7th International Conference on Nuclear Engineering

Tokyo, Japan April 19-23, 1999

ICONE - 7151

THE FRENCH NUCLEAR POWER PLANT

REACTOR BUILDING CONTAINMENT
IMPROVING CONFINEMENT PERFORMANCE WITH THE LATEST
CIVIL WORKS TECHNICS FOR STRUCTURE INTEGRITY,
DYNAMIC BEHAVIOUR AND SEISMIC DESIGN
Pierre ROUELL
ELECTRICITE DE FRANCE
NUCLEAR DEPARTMENT

Engineering and Construction Division

B.P. 900
92542 MONTROUGE CEDEX
FRANCE
E-mail : pierre.rouelle@de.edfgdf.fr
1. INTRODUCTION
The technique of prestressed concrete has been widely associated with the construction of
nuclear containment within the French nuclear program since 1962.
The two components of this technique, concrete and prestressing have been continually
improved.
As a result of the use of this technique, an excellent containment quality has been
achieved, this, being accompanied by a high level of operational safety with regard to the
extreme stress cases possible.
These extreme cases are the loss of coolant accident and the design basis earthquake.
The experience acquired during the construction of the French nuclear program, notably
with the French standard project from 1974, has been used advantageously for the design
and construction of the containment for the most powerful 1450 MWe series of nuclear
power stations and can be reasonably considered for the next European Pressurised
Reactor.
2. FROM 900 MWe TO 1450 MWe AND NEXT EPR 1500 Mwe
2.1. The models
) 900 MWe (fig. 1)
The containment for the 900 MWe pressurised water reactors consists of a single
prestressed wall with a steel impermeable liner covering the full internal surface.

1 - Copyright 1999 by JSME

) 1300 then 1450 MWe (and, later, EPR 1500 MWe) (fig. 2 and 3)
In the 1300 MWe and 1450 MWe (and 1500 MWe project), the containment is
similar.
The Reactor building of a 1450 MWe nuclear power plant (the latest step in terms
of technology built by EDF that is called N4 in the jargon) consists of 2
concentric containment walls (fig. 2). The inner containment wall, biaxially
prestressed and 120 cm thick, is designed to withstand an internal pressure of
0.53 MPa, which leads for the units to a mean initial prestress of 9.3 MPa along
the vertical axis (zz) and 13.3 MPa tangentially (). The outer one, 55 cm thick,
designed to withstand external aggressions, is made of reinforced concrete.
Finally, the space left between the two containment walls is kept in depression
(0.0015 MPa) in order to suck in and filter the possible leaks from the inner
containment. The construction of the containments lasts 5 years; the prestressing
begins at the end of the 2nd year and takes 1 year, in a complex site staging. The
Reactor is commissioned approximately 7 years after the start of construction.
To simplify, EDF must justify in front of the French Safety Authority (equivalent
to US-NRC) the capability of the inner containment wall to ensure, in case of an
accident, a leak rate less than 1.5 % per day of the total mass of fluids in the
containment at the LOCA temperature and pressure scenario (Loss Of primary
Coolant Accident that leads to a mean temperature of 160 C and an absolute
pressure of 0.53 MPa). To evaluate experimentally this leak rate, each
containment undergoes a leakage test at 0.53 MPa in dry air at atmospheric
temperature at the end of the civil engineering construction (containment preoperational pressure test), at the first refueling shutdown and then periodically
every 10 years. Only the 1.5 % leak rate is mandatory but in the case of the
leakage test, the leak rate should not exceed the value of 1 % that is considered as
a construction criterion.
The move from 900 MWe to 1300 MWe and now 1450 MWe is accompanied by
improvements of the projects and construction methods:
the elimination of the steel liner from the internal wall and the creation of an
external wall, reducing the level of stresses of thermal origin,
the construction of this external wall at the beginning of civil works facilitates
the carrying out of the projects by permitting the execution of prestressing
operations with great flexibility of phasing and without interferences to the
construction of neighbouring structures : previously, in the case of single-wall
containment, parts of the structures were left waiting until the prestressing was
completed.
Fig. 1

Fig. 2

Fig. 3

CROSS SECTION OF CONTAINM ENT

2 - Copyright 1999 by JSME

2.2. CONCRETE
In a NPP where the main goal is to maximize the leaktightness of the containment and
thus to minimize the risks of cracking, the qualities or technical specifications that are
asked to the concrete are mainly the following:
1. A good stability of fresh concrete to ensure a minimum segregation in the
formworks,
2. A low viscosity of fresh concrete allowing it to be pumped over a distance greater
that 100 m;
3. A low autogenous shrinkage (hydration shrinkage) in order to minimize the stresses
that develop at construction joints;
4. A low exothermia of the hydration reaction to minimize the thermal shrinkage
responsible for periodic (2 m) vertical cracks on the structure. The temperature
increase due to hydration is very important for this kind of structure because of the
size effect;
5. A low permeability in air and water and a low porosity of the concrete;
6. A good durability (low carbonation, low chloride penetration, etc.) since the
Reactor containment is designed to have a lifespan greater than 50 years;
7. Low delayed strains (creep and shrinkage) to ensure a minimum prestress loss at 50
years;
8. A high tensile strength to reduce cracking.
As it can be seen above, the compressive strength will be a logical consequence of some
of the above properties.
From this technical specification list, the final choice by EDF has been based mainly on
the work of three researchers in LCPC, Dr. F de Larrard [2, 5] in the formulation,
optimisation of mix design and mechanical properties of HPC, Dr. P. Acker [1] in the
physico chemical properties of concrete and Dr. J. -M. Torrenti [8] in the modelling of
temperature increase and stress development in early age concrete.
It is now known that it is possible to improve the intrinsic properties of concrete with an
optimisation of its granular skeleton and addition of new products like superplasticisers,
fillers and silica fume in order to significantly increase the compressive strength of
concrete. However, the above technical specifications can be obtained for a High
Performance Concrete (as opposed to High Strength Concrete where the main focus is
the strength). Indeed, properties (1), (5), (6) and (7) are highly correlated to the
compactness of the concrete. In order to reduce the exothermia of the concrete (4), it
has been decided to reduce the amount of cement and replace it by addition of fillers
(for compactness) and silica fume (to ensure an even better compactness without
diminishing the compressive strength too much). In order to ensure low delayed strains,
(3) and (7), a good possibility is to reduce the volume of cement paste (cement + water
+ silica fume). In parallel, in order to obtain a low autogeneous shrinkage (often very
high for HSC compared to normal concretes) a good solution is to have a high
water/cement ratio close to 0.6 where the autogeneous shrinkage is greatly reduced.

3 - Copyright 1999 by JSME

Finally, the basic creep will be quite low due to the low volume of cement paste, the
drying shrinkage will also be low due to the low total amount of free water and the
drying creep was experimentally measured very low (6) as is rather usual for a
HSC/HPC with silica fume.
All this analysis has been performed and presented internationally in [3, 4].
Furthermore, as far as the long run is concerned, an experimentally based simulation
performed in [6] shows that the delayed strains and the prestress losses expected on the
120 cm containment wall should be almost twice lower that for the regular concrete.
2.3. Prestressing
While maintaining the basic concepts and technology that permitted the development
of the 900 MWe (fig. 4), the standard project, and particularly:
the technique of placing prestressing cables by pushing a strand at a time into the
ducts,
the verification of moderate and regular values of coefficients of friction,
the final protection of these same cables after stressing by grouting with a special
cement grout,
resulted in the adoption of the following arrangements for P'4 1300 MWe / N4 1450
MWe units (fig. 5) (and EPR 1500 MWe project):
Fig. 4
PWR 900 MWe

Fig. 5

P'4 PWR 1300 MWe

and N4 PWR 1450 MWe

PRESTRESSING LAYOUT

4 - Copyright 1999 by JSME

The figure 5 arrangements shows the difference with the 900 Mwe:
use of higher strength 37T15S (even 55T15S for EPR) tendons,
use of complete revolution horizontal tendons instead of 3/4 revolution,
use of "inverted J" vertical tendons continuing across the dome instead of pure
dome tendons

These arrangements enabled the number of vertical buttresses to be reduced to two

which had the double advantage of situating these buttresses outside of the material
lock zone, and also to enable the threading and stressing operations of a same tendon
to be performed from a single work platform.
Similarly, for prestressing the dome, the use of vertical tendons continuing across the
dome in two layers - instead of three- had the effect of reducing the anchorages
number while lowering their level, therefore creating an improved distribution of
prestressing forces in the peripheral ring girder zone.
The increase in the average length of tendons, resulting in the reduction of the
number of anchorages, also brought about a simplification of the whole anchorage
recess geometry and a reduction of the number of prestressing operations.
It was however essential to ensure that from a technical point of view, the
differences between the initial unit tensions had only minor consequences on the
evaluation of suitable prestressing forces at the time of testing the containment and
even more negligible during the service life of the structure (see III).
These different arrangements have, without a doubt, contributed positively in the
reduction of construction costs (see IV).

5 - Copyright 1999 by JSME

STRAND
MODEL

SITE

TENDON
Number Initial tenof strand sioning Kn

Anchorage

JACK

2450

12T15

Freyssinet SF

19

3928

19T15
monogroup
system

Freyssinet K500

252,1

19

3928

19T15
monogroup
37T15
monogroup

Freyssinet K500

MM

Smm2

RkN

15,2

139

240

12

15,2

139

252,1

15,2

139

900 MWe - CP0

USA - 3rd Generation
Single wall Containment
with steel liner
900 MWe - CP1
EDF - 1st Generation
Single wall Containment
with steel liner
900 MWe - CP2
EDF - 2nd Generation
Single wall Containment
with steel liner

FESSENHEIM
BUGEY
TIHANGE

CRUAS

15,2

139

252,1

37

7649

1300 MWe - P4
EDF - 1st Generation
Double wall Containment
without steel liner
1300 MWe - P'4
EDF - 2nd Generation
Double wall Containment
without steel liner

PALUEL
ST ALBAN
FLAMANVILLE

15,2

139

252,1

37

7649

CATTENOM 1-3-4
CATTENOM 2 (Val
(Hal

15,2
15,2
15,7

139
139
150

252,1
252,1
265

37
37
37

7649
7649
7844

15,7

150

265

36

7632

15,7
15,7
15,7
15,7
15,7

150
150
150
150
150

265
265
265
265
279

36
37
37
37 and 55
54

7632
7844
8258
8258
12023

DAMPIERRE
GRAVELINES
TRICASTIN
BLAYAIS
ST LAURENT
CHINON

BELLEVILLE
PENLY
NOGENT
GOLFECH
1450 MWe - N4
EDF
Double wall Containment
without steel liner
1500 MWe - EPR
NPI
Double wall Containment
without steel liner

CHOOZ l
CHOOZ 2
CIVAUX 1
CIVAUX 2

Freyssinet K1000

37T15
monogroup

GPN ZPE1000

37T15
monogroup

GPN ZPE1000

37T15
monogroup
"
55 C 15 locally
55C15
Systme C

GPN ZPE1000

C 1500 FE
C1500 FE

6 - Copyright 1999 by JSME

3. SAFETY / INTEGRITY
In 1990, the Engineering and Construction Division of Electricit de France (EDF) was
choosing a High Strength / High Performance Concrete (HSC/HPC) as defined in II.2. for
the internal containment of CIVAUX 2 Nuclear Power Plant (NPP) Unit near Poitiers, the
third and last barrier in case of an accident.
From January 17th to 24th, 1996, the Reactor containment of the Civaux 2 unit, has
successfully undergone its containment building pressure test up to 0.53 MPa (absolute
pressure) which corresponds roughly to 5.3 times the atmospheric pressure. The leak rate
obtained, 0.19 % per day of the total mass of gas (dry air for the leakage test) present in
the containment, can be regarded as a world record for this kind of double prestressed
concrete containment design without a metallic or composite liner. This leak rate is firstly
to be compared with the construction criterion of 1 % (in the case of a double
containment) and secondly with the leak rate of the Civaux 1 unit (same design but normal
concrete instead of a HPC), equal to 0.38 %, that is, exactly twice as much as for the HPC.
The announced leak rate of 0.19 % per day of the total mass of gas present in the
containment corresponds to a leak volume of 28.7 m per hour measured in normal
conditions at 0 C and atmospheric pressure (1.013 105 Pa). A large part of this volume
goes through concrete micro-cracks, porosity but mainly through the cracks formed at
early age which are due to thermal shrinkage combined with autogenous shrinkage. These
cracks have been for sure re-closed by the prestressing forces. However, they may partly
re-open when the compression of the concrete diminishes as long as the pressure in the
containment increases.
So, the leak rate of the containment is closed to 0.162 % per day, which corresponds to the
leak rate safety criterion of a single containment with a metallic liner (as was previously
taken into account on the EDF 900 MWe NPP containment).
The results of EDF N4 technology double walls containment leak tests - Comparison with
the mean of all the EDF NPP double containment. - is as follows:

Leak rate in % per day

0,9
0,8

Mean of all double

containment

0,7
0,6

0,75 %

EDF N4 technology

0,5
0,4
0,3

0,34 %

0,39 %

0,38 %

0,2
0,19%

0,1
0

Mean

Chooz 1

Chooz 2

Civaux 1

Civaux 2

7 - Copyright 1999 by JSME

4. COST SAVING / ECONOMY

As indicated previously, the arrangement adopted enabled to obtain a reduction of
construction costs, and it seemed interesting from this point of view to examine
comparatively most currently built containment.
More precise values of expenditure or cost saving can be easily evaluated by nuclear civil
engineering specialists. Site conditions and lead time limitations that are so determinant
under the circumstances, must be taken into consideration when making an estimation.
From the French experience in the construction of containment, it should be emphasised
that all the technical improvements adopted when passing from 900 MWe to 1450 MWe
had a very beneficial influence on cost saving for the project.
It can in fact be estimated that for a performance 61 % higher (1450 MWe against
900 MWe) the overall expenditure for the civil engineering construction of containment is
only increased by 30 % including the HSC/HPC using.
The cost of the construction, when correlated to the power level, is consequently reduced
by 19 % (1.30/1.61 = 0.81).
On an investment point of view, the lifespan increasing from 40 (N4) to more than 50
years (EPR) is an additional cost saving.

5. WHAT KIND OF CONTAINMENT FOR THE FUTURE ?

As it was explained, the step that was conducted for Civaux 2 has allowed the overall
properties of the prestressed concrete used to improve a lot. It is however only the first
stage. The second stage consists really in designing the structure for a HPC/HSC using in a
more adequate way the margins given by the performances of the concrete such as the
compressive strength and the low creep and shrinkage delayed strains in order to diminish
the extra thickness of certain parts of the structure where thermal cracking happens
preferentially and finally impose a higher level of prestressing in order to improve the
overall safety of the nuclear plant.
This last possibility has already been chosen for the future European Pressurised Reactor
(EPR) that EDF is developing with Siemens and Framatome in the framework of NPI
(Nuclear Power International). EPR will be built with a HPC and will be designed to
withstand an internal pressure of 0.65 MPa with a thickness of only 130 cm.
This technique, allowing more stresses with the same geometry, unites common interest :
SAFETY / INTEGRITY and ECONOMY / COST SAVING.

8 - Copyright 1999 by JSME

6. ACKNOWLEDGEMENTS
It would be too long to thank every person that has participated in this success.
However, the author would like to mention EDF SEPTEN-GC (Services Etudes et Projets
Thermiques et Nuclaires - Division GC), EDF-CNEN (Centre National d'Equipement
Nuclaire), GPN ("Groupement pour la Prcontrainte Nuclaire" of French prestressing
companies) with FREYSSINET Cy, that have been in charge of the prestressing works,
French Civil Works Companies in charge of the French NPP containments construction
and COYNE & BELLIER, the Design offices responsible for the calculations and the
constructions drawings of the containments.

1970's Only one 19 T 15 prestressed containment wall with steel liner.

1980's Two containment walls:
one 37 T 15 prestressed concrete inner wall without steel liner,
one reinforced concrete outer wall.
1990's Two containment walls:
one 37 T 15 S prestressed high performance concrete inner wall without steel
liner,
one reinforced concrete outer wall.
2000's Two containment walls:
one 55 C 15 S prestressed high performance concrete inner wall without steel
liner
one reinforced concrete outer wall.

CONCLUSION:
Our civil engineering answer to increase the safety level whilst lowering the costs:
IMPROVE EVER MORE CIVIL WORKS TECHNICS, NOTABLY IN
PRESTRESSING AND CONCRETE PERFORMANCES

9 - Copyright 1999 by JSME

REFERENCES
[1]

Acker P. (1988) "Comportement mcanique du bton : apports de l'approche

physico-chimique", Rapport de recherche LPC n 152.

[2]

de Larrard F. (1988) "Formulation et proprits des btons trs hautes

performances", Rapport de recherche LPC n 149.

[3]

de Larrard F., Acker P. (1990) "Un exemple d'ingnierie du matriau : amlioration

de l'tanchit l'air des enceintes internes de centrales nuclaires. Intrt de
l'emploi d'un bton hautes performances de formulation spciale", Rapport des
Laboratoires LPC, Srie Ouvrages d'Art, OA-7.

[4]

de Larrard F., Ithurralde G. Acker P. Chauvel D. (1990) "High-Performance

Concrete for a Nuclear Containment", 2nd Int. Conf. on "Utilisation of HSC",
Berkeley, ACI SP, pp. 121-127.

[5]

de Larrard F., Malier Y. (1990) "Engineering properties of very High Performance

Concrete" in "High Performance Concrete - From materials to structures", Y. Malier
Editor, Presses de l'ENPC, pp. 85-114.

[6]

Granger L. (1995) "Comportement diffr du bton dans les enceintes de centrales

nuclaires - Analyse et modlisation", PhD Thesis of Ecole Nationale des Ponts et
Chausses (France).

[7]

Ithurralde G. (1992) "Permeability, the owner's point of view", in "High

Performance Concrete - From materials to structures", Y. Malier Editor, Presses de
l'ENPC, pp. 276-294.

[8]

Torrenti J.M., Paties C, Piau J.M., Ackder P, de Larrard F. (1992) "La simulation
numrique des effets de l'hydratation du bton", Colloque Stru Co Me, Paris.

[9]

Granger L. (1996) "Civaux 2 Nuclear Power Plant Unit - A High Performance

Containment".

10 - Copyright 1999 by JSME