Dismantlement Technologies

Lawrence E. Boing
Argonne National Laboratory
Decommissioning Program
Outline

 Reasons for dismantlement
 Typical applications
– Segmentation
– One piece removals

 Parameters for selecting a specific technology
 Mature technologies
 Evolving technologies

2
Dismantling

 Dismantling is defined as the removal of equipment or 
structures (clean or radioactive) typically to allow for the 
completion of the decommissioning process (or of the 
contracted work scope) by use of any of or some combination 
of thermal, mechanical, or electrical removal methods

 In some cases no dismantling will be required to complete 
decommissioning and in other cases only minimal dismantling 
will be required; dependent upon desired end‐state

 Some techniques useful ex‐situ while others are useful in‐situ

3
Reasons for Dismantling

 Removal of components or structures – partially or 
completely
 Removal of highly activated items
 Size reduction
 Decontamination
 Packaging and/or shipping constraints
– Is intact/one‐piece a viable removal option ?
– Is entombment in place a viable option ?

4
Typical Applications

 Metal structures and components
 Concrete structures and foundations 
 Tanks, equipment, piping and pumps
 Gloveboxes
 Concrete shielding
 Pressure vessels including RPVs
 Reactor vessel internals

5
DOE-Fernald Site / Plants 2 and 3

DOE-Fernald Site Plants #2 and #3 were

“Large Industrial Radiological Facilities”
6
Tokamak Fusion Test Reactor

TFTR Facility at DOE-PPPL, Princeton, NJ circa 1997

7
One of a Kind Structures

Former Vit Cell @DOE - West Valley PFP Glovebox @ DOE-Hanford

8
Technique Selection & Optimization

 Material to be cut  Waste generation
– Type, thickness and geometry
 Schedule / lead time / cost
– Reinforcement if concrete
 Highly unlikely that only 
– Reactionary forces
one technique can be used 
 Environment for the project
– Type of facility
– In air or underwater
– Review, evaluate and learn 
– Contamination / activation 
from what others have 
levels and dose rates
already done !
– Pollution controls ‐ air and 
water

9
100 cutting speed (cm/min) 100 Aerosols (g/m) flame cutting arc saw
Plasma cutting

10 10 plasma cutting
flame cutting grinding

1 grinding arc saw 1

mech. saw
0,1 mech. saw 0,1

thickness steel (mm) thickness steel (mm)

0,01 0,01
0 10 20 30 40 50 0 10 20 30 40 50
BR-3 Decommissioning Project in Belgium
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Training & Mock-Up Testing

11
Typical Cutting Scenarios

 High contact dose rates
– More remote, semi‐remote, standoff type approaches
 Low contact dose rate, but high contamination levels
– More hands on, size reduction station approach, worker 
protective equipment issues
 Low dose rate and contamination levels
– Production rate priority, safety aspects are classic 
industrial safety ones

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One-Piece Removal

 Reactor vessels, steam generators, heat exchangers 
and pressurizers (25 ton – 1100 ton)
 Factors to consider
– Burial rates – RPV ‐ $4‐7 M USD
– Characterization data
– Safety analyses
– Transportation issues
– Preparations ‐ inside and outside facility ‐ dredging
 Use of fillers and coatings
– Grouts – used as a void filler
– Poly‐urea coatings – used as a fixative over shrink wrap
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Tent Erection

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Small Research Reactor
One-Piece Component Removal
 Heat Exchanger from 
the 5 MW CP‐5 
Research Reactor

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La Crosse NPP RV

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Trojan NPP RPV Package

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Big Rock Point NPP Reactor Vessel

 Shipped to Barnwell Site for disposal
 Shipping container: 25’ long, 13’ diameter with walls 
up to 7” thick
 Vessel and canister were filled with 114,000 pounds 
of concrete
 Entire package weighed over 565,000 pounds
 October 7, 2003 – left plant site
 October 30, 2003 – arrived @ disposal site

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Use of Insta-Cote™ SE at Rocky Flats

 Sprayable rapid‐curing polyurea elastometer – DOT 
strong tight container
 16 oversized waste items ‐ included 3 large machine 
tools – up to 25’ x 10’ x 9’ weighing 150 tons
 Used 10‐axle ‘low‐boy’ trailer for shipment for 
disposal at Envirocare
 Used on Supercompactor and Repackaging facility 
equipment

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Use of Insta-Cote™ at Rocky Flats (ctd)

 Special base unit of molded material
 Poly‐urea coat base unit & add waste item
 Plastic sheet wrap the waste item and shrink wrap 
item with heat gun & inspect to ensure 100% 
coverage of item
 Repeatedly poly‐urea coat the item up to a thickness 
of ¼”
 Used as a lock‐down agent during demolition
 http://www.instacote.com
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Dismantlement Technology
Groupings
Dismantlement Technology Groupings

 Metal Cutting   Concrete Cutting 
Technologies Technologies
– Mechanical – Mechanical
– Thermal – Thermal
– Electrical – Other
– Other

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Metal Cutting Technologies

 Mechanical

 Thermal 

 Electrical

 Others

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Mechanical Metal Cutting Technologies

 Shears and nibblers
 Saws ‐ circular, 
reciprocating and band
 Abrasive wheels
 Diamond wire
 Milling
 Circular cutters

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Common Saws

Circular Saw Port-a-Band Saw

25
Nibblers by Trumpf

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Shears

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High Speed Clamshell Pipe Cutter

 Can make remote cuts 
up to 250 feet away
 No applied heat or 
flame results in no 
smoke generation
 Does not generate 
airborne contaminants

28
Plunging Pipe Crimper/Cutter

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Rancho Seco RPV Head Segment

Diamond wire sawing used to perform cutting operations

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TFTR Vacuum Vessel Segments

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Special Designs

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Cable Tensioning for Structural
Demolition

 Cable tensioning – pull structures down with cables 
attached to supporting structural members – being 
used at many DOE sites

33
Thermal Metal Cutting Technologies

 Plasma Arc (Electrical/Gas) Torch
 Oxy‐fuel Torch
 Controlled Explosives

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Plasma Arc Cutting Technology

•Torch is an energy converter from an electric arc (pilot arc) to a plasma gas (usually
Argon) and a second arc is transferred to the work piece.
• Conversion process is only about 50% efficient – the balance is radiant light and
sound.

extracted from www.plasmateam.com website

35
Controlled Explosive Demolition
 Uranium mill structural demolition, Canada
 USDOE
– Hanford Site, Production Reactor stacks
– Nevada Test Site, Test Cell A Shield wall structure
– INL Site, Numerous decommissioning sites
– Fernald Site, Building structures

 Maine Yankee NPP Containment Building demolition, 
USA
 Commercial NPS ‐ Cooling towers 
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Explosive Demolition of the IET Exhaust Line -
INEEL

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Electrical Metal Cutting Technologies

 Metal Disintegration Machining (MDM)
 Electrical Discharge Machining (EDM)
 Arc Saw
 Electric Arc Gouging
 Consumable electrode cutting (in development)
 Contact arc metal cutting (in development)

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Other Metal Cutting Technologies
 Abrasive Water Jet (AWJ)
 Laser

AWJ Cutting was used for several

NPP reactor internals size reduction
Tasks – San Onofre, Connecticut
Yankee and Maine Yankee

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Test Results – Laser Cutting
Laser Type Cutting Capability  Speed  Power  Condition Source
(thickness) (in mm /  (in kW)
minute)
CO Laser 30‐150 mm 10‐260 21 UW NUPEC
(SUS‐304)

CO laser 200‐310 mm 20‐30 21 In Air NUPEC

(SUS‐304)
YAG laser 281 mm 100 7.5 In Air NUPEC
(CS / insulator / Al)
YAG laser 40 mm 100 7.5 UW NUPEC
(SUS)
YAG laser 3 mm 2500 0.5‐1.0 In Air NUPEC
(SUS lining)
Chemical Oxygen  23 mm 0.5 1.0 UW RANDEC
Iodine Laser (COIL) (SUS‐304)

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Concrete Cutting Technologies

 Mechanical

 Thermal

 Other

41
Mechanical Concrete Cutting
Technologies
 Diamond Wire Saw
 Other Saws
 Hydraulic or Pneumatic 
Hammers / Hoe Rams
 Crushers and Shears
 Rock Splitters
 Wrecking Ball

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Diamond Wire Cutting

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Diamond Wire Cutting (cont’d)

Battelle Columbus Labs Decommissioning Project

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Brokk

BROKK 330

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Brokk End Effectors

Concrete Crusher Bucket Grapples with rotator

Breaker Hammer Scabbler 46

BROKK Technical Data
Weight Work Area  Reach  Transport Min‐Max Lift 
(lbs) Radius Overhead  Width x Length x  Capacity (lbs)
(inches) w/att (inches) Height
(inches)
Model 40 794  95 96 24 x 47 x 37 264‐1056
w/att 
+66
Model 90 2050  142 156 31 x 72 x 48 374‐1452
w/att
+265
Model 180 4190 w/att  179 186 31 x 98 x 54 814‐4400
+550

Model 250 6750 w/att  236 252 47 x 142 x 59 ‐‐‐‐‐

+660

Model 330 9240 w/att   256 264 59 x 154 x 60 1650‐8250

+1200

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Demolition of former Pu Production Facilities
at Rocky Flats

www.demcodemolition.com
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Thermal Concrete Cutting Technologies

 Flame Cutting 
 Oxygen Lance
 Explosives

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Other Concrete Cutting Technologies

 Abrasive Water Jet
 Lasers
 Concrete Fracturing Products / Expansive 
Grout – similar products sold under a variety 
of names
– Bristar
– Bustar
– DEXPAN

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Abrasive Water Jet

 Abrasive Water Jet Cutting ‐
used extensively for size 
reduction/cutting of 
concrete structures and a 
wide spectrum of other 
materials in various 
industries

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Concrete Fracturing Products
 A non‐explosive controlled demolition agent
 Expansive Grout – similar products sold under a 
variety of names used for fracturing the concrete 
and then rubblizing it further 
– Bristar, Bustar, DEXPAN
 Useful in areas with smaller sized concrete pad 
structures or in areas where noise and shock 
techniques (explosive demolition) are not viable
 Mix with water, pour into drilled holes, expand and 
demolish; 18,000 lbs / cubic inch expansive strength 
when mixed with water
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Remote Technologies
Use of Remote Technologies
 Reduce Personnel Radiation Exposures to ALARA
 Reduce Personnel Exposure to Harsh Conditions – Underwater, 
Radiation, Temperature, Accessibility
 General Types
– Manual Human Placed Devices
• Long Handled Tools or Diver Deployment

– Master‐Slave Manipulators
– Power Manipulators – use servo systems to amplify the operator force ‐
ARTISAN
– Tele‐robots – similar to Power Manipulators only joystick / remote 
controlled ‐ NEATER
– Wheeled vehicles and travelling robots
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Long Handled Tool End-Effectors

1. Tore Jet Lance

2. Grabber / Clamper
3. Sheer
4. Rotary Disk Cutter
5. 5-Function Manipulator

From www.hydro-lek.com website

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Efficiency Considerations
 Human Entry versus Remote Equipment 
– Must Consider Operating Efficiencies and Other Supporting Needs to 
Implement
• Support services required and access factors – ventilation, containments, 
decontamination capability and rigging features

• Radiological, industrial safety and environmental impacts 

• Schedule and costs including lead time and maintenance needs

 Remote Equipment Cost versus  Personnel Exposure
– One person‐rem of exposure = $1,000 to $25,000 or higher in some cases 
– is geographic dependent
– Remote equipment is very expensive with training and maintenance 
difficult and time consuming

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Use of Divers

57
Large Remote Dismantling Tooling

58
Mast Type Deployment

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Robotic Systems

60
Dual Arm Work Platform
 Robotic system used where 
exposure levels prevent 
prolonged human exposure
 Max lift capacity of 240‐lbs 
at full extension of 78”
 Tether supplies hydraulics, 
power and control signals
 Deploys a variety of tools 
and equipment
 50% cost savings compared 
to manual dismantling

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Demolition Lessons Learned

 Fixative applications are effective
 Misting devices and water sprays are effective at 
controlling contamination
 Dispersion modeling used to help establish 
radiological boundaries 
 Surgical demolition is difficult work

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Innovative Processes

 Some recent emerging dismantlement technologies 
include more evolutionary than revolutionary 
technologies:
– Lasers – needs further development
– Tele‐operated Systems – various industrial 
– Oxy‐gas Cutting System ‐ construction
– Liquefied gas cutting

63
Conclusions
 Large variety of dismantling tools available 
spanning a wide range of costs
 The tool needs to be evaluated for the job taking 
into consideration ‐ safety, radiation dose, 
environmental impacts and other site specific 
parameters
 Remote operations can and will bring numerous 
problems along with them
 ‘Keep it simple stupid’ or the ‘KISS Concept’ is your 
best friend
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Suggested Reading

 IAEA Technical Reports Series #395
 IAEA Technical Reports Series #440
 Health Physics Society ‘1999 Summer School on 
Decommissioning’
 European Commission ‘Decommissioning Handbook’
 U S Department of Energy ‘Decommissioning 
Handbook’
 American Welding Society, ‘Welding Handbook, 
Volume 2, Welding Processes’
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67
MECHANICAL METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
SHEARS & NIBBLERS First Controlled Cutting Limited Thickness Cut
Blade/Punch Very Low Waste Generation Limited Material Type
Cutting Head Remote Operation Reaction Forces
Electric, Hydraulic, Pneumatic Cuts Mild Steel & Stainless Steel Space Envelope
Powered In Air & Underwater

SAWS Controlled Cutting Limited Thickness Cut

Circular Blade Low Waste Generation Limited Material type
Reciprocating Blade No Off-gas or Fumes Reaction Forces
Band Manual or Remove Slow Cutting
Electric, Hydraulic, Pneumatic Operation Blade Sticking
Powered In Air & Underwater Blades Wear

ABRASIVE WHEELS Manual or Remote Operation Limited Thickness Cut

Circular Wheel In Air & Underwater Limited Material Type
Cutting head Reaction Forces
Electric, Hydraulic Pneumatic Airborne/Underwater Particles
Powered Possible Sparking
Blades Wear Quickly

68
MECHANICAL METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
DIAMOND WIRE Cut Various Shapes Requires 360 Degree Access
Wire Cuts Very Thick Objects Water Discharge
Pulley System Remote Operation Wire Sticking & Breaking
Water Lube System Slow Cutting
Electric, Hydraulic Powered

MILLING Cuts Intricate Geometries Limited Thickness Cut

Milling Head Controlled Cutting Slow Cutting
Milling Support Frame Remote Operation Tool Sticking & Breaking
Lube System In Air & Underwater Lubricant Discharge
Electric, Hydraulic Powered Reaction Forces

CIRCULAR CUTTERS Cuts Hollow Circular Shapes Limited Thickness Cut

OD or ID Mounted Controlled Cutting Slow Cutting
Circular Saw Type Remote Operation Blade or Bit Sticking & Breaking
Single Point Type Low Reaction Forces Lubricant Discharge
Circular Machine Frame
Electric, Hydraulic, Pneumatic
Powered

69
THERMAL METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
PLASMA ARC Fast Controlled Cutting Off-gas & Fumes
Torch Manual or Remote Operation Very Murky Water
Electric Power Supply Cuts Thick Plates Debris Control
Gas Source Cuts Carbon & Stainless Steel Limited Geometries
Motion Control In Air & Underwater
Low Reaction Forces
OXY – FUEL TORCH Fast Controlled Cutting Off-gas & Fumes
Torch Manual or Remote Operation Very Murky Water
Electric Starter Cuts Thick Plates Debris Control
Gas Source Cuts Carbon Steel Limited Geometries
Motion Control In Air & Underwater Does not Cut Stainless Steel
Low Reaction Forces
CONTROLLED Fast Cutting Off-gas & Fumes
EXPLOSIVES Remote Application Dust Control
Shaped Explosive Charge Cuts Thick Sections Debris Control
Ignition System Cuts Any Metal Shock & Vibration
In Air & Underwater Placing Charges

70
ELECTRICAL METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
MDM Cuts Various Shapes Off-gas & Fumes
Electrode Cuts Very Thick Objects Very Murky Water
Cutting Head Remote Operation Debris Control
Electric Power Supply Controlled Cutting Slow Cutting
Flush System In Air & Underwater Flush Discharge
Motion Control Low Reaction Forces

EDM Cuts Various Shapes Some Off-gas & Fumes

Electrode Cuts Intricate Geometries Very Slow Cutting
Cutting Head Controlled Cutting Flush Discharge
Electric Power Supply In Air & Underwater
Flush System Low Reaction Forces
Motion Control Sample Cutting
ARC SAW Cuts Various Shapes Off-gas & Fumes
Circular Blade Electrode Controlled Cutting Slow Cutting
Cutting Head In Air & Underwater Debris Control
Electric Power Supply Low Reaction Forces Flush System in Air
Motion Control

ELECTRIC ARC GOUGING Manual Operation Off-gas & Fumes

Consumable Electrode In Air & Underwater Debris Control
Gas or Water Source Low Reaction Force

71
OTHER METAL CUTTING TECHNOLOGIES

PROCESS ADVANTAGES DISADVANTAGES

ABRASIVE WATER JET Cuts Thick Plate Abrasive Waste

Focusing Nozzle Remote Operation Debris Control
Water Source Controlled Cutting
Abrasive Source In Air & Underwater
High Pressure Low Reaction Forces
Generator
LASER Remote Operation In Air Only
Laser Beam Generator Controlled Cutting Debris Control
Beam & Focus Optics Low Reaction Forces Expensive Equipment
Gas Source Usually Thin Plates
Cutting Nozzle Slow cutting – but improving
Motion Control

72
MECHANICAL CONCRETE CUTTING
TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
DIAMOND WIRE Cut Various Shapes Requires 360 Degree Access
Wire Cuts Very Thick Objects Water Discharge
Pulley System Cuts Through Rebar Wire Sticking &
Water Lube System Remote Operation Breaking
Electric, Hydraulic Slow Cutting
Powered
SAWS Controlled Cutting Limited Thickness Cut
Circular Blade Low Waste Generation Reaction Forces
Electric Hydraulic Powered No Off-gas or Fumes Slow cutting
Manual or Remote Operation Blade Sticking
In Air Blade Wear
Difficult Rebar cutting

HAMMERS No Off-gas or Fumes Uncontrolled Cutting

Chisel/Spade Bit Manual or Remote Operation Dust & Debris Control
Hammer Device In Air Slow & Labor Intensive
Hydraulic or Pneumatic Worker Fatigue
Powered Vibration
Rebar Not Cut 73
MECHANICAL CONCRETE CUTTING
TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
CRUSHERS / No Off-gas or Fumes Semi-Controlled Cutting
SHEARS Remote Operation Dust & Debris Control
Jaws In Air Reaction Forces
Hydraulic Powered Non Explosive Vibration & Shock
Delivery Device Low Tech Solution
SPLITTERS Non Explosive Semi-Controlled Cutting
Rock Splitter Vibration Force Rebar Not Cut
Hydraulic Cylinder No Reaction Forces Slow Method
Hydraulic Powered Remote Operation Hole Drilling
Low Tech Solution
WRECKING BALL Non Explosive Uncontrolled Cutting
Ball Inexpensive Rebar Not Cut
Crane or Boom Low Tech Solution Reaction Forces
Vibration & Shock

74
THERMAL CONCRETE CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
FLAME CUTTING Remote Operation Off-gas, Fumes, Smoke
Torch Concrete & Rebar Cut Semi-Controlled Cutting
Oxygen Source No Reaction Forces
Powdered Iron/Aluminum
Electric Ignitor
OXYGEN LANCE Cuts Anything Off-gas, Fumes, Smoke
Consumable Lance (Pipe Manual Operation Semi-controlled Cutting
with Rods)
Oxygen Source
Electric Ignitor
CONTROLLED Fast Cutting Off-gas & Fumes
EXPLOSIVES Remote Application Debris Control
Explosive Charges Cuts Thick Sections Shock & Vibration
Ignition System In Air & Underwater Charge Placement
Drill Holes
Rebar Not out

75
OTHER CONCRETE CUTTING TECHNOLOGIES

PROCESS ADVANTAGES DISADVANTAGES

ABRASIVE WATER JET Cuts Thick Plate Abrasive Waste
Focusing Nozzle Remote Operation Debris Control
Water Source Controlled Cutting
Abrasive Source In Air & Underwater
High Pressure Generator Low Reaction Forces
LASER Remote Operation In Air Only
Laser Beam Generator Controlled Cutting Debris Control
Beam & Focus Optics Low Reaction Forces Expensive Equipment
Gas Source Usually Thin Plates
Cutting Nozzle Slow cutting – but improving
Motion Control
EXPANSIVE GROUT Low tech process Slow process
Grout Mixture Easy to Use Labor intensive
Concrete Drill Inexpensive

76