1. Warm Vessel Leveling Islands (Piers)
SBN – Far Detector
Warm Vessel Leveling Islands (Piers)
Andy Stefanik for the Installation and Integration Team
January 17, 2016
CERN - Fermilab

2. Outline Vessel description Weight summary
Bearing pressure on the floor islands
Bearing pressure on the wall islands
Far Detector Building floor flatness
Support islands for the 20 warm vessel floor feet
Summary for the Review
Grout info
G-2 magnet base
NuMI Target Pile Grout Rails
Depth of concrete for the anchors
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

3. Vessel description
Iso view: Warm Vessel with cryogenic piping on the roof. Electronics are also installed on the roof.
32’
18.6’
Warm Vessel
72.5’
Outside dimensions
of the steel vessel plates
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

4. Vessel description Top view with the warm vessel roof removed
64.6’ inside
11.8’ inside
Cold Detector Vessel #1
Cold Detector Vessel #2
Warm Vessel Walls
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

5. Vessel description Lateral cross section view 11.8’ inside 12.8’
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

6. Vessel description The 20 support feet on the warm vessel floor
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

7. Vessel description Picture of the floor support foot
Schematic of the load path (No Scale):
45.3”
5.9”
(TYP)
46.5”
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

8. Vessel description 9” x 12” interface NO SCALE 36.5” ~5 to 6” 41.8”
A load normally spreads out at an angle of 45°. The load from the cold foot spreads out at 25° so we conclude the load is uniformly distributed on the warm vessel foot. In addition to this angle, the insulation crushes and helps distribute the load uniformly on the warm vessel foot.
9” x 12” interface
NO SCALE α
36.5”
~5 to 6”
45° y
41.8”
CAD
36.5”
24.5”
tan α = y/36.5”
y = 45/2 = 24.5”
α = 34° maximum
12”
∑ = = 36.5”
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

9. Vessel description ~1” 7.1” 31.5” ~23.5” Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

10. Maximum contact pressure on the floor islands
The machining allowance on this plate to adjust for high elevation is 25 mm. 25 mm < 126 mm.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

11. Vessel description Picture of the wall support feet 6.8”x 12.6”
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

12. Weight summary (pounds)
Warm vessel floor and walls – 165,000 (Shipping weight, which is 10% more than the CAD model)
Warm vessel roof and walk way – 57,500 (CAD model + 10%)
Foam insulation – 37,000 (CAD model +10%)
Cold vessel and detector (No LAr) – 120,000 (CERN)
LAr in cold vessel – 853,000 (Full with no detector inside.)
Piping and equipment installed on the roof – 60,000 (Guess)
∑ = 2,265,500 pounds = 1,133 US short tons
For the floor supports: The total weight is uniformly distributed on the 20 warm vessel floor support feet; ignore the wall feet.
Load on each floor support foot = 2,265,500/20 = 113,275 pounds = 56.7 tons.
Use 15% contingency on the island design load.
Thus, floor island design load = 113,275(1.15) = 130,300 pounds = 65 tons.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

13. Weight summary
The load path for 85% of the total weight goes through the 20 floor support feet. The 85% includes both of the cold vessels, their internal detectors, and the LAr in them: [2(853, ,000)] / 2,265,500 = 0.85.
Thus, having the 20 floor islands carry all of the load is not too harsh of a design basis to calculate the bearing pressure.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

14. Maximum loaded contact area on the floor islands
Each pair of center floor support feet share a common member. Thus, this member transfers twice the load as the rest of the support.
46.5”
45.3”
Pair of center support feet
5.9”
(TYP)
Single support foot
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

15. Bearing pressure on the floor islands
Contact area of one single floor support = 1,480 in^2
Bearing pressure on a single floor support island = 130,300 pounds/1,480 in^2 = 90 psi.
Bearing pressure on the common member in a double floor support island = 90 psi (2) = 180 psi.
Minimum ultimate compressive strength for Unisorb Bulk Pour V-100 Epoxy Grout structural epoxy grout is 15,000 psi after 7 days of curing, and 16,000 psi after 28 days.
Why epoxy grout? In my notes from our Nov 17-18, 2016 meeting with Marzio and Claudio, I wrote “Epoxy grout base” in my notes when Marzio was describing the “Engineered shims” to compensate for as-built floor flatness. We need to confirm with Marzio and Claudio that epoxy grout is a requirement.
Grout product data sheet: Grout safety data sheet:
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

16. Bearing pressure on the wall islands
The wall support feet carry about 100% – 85% = 15% of the full design load.
[2,265,500 (0.15)] * 1.15 ~ 400,000 pounds. Note: This weight includes the floor which strictly speaking should be subtracted from the bundled total on slide 6 because the floor weight is supported on the floor islands, not the wall islands.
Number of wall support feet= 38
Contact area of one wall support foot ~ 80 in^2
Load on one wall support foot = 400,000/38 = 10,500 pounds
Bearing pressure on a single wall support island = 10,500 pounds/ 80 in^2 = 132 psi < 180 psi calculated for the floor islands on the previous slide.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

17. Far Detector Building floor flatness
The Far Detector will be installed on the building pit floor
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

18. Far Detector Building floor flatness
The Far Detector Building pit floor has been surveyed by the Fermilab Alignment Group to measure its flatness. Here is a picture of the survey grid.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

19. Far Detector Building floor flatness
The 4 corners and center of each floor support area were surveyed.
Floor height variation: 0 is the high point and the lowest point is -0.8”. I will round this to 1”.
The survey report is in SBN-doc-1525.
The wall supports will be shimmed to the as-built dimensions.
We will use flow-able structural epoxy grout to level the floor support islands and provide a relatively flat plane on which the detector will be placed.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

20. Support islands for the 20 warm vessel floor feet
The underside of the bearing plate at the floor high spot is set 3” above the local high point. The flatness is adjusted to +/- 1 mm max. Each bearing plate has 3 tapped holes for jacking screws to adjust elevation and flatness.
Elevations of the other 19 bearing plates are set to the elevation of the first bearing plate to the tolerance of +/- 1 mm maximum. Flatness of each bearing plate is adjusted to +/- 1 mm maximum.
G-10 ELECTRICAL ISOLATION, 0.125” THICK
RUBBER-STEEL ISOLATOR, 0.6” THICK
BEARING PLATE, 0.5” THICK
STRUCTURAL EPOXY GROUT BASE TO LEVEL THE 20 FLOOR SUPPORT AREAS, THICKNESS RANGES FROM 3” AT THE HIGH SPOT TO 4” AT THE LOW SPOT
UNEVEN FLOOR
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

21. Support islands for the 20 warm vessel floor feet
After the 20 pads are in position, grout dams are installed around each bearing plate.
Each bearing plate will have vent holes drilled through it if required by the grout manufacturer’s instructions.
Pour the grout.
After the grout cures, remove the grout dams and the jacking screws.
As-built survey for elevations and flatness.
Place the isolator pad and G-10 sheet on each bearing plate.
Ready to use.
G-10 ELECTRICAL ISOLATION, 0.125” THICK
RUBBER-STEEL ISOLATOR, 0.6” THICK
BEARING PLATE, 0.5” THICK
STRUCTURAL EPOXY GROUT BASE TO LEVEL THE 20 FLOOR SUPPORT AREAS, THICKNESS RANGES FROM 3” AT THE HIGH SPOT TO 4” AT THE LOW SPOT
UNEVEN FLOOR
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

22. Support islands for the 20 warm vessel floor feet
Outside support island dimensions are 2” larger than the outside dimensions of the warm vessel feet. This is 1” beyond the foot.
Total thickness of the support pad at the floor high spot = ∑ = = 4.25”.
Total thickness of the support pad at the floor low spot = ∑ = = 5.25”.
G-10 ELECTRICAL ISOLATION, 0.125” THICK
RUBBER-STEEL ISOLATOR, 0.6” THICK
BEARING PLATE, 0.5” THICK
STRUCTURAL EPOXY GROUT BASE TO LEVEL THE 20 FLOOR SUPPORT AREAS, THICKNESS RANGES FROM 3” AT THE HIGH SPOT TO 4” AT THE LOW SPOT
UNEVEN FLOOR
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

23. Summary for the Review
The bearing load on the structural epoxy grout has been calculated at 180 psi maximum.
Thickness of the structural epoxy grout layers will range from 4” to 5”.
Minimum ultimate compressive strength for Unisorb flow-able structural epoxy grout is 14,000 psi for our thickness range after 7 days of curing.
Items to discuss with the structural epoxy grout vendor:
Details of our application.
Best product for our application?
Can we successfully pour and cure a full size island?
Load capacity as a function of our temperature range?
Installation instructions.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

24. Grout info
Technically, we can use either epoxy or cement-based grout. For our job, the only difference is that epoxy bonds to steel, whereas cement-based grout does not.
The warm vessel does not have anchor bolts. Maybe this is why Marzio said “epoxy grout base.”
We need 100 cubic feet of grout. The grout vendor recommends 10% extra. So, our requirement is 110 cubic feet.
One kit of Unisorb Bulk Pour V-100 Epoxy Grout yields 2 cubic feet of grout. The kit cost is $500 for our quantity.
We need 110/2 = 55 kits. The cost is $500*55 = $27,500.
The unit epoxy grout cost is $500/2 = $250/ft^3 = $0.145/in^3. Unit cost for hot-rolled steel is $0.50 to $0.75/pound (low, remember Jim said ~$1/pound). $0.75/pound = $0.21/in^3.
Cost of 110 cubic feet of cement-based grout ~= $5,500 plus the cost of 3/8” pea gravel mix, grout to gravel.
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

25. G-2 magnet base
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

26. NuMI Target Pile Grout Rails
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting

27. Depth of concrete for the anchors
Nov 18, 2016
Andy Stefanik SBN-FD Joint Installation & Integration Meeting