the seismic design load by the results of analysis for structural safeness2). No
trouble occurred and the turbine generator is stably, operated continuously till now.
To maintain TG foundation soundness in the future, it is recommended to repair exterior cracks in order to prevent
reinforcement corrosion which are exposed since 2002, and continuous monitoring of the TG foundation to be
considered including monitoring the operation. Outline of TG foundation is shown on Fig.1.

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.
Sea side

Low-pressure steam
Low-pressure steam
50

11
Axle
High-pressure turbine casing

2.5 Generator
発電機

No.2 Low-pressure
第２低圧タービン turbine
TG Foundation High-pressure steam
No.1 Low-pressure turbine
第１低圧タービン
3.0 4.0 15
2.5 High-pressure
高圧タービン turbine
3.0 High-pressure steam
2.5

2.5 5.0

4.76
2.5
18.7

Mountain Side
Units : m

Fig.1 Outline of the Turbine Generator Foundation

3. ACTUAL CONDITION OF TG FOUNDATION

3.1 OVERVIEW OF TG FOUNDATION
Construction of this TG foundation was completed in 1975. Commercial operation of turbine generator was
commenced in 1977, after completion of turbine generator installation. The size and specification of TG foundation is;
50.0m entire length, 15.0m width, 18.7m height, typical beam size; 3.19m width and 4.0m depth, and categorized as
mass concrete. The TG foundation structure consists of; concrete of strength 20.6N/mm2 using moderate heat Portland
cement, SD345 deformed bar, washed fine aggregate of sea origin, crushed aggregate. A soil stratum below TG
foundation is bedrock.
The change of turbine generator setting value was observed during annual inspection. And cracks were appeared on
the exterior side of the TG foundation concrete surface. It was confirmed that the TG foundation had been deformed
due to expansion affected by ASR, based on various investigations for the cause and by examinations such as
mechanical investigation of the turbine generator and core sampling of concrete.

3.2. EXPANSIONS DUE TO ASR AND PHYSICAL PROPERTY

The previous investigation report of monitoring for the affected TG foundation was reported on the literature
reference 1). This paper reports current condition of the TG foundation including report of previous monitoring results.
① The development of ASR has been already subsided around 1989 and same situation continued. The maximum
expansion rate in longitudinal direction (axial direction of the turbine generator) on the table deck is 50mm (1000
micro) including temperature increment1). The expansion trend of the table deck in axial direction is shown on
Fig.2. Further investigation concludes that the expansion rate seems to tend shrinking in recent few years.

② The reinforcement tends to be expanding according to the table deck expansion. The typical trend of
reinforcement strain is shown on Fig.3.

③ From the results of exterior observations of cracks and decreasing of elastic modulus, it has pronounced that the
table deck has been conspicuously affected by ASR. However, other portions have not affected by ASR tendency.
The cracks developments on the table deck are harmonically developed due to the expansion of table deck. The
trend of total crack extent in longitudinal (axial) direction at table deck is shown on Fig.4, and the cracks observed
are shown on Fig.5.

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.
60

50

40

変位(mm)(mm)
Displacement

30

20

10

0
1975 1977 1979 1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005
年 (year)
Longtuidinal Couse
海側計測値
Seaside Measurements 山側計測値
Mountain side Measurements 海山計測差
Differential of Seaside and Mountain side
Seaside Measurements Mountain side Measurements Differential of Seaside and Mountain side
海側計測値(定検時) 山側計測値(定検時) 海山計測差(定検時)
(annual inspection) (annual inspection) (annual inspection)
Endplea
エンドプレー値 Approximate
多項式 Expression
(海山計測差(定検時))

Fig.2 Expansion Trend of Table Deck in Axial Direction of Turbine Generator

Main
主筋ひずみReinforcement Strain
(µ )
1800

1600

1400

1200

1000

800

600

400

200
'86 '87 '88 '88 '89 '90 '91 '92 '94 '97 '00 '03 '06
Longtuidinal Couse (year)
1u 鉄筋ひずみの推移（Ｍ-1）
Development of Main Reinforcement Strain

Fig.3 Trend of Reinforcement Strain (Typical example)

0.060

Sea side
海側軸方向 Mountain
山側軸方向
0.050 total breadth
ひび割れ合計 side
ひび割れ合計
Total Crackひび割れ幅(%)
Breadth

0.040

0.030

0.020

0.010

0.000
76
00 78
02 80 0682 08 84 10 8612 8814 90
04 16 92
18 94
20 96 2498 遷移(年)
22 00
Longtudinal Course (Year)

Fig.4 Trend of Total Crack extent in Longitudinal Direction at Table Deck

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Fig.5 Sketches for Cracks of the TG Foundation

④ From the tests results of core sampling specimen test executed in 1986 it has been confirmed that the concrete
compressive strength was sufficient, which has been more than the design intensity and deterioration of elastic
modulus. However, it was not clear from tendency that the deterioration was due to aging. The across the ages
of concrete compressive strength is shown on Fig.6, and across the ages of elastic modulus is shown on Fig.7.

45 TD圧縮強度
Table Deck
Compressive 圧縮強度（N/m㎡)

40 Column
柱圧縮強度
Mat FDN.
ﾏｯﾄ圧縮強度
35
30
strength

25
設計強度
Design intensity
20
15
10
5
0
77 79 81 83 85 87 89 91 93 95 97 99 01 03 Longitudinal
経過（年） course (Year)
00
02
04
06
08
10
12
14
16
18
20
22
24
26

Fig.6 Across the Ages of Concrete Compressive Strength

4.5 TD弾性係数
Table Deck
Elastic静弾性係数（N/m㎡)10＾4

4.0 Column
柱弾性係数
Mat FDN.
3.5 ﾏｯﾄ弾性係数

3.0
2.5
coefficient

2.0
1.5
1.0
0.5
0.0
77 79 81 83 85 87 89 91 93 95 97 99 01 03 Longitudinal
経過（年） course
00
02
04
06
08
10
12
14
16
18
20
22
24
26

(Year)
Fig.7 Across the Ages of Elastic Modulus

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. ⑤ After-expansions are tested by accelerated expansion method which used core sampling specimens that were
extracted from the table deck and executed according to JCI*1-DD2. At the table deck in which ASR was
developed, after-expansion rate was indicated beyond 1.0% in the test results of after-expansion test executed in
1986. However, after-expansions tested in 1989 or later, indicated expansion rate is less than 0.04%. In the
after- expansion test results by core sampling specimens, it seems that the potential expansion abilities had been
spent by around 1989. The result of surviving expansion test is shown on Fig.8.
*1; Japan Concrete Institute
0.120 Ave. on Table deck in 1986
10年後ﾃｰﾌﾞﾙﾃﾞｯｷ平均

0.100 Ave. on Mat FDN. in 1986

10年後MAT平均

Ave. on Table deck in 1989

13年後ﾃｰﾌﾞﾙﾃﾞｯｷ平均
0.080
残存膨張量（％）

Ave. on Columns/Beam
13年後柱梁 平均 in 1989
Rate

0.060 Ave. on Table deck in 1992

16年後ﾃｰﾌﾞﾙﾃﾞｯｷ平均
Surviving Expansion

Ave. on Tabledeck in 2002

26年後ﾃｰﾌﾞﾙﾃﾞｯｷ平均
0.040
Ave. on Columns/Beam
26年後柱梁 平均 in 2002

0.020 Ave. on Mat FDN. in 2002

26年後MAT平均

0.000
1 1 2 3 4 5 6 7 8 9 10 11
Longitudinal
経過月 course (month)
Fig.8 Test Result of After-Expansion Rate

It is well known that environment such as water absorption and/or temperature are effect much for the development
of ASR. However, the causes for ASR developing in the TG foundation would be not identified. On the other hand,
the temperature at the table deck is tending to be high in comparison with other portion due to the presence of
equipment heat.

3.3 SAFENESS OF TURBINE GENERATOR OPERATION

The condition of the turbine generator operation as of now is as follows. The turbine generator has sufficiently been
made an obsequious by the adjustment of alignment during annual inspection to slow down the deformation behavior
affect due to ASR. Therefore, the turbine generator has been operating safely and continuously. The operation
characteristic of the turbine generator and the TG foundation has been reported by the literature reference 3).

⑥ The spacer has been incorporated in order to adjust the distance between the turbine and the generator due to the
expansion of the table deck, most of the expansion is because of the deformation in table deck. Trouble free
operation of turbine generator has continued including no abnormal shaft vibration. The shaft vibrations and
bearing metal temperature have continuously monitored, and automatic trip and alarm have set. However, no
alarm and trip have been occurred even during/after earthquake. The turbine generator has continuously operated
and safe till now.

3.4 STRUCTURAL SOUNDNESS OF TG FOUNDAITON BY ANALYSIS

The TG foundation is affected by the ASR, self strain and it is a deformed state structure, constitute of expanded
table deck affected by ASR and base structure such as columns which were affected by table deck expansion.
It was judged from the indoor bearing test conducted on ASR3)4) affected reinforced concrete and existing literatures
that the load bearing ability of the table deck affected by the ASR was not deteriorated. A self-strained stress which
was occurred on statically indeterminate structure due to expansion and/or shrinkage by temperature variation and/or
dehydrated shrinkage, in spite of this the structure has enough toughness strength and also it withstood to seismic
impact without effecting the ultimate loading. However, in the case of easily destroyed local destruction was occurred,
it was concerned a deterioration in ultimate bearing capacity of the whole structure. Then, the following conclusion
was obtained as a result of analysis for structural soundness2).

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. ⑦ In the result of analysis based on investigation by monitoring such as expansion rate (1000 micro in axis direction)
of the table deck, it was confirmed that the table deck has sufficient margin to design seismic load in the current
condition which is actualized ASR.

4. EVALUATION FOR ASR DEVELOPMENT IN TG FOUNDATION - IN FUTURE

4.1 POSIBILITIES OF ASR DEVELOPMNET
As aforementioned on clause 2, continuously monitoring results of the table deck where there was strong indications
of ASR are follows; i) The tendency has been that the expansion affected by ASR is rested around 1985, and these are
shrinking at the present. ii) The tendency has been that reinforcement strain has been indicated on same trends with
table deck expansion accordingly. iii) Also, the tendency has been that crack developments have been indicated on
same trends with table deck expansion accordingly. iv) In the result of after expansion rate test, it seems potential
expansion abilities was prevailed till 1989. According to these results, the TG foundation would be measured.
Therefore, it was concluded that further expansion of the TG foundation would be occurred due to be re-development
affected by ASR.
The reinforcement breaking due to various causes such as significant concrete expansion affected by ASR would be
not expected according to following reasons; i) It is located in a building without taking a rain fall. ii) The
incorporated reinforcement is blast-furnace reinforcement, and it was properly manufactured. iii) The expansion rate
would not reach reinforcement breaking range. No major cracks appeared on the of concrete surface which was
affected to reinforcement breaking.

4.2 EVALUATION BY ANALYSIS IN THE CASE OF ASR RE-DEVELOPMENT

According to aforementioned, prediction of occurrence of ASR re-development is not envisaged. In case if ASR is
re-developed on the TG foundation, structural bearing capacity of the TG foundation will not be affected by ASR,
immediately. However, following analysis was examined for the confirmation of prior necessary remedy planning.
Analysis and evaluation are as follows; The table deck assumed ASR was re-developed, and expansion rate of the
table deck was assumed to 1.2 times (60mm) of current maximum expansion rate. Concrete strength and elastic
modulus values applied are lower limit values which are considered to be of deteriorated concrete affected by ASR2)5)6).
Analysis method and evaluation ways are same as previous reports reference 2), 5) and & 6). The result of analysis the
margin to design seismic load reduced only less than ten percent in the current condition. Therefore if the TG
foundation expanded into by 1.2 times compared with current expansion rate, it was verified that the TG foundation has
enough bearing capacity to lateral load like an earthquake. If ASR is re-developed, the bearing capacity of the TG
foundation would not be an immediate problem in the future.

5. TG FOUNDAIION MAINTENANCE
At present, ASR development in the TG foundation is halted, but the TG foundation is under continuous monitoring
for ensuring safe operation of the turbine generator. The monitoring items which have already been executed and
additional monitoring items to be included from now on are listed up and define in this clause.
The TG foundation has been monitored for regular investigations and measurement such as exterior cracks,
deformation by the expansion and reinforcement strain, since 1981. Further vibration monitoring instrument has been
added into the TG foundation for TG foundation vibration character monitoring, since 2002. Also thermohygrometers
were added for examination of condition changes if ASR is re-developed. On the other hand, the turbine generator has
been monitored for shaft vibration and metal temperature control during equipment operation since commencement of
commercial operation.
The table deck and column capital were repaired for prevention of water influx, prevention of reinforcement and ASR
suppression at cracks by adding inorganic injection of lithium nitrite contained material during 2002 and 2003.
Further cracks and/or deterioration have been not observed after these treatments.

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. Monitoring items which are now executing are as follows;

1) Monitoring items which would indicated some changes to the TG foundation due to ASR development.
i) Table deck expansions
[ 4 times/year ( 1 time during annual inspection, 3 times during operation )],
[ Measurement of bench mark distance in longitudinal direction.]
ii) Reinforcement strain
[3 times/year ( 1 time during annual inspection, 2 times during operation )],
[Total at 9 locations for measurement of hoops, stirrups and main bars at table deck, columns and mat
foundation]
iii) Cracks condition at exterior surface of the TG foundation
[1 time/year during annual inspection],
iv) TG foundation vibration character measurement
[Continuously measured and record each month],
[Total at 9 locations measurement on the table deck]
v) Enjoinment temperature and humidity around the table deck
[Continuously measured and record each month]
[Total at 4 locations measurement under the table deck]

2) Monitoring items which are kept continuously for safe operation of the turbine generator against ASR
development. The following monitoring items are executing for operation and control. And in the case of arisen
same changes influenced by the affect of ASR, alarm and/or automatic tripping will be made for ensuring
safe operation of turbine generator.
vi) Monitoring Shaft vibration
[continuously monitored]
vi) Monitoring Bearing metal temperature
[continuously monitored]
Same monitoring system would be followed in future also.
Additional monitoring items will be considered to grasp in deeply the TG foundation deformation and/or a slant of
columns, and nondestructive test for direct measurement of concrete character due to deformation by other causes except
ASR.

3) Planned additional monitoring items

viii) Nondestructive concrete test (rebound hammer test, etc.)
ix) Deformation measurement of the TG foundation (slant measurement of columns, etc.)

If re-development of expansion at the table deck due to the affect of ASR or significant changes are recognized by
monitoring, examinations for cause would be investigated according to the monitoring data. Structure soundness
analysis, verification method, monitoring items and measurement methods, these methods will be reviewed in that stage.
Also, technical report or new scientific knowledge of ASR will continuously corrected whenever it is updated, these
technical knowledge would reflect evaluation of soundness and planning of maintenance for the TG foundation.
Nondestructive concrete test method to verify reinforcement soundness in concrete structure has researched and
developed by us and other parties. The applicability and possibility of these technologies will be considered and
examined with to watch status of progress.

6. CONCLUSION
Till now current condition of the TG foundation is reported in this paper, ASR has been rested, expansion has been
diminished, and these expansions tend to shrinkage at the present. The maximum expansion rate of the TG foundation
due to the affect of ASR is 1000 micro (50mm) in longitudinal direction. And, possibility of ASR re-development in
the future is not envisaged in the results of after-expansion tests and the deformation trend of the table deck. In the
results of various monitoring and analysis till now, the TG foundation bearing capacities to withstand seismic load has

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. sufficient capacity even if expansion rate was expanded by 1.2 times to the current expansion rate.
Monitoring items what were executed for ensuring the safe operation shall be continued such as expansion
measurement of the table deck, reinforcement strain, exterior cracks observation, TG foundation vibration character
measurement and temperature and humidity monitoring around the TG foundation. Also continuous monitoring items
such as shaft vibration monitoring and bearing metal temperature shall be continued. Nondestructive concrete test
and/or measurement of TG foundation deformation will be executed, additionally.
If re-development of expansion at the table deck due to the affect of ASR or significant changes was recognized by
monitoring, examinations for cause would be investigated according to the monitoring data. And, Structure soundness
analysis, verification method, monitoring items and measurement methods, these methods will be reviewed in that stage.
Also, technical report or new scientific knowledge of ASR will continuously corrected whenever it is updated, these
technical knowledge would reflect evaluation of soundness and planning of maintenance for the TG foundation.

REFERENCES
1). T. Takakura, T. Ishikawa, N. Matsumoto, S. Mitsuki, K. Takiguchi, Y. Masuda, I. Nishiguchi, “Investigation on The
Expansion Value of Turbine Generator Foundation Affected by Alkali-Silica Reaction”, 18th International Conference on
Structural Mechanics in Reactor Technology (SMiRT 18), pp2061-2068, H03_7, August 2005
2). H. Shimizu, Y. Asai, T. Hosokawa, H. Sekimoto, K. Sato, R. Oshima, K. Takiguchi, Y. Masuda, I. Nishiguchi.,
“Investigation of Safety Margin for Turbine Generator Foundation affected by Alkali-Silica Reaction based on
Non-linear Structural Analysis”, 18th International Conference on Structural Mechanics in Reactor Technology
(SMiRT 18), pp2049-2054, H03_4, August 2005
3). T. Takakura, Y. Asai, T. Hosokawa, T. Momoo, S. Harada., “Evaluation on an Influence to Turbine Generator Installed
on a Concrete Foundation Structure Affected by Alkali-silica Reaction”, TRK1 Plant Operations, Installation and Life
Cycle, Technical 1-5 Component Reliability Management, No.50175, 13th International Conference on Nuclear
Engineering (ICONE13), Beijing China, May 2005
4). Y. Murazumi, Y. Watanabe, N. Matsumoto, S. Mitsugi, K. Takiguchi, Y. Masuda., “Study on The Influence of
Alkali-silica Reaction on Structural Behavior of Reinforced Concrete”, 18th International Conference on Structural
Mechanics in Reactor Technology (SMiRT 18), pp2036-2042, H03_2, August 2005
5). H. Shimizu, Y. Watanabe, T. Ishikawa, H. Sekimoto, R. Oshima, K. Takiguchi, Y. Masuda, I. Nishiguchi., “Study on
Material Properties in order to Apply for Structural Analysis of Turbine Generator Foundation Affected by
Alkali-Silica Reaction”, 18th International Conference on Structural Mechanics in Reactor Technology (SMiRT 18),
pp2055-2060, H03_5, August 2005
6). Y. Murazumi, T. Hosokawa, N. Matsumoto, S. Mitsugi, K. Takiguchi, Y. Masuda., “Study on The Influence of
Alkali-silica Reaction on Mechanical Properties of Reinforced Concrete”, 18th International Conference on Structural
Mechanics in Reactor Technology (SMiRT 18), pp2043-2048, H03_3, August 2005