TOP lob Nor ieee PROJECT MANAGEMENT PROCEDURE at F-NC-174 (an) (Elephant) Field Development Project - GOSP | fniiéitin| — TA obs 520 02 21270 PROCEDURE NO. GS-MO-Q-PR-00-037-C1 FOR CONCRETING ACTIVITIES, SURFACE REPAIR AND PROTECTIVE COATING e 1.0 20 3.0 Responsibilities 4.0 Procedure 41 General 42 Formwork, 43° Curing of Concrete 4.4 Removal of Formwork 4.5 Hot Weather Concrete 46 47 48 SASSGSovaanwow 49 opicaion of Protective e 50 References aD BEvELor a 1 seem { 08.05.03 “ae Exams Y Dr. Suckil] | APPROVED FOR CONSTRUCTION ct on | o7. ED Fkunstein | Dr. Suckit ISSUE FOR APPROVAL, Rev Checked | Approved Description of Revision+ |Procedure No. GS-MO-Q-PR-00-037-C1 Page 2 of 17 Iconcrating Activities, Surface Repair and Protective Coating (a Revision C1 dated 08.05.2003 Indutrieandapen, INDEX SHEET FOR REVISION Sect. Page Revision No. Contents No | ot [ ct 1.0 [Purpose 3] x 2.0. [Definitions and Abbreviations 3 |x 3.0 [Responsibilities 3 x 4.0 |Procedure 4 x 4.1 |General 4 x 4.2 |Formwork, Placing and Compaction of Concrete 5 x 4.3 [Curing of Concrete 7] x 4.4 [Removal of Formwork 8 | x 45. |Hot Weather Concrete so] x @ 4.6 |Concrete Surface Repair and Preparation for Coating 15 x 4.7 | Repair of Broken-Off Edges 16} x 4.8 |Repair of Cracks t6| x 4.9. [Application of Protective Coating wl x 5.0 |References 2 xProcedure No. GS-MO-Q-PR-00-037-C1 Page 3 of 17 {Concreting Activities, Surface Repair and Protective Coating (am) Revision C1 dated 08.05.2003 tera, 4.0 PURPOSE This procedure shail provide a minimum guideline for the casting of concrete, concrete repair and the application of a protective coating. {t shail not release the engineer or supervisor on site to be familiar with relevant construction standards nor shall this procedure limiting any common construction practice which shall have the aim to produce a durable concrete. {tis understood that this procedure can not cover the whole field of activities related to producing of concrete and concrete structures {t shail be stated that different applicable national standards sometimes specifying different limits or tolerances for the same topic, Sometimes the specified limits or tolerances are not applicable to the current situation, €.g. ambient conditions or a combination thereof resulting in required limits are often not existing, ‘Sometimes local conditions or experience will require more stringent limits or diferent construction practice described by recognized standards and code of practices. Above statements shall not provide the justification to ignore limits specified in specifications or national standards. ‘Any deviations shall be justified by an engineering statement and shall be subject to the ‘owners approval. 2.0 DEFINITIONS AND ABBREVIATIONS QA/QC - Quality Assurance/Quality Control FND — - Foundation 3.0 RESPONSIBILITIES The preparation, review and approval of this procedure is described in GS-MO-Q-QA- 00-001, section 7.0. The Site Manager or his designee shall be responsible for the implementation of and adherence to this procedure on site. The supervisor shall be responsible fo fulfil the requirements ofthis procedure during construction on site,|Concreting Activities, Surface Repair and Protective Coating “jProcedure No. GS-MO-Q-PR-00-037-C1 Page 4 of 17 fun’ Revision C1 dated 08.05.2003 nation 4.0 PROCEDURE 44° GENERAL A durable concrete is one that is designed and constructed to protect embedded metal ‘from corrosion and to perform satisfactorily in the working enviroment for the life-time of the structure. To achieve this it is necessary to consider many interrelated factors at various stages in the design and construction process. Thus the structural form, cover to steel are considered at the design stage and this involves consideration of the enviromental conditions. If these are particularly aggressive, it may be necessary to consider the type of cement at the design stage. ‘One of the main characteristics influencing the durability of concrete is its permeability to the ingress of water, oxygen, carbon dioxide and other potentially harmful substances. Permeability is governed by the constituents and procedures used in making the concrete. With normal-weight aggregates a suitable low permeability is achieved by having an adquate cement content, a sufficient low free water/cement ratio, by ensuring complete compaction of the concrete and by sufficient hydration of the cement through proper curing methods. ‘The factor influencing durability include: ~ the shape and bulk of the concrete = the cover to embedded stee! = the environment = the type of cement = the type of aggregate = the cement content ~ the water/oement ratio ~ the workmanship, to obtain full compaction + efficient curing ‘Since many processes of detericration of concrete only occures in the presence of free water the surface should be designed, wherever possible to minimize uptake of water Care shall be taken to minimize any cracks that may collect or transmit water. In very severe environment with high sulphate exposure some form of lining such as sheet polyethylene or polychlorophene or surface coating based on asphalt chlorinated rubber, ‘epoxy or polyurethane materials should be used in conjuction with the use of sulphate resistant cement and a low water/cement ratio,Procedure No. GS-MO-Q-PR-00-037-C1 Page § of 17 IConcreting Activities, Surface Repair and Protective Coating Raa Revision C1 dated 08.05.2003 ete 42 FORMWORK, PLACING AND COMPACTING OF CONCRETE ‘The design and construction of formwork shall take account of safety and of the surface: finish required. The formwork shall be sufficient rigid and tight to prevent loss of grout or mortar from the fresh concrete, Formwork and its supports shall: maintain their correct position and be to correct shape: and profile, ‘The formwork shall be capable of being dismantled and removed from the cast concrete without shock, disturbance or damage. All rubbish shall be removed from the interior of the forms before the concrete will be placed. ‘The faces of the forms in contact with the concrete shall be clean and treated with a release agent. The release agent shall be applied so as to provide a thin uniform coating to the forms without contaminating the reinforcement, itis therfore recommended if possible to apply the release agent prior to the installation of the rebar. All placing and compacting of concrete shall be carried out under suitable supervision and a8 soon after mixing as is practible. Mixed concrete which is transported in truck mixers of agitators, or concrete which is truck mixed, shall be discharged within 1-1/2 hours after introducing of cement to the aggregates which contain free moisture except that when the concrete temperature exceeds 29°C this time shall be reduced to 45 minutes. Concrete shalll be placed within 15 minutes after it has been discharged from the truck. If the concrete contains a water reducing/retarding admixture and the concrete has not been retempered subsequent to batching and further the concrete possesses adequate ‘workability to ensure proper placement, the above time restriction may be waived. ‘A longer time after loading may be appropriate in cool, humid weather. A significant sign if the fresh concrete is affected by high temperature condition is the rapid loss of workability arriving at the place of unloading, retempering shall not be allowed. Delays in placing may be permitted by the owner provided that the concrete can still be placed and fully compacted without addition of water. In general the concrete temperature shall not exceed 32°C. at the point of unloading. ‘When the temperature of the concrete mixture exceeds 32°C mixing and placing shall be terminated if the workability of the concrete is significantly reduced, and the owner notified. For hot weather concreting refer to para 4.5 of this procedure. During placing the concrete, care shall be taken to avoid displacing reinforcement, tendon ducts and anchorage, formwork and damage fo the formwork particularly when the concrete is allowed to fall freely through the depth of lif Conerete shall be deposited as close as possible to its final position in the forms and there shall be no vertical drop greater than 1.5m except where suitable equipment is provided to prevent segregation and where specifically authorized by the quality control inspector. Depositing of the concrete shall be so regulated that it will be effectively consolidated in horizontal layers not more than 30cm thick, except that slabs shall be placed in a single layer. Concrete shall not be moved across the surface by means of using the vibrator as this may lead to localized honeycombing and inadequate bonding between the concrete and the reinforcement. Concrete shall be thoroughly compacted by vibration or other means during placing, and