DOCUMENT | \ COLLECTION / tia, a PF Technical Report Sponsored by NAVAL FACILITIES ENGINEERING COMMAND March 1974 CIVIL ENGINEERING LABORATORY NAVAL CONSTRUCTION BATTALION CENTER Port Hueneme, California 93043 Navy submersible TURTLE performing inspection of concrete spheres. LONG-TERM DEEP-OCEAN TEST OF CONCRETE SPHERICAL STRUCTURES— Part I: Fabrication, Emplacement, and Initial Inspections by Harvey H. Haynes Approved for public release; distribution unlimited. so i 4 ray, We : Rada Oe Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) READ INSTRUCTIONS REPORT DOCUMENTATION PAGE BEFORE COMPLETING FORM T. REPORT NUMBER 2. GOVT ACCESSION NO| 3. RECIPIENT'S CATALOG NUMBER TR-805 4. TITLE (and Subtitle) 5. TYPE OF REPORT & PERIOD COVERED LONG-TERM DEEP-OCEAN TEST OF CONCRETE SPHERICAL STRUCTURES~—Part I: Not final; July 1971—June 1973 Fabrication, Emplacement, and Initial Inspections 6. PERFORMING ORG, REPORT NUMBER 7. AUTHOR(s) 8. CONTRACT OR GRANT NUMBER(s) Harvey H. Haynes 9. PERFORMING ORGANIZATION NAME AND ADORESS 10. PROGRAM ELEMENT, PROJECT, TASK CIVIL ENGINEERING LABORATORY Naval Construction Battalion Center 3.1610 Port Hueneme, California 93043 11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE Naval Facilities Engineering Command March 1974 Alexandria, VA 22332 43 Bee RICE ACES AREA & WORK UNIT NUMBERS 14. MONITORING AGENCY NAME & ADORESS(if different from Controlling Office) 15. SECURITY CLASS. (of this report) Unclassified 15a. DECLASSIFICATION’ DOWNGRADING SCHEDULE 16. DISTRIBUTION STATEMENT (of this Report) Approved for public release; distribution unlimited. 17. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, if different from Report) 18. SUPPLEMENTARY NOTES 19. KEY WORDS (Continue on reverse side if necessary and identify by block number) Concrete structures, pressure-resistant structures, concrete spheres, permeability, implosion, submerged concrete structures, seawater permeability of concrete, long-term loading, unreinforced concrete. 20. ABSTRACT (Continue on reverse side if necessary and identify by block number) This report summarizes the fabrication, emplacement and inspections during the first 1.2 years of submergence of eighteen 66-inch-OD concrete spheres. The spheres are located 4 miles south of Santa Cruz Island, California, in depths of water from 1,840 to 5,075 feet. The purpose of the test is to collect data on time-dependent failure, permeability and durability of concrete pressure-resistant structures. Findings from the inspections showed that two spheres located at the depths of 3,725 and 4,330 feet had imploded and that the FORM pe DD , TAN SA 1473 EDITION OF 1 NOV 65 IS OBSOLETE Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) Wmnou MT 0 0301 0 Unclassified SECURITY CLASSIFICATION OF THIS PAGE(When Data Entered) 20. Continued quantity of seawater which permeated through the concrete for phenolic-coated spheres was about 0.8 cu ft and for uncoated spheres it was about 1.6 cu ft. This test peoyetan is planned to continue through 1981 (total of 10 years). Unclassified SECURITY CLASSIFICATION OF THIS PAGE(When Data Entered) CONTENTS INTRODUCTION TEST DESCRIPTION . FABRICATION EMPLACEMENT . INSPECTIONS RESULTS | Implosion Permeability SUMMARY ACKNOWLEDGMENTS REFERENCES APPENDIXES A — Concrete Materials . B — Soil Properties C — Compressive Strength of Concrete for Sphere 3 D — Calculation of Seawater Intake. LIST OF SYMBOLS page INTRODUCTION Numerous experimental studies have been performed at the Civil Engineering Laboratory (CEL)* on the behavior of concrete structures under hydrostatic loading [1-11] > These studies have shown that concrete is well suited as a construction material for pressure-resistant structures to depths of 3,000 feet. The empirical data were obtained from test specimens subjected to relatively short-term loading conditions where the longest loading-period for any specimen was 42 days. This series of ocean tests was conducted to supplement the earlier research by providing data on concrete structures subjected to in-situ deep-ocean conditions for periods of up to 10 years. The objectives of the test program were to obtain design information on time-dependent failure, permeability, and durability of the concrete spheres. Data on time-dependent failure will permit a rational factor of safety to be applied to pressure-resistant structures; data on seawater permeability of concrete will allow predictions of the quantity of water to be expected to penetrate to the structure’s interior; and data on the durability of plain and steel reinforced concrete will determine such factors as strength changes with time, chemical composition changes of the concrete, and steel corrosion problems. TEST DESCRIPTION Eighteen, 66-inch-OD concrete spheres were placed in the ocean at depths ranging from 1,840 to 5,075 feet (Table 1). This depth range corresponds to a sustained pressure-to-short-term implosion pressure ratio, P./P; e HG of 0.36 to 0.83. It was anticipated that the spheres subjected to a P./P;,, ratio of 0.70 or greater would implode with time [8]; therefore, the six spheres at greatest depths were equipped with clocks that would count days in periods up to three years. If a sphere imploded, the clock would record the day of failure. Permeability data will be gathered using the following method: the spheres are buoyant by approximately 1,000 pounds and are tethered 32 feet off the seafloor by a 2-1/4-inch-diameter chain. As seawater permeates the concrete, the weight of the sphere will increase. The reduced buoyancy of the sphere means less chain can be suspended off the sea- floor, so the sphere moves closer to the seafloor. A change in height of one chain link (2-1/4-inch chain) corresponds to 0.5 cu ft of seawater which has permeated to the hull interior. The permeability waterproofed and nonwaterproofed concrete will be rate of seawater through determined. Eight spheres were coated on the exterior with a two-part phenolic coating; another eight spheres remained uncoated. All sixteen of these permeability specimens were of unreinforced concrete. The remaining two spheres were reinforced with conventional steel bars of 0.5-inch diameter. The reinforcement was covered with 1 or 2.5 inches of concrete. Also, one-half of the exterior of each sphere was coated with the phenolic compound while the other half remained uncoated. The durability of the concrete will be studied by determining the changes in strength and chemical composition with time. The concrete compressive strengths will be obtained from core specimens drilled from 14x 18x 18-inch blocks. Blocks are located with the spheres in the deep ocean and on land, a Formerly the Naval Civil Engineering Laboratory; now a detachment of the Naval Construction Battalion Center, Port Hueneme, California. Numbers in brackets indicate references. C A A The short-term implosion pressure, P;_,, Pasa pas [5.02(t/D,) - 0.038] f¢ is calculated by the following empirical equation [8] : Table 1. Test Description Concrete Water- proofed Comments 1 2: 3 4 5 6 7 8 9 clock inside sphere clock inside sphere clock inside sphere clock inside sphere clock inside sphere clock inside sphere steel reinforcement in walls steel reinforcement in walls a : : : F Sustained pressure-to-short-term implosion pressure ratio. > One hemisphere is waterproofed while the other hemisphere is not waterproofed. exposed to ambient conditions. Chemical composition changes of the concrete will be determined by comparing x-ray diffraction patterns with those of the concrete at age 20 months. FABRICATION Concrete hemisphere sections were cast in a steel mold and the following day were removed from the mold. Twelve 6 x 12-inch-long control cylinders and one 14 x 18 x 18-inch control block of concrete were also cast with each hemisphere. Moist-curing of the hemisphere, six control cylinders, and the control block was accomplished by wrapping the specimens in wet burlap and then in polyethylene film: the remaining six control cylinders were placed in the fog room. Moist-curing continued for 28 days at ambient temperature inside an open building followed by 28 days of room-curing condi- tions, and then on-land field-curing conditions. After weeks of field curing, the hemispheres were prepared for assembly into spheres. The equatorial edges were ground flat by using a large steel plate, and silica carbide grit and water as the cutting agent. A titanium hull penetration at the apex several Figure 1. Fabrication of spheres. Y of each hemisphere was epoxy-bonded into place. ( The exterior surfaces of the hemispheres were lightly | sand blasted and a two-part phenolic compound (Phenoline No. 300) was applied.@ Finally, to fabri- | cate a sphere two hemispheres were bonded together, with an epoxy adhesive (Furane Epocast 8288)> Figure 1 shows several of these operations. All of the spheres had the same dimensions and variations in out-of-roundness. Extensive measure- ments [8] were taken on one hemisphere, and Table 2 summarizes the dimensions. In summary, the mean outside diameter was 65.886 inches and the mean wall thickness was 4.124 inches. - Conventional 1/2-inch-diameter steel reinforcing - bars were embedded in the concrete of two spheres. # Arrangement of the steel bars is shown in Figure 2. Alternate longitudinal bars had a nominal concrete cover of 1 or 2.5 inches; however, in certain locations near the apex the minimum cover was as low as 0.5 inch. Clocks were placed in Spheres 1 through 6 to record the day of implosion, if the sphere should fail. The clock records days on a counter and has a projected life of 3 years.” Figure 3 shows the clock and its pressure housing which was a 4-inch-OD pipe section. The pipe was attached to the top penetrator of the sphere! di Pinholes existed in the final waterproof coating at a rate of approximately 1 per 2 sq in. © For zero time in the ocean, the clocks read 41 days for Spheres 1-3, and 38 days for Spheres 4-6. Upon retrieval, safety precautions should be followed in handling the pressure housing because water at high pressure could be inside. Prior to opening, drill a 1/8-inch-diameter hole through the steel wall to relieve any internal pressure. Figure 2. Arrangement of steel bar reinforcement for Spheres 17 and 18. Figure 3. Clock mechanism and its 4-in.-OD pressure housing. Table 2. Hemisphere Dimensions and Out-of-Roundness Variations M Standard Deviation Maximum Local Variation ean Dimension (in.) Measured (in.) Interior radius Exterior radius Wall thickness Power was supplied to the clock from dry-cell batteries placed in a watertight, but not pressure- resistant container located at the bottom of the sphere. When implosion occurs, the batteries are destroyed or shorted, and the lead wires running to the clock are broken. Percent of Measured Percent of Wall Thickness (in.) Wall Thickness Final assembly of the spheres is shown in Figures 4 and 5. The descriptive information on Figure 5 gives important details on the assembly. Documentation of the concrete material is given in Appendix A. The mix proportions, compressive strengths, cement compositions, and x-ray diffraction VA / patterns of the concrete are presented. In general, the concrete was made from a high-quality mix design where the cement factor was 7.8 sacks per cu yd and water-cement ratio was 0.40; the compressive strength at 28 days was an average 7,660 psi. Disposition of the control cylinders and blocks is as follows: of the six control cylinders placed in the fog room, three were tested at 28 days; their com- pressive strengths are given in Appendix A, Table A-2. The remaining three control cylinders will stay in the fog room and will be tested when the spheres are retrieved from the ocean. Three of the six control cylinders cured with the hemisphere were tested at age 28 days and the remaining three were tested approximately one month prior to emplacing the spheres in the ocean (Table A-2); these later tests gave the compressive strength used in calculating the short-term implosion pressure, P;,,. There were two control blocks per sphere; one block went with the sphere into the ocean and the other block stayed on land, located within 50 yards of the ocean. Both blocks will be cored and tested when the sphere is retrieved. — EMPLACEMENT The spheres were emplaced in the ocean 4 miles south of Santa Cruz Island, California (Figure 6), on 23 September 1971. The method of emplacing the spheres was as follows: a barge loaded with the spheres (Figure 7) was towed by a surface vessel (USNS Gear) which maintained a constant course over a location where the seafloor increased in depth at a fairly uniform rate. At predetermined depths, the appropriate sphere was pushed overboard to free-fall to the seafloor. The method worked well with most of the spheres landing within a few hundred yards of the target location. Final location of the spheres is given in Table 3. Figure 8 shows a plan view and Figure 9 a profile view of the sphere locations. Water samples were obtained from the depth of 2,530 feet and gave the following data: temperature of 5.33°C, salinity of 34.41 ppt, pH of 7.2, oxygen content of 0.06 ml/l, and velocity of sound of 1,483.9 m/sec. A water sample from 4,740 feet gave a temperature of 5.16°C and a pH of 7.0. Figure 4. Final assembly of sphere. concrete sphere clock batteries electric wire sonar target buoyancy element nylon rope penetration padeye identification tag chain shackle anchor chain concrete block 5.5-ft OD by 4-in. wall; weight in air = 4,400 lb Inside steel pipe capsule, 4in. OD by 10-in. long, weight in air = 15 |b Dry cell batteries inside PVC pipe Lead between batteries and clock Aluminum pipe, 10-in. OD by 12-in. long, by 1/8-in. wall Syntactic foam, 4-in. min width by 7-in. max width by 14-in. long by 4-in. deep 1/2-in. diameter Titanium Ti-6AI-4V; conical plug, 4-in. major diameter and 3-in. minor diameter Titanium, 1/2-in.-diameter rod, 3.5-in. radius Plastic tag with sphere number engraved (sphere number also stamped on most metal parts) 5/8-in. steel chain wrapped around sphere and through padeyes 2-1/4-in.-diameter steel chain, die-lock type, total length 53 ft, bottom links welded in triangle shape so hanging length = 42 ft, weight in air = 2,630 |b 18 in. sq by 14 in. high; weight in air = 400 lb * Note: Items b, c, d, e, f, and g were used with only Spheres 1-6. JHORY WH" a = Baa 7, Figure 5. Details of sphere assembly. Table 3. Location of Spheres Surface Location at Launch Seafloor Location Found by Turtle Azimuth Sphere Lorac Distance }| Azimuth Lorac Distance Depth | Sphere (ft) No. No. Coordinates Between | Between Coordinates Between | Between Spheres | Spheres 1 479.6" | 324.4 Spheres (yd) Spheres (°T) 346 2 | 481.5 | 320.0 340 3. | 489.9 | 305.2 490.0 | 302.0 341 Am |491-4~ || 302.6 491.0 | 299.2 340 5 | 492.6 | 300.8 344 Gee 5 01:97 284.3 344 7 \503:2 | 282.2 500.0 | 280.9 343 BP 1506:6 | 277.1 504274 | e2 7702 350 Ober 510-2. 1268.0. 509.0 | 265.5 350 NO | 511.7 | 266.6 511.7 | 264.4 345 ile 516.0 | 259.3 516.0 | 258.0 337 1s 2404" 25018 523.5 | 249.5 337 13 527.0 | 248.0 532.57] 249.7 347 14 | 528.8 | 244.4 536.1°| 246.8 355 Seal |e53022.|| 24254 534.6 | 242.6 345 6) | 530-7, 240°8 535.0 | 239.5 324 Ieee 3EO! |) 23984 535.0 | 238.3 352 18 534.0° | 238.3 5315230 ee 2oiieo) “ Geographic coordinates 33°49'15”N by 119933730’ W. > These locations may be in error. © Geographic coordinates 33°56'15”'N by 119°36715’W. California N Anacapa Island SNS 34°00’N Santa Cruz Island Sphere 18 33°56'15"'N \ 119°36715"W \ Sphere 1 33°49'15"N \ 119°33730"W Figure 7. Spheres rigged on barge in preparation for free-fall launch. ” 119°38'00 deep 5] “pz 16 33°56'00” these locations G550 could be in error 33°54'00” 33°52'00’ Surface location of sphere when launched TW Seafloor location (approx) of sphere found by Turtle aet: 33°50'00 2—'© R325 \ 1 ~ a0} Tr ila Figure 8. Plan view of sphere location. 1,000 2,000 3,000 Depth (ft) 4,000 5,000 | 10,000 15,000 Distance (yd) Figure 9. Bottom profile at sphere location directly below surface launch. A soil sample was obtained at the depth of 4,100 feet near Sphere 5. Data from the core are presented in Appendix B, Table B-1. INSPECTIONS Three inspection visits have been made to view as many spheres as possible. Of the 18 spheres, 15 have been viewed once, and of those 15, five have been viewed twice. The first and third inspections were made by the Naval Submarine Development Group One using the submersible Turtle. The second inspection was made by Scripps Institution of Oceanography using the Remote Underwater Manipulator (RUM). Turtle is a manned submersible capable of operating to depths of 6,500 feet. During the inspections with the submersible, however, those spheres at depths greater than 3,800 feet were not inspected because of the possibility of implosion of a test sphere. Investigators with the Turtle were 10 successful in inspecting Spheres 7-18. The spheres at greater depths (1-6) were to be inspected with the unmanned RUM vehicle. Within the time available for the inspection cruise with RUM, Spheres 3-5 were inspected successfully; the remaining spheres (1, 2, and 6) have not been inspected. Data collected during the inspections are given in Table 4. The chain link count is the number of links of chain suspended off the seafloor by the buoyant spheres. If a sphere was found imploded or if anything unusual was observed, this information was recorded. Figures 10 and 11 show an uncoated sphere and a coated sphere tethered off the seafloor. RESULTS Implosion Two spheres, 3 and 7, have imploded. Fragments of Sphere 3 were observed during the RUM inspec- tion to be scattered over an area of what appeared to Figure 10. View of uncoated sphere (No. 12) at a depth of 2,790 feet after 431 days. be a 25-yard radius. To retrieve the clock, the manipulator on RUM picked up the 5/8-inch chain to which the clock was attached. Once on the surface, it was learned that the clock was not retrieved. Implosion forces must have ‘‘blown” the clock off the chain. Hence, the time to implosion for Sphere 3 not obtained; however, from information obtained during the third inspection it has been deduced that the sphere imploded during descent. The Turtle operators thoroughly searched the Sphere 3 site for the clock, which was not located, but observations showed that fragments of concrete were spread over a radius of 50 yards. Also, the anchor was chain was not at the center of debris or at the loca- tion of highest fragment density. This information ital Figure 11. View of coated sphere (No. 13) at a depth of 2,635 feet after 431 days. Material on top of sphere is sediment. Nylon rope on left side of sphere was used to secure 5/8-in. chain around sphere (see Figure 4). meant that the sphere probably imploded during descent which allowed the fragments to disperse. In the case of Sphere 7, the fragments were all located within a 10-yard radius. Sphere 7 did not contain a clock, so the time to implosion is between 1 and 431 days. For Spheres 3 and 7, the P,/P;,, ratio was 0.72 and 0.58, respectively. This level of long-term loading was considered relatively low for implosion to occur. However, seven other spheres are subjected to P./P;,, ratios greater than 0.58, four of which have been inspected and are performing well. The concrete control block for Sphere 3 was retrieved. The compressive strengths of this block and other control specimens stored at on-land field Table 4. Inspection Data Chain Link Count” at— Emplacement Inspection No. 1 Inspection No. 2 | Inspection No. 3 dime i Implosion : Comments (By: CEL (By: Turtle (By: RUM (By: Turtle (aoe) Date: 23 Sep 71 | Date: 4Mar72 | Date: 26 Aug 72| Date: 1 Dec 72 u/ Time: 0 days) Time: 163 days) | Time: 340 days) | Time: 431 days) imploded 23 Insp. No. 3, observed sphere intact and floating high. Insp. No. 3, sphere intact but on seafloor. Insp. No. 3, chain tangled on block. * Number of links suspended off seafloor by buoyant sphere. Calculated number of links suspended off seafloor by sphere with concrete at room dry condition. 12 conditions and fog-room conditions are given in Appendix C. The control block from Sphere 7 was not retrieved as the Turtle was not rigged for a retrieval operation. Permeability The method used to determine the permeability of seawater through the concrete walls produced a fairly accurate indication of in-situ permeability behavior of the spheres. This method used the change in number (reduced number) of chain links to calculate the gain in weight of the sphere due to sea- water intake. The accuracy of the quantitative results depend on several approximations; these are discussed in Appendix D. The accumulative effect of these approximations is estimated to be a maximum of + 0.8 cu ft of seawater. This error can be reduced to + 0.3 cu ft by comparing the change in link counts from actual inspections instead of using the calcu- lated link count from zero days. Table 5 gives the total quantity of seawater intake, Q, for the different time intervals between emplacement and inspections. Seawater includes the seawater absorbed by the concrete and the seawater that permeated through the concrete. Figure 12 shows the Q versus time behavior. Three intake items of interest are observed. One item is that the uncoated concrete spheres have a greater Q than the coated spheres; after 431 days, the coated spheres showed an average Q of about 2.6 cu ft and the uncoated spheres about 3.6 cu ft. Another item is that the spheres which have been inspected twice showed a considerable decrease in the rate of sea- water intake. The last item is that Q increased for specimens at greater depth, but the increase was not pronounced. The actual quantity of seawater permeating the wall, Q,, was estimated by subtracting the quantity of absorbed seawater from the total seawater intake. Earlier work on 66-inch-OD spheres [8] showed that the concrete (same concrete as used in this study) absorbed approximately 3 percent by weight (or 7 percent by volume) of seawater. This corresponds to 2.0 cu ft of seawater absorbed by the concrete. Table 5 shows the Q, values for the different time intervals. At 431 days, the average Q, for the coated spheres was 0.8 cu ft and for the uncoated spheres was 1.6 cu ft. Reference 8 reports permeability results from two 66-inch-OD concrete spheres subjected to seawater hydrostatic pressure tests. The permeability data are shown in Table 6. D’Arcy’s permeability coefficient, K,, was determined from the data as an average of 0.13 x 10°!2 ft/sec. D’Arcy’s permeability coefficient can be expressed as follows for the spheres: Qt Wa Saas (1) where K, = permeability coefficient, ft/sec Qs quantity of permeability seawater, cu ft DT ="timessec t = wall thickness, ft A = exterior surface area, cu ft h = depth (or pressure head), ft Using the K, value of 0.13 x 10°12 ft/sec as a baseline, the data from the spheres in the ocean can be compared to that from the pressure vessel tests. Table 5 lists the K, values for the ocean spheres. In all cases, the permeability coefficient was lower for the spheres in the ocean than for the spheres in the pressure vessels. The average K. values for the coated spheres were 0.06x 10}? ft/sec at 163 days and 0.02 x 10°12 ft/sec at 431 days, and for the uncoated spheres were 0.11 x 10°}? ft/sec at 163 days and 0.06 x 10}? ft/sec at 431 days. Other K, values were those attained between the time interval of 163 to 431 days; for the coated spheres, no increase in Q, was observed, so K, was zero, and for the uncoated spheres the average K, was 0.04 x 101 ft/sec. The permeability data from the pressure vessel tests showed that a straight line curve of Q, versus log T fit the data with fair accuracy. The empirical semtlog relations’ for one sphere (specimen CWL-9A) at a simulated depth of 2,520 ft was: Q, 0.34 log 49 T 0.11 (2) & Equations 2 and 3 are presented in this report with time, T, in days. These equations are different from those in Reference 8 which give time, T, in hours. 13 2 a sdeq TEb-€91 103 Oy uatayyao05 Aryiqeaurag s,Ar1V,q pue B5 ‘JOMII1U] BUIIVAUIag 19IVMtIS ‘DO ‘9yPIUI 1aIVMeas 10) at) WIJ pajoesqns sem pure 1 nd QO°Z se payeuiNsa sem aja19U0d ayi Aq paqiosqe JaeMeas ay? ‘dy ‘Ai piqeauiiad 133eMeaIS UIeIGO OL 5 (syuty) Iv skeq TE 4-91 = (aj no) | (sur) | Gz no) (syury) ro) Iv ro) IV pajooid -191BM skeq OFE-0 s&eq £91-0 3121905 —10J ‘O ‘dxkIU] 19IVMEIS [2I0.L pure “Jy ‘uno Yury ur adueyD sAeq 1£b-0 vieg Aljiqvauliag “S aqeL 14 Total Seawater Intake, Q (ft?) Qis Average Nominal for Depth Symbol Sphere Nos. (ft) 4and5 4,100 11 3,100 10 and 12 3,000 13 and 14 2,500 15 and 16 2,200 17 and 18 1,900 uncoated sphere — — _ coated sphere —— — — half-coated sphere 0) 100 200 300 400 500 Time on Seafloor (days) Figure 12. Total seawater intake of concrete spheres. 15 and for another sphere (specimen CWL-6) at a simulated depth of 3,760 feet it was: Q, = 0.32 logyoT 0.01 (3) where T is time (days). Figure 13 shows a comparison between D’Arcy’s equation, Equation 1, using K, = 0.13 x 10! ft/sec and the empirical equations, Equations 2 and 3. Data from the ocean spheres are shown to be bracketed by the D’Arcy and empirical semrlog relations. D’Arcy’s 5.0 i ° Ocean Symbol Sphere O uncoated @ coated (@) half-coated Quantity of Seawater Permeating Wall, Q) (cu ft) N w tf) ° Empirical Semi-Log Relations Depth (ft) 3,760 (Eq 3) 1.0 2,520 (Eq 2) 1 10 — —— — Same sphere inspected twice relation assumes a constant rate of permeability, whereas the extrapolation of the empirical semi-log relation assumes a decreasing rate with time. It is not apparent at this time which approach defines the permeability behavior of the concrete spheres. Additional data from inspections are required. Sphere 8 was found intact but sitting on the seafloor after 431 days. A total seawater intake of 15.3 cu ft or more was required to overcome the positive buoyancy of the sphere. This quantity of sea- water was three to four times that of the other D’Arcy’s Equation, Eq 1 Depth (ft) 3,760 2,520 1,000 Time, T (days) Figure 13. Comparison of ocean sphere permeability data with the D’Arcy equation and the empirical semi-log relations as given in Reference 8. NY Table 6. Permeability Data (After Haynes and Kahn [8] ) Simulated Depth (ft) Specimen No. D’Arcy’s Permeability Coefficient, K, (ft/sec x 10°12) Permeability, Q, (cu ft) NOTE: Spheres started the test having the concrete in a wet condition. The procedure for obtaining wet-concrete walls was to place an uncoated sphere on the bottom of the pressure vessel and allow the seawater to fill the inside of the sphere, and then apply hydrostatic pressure. The pressure was maintained usually for 7 days at 500 psi or until the pressure became constant and showed no decrease, thus indicating that the voids of more significant size were filled with water. spheres, so it was evident that Sphere 8 leaked. Experience in fabricating concrete spheres has shown that periodically a specimen leaked at a concrete- epoxy joint. SUMMARY Of the original eighteen spheres emplaced at depths between 1,840 and 5,075 ft, fifteen spheres have been inspected at least once. Of the spheres that were inspected, the one at greatest depth was at 4,185 feet, and was performing well after 431 days. Two spheres have imploded; one sphere imploded during emplacement to the depth of 4,330 feet and the other sphere imploded during the time interval of 1 to 431 days at a depth of 3,725 feet. The quantity of seawater that had permeated through the concrete walls was about 0.8 cu ft for the coated spheres (waterproofed concrete) and 1.6 cu ft for the uncoated spheres (non-waterproofed concrete). 17 D’Arcy’s permeability coefficient, K,, was on the average 0.02 x 10°! ft/sec for the coated spheres and 0.06 x 10°12 ft/sec for the uncoated spheres between the time interval of 0 to 431 days on the seafloor. These K, values were less than the K, value of 0.13 x 10°!2 ft/sec obtained from pressure vessel tests on similar uncoated spheres for time intervals up to 42 days [8]. The concrete spheres are to remain in the ocean through 1981 with periodic inspections to determine implosion and permeability data. ACKNOWLEDGMENTS The author wishes to acknowledge the assistance of Mr. L. F. Kahn during the planning and fabrication stages, of Mr. N. D. Albertsen in emplacing the spheres in the ocean, of Mr. P. C. Zubiate as senior project technician, and of Mr. D. W. Widmayer in fabricating the spheres. REFERENCES 1. Naval Civil Engineering Laboratory. Technical Report R-517: Behavior of spherical concrete hulls under hydrostatic loading, pt. 1. Exploratory investigation, by J. D. Stachiw and K. O. Gray. Port Hueneme, CA, Mar. 1967. (AD649290) 2: . Technical Report R-547: Behavior of spherical concrete hulls under hydrostatic loading, pt. 2. Effect of penetrations, by J. D. Stachiw. Port Hueneme, CA, Oct 1967. (AD661187) 3h Relationship between thickness-to-diameter ratio and critical pressures, strains, and water permeation rates, by J. D. Stachiw and K. Mack. Port Hueneme, CA, Jun. 1968. (AD835492L) . Technical Report R-588: Behavior of spherical concrete hulls under hydrostatic loading, pt. 3. 4. . Technical Report R-679: Failure of thick-walled concrete spheres subjected to hydrostatic loading, by H. H. Haynes and R. A. Hoofnagle. Port Hueneme, CA, May 1970. (AD708011) 5: cylindrical hulls under hydrostatic loading, by H. H. Haynes and R. J. Ross, Port Hueneme, CA, Sep. 1970. (AD713088) . Technical Report R-696: Influence of length-to-diameter ratio on behavior of concrete 6. ; Technical Report R-735:Influence of stiff equatorial rings on concrete spherical hulls subjected to hydrostatic loading, by L. F. Kahn and J. D. Stachiw. Port Hueneme, CA, Aug. 1971. (AD731352) th . Technical Report R-740:Influence of end-closure stiffness on behavior of concrete cylindrical hulls subjected to hydrostatic loading, by L. F. Kahn. Port Hueneme, CA, Oct. 1971. (AD732363) 8. . Technical Report R-774: Behavior of 66-inch concrete spheres under short and long term hydrostatic loading, by H. H. Haynes and L. F. Kahn. Port Hueneme, CA, Sep. 1972. (AD748584) os . Technical Report R-785: Hydrostatic loading of concrete spherical hulls reinforced with steel liners, by H. H. Haynes, G. L. Page and R. J. Ross. Port Hueneme, CA, Apr. 1973. (AD 759684) 10: . Technical Report R-790: Influence of compressive strength and wall thickness on behavior of concrete cylindrical hulls under hydrostatic loading, by N. D. Albertsen. Port Hueneme, CA. June TOTS: t= . Technical Note N-——: Influence of steel bar reinforcement on the behavior of concrete spherical hulls, by N. D. Albertsen. Port Hueneme, CA. (To be published.) 12. Informal correspondence, J. Baker, Graduate student, University of California, Berkeley, CA, letter of 8 February 1973, to H. H. Haynes, Naval Civil Engineering Laboratory, Port Hueneme, CA. 13. Amelyanovich, K. K., Verbitsky, V. D., and Sintsov, G. M., “Results of research into performance of concrete and reinforced concrete members under high pressure head,” iv Proceedings of Federation Internationale de la Precontrainte (FIP) Symposium on Concrete Sea Structures, Tbilisi, USSR, Sep. 1972. {Translated London, 1972.] 18 Appendix A CONCRETE MATERIALS The mix design for the concrete is given in Table A-1. Transit-mix trucks delivered the concrete, and final determination of water content was based on workability. Table A-2 gives the properties of the fresh concrete; average values were (1) water-to- cement ratio of 0.40, (2) slump of 1-1/2 inches, (3) air content of 2.4 percent by volume, and (4) unit weight of 145.2 lb/cu ft. Compressive strength of the concrete at age 28 days (Table A-2) averaged 7,660 psi for the fog- room-cured specimens and 7,690 psi for the on-land field-cured specimens (moist-cured in wet burlap and wrapped in plastic for first 28 days). The compressive strength of the concrete at ages varying from 45 to 174 days was obtained prior to emplacing the spheres in the ocean (Table A-2). These strengths were used to calculate the short-term implosion pressure of the spheres (the compressive strength of the weaker hemisphere was used) so that projected emplacement depths could be calculated. For the uncoated spheres, the control cylinders were saturated with seawater prior to testing. The method of saturation was to place the specimens in a pressure vessel and apply 500 psi pressure for 7 days. The strength of saturated con- crete has been found to be 10% lower than room-dry concrete [8]. The coating was assumed to maintain the concrete in a dry condition, so the control cylinders were tested in a dry condition. Table A-3 is a copy of a typical mill test report on the portland cement used by the transit-mix supplier, Southern Pacific Milling, during the fabrication of the hemispheres. All of the cement meets ASTM specification C-150-70, Type H, Low Alkali, Portland Cement. X-ray diffraction patterns for three concrete blocks, W-15, W-39, and W-41, (Figures A-1 through A-3) for documentation of the were obtained chemical composition of the concrete at the early stages of the test program. At the end of the test program, which could be many years away, samples of concrete can be analyzed to determine whether or not the concrete has been attacked by the sulphates in seawater. Table A-4 gives the diffraction angle (20) of the expected intensity peaks for concrete attacked and unattacked by sulphates in seawater [12]. Table A-1. Concrete Mix Design Portland cement, Type II, low-alkali Santa Clara River aggregate Water-to-cement ratio = 0.41 Sand-to-cement ratio = 1.85 Coarse aggregate-to-cement ratio = 2.28 Water-reducing admixture = 2 02/slack of Plastiment 10) Material ; : Sieve Size Designation 3/8 inch no. 4 2, no. 8 13 no. 16 30 no. 30 58 no. 50 no. 100 pan 3/4 inch 3/8 inch no, 4 Coarse aggregate 19 penunuos 92} 219U0D jo uonipuop Juawiase|durg ueIdO 0} 101g 25 ‘ya8uais oatssaiduio5 pure ‘uontpuoy ‘adv dstg pue di dejing 19M poddeim (isd) skeq gz ie 93 ‘yaBuans aatssaidurog (aj n9/q]) Alsuaq (%) aumnjo, Aq quaquoy ny siapul[AD a1019U05 Ysai4 JO solasiiaqoeaeyD RIV JapulfAD [oaUOD a1aI9U0D *Z-V I1qRL oney quaulay -O7 -1918M p ON aiaydstuiay 20 ‘JapulfAd ul punoj a3¥dai88e ajeys papuedxa autos 2 ‘sAep £ 10} Isd OOS JapuN JaIVMeas UI pase|d siaput[AD 03 S19J91 19M “SUONIPUODS Pjalj Puv]-UO UWOIZ S1apuT[AD OI sJajar AIG 5 “slapulfAd [O1]U0D BUO]-"UI-Z] X 9 aaIyI JO asvIaAYy q ‘atayds ayi Jo araydsturay do ayi 03 siajos aSAy parst] saquinu asaydsiurayy 5 923019005 gosta pue (%) oney jo deping 19M ae auinjo,a Aq quawiay uonipuo) poddeiy, quaqUoyD ITY -01-191B aN Dv dstura quawase|durg uers9Q 0} 101g (isd) Ra aco ay ‘yaduans aatssaidwoy sAeq 87 1e oy pug ‘uonipuog ‘a38y ‘yasuans aatssoidwo7 saapulj[A9 aja19U05 yYsai4 jO sostiajoeieyD penunuoy *Z-v 3981 Zak Table A-3. Copy of Mill Test Report on Cement PACIFIC WESTERN INDUSTRIES, INC. LOS ROBLES CEMENT DIVISION POST OFFICE BOX 1247 e (805)248-6733 LEBEC, CALIFORNIA 93243 MILL TEST REPORT We certify that 17,982 bbls. of LOS ROBLES Portland Cement in Silo or Lot No. 1-802 has the following chemical and physical characteristics as tested in our plant laboratory: CHEMICAL ANALYSIS: FINENESS: Silicon Dioxide, Si0,_. . Blaine, Sq. Cm. per Gram Aluminum Oxide, Al,O3 . Wagner, Sq. Cm. per Gram Ferric Oxide, Fe,03. 4 Calcium Oxide, CaO . SOON INES: Magnesium Oxide,MgO_.. Autoclave, Percent Expansion Se eer sed TIME OF SETTING: Loss on Ignition Insoluiblede sear eye wee Vicat 1 hrs. Alkalies, Comb. asNa,O_ . Gilmore, Initial Set 2 hrs. Final Set 4 hrs. POTENTIAL COMPOUNDS: COMPRESSIVE STRENGTH: 3 CaO.Si0, iday 2 CaO.Si0, 3 days SiCAOFA ORs wy 8 a) : 7 days 4Ca0.Al,03.Fe,03. . . : 28 days . THIS CEMENT MEETS OR EXCEEDS THE FOLLOWING DESCRIBED SPECIFICATIONS: ASTM: C-150-70 Type II Low Alkali FEDERAL: SS-C-192g Type II Low Alkali CALIFORNIA: State Div. of Hwys. Std. Spec. 90-2.01 Mod. Type II Low Alkali OTHER: MAIN OFFICE: 3810 Wilshire Boulevard Pacific Western Industries, Inc. Los Angeles, California 90005 4-2-7.1 (213) 381-3181 CHIEF CHEMIST DATE D2, Table A-4. Expected Intensity Peaks [12] From X-Ray Diffraction Analysis of Concrete Attacked and Unattacked by Seawater Diffraction Angle (20) at Intensity Peak Material Remarks (deg) Concrete Attacked by Sulfates in Seawater 9.1 Ettringite, 3CaOA1,03 3CaSO,432H,0 Hydrocalumite, Ca, ¢Al,g(OH)54CO321H,0 May not be present. Gypsum, CaSO,2H,O0 Very soluble, may not be present. Calcite, CaCO; Due to carbonation. Formed at cold temperatures, agree es may not be present. Concrete Unattacked 18.1 34.1 Lime, Ca(OH), Created from hydrated cement. d peak : eae Tobermorite gel Created from hydrated cement. 32.3 C3S Traces of unhydrated cement, 3221 C3S and C,S usually hard to see in older 338i C3A concrete. 29.4 Calcite, CaCO; Due to carbonation. 10.5 20.9 Aggregates Some of the larger peaks from the 26.6" aggregate. 27.8 “ Quartz aggregate. 23 Concrete curing: on-land field Concrete age: 22 months Tube: Copper k-alpha, Current: 15 ma Voltage: 35 kv Time constant: 4 sec Scan rate: 1 deg/min Diffraction Angle, 20 (degrees) Figure A-1. X-ray diffraction pattern for concrete from W-15 control block. 24 imiimrs mena i i ee a aggregate (quartz) ian aggregate tobermorite gel (board peak) aggregate th chile Web alwed eotian St" ees MAM | | | me ee ies tT 44 41 38 3 32 29 26 23 20 17 14 11 8 Diffraction Angle, 20 (degrees) =~ s a Y a vo ae o a vo Fa ~ > aS a i=] vo y c = Tube: Copper k-alpha, Current: 15 ma Voltage: 35 kv Time constant: 4 sec Scan rate: 1 deg/min Concrete curing: on-land field Concrete age: 20 months Figure A-2. X-ray diffraction pattern for concrete from W-39 control block. 25 *y20]q [ONUOD [p-M WIZ a1919U0 OJ UsaIed UONDeAyJIP Avi-Kx “¢-W oINS1Ly syIUOW QZ :988 a1919U0D PpPy puvj-uo :Burimd aj919u0D = UIWI/Sap [ :91R1 URIS 39S $ :UBISUOD SUIT, AY SE :98RI]OA Bul Cy :quoqing Teydye-yaaddoy :aqny (zqienb) aieda133e (seaisap) 97 ‘ajsuy uonoeazyiq Pp gq gg Lad oO a io o oO (ajeos aatqeyar) Aqisuaquy 26 Appendix B SOIL PROPERTIES Table B-1. Soil Data (Core specimen obtained at 4,100 feet near Sphere 5; core diameter was 2.75 inches.) Properties of Soil Sample From Core by Intervals Bulk wet density (pcf) Water content (%) Vane shear strength (psi) Remolded shear strength (psi) Sensitivity Liquid limit Plastic limit Plasticity index Specific gravity Unified soil classification CH Type of soil clay-silt 27 Appendix C COMPRESSIVE STRENGTH OF CONCRETE FOR SPHERE 3 Even though Sphere 3 imploded on descent to the seafloor, the control block of concrete was not retrieved until 340 days later. This control block was fabricated of the same concrete as one of the sphere’s hemispheres, W-16. This concrete experienced a history of 172 days of on-land field curing and 340 days of in-ocean field curing. The other hemisphere, W-15, had a corresponding control block that was continuously stored out-of-doors; hence, this concrete underwent a continuous 514 days of on-land field curing. Simulta- neously, three 6 x 12-inch-long cylinders for both hemispheres underwent continuous fog room curing. The compressive strengths for the concrete are shown in Table C-1 and Figure C-1. The fog-cured concrete increased 23 percent in average strength, from 8,460 to 10,420 psi. The on-land field-cured concrete leveled off in strength at an average of 8,650 psi after 134 days. The in-ocean field-cured concrete decreased in strength from an average of 9,650 psi after 132 days of on-land curing to an average of 7,600 psi after 340 days in the ocean; this was a 21 percent decrease in strength. Wetting of the dry concrete would account for 10 percent of the decrease [8]; perhaps under the long-term hydrostatic pressure the total decrease in strength was due to saturation of the concrete. Previous work by Russians [13] showed a decrease in compressive strength of 28 percent due to saturating dry concrete under high hydrostatic pressure; however, the test procedure used to obtain the saturated concrete was not discussed. Concrete from block W-16 was analyzed by x-ray diffraction techniques. It was found that the concrete was not attacked by the seawater. 28 Curing Condition Hemisphere Fog Room Field® With Hemisphere® Fog Room Field at CELA? Fog Room Field? With Hemisphere? Fog Room In ocean® (at 4,400 ft for 341 days) Table C-1. Control Cylinder Data for Sphere 3 Saturated With Seawater Prior to Test Number of Control Specimens * First 28 days: moist-cured in wet burlap wrapped in plastic sheeting. > 6x 12-in.-long cylinders cored from block 18 x 18 x 14 inches. 29 Coefficient of Variation (%) Compressive Strength, £2 (psi) 8,520 7,260 8,840 10,470 8,650 8,400 7,940 9,650 10,360 7,600 (psi) ’ c Compressive Strength, f 12,000 10,000 § ° =) i) Sy ° ra) ro) 4,000 2,000 6 x 12-In.-Long Control Cylinders From Sphere 3 placed in ocean 100 200 Hemisphere No. W-15 W-16 Each point represents average of minimum 3 specimens Fog-room curing —— =—— On-land field curing — ———!In-ocean field curing 300 400 500 Age of Concrete (days) Figure C-1. Compressive strength of concrete for Sphere 3. 30 Appendix D CALCULATION OF SEAWATER INTAKE The method used to calculate the total quantity of seawater intake by the spheres depends on obtaining the change in number of chain links suspended off the seafloor by a sphere. The reduction in number of links is converted into quantity of seawater intake, Q. The accuracy of determining Q is dependent on several approximations. One approximation is the criterion by which the submersible operators counted the chain links. They counted only whole links; or, in other words, the bottom-most link counted was the one in a vertical position. Another approximation is estimating the original number of links suspended off the seafloor when the spheres had dry-concrete walls. The associated calculations are shown below, in part, and are completed in Table D-1. Buoyancy of Hull Dimensions D, = 65.886 inches and D; = 57.640 inches Weight of Displaced Seawater, Wp Wp = 64 pcf (86.64 cu ft) = 5,545 Ib Weight of Concrete Sphere, Wc Wc = 145.2 pef (28.625 cu ft) = 4,156 Ib Positive Buoyancy = 1,389 lb for bare concrete hull In-Water Weight of Components on Spheres S/Sainchve hain: Aer, Beye Ber wee Mie Moree ciel eve Ae AUER thn Beene a mme iee 67 |b Wiet.concrete:controliblock | ey) et 2) ey Clee cee 22 O81 Steelicomponents! 72s. oa espe as ky cy pel Loe eran enes) preven 40 Ib INERTIA CopeayoXonVsy Hews Ss BUR 4 a 5 go 6 8 a wm b 4 8 lb Load on Spheres 7-16 (also common load to other spheres). . . . 335 1b Glo (Gauiniriaclinenteyordde) oi5 6 6 a A 6 oe = Sag % a 20 Ib Batteries: (estimate doutairweloit)) arses a. esy ren tesco sun csr te nes 40 |b Commoniloddi. 5s) cnechin- ce ae fe See me Oe oo ee ee ees SONI LONG OM Gnas le go 9 6 Boe 8 6 6 5 os p o oe SOR ID Steclibar reinforcement Gn-water weight) 9) sy eee ie 150 |b Commoniloddiny) Aes, We tuaiweee tue case sy seal a ae chs the Si akleu leer ate MUeeeeet 313/921 byoyKel Whar Solevacas aly eho} 5 gg oo ow ofa & © oo o oy CHSy Io) Column D in Table D-1 was another approximation. This was the apparent weight gain of the system due to the change in volume of the sphere under load. Using data from Reference 8, it was assumed that the maximum long-term strain for the spheres at greatest depths was 2,500 min./in. This strain resulted in a 31 change in volume sufficient to reduce the buoyancy by 40 pounds. For the spheres in shallower water, a proportional buoyancy adjustment was made. It was estimated that the maximum error in the net positive buoyancy values was 50 pounds. In terms of chain links (2-1/4-inch chain), the error was +1.5 links; or in terms of seawater intake, the error was +0.8 cu ft. The error associated with permeability reading between inspections is +20 pounds, or +0.3 cu ft. t 32 Table D-1. Calculation of Number of Links Off Seafloor at Zero Days A Positive Buoyancy of Concrete Hull (Ib) B Cc D G E=A- =E Weight” of Weight® Apparent Capen ae +0) Weight® H iG : Net Positive Number Components of Weight Boyan of Each annie peek : et on Hull Shackles Gain (ib) Chain Link Off Seafloor (Ib) (Ib) (Ib)? (Ib/link) a : In-water weight. Due to change in volume of sphere under load. 33 LIST OF SYMBOLS A Exterior surface area, cu ft D; Inner diameter of concrete sphere, in. Do Outer diameter of concrete sphere, in. ite Uniaxial compressive strength of concrete, psi h Depth (or pressure head), ft K, Permeability coefficient, ft/sec Pe Short-term implosion pressure, psi P, Sustained pressure, psi Q Total quantity of seawater intake, cu ft Q, Quantity of seawater permeating wall of sphere, cu ft T Time, sec, hr, days t Wall thickness, ft, in. We Weight of concrete sphere, Ib Wp Weight of displaced seawater, lb 35 wire een 7) poe ara, a Tish oa Weleriiac ga * on chan pie ee ines ey 1). 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