In another blow to the National Nuclear Security Administration’s project management record, the agency confirmed yesterday that the multi-billion-dollar Uranium Processing Facility must be redesigned to fit the necessary equipment into the 340,000-square-foot building that’s been under design for years. Project officials, including Federal Project Director John Eschenberg, had previously suggested that space issues were not that unusual and would be worked out during the final stages of design, but he said yesterday during a field hearing convened by the Defense Nuclear Facilities Safety Board in Knoxville that the roof of the facility must be raised by 13 feet and the walls and basemat need to be strengthened. The facility’s concrete foundation will grow by about a foot, Eschenberg said, while the walls must be thickened from 18 inches to 30 inches. The changes would boost the cost of the project, which is currently estimated to cost between $4.2 and $6.5 billion. “The project prematurely established a hard footprint,” said Eschenberg, who added that the NNSA had not yet determined the root causes for why the building’s design didn’t meet the UPF space needs. He noted that it could have been related to having the early design team doing work from three different geographic locations.
Eschenberg said the scope of UPF has not changed from the beginning, so that wasn’t to blame for the space shortfall. More information should be available in about three weeks, after an engineering evaluation is completed, he said. The DNFSB reacted skeptically at the hearing to the news of the changes. Steven Stokes, the staff leader for the DNFSB’s Nuclear Facilities Design and Infrastructure Group, noted that such a redesign “is a serious undertaking with the potential for significant impacts on public and worker safety,” with greater impacts on the projects because the problem had been found in the late stages of design.
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