Urethane foam void filling. Innovative technology summary report

Under the decontamination and decommissioning (D and D) Implementation Plan of the United States Department of Energy`s (DOE`s) Fernald Environmental Management Project (FEMP), non-recyclable process components and debris that are removed from buildings undergoing D and D are disposed of in an on-site disposal facility (OSDF). Critical to the design and operation of the FEMP`s OSDF are provisions to protect against subsidence of the OSDF`s cap. Subsidence of the cap could occur if void spaces within the OSDF were to collapse under the overburden of debris and the OSDF cap. Subsidence may create depressions in the OSDF`s cap in which rainwater could collect and eventually seep into the OSDF. To minimize voids in the FEMP`s OSDF, large metallic components are cut into smaller segments that can be arranged more compactly when placed in the OSDF. Component segmentation using an oxy-acetylene torch was the baseline approach used by the FEMP`s D and D contractor on Plant 1, B and W Services, Inc., for the dismantlement and size-reduction of large metal components. Although this technology has performed satisfactorily, it is time-consuming, labor-intensive and costly. Use of the oxy-acetylene torch exposes workers to health and safety hazards including the risk of burns, carbon monoxide, and airborne contamination of residual lead-based paints and other contaminants on the surface of the components being segmented. In addition, solvents used to remove paint from the components before segmenting them emit flammable, noxious fumes. This demonstration investigated the feasibility of placing large vessels intact in the OSDF without segmenting them. To prevent the walls of the vessels from collapsing under the overburden or from degradation, an innovative approach was employed which involved filling the voids in the vessels with a fluid material that hardened on standing. The hardened filling would support the walls of the vessels, and prevent them from collapsing. This report compares the cost and performance of the baseline segmentation technology and the innovative void filling technology using expanded polyurethane foam