1. Roof design Bunker Project CDR
Dawid Patrzalek
Mechanical Design Engineer
28 April, 2019

2. Agenda Blocks construction Blocks pinning strategy
Installation strategy
Dilatation joints
Monolith skirt shield wall interface
Statistics

3. Blocks construction – new design overview
Since the IR held in June 2017, significant progress has been achieved:
Roof’s design has been optimized
Detail design of the roof has been finished
Key detail drawings have been done
All required documentation has been written
Design wise, the roof is finished and ready for manufacturing.

4. Blocks construction – new design overview
Level
Layer
In total:
31 slabs (50 mm each)
7 layers
3 levels
Slab
Roof layering
Layer no.
Material
Thickness [mm] 1
Borated HDPE
100 2
Steel 50 3
HDPE
200 4
450 5
400 6
250 7
Total thickness of the roof
1550
Hook clearance
Description
Value [mm]
Distance from TCS to the hook
6000
Distance from TCS to the roof
1700
Roof thickness
1550
Roof slabs flatness imperfections 85
Roof blocks spreader bar height
1200
Hook clearance left
1465

5. Blocks construction – assembly
Steel slabs welded together on the edges
Borated HDPE slabs supported by the pin assemblies
Pin assemblies bolted from top to the steel slab
Lifting pockets integrated into the steel slabs
Frame’s pins welded to the steel slabs
Hole–slot solution ensures isostatic design
M42 threaded connection
Lifting pockets
M42 nut and washer
Fillet weld
Butt welds (8x500 mm)
Pin assembly
M36 bolt

6. Blocks – hand and FEA calculations
Both hand and FEA calculations have been performed:
Welds calculations,
Bolt connections calculations,
Deformation of the steel and HDPE slabs
All of the calculations have been performed for the worst-case scenario block in hanging position, in accordance with SS-EN
For full calculations report, please refer to ESS

7. Blocks pinning – design overview
It is mandatory to pin all of the blocks together across all of the levels, due to H4 seismic event.
Rounded shape pin creates a point contact with the hole, what mitigates jamming possibility during the blocks installation.
1st level blocks to frame pinning:
Ø60 mm hole, Ø58.1 mm pin
From R6.2 m to R9 m – two pins and two M36 bolts per block
Outwards of R9 m – two pins per block
R6.2 m box beam
M36x580 mm bolt
Pin
Rounded shape pin

8. Blocks pinning – design overview
1st to 2nd, 2nd to 3rd level pinning
Ø37.5 mm hole or slot, Ø35.6 mm pin
Two pins per block
Hole–slot connection provides isostatic connection
Hole
Slot

9. Blocks pinning – installation clearance gaps
Position deviation of the blocks after the installation can be calculated in accordance with ISO 9013 (Tolerances for thermal cutting) and ISO 2768 (Tolerances for linear and angular dimensions).
20 mm clearance gap in 2nd level
Level no.
Min. clearance gap [mm]
Clearance gap [mm] 1
14.6 15 2
19.0 20 3
23.5 25

10. Blocks installation - strategy
Thanks to the pins, which provide good position accuracy of the blocks, none specific pattern, nor strategy is required during an installation of the blocks, although:
Blocks are not interchangeable
Blocks have to be installed level by level (lower levels have to be installed first)
In order to avoid mistakes during an installation, each block will be marked (painted labels on two sides and on top of each block), e.g. Block NW stands for:
North-West Sector
Second level
First row
Third block
For more detailed installation and labelling instruction, please refer to ESS
NW 2.1.3
SE 2.2.1

11. Blocks installation – cranes coverage areas
Each block of the roof has been designed in order to be reachable by the Monolith, or by the Experimental Hall crane.
Experimental Hall crane coverage area
Cranes crossover (load interchange) area
Monolith crane coverage area
Third level block and its CoG

12. Blocks installation – access cases
The table presents illustrative access cases, as each one can be fully customized.
Location
Number of required lifts
W6 (MAGIC), R6.2-R28 41
N8-N9, R6.2-R15 27
N8-N9, R6.2-R9 12
N8, R9-R11.5 11
N8, R6.2-R9 6

13. An access case example - LOKI
A full, 6° access to LOKI (N7 beam line) requires 16 lifts:

14. Dilatation joints – the newest design overview
The dilatation joints must assure 65 mm clearance between D02 and D01/D03, in order to compensate big movements during a H4 seismic event:
Dilatation joints are integrated in all three levels
Burstable cans inside the joints are integrated
First level dilatation joint

15. Dilatation joints - cans
Conventional dilatation joints of 65 mm create too big streaming path – additional measures are mandatory.
Convectional dilatation joints of 65 mm

16. Dilatation joints - cans
Design of the cans provided by Senad Kudumovic!
The cans can burst and squeeze up to 65 mm.
Thank to the cans, the dilatation joints have been artificially reduced by 40 mm.
80 mm width can, Zinc bromide filled
Dilatation joints of 105 mm

17. Monolith skirt shield wall interface
The roof cannot impact the monolith during an installation and during a H4 seismic event. Larger than usual clearance gap of 75 mm between the monolith and the roof has been integrated.
75 mm clearance
25 mm clearance
20 mm clearance
Monolith skirt shield wall
R6.2 m box beam

18. Statistics Statistics: In general: Blocks specific:
Total roof’s mass – 4529 t
Steel – 4010 t
HDPE – 519 t
In general:
Total quantity of the parts – 9176
Quantity of the unique parts – 800
Blocks specific:
Total quantity of the slabs – 4869
Quantity of the unique slabs – 753
Total quantity of the blocs – 443
Quantity of the unique blocks – 208

19. Questions and ideas
Any questions or ideas?