Upgrade GCs Water Facilities and Mitigation Works Technical Specification

TECHNICAL SPECIFICATION PART-V (CIVIL)
ANNEXURE- 5A
EF/2092 Part-A
Scope of Civil and Structural Works Works Doc. No. 2092A-SOW-C-01 Rev. C Page 2 of 49
Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022)
KUWAIT OIL COMPANY (K.S.C.)

(REGISTER OF COMMERCE NO. 21835)
PROJECT REF. EF/2092 Part-A
UPGRADE OF GCs WATER DISPOSAL FACILITIES AND OTHER WATER

MITIGATION WORKS (WI TFT- YEAR 2022)
Scope of Civil and Structural Works
Doc. № 2092A-SOW-C-01
Rev. B
Revision Log
EF/2092 Part-A
B 1-July-2020 Revised as per latest scope for DSP1.0 Amwal
A 31-Jan-2020 Issued to OTS (S&EK) /Planning (S&EK) for DSP1.0 Amwal
Rev. Date Revision By
INDEX
1. INTRODUCTION
2. SCOPE OF WORK
2.1. Overview
2.2. General
2.3. Site Finished Grade Levels
2.4. Windblown Sand/Loose Soils
2.5. Equipment Foundations
2.6. Pipe/Valve Supports, Operating/ Maintenance Platform/ Crossovers
2.7. Reinforced Concrete Drain Pits (Drain Sumps)
2.8. Drainage of HPS Pumps & Booster Pump Area
2.9. Soil Treatment
2.10. Temporary Works
2.11. Miscellaneous Works
3. SERVICE CONDITIONS
4. DESIGN
4.1. Design and Drawings

4.2. Documents
5. SPECIFICATIONS, CODES AND STANDARDS
6. BASIC DESIGN DATA
6.1. General
6.2. Topography
6.3. Wind / Seismic Data
6.4. Rainfall
6.5. Soil Parameters
6.6. General Design Basis
6.7. Dynamic Equipment
6.8. Overhead Pipe Racks
6.9. Paving, Walkways and Access-ways
6.10. Pipe and Cable Crossings through Roads
6.11. Pipe Crossings through Structures
7. TOPOGRAPHICAL SURVEY
7.1. General
7.2. Scope
7.3. Reference Datum
7.4. Contractor’s Deliverables
8. GEOTECHNICAL INVESTIGATION
8.1. General
EF/2092 Part-A
8.2. Field Investigations

8.3. Laboratory Tests
8.4. Soil Investigation Report
9. SITE PREPARATION
9.1. General
9.2. Commencement Requirements
9.3. Relocation and Re-routing of existing Facilities
9.4. Demolition and Site Clearance
9.5. Disposal of Surface Water, Dewatering and Disposal of Oil Spills
10. EARTHWORK
10.1. General
10.2. Excavation
10.3. Filling
10.4. Compaction of Earthworks
10.5. Disposal of excavated materials
10.6. Selection of Materials
10.7. Excavation and Backfilling around Pipe and Cable Trenches
10.8. Inspection and Testing
11. CONCRETE WORKS – MATERIALS AND CONSTRUCTION
11.1. General
11.2. Cement
11.3. Aggregates
11.4. Water
11.5. Concrete Mix Requirements
11.6. Reinforcement and Embedded Items
11.7. Concrete Trial Mix
11.8. Formwork and Finishing
11.9. Concrete Production
11.10. Placing Concrete
11.11. Bonding Concrete
11.12. Testing for Quality of Concrete
11.13. Concrete Joints
11.14. Curing
11.15. Protection to Concrete Surfaces
12. GROUTING
12.1. General
12.2. Non-shrink Cementitious Grout
12.3. Epoxy Grout
12.4. Grout Thickness
13. STRUCTURAL STEEL WORKS - MATERIALS, FABRICATION AND ERECTION
13.1. General
13.2. Materials
EF/2092 Part-A
13.3. Fabrication
13.4. Erection
13.5. Fabrication Drawings
13.6. Welding
13.7. Acceptance of Welds
13.8. Miscellaneous Structural Works
13.9. Metal Cladding
13.10. Fencing
13.11. Painting and Galvanizing
13.12. Surface Preparation
13.13. Paint application
13.14. Paint mixing and thinning
13.15. Restrictions on painting
13.16. Surface preparation and Painting scheme
13.17. Galvanizing
13.18. Materials
13.19. Workmanship
14. ROADWAYS AND PAVING
14.1. General
14.2. Basic Engineering Information
14.3. Horizontal Clearances
14.4. Vertical Clearances
14.5. Material Requirements
14.6. Construction of Sub-Grade
14.7. Construction of Sub-Base
14.8. Construction of Asphalt Concrete Courses
14.9. Road Shoulders
14.10. Drainage of Roadways and Paving
14.11. Testing
14.12. Crash Barriers, Protection Bollards and Guard Rails
14.13. Traffic Markings and Signs
15. DRAINAGE
15.1. General
15.2. Design Volumes
15.3. Drainage Layout within Process Areas
15.4. Drainage Layout outside Process Areas
15.5. Storm/Surface Water Drainage System
15.6. Drainage from Buildings
15.7. Impounding Basin
15.8. Hydraulic Design
15.9. Design of Buried Pipe Work
15.10. Testing
1. INTRODUCTION
1.1. This part of the Technical Specification covers the scope and specifications of the Civil
and Structural Works as follows:
1.1.1. Section-A works related to work associated with water disposal facilities at nine (9) GCs
(GC01, GC02, GC04, GC09, GC10, GC11, GC19, GC 20 & GC21).
1.1.2. Section-B works related to Civil work associated with Electrical works (part of EF/2092A
project) at the Burgan water injection system facilities (constructed by another contractor
EF/2092 Part-A
under EF/2093B project). The facilities of EF/2093B comprise the Booster pump facility
outside EWDP-I and the pumping Hub 101 and 102 in the desert, along with its
associated injection manifolds.
1.2. The Contractor shall establish the work requirements in coordination with the stipulations
of the Technical Specification (various Parts).
1.3. The slit trench survey drawings and the geo-technical investigation reports (carried out by
Company) appended to this Part of Technical Specification are for Contractor’s reference
and guidance.
2. SCOPE OF WORK
2.1. Overview
2.1.1. Company’s another contractor (identified as the Lease contractor) will install the Booster
and HPS pump skids at all the nine (9) GCs. The Contractor, while executing the Section-
A works at the GCs, shall coordinate site works with the Lease contractor’s work.
2.1.2. The Contractor’s scope under Section-A works comprise the following work at 9 GCs:
2.1.2.1. Re-routing of underground services;
2.1.2.2. Site levelling, grading, excavation, compaction etc.;
2.1.2.3. Drainage works around equipment and facilities of the project;
2.1.2.4. Foundations for above-ground pipe headers and piping;
2.1.2.5. Foundations for electrical and instrumentation equipment and materials;
2.1.2.6. Civil works associated with underground piping;
2.1.2.7. Civil works associated with electric / instrument cablings including road and
pavement crossings in GCs, cable entries in control buildings etc.
2.1.2.8. Construction of equipment drain pits and chemical injection quill access pits;
2.1.2.9. Removal of fencing to make space for erection of piping;
2.1.2.10. Miscellaneous works including equipment operating platforms and piping

crossovers.
2.1.3. Another contractor (identified as EF/2093B contractor) will construct the complete
Burgan water injection facilities except the major Electrical works (which is part of
EF/2092A Contractor’s scope as part of Technical Specification-Electrical). Further, at
these EF/2092B facilities, another contractor (identified as the Lease contractor) will
install the Booster and HPS pump skids, and another contractor (identified as the Flow
line contractor) will work in the injection manifolds for installation of flow line
EF/2092 Part-A
instruments. The Contractor, while executing the Section-B works at the EF/2093B
facilities, shall coordinate site works with the Lease contractor’s work and the EF/2093B
contractor’s work and the Flow line contractor.
2.1.4. The Contractor’s scope under Section-B of the works comprise the following work to
support the EF/2092A Electrical work at Burgan water injection facilities (constructed by
another contractor under EF/2093B project):
2.1.4.1. Civil works to support the installation of electric cables (EF/2092A) from
existing substations to the EF/2093B facilities;
2.1.4.2. Construction of road crossing ducts (open cut method) and

walkway/pavement crossing in EWDP-I for installation of the cables from
substation in EWDP-I to the booster pump facility outside the EWDP-I
(EF/2093B facilities);
2.1.4.3. Construction of road crossing ducts (thrust boring) in the desert for installation
of cables from substation to the pump Hub 101 and Hub 102 (EF/2093B
facilities);
2.1.4.4. Civil works to support the installation of electric cables to the substations
(EF/2092A) inside the EF/2093B facilities;
2.1.4.5. Construction of civil works of outdoor substations (EF/2092A) at the

EF/2093B facilities comprising:
2.1.4.5.1. Foundations and structures for electrical equipment

(switchboards, transformers, distribution boards, junction
boxes);
2.1.4.5.2. Installation of pre-engineered steel roof shelter (with partially

open sides) for the substation, generally as per the tender
drawings entitled ‘Electrical Shelter’ appended to this Part, along
with foundations. The Contractor shall keep space in the
substation for certain equipment of EF/2093B
2.1.4.5.3. Chain link fencing around substation

2.1.4.6. Re-routing of underground services at EF/2092A substation locations in
EF/2093B facilities as required;
2.1.4.7. Drainage works at EF/2092A substation area in EF/2093B facilities;
2.1.4.8. Construction of foundations for EF/2092A lighting poles and junction boxes
etc. in EF/2093B facilities;
2.1.4.9. Civil works to support miscellaneous electric cabling works in EF/2093B

facilities;
EF/2092 Part-A
2.1.4.10. Miscellaneous civil works to support EF/2092A electrical works in EF/2093B

facilities
2.2. General
2.2.1. Design, engineering, construction, installation, fabrication, erection and testing of

complete Civil and Structural Works as required for the completion of the Contract works
including supply of materials, Manpower, labor, tools, equipment, temporary facilities
etc. complete. The works shall be as per the Contract scope, applicable specifications,
codes and standards. The works shall conform to the approved design calculations;
approved detailed engineering drawings, approved vendor documents; of all engineering
disciplines such as civil, structural, process, mechanical, piping, electrical,
instrumentation, etc. and shall be executed to the complete satisfaction of the Company.
2.2.2. The scope shall include but by no means shall be limited to complete detailed design and
engineering works including preparation and submission of design calculations, drawings,
specifications, vendor documents etc. complete and obtaining Company approval on the
same prior to proceeding with construction works. The scope shall include complete
topographical survey works, geotechnical investigation works, site preparation works
including exploratory slit trenching, identification, protection, re-routing / re-location of
existing facilities, complete earth works such as cutting, filling, grading, excavation in all
types of soils including hard strata/rocks, backfilling, leveling, compaction, hauling,
disposal etc. complete. The scope shall include complete drainage works, gatch roadwork,
complete fencing works, complete concrete works, complete structural steel works
including painting, galvanizing. The scope shall include all other works and activities of
whatsoever nature required for execution of the Contract to the complete satisfaction of
the Company.
2.2.3. The work items covered in the scope of the Contract described below. All works
described in the preceding clauses are also included.
2.3. Site Finished Grade Levels
2.3.1. In general, the site grading levels/finished levels of the site shall be determined during
detailed engineering.
2.3.2. Information related to existing ground levels are available on the survey drawings
attached with the tender.
2.4. Windblown Sand/Loose Soils
Contractor shall remove all wind-blown sand and loose soils from the fenced areas and
external areas, shall replace the same with approved gatch laid in well-compacted layers
EF/2092 Part-A
in accordance with KOC Standard KOC-C-005. In any case, all finished surfaces shall
comprise of a minimum 300mm thick top layer of well-compacted gatch.
2.5. Equipment Foundations
Wherever required as per detailed engineering, necessary structural steel and/or

reinforced concrete supporting arrangement shall be provided to transfer the loads to the
foundations Design and construction of reinforced concrete foundations for equipment,
such as Local Control Panel, Light Pole, Distribution Board, Junction Box,
switchboard, transformer etc. Design shall be based on equipment vendor drawings
approved by the Company.
2.6. Pipe/Valve Supports, Operating/ Maintenance Platform/ Crossovers
2.6.1. Design and construction of structural steel supports for piping/valves, Operating/
maintenance platform/crossovers along with their reinforced concrete foundations.
2.6.2. Layout, location, type and height of pipe /valve supports, size and height of platform/
crossovers shall be as per approved mechanical/piping layout drawings
2.7. Reinforced Concrete Drain Pits (Drain Sumps)
2.7.1. Design and construction of reinforced concrete drain pits (or drain sumps) based on
process/mechanical scope of the Contract. Access pits shall be provided for chemical
injection quill. Volume and size of the drain pits proposed in the tender drawings are the
minimum requirements. If higher size and depths of the pits are required as per detailed
engineering, provision of the same shall be deemed included in the scope of the Contract.
Minimum requirements of KOC Standard Drawing No. “55-02-39” shall be met where
deemed relevant.
2.7.1.1. Design and construction of drain pits shall be in accordance with the
requirement of liquid retaining structures as specified in ACI 350.
2.7.1.2. The pits shall be made of water tight construction to prevent any ingress of
ground water or rainwater through the side walls and bottom slabs.
2.7.1.3. Where pipes penetrate walls of pits, the pipe should be fitted with puddle
flanges located in the center of the wall and the wall near to the pipe shall be
at least 250mm thick.
2.7.1.4. The drain pits shall be provided with galvanized structural steel framing and
minimum 6mm thick removable galvanized checkered plate cover at top. The
cover of the drain pit shall be designed for a minimum live load of 5KN/sq.m.
The cover shall be provided with inspection holes with hinged covers and a
manhole entry with frame and cast iron cover. The cover shall also be
provided with cutouts for pipe /hose entry/vent.
2.7.1.5. Drain pits shall be provided with adequate venting arrangement by provision
of vent pipes at a safe location. The vent pipes shall extend to minimum 3m
above the top of the pit.
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Scope of Civil and Structural Works Works Doc. No. 2092A-SOW-C-01 Rev. C
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2.7.1.6. The periphery of the pits at top shall be provided with handrails on all sides.
2.7.1.7. The pits shall also be provided with a caged ladder for direct access to the pit
bottom.
2.7.1.8. Pit floors shall be sloped to a shallow sump to allow for pumping out of the
liquids. The pit shall be provided with piping arrangement with facility for
vacuum truck connection for drawing out liquids.
2.7.1.9. The top of the pits shall be finished at least 150mm above the finished grade
levels in paved areas and 450mm above the ground level in unpaved areas.
2.7.1.10. Pits located in unpaved areas shall be provided with minimum 1000mm wide
reinforced concrete walkway all around.
2.7.1.11. The pits located within the Gathering Center fencing shall be provided with
crash barriers all around in accordance with the details shown on KOC
Standard Drawing No. “55-02-40”. If pits are located outside the Gathering
Center fencing, the pits shall be provided with fence in accordance with the
details shown on KOC Standard Drawing No. “55-02-39”.
2.7.1.12. All internal faces of drain pits not holding chemicals, the bottom slab and the
side walls, shall be protected with suitable lining and hydrocarbon resistant
epoxy paint. All other exposed faces of the concrete shall be painted with
approved hydrocarbon resistant epoxy paint.
2.7.1.13. In case of drain pits holding chemicals, all internal faces of the walls and the
bottom slab shall be protected as per clause 19.7.3 of KOC Standard
Specification # KOC-C-025. All other exposed faces of the concrete shall be
painted with approved chemical resistant epoxy paint
2.8. Drainage of HPS Pumps & Booster Pump Area
2.8.1. Design and construction of a comprehensive drainage system encompassing the complete
facilities including all the areas inside and outside the fencing and as per detailed
engineering. The drainage system shall cater for storm water (rain water), fire water,
contaminated water, oily water, diesel, chemical drainage and all other types of wastes
generated and shall encompass all elements such as gutters and downspouts for shelters,
swales/flumes, drain piping, drain pits, valve pits, impounding basin, rain water holding
ponds etc. complete.
2.8.2. The Contractor shall provide the design basis, design drawings and calculations of the
complete drainage system and the same shall be subject to review and approval of the
Company. In general, the design, materials, construction and testing of drainage system
shall be in accordance with KOC Standard # KOC-C-025.
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Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022) 2.8.3.
D
rainage of clean and uncontaminated storm water system shall conform to clause 12 of
KOC Standard KOC-C-025. The storm water drainage system shall connect to
ditches/trenches/channels, reinforced concrete lined flumes/swales discharging into rain
water/storm water holding pond lined with reinforced concrete lining on the side slopes
and unlined at the bottom surface. The holding pond shall be provided with low security
fencing with gate in accordance with KOC Standard KOC-G-019 Part 2 and KOC
Standard drawings 55-02-17 and 55-02-20. A minimum clearance of 3.5m shall be
maintained between the fencing and the upper edges of the side slopes of the holding
pond.
2.9. Soil Treatment
All soils under the chemical injection quill access pit shall be treated with anti-termite
chemicals in accordance with clause 22.0 of Company standard KOC-C-006
2.10. Temporary Works
2.10.1. Contractor shall construct temporary diversion roads, access-ways, walkways in case the
works for pipe crossings, cable crossings, roads or any other works should interrupt or
obstruct vehicular flow or pedestrian movement. Construction of temporary diversion
road shall be in accordance with clause 14.0 of KOC Standard # KOC-C-024 Part-1. The
length of diversion road shall be such as to allow smooth traffic flow in the area of
construction and shall be provided with barriers, flashers and traffic signs all in
accordance with KOC- S -001 “Standard Guideline for Safe Roads, Road Closure and
Installation of Display Boards / Signs on KOC Roads”.
2.10.2. The Contractor shall design, fabricate, supply and install temporary security paneling to
completely seal off the construction areas located outside the GC fencing. Contractor shall
make use of metallic sheets, adequately stiffened and supported to form these panels. The
temporary panels shall be removed upon satisfactory completion of whole of the works.
2.10.3. The Contractor shall submit a proposal in the form of drawings indicating the proposed
temporary works prior to commencement of the preparatory works on the Site for the
approval of the Company. No works shall commence until such approval is obtained.
2.10.4. Temporary roads shall be made of gatch in accordance with clause 14.0 of KOC Standard
KOC-C-024 Part 1.
2.10.5. Construction of Temporary Disposal Pit for Hydro test Water:
2.10.5.1. Construct new temporary evaporation disposal pits for disposal of hydro-test
water. Location, number and orientation of the disposal pits shall be as per the
Contractor’s proposal, subject to approval by the Company, prior to the
commencement of work. Size of the pits shall be adequate to hold the entire
quantity of drained hydro test water. Twenty five percent (25 %) free board
shall be considered in sizing the pits.
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2.10.5.2. Contractor shall design, prepare and submit detailed drawing for the
temporary disposal. The Contractor shall utilize the approved drawing and
construct the disposal pit in accordance with KOC HSEMS Procedures.
2.11. Miscellaneous Works
2.11.1. All civil and structural works related to laying of underground pipes and cables.
2.11.2. Design and construction of all civil and structural works related to corrosion monitoring
works, supporting of corrosion monitoring equipment and for supporting of cable racks
and trays in conformance with applicable electrical and instrumentation drawings and
specifications.
2.11.3. Design and construction of all required supports along with reinforced concrete
substructure for mechanical, electrical and instrumentation equipment, control panels,
junction boxes, cabinets, gauges and their appurtenances etc. complete.
2.11.4. Design and construction of required supports along with reinforced concrete base slab
with upstand, sump and drainage arrangement for emergency stations with eye wash,
safety showers and chillers.
2.11.5. Design and construction of reinforced concrete foundations for fire hydrants and
construction of reinforced concrete pavements all around the fire hydrants with
curbs/upstand walls.
2.11.6. Design and construct reinforced concrete foundation with fence enclosure for the cathodic
protection rectifier and all other civil and structural works related to cathodic protection
works in accordance with the scope of the Contract.
2.11.7. Design and construction of reinforced concrete paving slab minimum 150mm thick and
1000 mm all around structural shelters, equipment, junction boxes, control panels, and all
other items on grade level requiring access for inspection, maintenance, operation.
2.11.8. Design and construction of structural steel access platforms, stairways, ladders for
inspection, operation, service and maintenance requirements for all vessels, skids,
packages, equipment, valves, junction boxes, control panels, instruments, gauges etc.
complete along with associated reinforced concrete foundations.
2.11.9. Fabricate, supply and install pipe crash barriers along with associated concrete works for
protection of shelters, skid, equipment, drain pits etc. complete from potential damage due
to loss of vehicle control. Crash barriers shall conform to KOC Standard drawing no. 55-
02-40. The requirement of crash barrier proposed in the tender drawings is schematic, if
Contractor’s detailed engineering necessitates a more elaborate requirement than shown
on the tender drawings, provision of the same shall be deemed included in the scope of
the Contract.
2.11.10. Fabricate, supply and install sign boards with mounting arrangement and concrete
foundations for warning, guide, safety and hazard signs. Sign boards shall be installed at
locations approved by the Company. Details of sign boards and mounting arrangement
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shall conform to KOC Standard drawings 55-02-80, 55-02-81 and to details prepared by
the Contractor and approved by the Company.
2.11.11. Design and construction of all other required structural steel/reinforced concrete supports
along with reinforced concrete foundations safety and security systems, pipe markers,
cable markers, assembly point sign boards and other miscellaneous structures in
accordance with the scope of the Contract.
2.11.12. Contractor shall supply and install windsocks at locations approved by Company
supported on minimum 4” Sch.40 galvanized pipe (ASTM A53 Grade B). Height of the
wind sock from the installed finished grade level shall be minimum 5m. Number and
details of wind sock shall conform to clause 7.17 of KOC Standard KOC-L-009. The
wind sock mast shall be supported on adequately designed reinforced concrete
foundation.
2.11.13. Contractor’s scope shall include design and construction works pertaining to the
modifications to existing facilities, structures and services which are deemed necessary
for proper completion of the Contract.
2.11.14. All existing works impacted by such modifications shall be made good and reinstated to
its original condition.
2.11.15. All demolition and disposal works in accordance with the scope of the Contract and as
required as per detailed engineering, making good with associated backfilling, grading
and clearing works.
2.11.16. All other works not mentioned above but which could reasonably be deemed necessary
for the proper completion of the Contract in order to provide the Company with complete
operable facilities shall be automatically deemed to be included in the scope of the
Contract.
3. SERVICE CONDITIONS
The environment in Kuwait is severe on all structures and equipment and must be
considered carefully before design, procurement and construction. It must be assumed
that all structures and equipment may be subjected to sand and fine particle dust storms,
sand laden winds, chemical contaminants, thunderstorms, heavy rains and extreme
temperatures. For data related to temperatures, rainfall, wind and other environmental
conditions refer KOC Standard KOC-G-007 “KOC Standard for Basic Design Data”
4. DESIGN
4.1. Design and Drawings
4.1.1. All design works shall be in compliance with KOC Standard KOC-C-001 “KOC Standard
for Basic Civil Engineering Design Data” and KOC Standard KOC-C-002 “KOC
Recommended Practice for Engineering Design Basis of Civil and Structural Works”.
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T
he Contractor shall carry out preliminary and detailed design of all Civil, Architectural
and Structural Works. The Contractor shall prepare design calculations, detailed
engineering, fabrication, erection and construction drawings and submit the same for
Company’s review and approval. The Contactor shall not commence work until approval
has been provided by the Company in writing. However, such approval shall not relieve
the Contractor of its responsibility for accuracy and sufficiency of works. Where the
Contractor has failed to carry out its Contractual obligation under the Contract in
preparation of its drawings and documents, all Company’s approvals shall be deemed as
null and void and the Contractor shall resubmit such drawings and documents for review
and approval of the Company. Such resubmission shall be deemed to be included in the
scope of the Contract.
4.1.3. Tender Drawings provided by the Company are preliminary and for guidance only and
are the minimum requirements for the Contract and shall not be construed or utilized as
detailed design drawings. The Contractor shall develop detailed engineering drawings to
suit the Contract requirements. Final design of all works related to the Civil, Architectural
and Structural discipline shall be in accordance with Contract scope, applicable Codes,
Standards and Specifications and the final approved detailed engineering drawings &
documents as well as vendor drawings of Mechanical/Piping/Electrical//Instrumentation
and other relevant engineering disciplines.
4.1.4. Design of reinforced concrete structures shall be in compliance with ACI 318M (latest
edition) and the design of steel structures shall be in compliance with AISC- Manual of
Steel Construction (ASD latest edition).
4.1.5. Structural Analysis and design shall be carried out and submitted in approved and widely
used STAAD – Pro software (latest version).
4.1.6. Lateral earth loads shall be calculated on the basis of geo-technical investigation study
recommendations. Minimum design surcharge load for calculation of lateral earth load on
reinforced concrete pit walls shall be 10 kN/m2
4.1.7. All structural steel works shall conform to clause 18.0 of KOC Standard KOC-C-002 and
to KOC Standard KOC-C-007. In particular, design of steel structures shall conform to
the requirements of clause 18.3 of KOC Standard KOC-C-002. Maximum slenderness
ratio for compression members and members in flexure shall not exceed 200. Maximum
slenderness ratio for tension member shall not exceed 300.
4.1.8. Unless approved otherwise, design of structural steel works shall be carried out by the
main detailed engineering sub-contractor. Design of structural steel works by structural
steel fabrication/erection contractor shall not be acceptable to the Company.
4.1.9. Only rolled structural steel sections shall be used including for purlins and girts. Built up
sections shall be accepted only if deemed necessary by detailed design. However, final
decision in this regard shall be by the Company. Where, built-up sections are allowed by
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the Company, welding for the built-up sections shall be continuous and on both sides and
shall be of minimum six (6) mm leg size fillet weld.
4.1.10. Main framing arrangement of all structural steel shelters shall be subject to prior approval
of the Company. The Contractor shall not proceed with detailed design drawings and
calculations unless the main framing arrangement is approved by the Company.
4.1.11. Contractor shall carry out 3-D (3 dimensional modelling) modelling of Structural Steel
Shelters in structural analysis and design software. Purlins and girts shall not be modelled
into the main model for carrying out analysis and design of the shelters. Design of purlins
and girts shall be carried out independent of the design of the shelters.
4.1.12. Contractor shall submit design calculations for thicknesses of road layers in accordance
with “AASHTO Guide for Design of Pavement Structures” for review and approval of
the Company. However thicknesses of the road layers shall not be less than the
thicknesses specified in KOC’s Standard drawing no. 55-02-94.
4.1.13. The Contractor shall be solely responsible for the accuracy and details of the works to be
performed, including where incorrect or inconsistent or omission of any information has
appeared in the drawings and documents supplied by the Company.
4.1.14. The Contractor shall co-ordinate the works with existing facilities and make all necessary
required field adjustments to elevations and grades as required. These adjustments shall
be submitted to the Company by the Contractor for review and approval prior to
execution of any part of the work.
4.2. Documents
4.2.1. All design calculations, documents and drawings are to be presented in SI units.
4.2.2. All correspondences, instructions, drawings, data sheets, design calculations or any other
information shall be in English language.
4.2.3. All documents (texts, specifications, data sheets, methods, drawings etc) shall be provided
with electronic files in approved software (MS Word, Excel, Autocad etc.). All software
utilized shall be agreed upon by the Company prior to its use.
4.2.4. The Contractor shall prepare the drawings exclusively on the UNI formats (A1/A0) unless
agreed otherwise by the Company.
4.2.5. The Contractor shall prepare drawings and documents within the agreed time frame and
submit the required number of copies to the Company. The sequence of submittals shall
match the order of construction works.
5. SPECIFICATIONS, CODES AND STANDARDS
5.1. Unless otherwise stated hereunder, all architectural, civil and structural works shall be
performed in accordance with KOC Specifications, Standards and Recommended
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Practices listed in Technical Specification. All international Standards, Codes and

Specifications referenced in KOC Specifications, Standards and Recommended Practices
shall be adhered to where applicable. In case certain aspect of the work scope is not
covered in the Specifications, Standards and Recommended Practices listed in Technical
Specification, other relevant International/KOC Codes, Specifications, Standards and
Recommended Practices shall apply to the Contract, subject to approval of the Company.
5.2. The Specifications provided in this document are not given by way of any limitations to
the KOC Specifications, Standards and Recommended Practices listed in Technical
Specification, but only as a means for summarizing and easy reference and in some cases
as amplification over relevant clauses of KOC Specifications, Standards and
Recommended Practices. In the event of any conflict between the Specifications provided
in this document with the KOC Specifications, Standards and Recommended Practices
listed in Technical Specification, the most stringent requirement shall apply to the
Contract.
5.3. Where conflict exists between different Standards, Codes, Specifications, Recommended
Practices, Tender Drawings or other Contractual requirements, the most stringent
requirement shall apply to the Contract.
5.4. Unless noted otherwise, all Standards, Codes, Specifications and Recommended Practices
shall conform in design and construction with the current issues and amendments
prevailing on the effective date of the Contract.
5.5. Compliance with Standards, Codes, Specifications and Recommended Practices shall not
relieve the Contractor of its responsibility to design and produce the required work suited
to meet the specified service conditions and applicable regulations.
6. BASIC DESIGN DATA
6.1. General
Contractor’s design shall conform to the design data and design basis provided in KOC
Standards # KOC-C-001, KOC-C-002 and KOC-G-007.
6.2. Topography
6.2.1. The topography shall be assessed from the area contour maps on the basis of
topographical survey of the site and adjoining areas carried out by the Contractor.
Topographical Survey work carried out by Company is meant for guidance only.
6.2.2. The basic design plinth levels shall conform to clause 7.5 of KOC Standard # KOC-C-
002.
6.3. Wind / Seismic Data
6.3.1. Wind loads shall be calculated in accordance with ASCE 07-2005 for basic wind speed of
45m/sec or 162 km/hr. corresponding to 3 second gust speed at 10m above grade,
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minimum exposure category “C” and topographic factor (Kzt) =1, all as per clause 8.4 of
KOC Standard KOC-C-001.
6.3.2. Seismic loads shall be calculated as per clause 8.13 of KOC Standard KOC-C-001.
6.4. Rainfall
6.4.1. Average total annual rainfall: 118mm.
6.4.2. Design Storm: 70mm/hour falling uniformly for 30 minutes.
6.5. Soil Parameters
6.5.1. Design shall be based on soil parameters and allowable safe bearing pressure as obtained
from approved Geotechnical Reports of the site based on a detailed Geotechnical
Investigation carried out by the Contractor. Geotechnical Reports based on Geotechnical
Investigations carried out by the Company are meant for guidance for the bidding stage of
the tender. For bidding purpose, the soil properties and bearing capacities as provided in
the Geotechnical Reports provided by the Company shall be utilized. At areas where no
boreholes have been drilled, soil properties and bearing capacities shall be interpreted
based on the nearest boreholes. In cases, where doubt remains as regards the applicability
of boreholes for any particular location on the site, the soil properties and bearing
capacities from the borehole with the lowest soil capacities shall be considered for
bidding purpose.
6.5.2. For preliminary design, subject to verification at site and in the absence of any available
relevant Geotechnical data of soil, the allowable net bearing pressure for pad/isolated
foundations in dry condition shall be as follows:
6.5.2.1. 50 KN/sq.m at 1.0m from natural ground level; and
6.5.2.2. 125 KN/sq.m at 1.5m from natural ground level.
6.5.3. Other presumed soil parameters for preliminary design and subject to verification shall be
in accordance with Tables 1 & 2, Appendix 1 of KOC Standard # KOC-C-001.
6.6. General Design Basis
6.6.1. All categories of applicable design loads such as dead loads, live loads, wind loads,
seismic loads, dynamic loads (impact and machine induced), pipe-way loads, friction
loads, temperature loads, vehicular loads, fire loads including any unusual loads shall be
considered for design.
6.6.2. All applicable load combinations that may result in worst condition to the structure in
terms of stresses and functional limits shall be considered.
6.6.3. Maximum allowable uniform settlement for foundations shall be 25 mm and maximum
allowable differential settlement shall be 18 mm.
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he net allowable soil bearing pressure under foundations may be increased by 25% due to
wind and seismic loads or as dictated by design codes/standards used. However in case of
wind sensitive tall structures no increase shall be allowed in the net allowable bearing
pressure.
6.6.5. Concrete structures retaining aqueous liquids and all below ground concrete structures
such as tanks and pits shall be designed and constructed as per the provisions of ACI 350
to make them water tight.
6.6.6. Minimum founding level (top of blinding concrete) for any type of foundation shall not
be less than 1.0 m below Natural Ground Level (NGL) or paving level/finished grade
level, whichever is lower except for the foundations of heavy equipment, shelters and
pipe racks for which the minimum founding level shall not be less than 1.5 m below
Natural Ground Level (NGL) or paving level/finished grade level, whichever is lower.
Where required to facilitate passage of underground services, the depth of foundation
shall be such that the top of footing is minimum 1.0 m below ground level/paved level
provided the founding level meets the criteria set hereinbefore for the minimum depth
from NGL. Deeper founding levels shall be provided wherever required based on design
calculations and recommendations of the Soil Investigation Report.
6.6.7. Plan size of the footings shall be decided based on the design calculations and
recommendations of the Soil Investigation Report. However, under no case the minimum
plan size of footing shall be less than 0.75m x 0.75m.
6.6.8. For all underground structures the minimum factor of safety against uplift due to
buoyancy effect of ground water table shall be 1.50 under empty condition.
6.6.9. The minimum stability ratio against overturning and sliding for any structure shall 1.75
under operating and shutdown conditions and 1.50 under erection and hydrostatic test
conditions.
6.6.10. The maximum concrete stress beneath base plates shall be 8N/sq.mm for sand cement
grout and 12 N/sq. mm for proprietary high strength grout.
6.6.11. Concrete sleepers for grade pipe-ways bases shall be minimum 600mm above the
adjacent/surrounding ground level and shall be provided with plain round steel bars to
reduce friction. Final levels of the concrete sleepers shall be decided to satisfy the piping
requirements.
6.7. Dynamic Equipment
6.7.1. Dynamic loads generated by reciprocating and rotary machines shall be supplied by the
approved machine supplier / manufacturer for design of foundations and supporting
structures.
6.7.2. The vibration limits of supporting structures shall be in compliance with manufacturer’s
recommendations.
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owever in the absence of the above data, in order to avoid resonance, the limiting natural
frequency and amplitude of vibration of the foundation system shall be as follows:
6.7.3.1. The natural frequency shall be clear of the range of (0.5 to 2.0) times the
frequency of exciting force for reciprocating machines;
6.7.3.2. The natural frequency shall be clear of the range of (0.8 to 1.2) times the
frequency of exciting force for rotary machines; and
6.7.3.3. The allowable amplitude limits shall be in accordance with clause 9.5.2 Table-
9 of Standard # KOC-C-001.
6.7.4. Distance from the edge of a pocket or bolt to the edge of the foundation block shall be
minimum 100mm to allow for reinforcement.
6.7.5. Separation joints of minimum 20mm width shall be provided between equipment
foundations and surrounding floor or paving slab and shall be filled with preformed
compressible mineral fiber board and non-shrink grout.
6.8. Overhead Pipe Racks
6.8.1. Overhead pipe racks shall be wide enough to include all the proposed pipes and shall have
additional 25 % space for future extension. For multilevel pipe rack the top tier shall cater
to utility line and cable trays.
6.8.2. Pipe rack shall be designed as moment resisting frame in transverse direction and braced
frame in the longitudinal direction of the pipes or as per approved design.
6.8.3. Overhead pipe racks having pipes conveying flammable material like gas/oil/crude shall
be fire proofed.
6.9. Paving, Walkways and Access-ways
6.9.1. The Contractor shall design paving, walkways and access-ways based on the
requirements specified in clause 12.0 of KOC Recommended Practice # KOC-C-002 and
KOC Standard # KOC-C-024 Part 2.
6.9.2. Concrete paving should be laid to a slope of 1 in 100 to ensure drainage without ponding.
Slope for bituminous paving shall not exceed 1 in 60.
6.9.3. Where access-ways from plant to surrounding roads are ramped, the slope should not
exceed 1 in 15.
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6.9.4.
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inimum thickness of concrete paving used by vehicles/mobile equipment and for drop
out areas where heavy loads may be placed or handled during maintenance shall be
200mm, adequately reinforced in top and bottom.
6.9.5. Paving not accessible to vehicles and heavy loads should be reinforced with a minimum
thickness of 150mm.
6.9.6. Paving tiles, wherever specified, shall be of 50mm thick pre-cast concrete of Company
approved quality, pattern, size & colour laid over 100mm thick evenly spread layer of
sand or compacted gatch and protected by pre-cast kerb stones at the edges.
6.9.7. Paving shall be discontinued around equipment bases, pedestals, columns, grade beams
etc. with a clear gap of 12mm to 25mm, filled with preformed compressible mineral fibre
board and sealed with approved sealant.
6.9.8. Concrete floor slabs under structural steel shelters for pumps, chemical skids and all other
storage and maintenance shelters shall be provided with Heavy Duty Surface Hardener in
accordance with clause 5.2.2 of KOC Standard 015-RH-1001.
6.10. Pipe and Cable Crossings through Roads
6.10.1. Load bearing carbon steel sleeves shall be provided to pipes crossing roads. The sleeve
size and wall thickness shall be designed to withstand the applicable traffic and other
loads. Pipe sleeves shall be provided in accordance with KOC Standard drawing # 55-04-
77.
6.10.2. Flexible end seals, hydrocarbon resistant, non-flammable, non-setting and non-toxic type
and capable of resisting hydrostatic pressure, should be fitted in the annular space
between pipes and sleeves at both ends.
6.10.3. Cable crossings in paved, unpaved, on-site, off-site areas shall be in accordance with
clause 14 of KOC Standard # KOC-C-002.
6.10.4. In case of pipes and cables crossing main roads, carbon steel casing shall be provided to
carrier pipes and cable ducts by the procedure of thrust boring in order to avoid
interruption of vehicular flow. The casing pipe shall be adequately vented.
6.10.5. The Contractor shall comply with all the requirements of the Company, Ministry of
Public Works and other concerned State Authorities and shall obtain all necessary permits
and pay all fees associated with pipe and cable crossings.
6.10.6. Irrespective of the method adopted for crossings (thrust boring or cutting), the Contractor
shall submit method statements, necessary design calculations, detailed working drawings
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and all relevant technical information for the Company’s approval prior to starting of
work.
6.10.7. In case of pipe and cable crossings by cutting of existing roads, the re-construction work
shall match the existing and shall be in accordance with KOC Standards # KOC-C-024
Part-1 & 2 and KOC Standard drawing 55-02-94.
6.10.8. Construction of temporary diversion road shall be in accordance with clause 14.0 of KOC
Standard # KOC-C-024 Part-1. However, the Contractor shall submit proposal for
temporary diversion road and obtain the Company’s approval, prior to cutting any road
facility.
6.11. Pipe Crossings through Structures
6.11.1. Pipes passing concrete walls or other structural elements shall be sleeved with carbon
steel sleeves. Sleeves in exposed condition above grade shall be of non-corroding material
in order to obviate rusting and spalling of surrounding concrete or mortar. Flexible end
seals resistant to hydrocarbon and of non-flammable, non-setting and non-toxic type
should be fitted between the pipe and its sleeve.
7. TOPOGRAPHICAL SURVEY
7.1. General
The Contractor shall carry out Topographical Survey Works for the Contract in
compliance with the requirements of KOC Recommended Practice # KOC-C-004. The
topographical survey drawings provided by the Company are only meant for guidance of
the Contractor.
7.2. Scope
7.2.1. The scope of topographical survey shall enable carrying out complete detailed
engineering and construction works for the Contract. The scope shall cover full Contract
scope in terms of plant areas, pipe routings, roads, drainages, areas internal and external to
the fencing etc. complete taking note of all existing structures, facilities, wells, above
ground pipelines, over-head transmission lines, markers of underground pipes and
services etc. complete.
7.2.2. The Contractor shall carefully survey the presence of underground/buried services for
their depths and locations by an approved modern technological detection equipment.
7.2.3. The Contractor shall carry out survey to review, check and confirm all levels,
measurements and dimensions shown in the documents and drawings supplied by the
Company.
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7.3. Reference Datum
7.3.1. Levels and co-ordinates for the Site shall be determined independently based on KOC
datum.
7.3.2. All elevations shall be referenced to Mina Ahmadi Construction Datum (MACD).
7.3.3. Site Co-ordinates shall be established with reference to Universal Transverse Mercator
(UTM) Zone 38N Projection, World Geodesic System (WGS-84) datum.
7.3.4. Minimum four (4) permanent bench marks shall be established for each site. Both UTM
co-ordinates and site local co-ordinates shall be specified for each bench mark.
7.4. Contractor’s Deliverables
7.4.1. The deliverables shall record all relevant surface features and objects within the specified
areas and shall include as a minimum contour maps, grading drawings, pipe routing
drawings and calculations for cut and fill requirements.
8. GEOTECHNICAL INVESTIGATION
8.1. General
8.1.1. The Contractor shall carry out Geotechnical Investigation Works for the Contract in
compliance with the requirements of KOC Recommended Practice # KOC-C-003. The
Geotechnical Investigation Reports provided by the Company are only meant for
guidance of the Contractor.
8.1.2. The scope of geotechnical investigation shall be planned on the basis of location, nature,
size of this Contract. The scope of geotechnical investigation works shall enable carrying
out complete detailed engineering and construction works for the Contract by accurate
determination of the soil properties at the work sites.
8.1.3. The number of boreholes, trial pits etc. shall be planned so as to get a reliable indication
of the geological and geotechnical character of the ground.
8.2. Field Investigations
8.2.1. Boreholes: Bore holes shall be located at positions of important structures, equipment and
pipe racks. In any case spacing between boreholes shall be limited to maximum of 25m to
30m. Exploration shall be done for an average depth of 10m to 20m for non-piled
foundations. Where rock is encountered, exploration shall be continued at least for 3.0m
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by rotary drilling to ascertain the soundness of stratum. The location and number of the
boreholes shall be subject to review and approval of the Company.
8.2.2. Trial pits and trenches: For underground piping, exploration by trial pits shall be
considered adequate. The depth of the pit shall be between 1.0 m to 2.0m below pipe
invert level for buried pipeline or below the anticipated foundation level for on-grade
pipelines. Pits and slit trenches shall also be made to ascertain presence of underground
services or presence of contaminants like hydrocarbons or to inspect soil layers for lightly
loaded foundations. Trial pits shall have a minimum base area of 1.5 sq.m. Trenches shall
be 1.0m wide. Depth of trial pits and trenches shall be minimum 1.5m. Location, size and
number of pits and trenches shall be subject to approval by the Company.
8.3. Laboratory Tests
8.3.1. Laboratory tests shall be conducted on collected samples in order to classify the soils and
to determine the physical, mechanical and chemical properties for proper used in design
and construction.
8.4. Soil Investigation Report
8.4.1. The final soil investigation report shall include as a minimum all the elements as specified
under clause # 13.2.3 of Standard KOC-C-003.
9. SITE PREPARATION
9.1. General
The Contractor shall carry out Site Preparation Works for the Contract in compliance with
the requirements of KOC Standard for Materials and Workmanship – Site Preparation and
Earth Works (KOC-C-005).
9.2. Commencement Requirements
9.2.1. The Contractor shall identify/verify the exact location of existing under-ground and above
ground services for all the areas of the Contract both within and outside the fencing of the
facilities and shall indicate the same on drawings. No major site work shall commence
until such drawings have been reviewed by the Company.
9.2.2. For the identification of the existing under-ground services, the Contractor shall manually
excavate exploratory slit trenches in X shapes or any other shape based on site condition
for all work areas covered under the Contract. In addition to the X shaped slit trenching,
the Contractor shall carry out additional slit trenching works wherever deemed necessary
to establish the full extent of the underground services in the work areas of the Contract.
Slit trenches shall be minimum 1.0 meter wide and 1.5 meters deep. In some locations,
the Contractor may have to excavate deeper in order to locate the existing services. Prior
to commencement of slit trenching works on site, the Contractor shall submit its slit
trenching proposal for review of the Company.
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Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022)9.2.3.
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he slit trenching drawings provided by the Company are only meant for guidance of the
Contractor.
9.2.4. The Contractor shall take all necessary precautions to protect existing services and
facilities from being endangered. In case of any damage the same shall be made good by
the Contractor.
9.2.5. The Contractor shall submit his detailed plan for protection of existing services for the
Company approval. No protection works shall commence prior to obtaining the Company
approval.
9.3. Relocation and Re-routing of existing Facilities
9.3.1. The Contractor shall relocate and re-route existing underground and aboveground
facilities such as pipes, cables, structures etc. that are in conflict with the proposed works,
discovered during topographical survey, geotechnical investigations and during the
progress of works.
9.3.2. The Contractor shall submit his detailed plan for relocation and re-routing of existing
services for the Company approval. No relocation and re-routing work shall commence
prior to obtaining the Company approval.
9.4. Demolition and Site Clearance
9.4.1. The Contractor shall demolish all redundant installations and underground obstructions
within the work areas in accordance with drawings and as directed by the Company.
9.4.2. All work areas shall be cleared of vegetation, contaminated soil, debris, refuse or other
deleterious materials. At all times work areas shall be free from surplus materials and
rubbish.
9.4.3. All loose soils, contaminated soils and wind-blown sand shall be removed from the sites
and replaced with approved gatch material to match the finished levels decided based on
detailed engineering. In any case a minimum soil depth of 200mm for work areas inside
the existing Gathering Center fencing and a minimum soil depth of 300mm for work
areas outside the existing Gathering Center fencing shall be removed and replaced with
approved gatch.
9.5. Disposal of Surface Water, Dewatering and Disposal of Oil Spills
9.5.1. The Contractor shall be responsible for disposal of all surface water during the
construction period. The Contractor shall provide necessary drainages in the form of
ditches, ponds, culverts, manholes, soak-away pits etc. for this purpose.
9.5.2. If necessary, the Contractor shall provide a complete dewatering system to keep the areas
of excavation dry and free from sub surface water and to maintain water table below the
required formation / foundation levels.
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9.5.3.
The Contractor shall also be responsible for disposal of oil spills during the course of works in an
appropriate manner as per KOC HSEMS Standards and as directed by the Company.
10. EARTHWORK
10.1. General
Contractor shall carry out Earthworks for the Contract in compliance with the
requirements of KOC Standard for Materials and Workmanship – Site Preparation and
Earth Works (KOC-C-005).
10.2. Excavation
10.2.1. In existing Company operation areas, only hand excavation shall be carried out unless
otherwise directed by the Company. Unless approved by the Company, machine
excavation shall not be carried out.
10.2.2. Depth of open excavations shall be limited to 1.50m without supports to the sides of the
excavated surfaces. For excavations deeper than 1.5m, the Contractor shall be responsible
for design, supply, fixing and removal of all planking, shoring, strutting or sheet piling
required to provide safe and adequate supports to the sides and the slopes of excavation.
10.2.3. When excavation for foundations is made below the founding level, the over excavated
areas shall be filled with concrete grade having characteristic strength of 15 N/Sq.mm.
10.2.4. Contractor shall refer to the Geotechnical Reports provided by the Company for the
nature of the subsurface soils, whether loose, medium dense, dense or very dense.
10.2.5. The Contractor shall carry out excavations as deemed necessary in all types of soils
including very dense soils, which includes hard strata as well as rocks.
10.3. Filling
10.3.1. Only fill materials classified as “suitable” shall be used and shall be generally deposited in
layers not exceeding 200mm loose depth, watered and well compacted by mechanical
means.
10.3.2. However for back filling around foundations and under floors, fill material shall be
deposited in layers not exceeding 150mm.
10.3.3. In no case shall backfilling commence before expiry of seven (7) days after casting of
foundations or other structures.
10.3.4. The areas to be graded shall be properly finished to required true lines and levels within
tolerances of +75mm/-75mm and +0mm/-25mm respectively.
10.4. Compaction of Earthworks
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ompaction of earthworks shall be proved by onsite field trials and laboratory tests to the
complete satisfaction of the Company.
10.4.2. Fill materials shall be wetted to within ±2% of optimum moisture content (OMC) and
placed in layers of maximum 200mm or 150mm loose depth as required and compacted
to at least 95% of maximum dry density at OMC for foundations and other critical areas.
For non-critical areas the soil shall be compacted to at least 90% of maximum dry density
at OMC.
10.4.3. After completing all cut and fill operations, foundation bearing and other critical areas
shall be proof rolled with at least four (4) passes of a 10 ton vibratory roller.
10.5. Disposal of excavated materials
10.5.1. Excavated materials designated as suitable shall be stored at near the excavation for
immediate use or stockpiled judiciously elsewhere for later use as directed by the
Company.
10.5.2. Materials designated as surplus or unsuitable shall be removed or disposed off to the
approved dump yard.
10.6. Selection of Materials
10.6.1. Materials accumulated from common excavation shall be selected and classified as
“suitable” for filling and compaction provided the minimum criteria of soil properties as
described in clause 7.2.1 Table-1 of KOC Standard # KOC-C-005 are met.
10.6.2. Gatch shall be used as filling materials for road sub-base, embankments, bundwalls, under
floors, paved areas and for other specified areas. Gatch shall be light yellow to mottled
white color, free from organic matters and stones and shall satisfy the minimum soil
properties as specified in clause 7.2.3 Table-III of KOC Standard # KOC-C-005.
10.7. Excavation and Backfilling around Pipe and Cable Trenches
10.7.1. Excavations shall be done to proper gradients as shown on drawings or as instructed by

the Company.
10.7.2. In the Company operation areas excavation shall be carried out by hand within 3.0m
either side of pipes, cables or the like.
10.7.3. No work shall be carried out within 9.0m of an overhead power cable unless permitted in
writing by the Company.
10.7.4. Trenching shall not exceed more than 300m in length until laying of pipes or cables
commences.
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rench excavations for all pipes (except stoneware sewer pipes laid over concrete beds)
shall be taken down to extra depths, back filled with fine sandy material and consolidated
to provide continuous bearing of pipe throughout length as follows:
10.7.5.1. 75mm extra for pipe diameters upto 150mm.
10.7.5.2. 100mm extra for pipe diameters exceeding 150mm but upto 300mm.
10.7.5.3. 150mm extra for pipe diameters exceeding 300mm.
10.7.6. Backfilling shall be completed after testing of pipes and shall be compacted by hand
rammers to a depth of not less than 450mm above the crown of the pipe. The remaining
part shall be backfilled by hand or machine, well compacted in layers of 150mm and
finished to a height of 150mm above surrounding ground levels.
10.7.7. Pipes passing through rock formation shall be encased in approved sandy materials to a
depth not less than 450mm above the crown of the pipe.
10.8. Inspection and Testing
10.8.1. Minimum five (5) samples collected randomly for each source of material to be used as
fill or backfill shall be tested.
10.8.2. Within foundation bearing and other critical areas minimum one (1) field in-place density
test shall be carried out for every 250 Sq. m. area.
10.8.3. For non-critical areas minimum one (1) field in-place density test shall be carried out for
every 1000 Sq. m. area.
11. CONCRETE WORKS – MATERIALS AND CONSTRUCTION
11.1. General
The Contractor shall carry out concrete works for the Contract in compliance with the
requirements of KOC Standard for Concrete Work – Materials & Construction (KOC-C-
006).
11.2. Cement
11.2.1. Cement for use in concrete works above ground level shall be ordinary Portland cement
(OPC) conforming to BS EN 197-1 or ASTM C150/C150M designated as type I.
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ement for use in concrete works below ground level including blinding or mud-mat
concrete shall be sulphate resisting Portland cement (SRPC) conforming to BS 4027 or
ASTM C150/C150M designated as Type V.
11.3. Aggregates
11.3.1. Aggregates shall include both course and fine aggregates complying with requirements of
ASTM C33 or BS EN 12620.
11.3.2. Coarse aggregates shall be limited to 20mm nominal maximum size and shall be well
graded. It shall meet the requirements of Table 2 of KOC Standard # KOC-C-006.
11.3.3. Fine aggregates shall have nominal sizes between 150 microns to 10mm maximum and
shall be well graded. It shall meet the requirements of Table 3 of KOC Standard # KOC-
C-006.
11.4. Water
11.4.1. Water shall be of drinkable quality and unless otherwise authorized by the Company,
fresh water from Kuwait Ministry of Electricity and Water (MEW) shall be used and shall
be tested as per BS EN 1008 or ASTM C94/C94M. Sea or brackish water shall not be
used.
11.5. Concrete Mix Requirements
11.5.1. Concrete shall have a minimum characteristic compressive cube strength of 30 N/sq.mm
at 28 days of curing and 21 N/sq.mm at 7 days of curing.
11.5.2. The minimum cement content shall be 380 kg/m3 of OPC or SRPC depending on above
or below ground applications. However for severe below ground conditions with sulphate
over 1500 ppm in water the cement content shall be minimum 342 kg/m3 of SRPC+ 38
kg/m3 of Silica fume (SF).
11.5.3. Blinding or mud-mat concrete shall have a minimum characteristic compressive cube
strength of 10 N/sq.mm at 28 days of curing.
11.5.4. Slump shall be measured as per ASTM C143/C143M or BS EN 12350 Part 2 and shall
generally be within the range of 50mm to 100mm when no plasticizers are used. When
concrete is conveyed by transit mixers, the recommended values for slump shall be as
follows:
Description Maximum Slump Minimum Slump

Foundations, paving and slabs on grade. 75mm 25mm
Columns, pedestals and retaining walls 100mm 25mm
Beams, slabs, mass concrete 50mm 25mm
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Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022) 11.6.
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einforcement and Embedded Items
11.6.1. All main reinforcements shall be high yield strength deformed bars with specified yield
strength of 60,000 psi (414 N/sq.mm) as per ASTM A615/A615M.
11.6.2. Plain round bars may be used for spirals, stirrups (links) and ties (binders) with specified
yield strength of 40,000 psi (276 N/sq.mm) as per ASTM A615/A615M.
11.6.3. Welded wire mesh fabric shall conform to BS 4483 or ASTM A185 /ASTM A496.
11.6.4. Minimum concrete cover to reinforcing bars shall be as follows:
Location Minimum Cover

Concrete in contact with ground / soil and in foundations upto
75mm
base plate level.
Concrete exposed to saline water 75mm
Formed concrete surfaces exposed to weather (exterior) but not in
50mm
contact with ground / soil.
Formed concrete surfaces not exposed to weather (interior) and
38mm
not in contact with ground / soil.
11.6.5. Test certificates shall be furnished to the Company for approval for each consignment of
reinforcements delivered to the site and the material shall be new and free from rust,
mills, scales and free from harmful amounts of deleterious salts or coatings which may
reduce or destroy bond with concrete.
11.6.6. Anchor bolt material shall conform to ASTM A307 or BS EN ISO 898 and shall be
galvanized as per ASTM A153 or BS EN ISO 1461.
11.7. Concrete Trial Mix
11.7.1. Six (6) test mixes shall be prepared separately and six (6) test cubes shall be prepared for
each test mix for each grade of concrete in presence of the Company representative. The
test cubes shall be cured and tested in accordance with BS EN 12390-2.
11.7.2. Test mixes for each grade shall be acceptable provided the Standard deviation is 3.5
N/sq.mm or less and the characteristic strength calculated as 6 N/sq.mm below the mean
strength, is equal or more than specified design strength.
11.7.3. For blinding concrete three (3) test mixes shall be prepared separately and three (3) test
cubes shall be prepared for each test mix for testing after 28 days. The trial mix shall be
approved if the average strength of the nine (9) mixes is not less than the specified
characteristic strength.
11.8. Formwork and Finishing
11.8.1. Contractor shall be responsible for design, material supply and construction of all
formworks and for its safety and adequacy.
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11.8.2.
The Contractor shall give the Company a minimum of 24 hour notice of readiness of form work for
inspection and shall be deemed to have allowed in its scope for any necessary adjustment
and re-inspection.
11.8.3. Any form work showing sign of damage or failure through premature loading shall be
replaced, repaired or reconstructed by the Contractor as deemed necessary by the
Company.
11.8.4. Formwork shall be constructed of new timber of sound quality without any fissures and
cracks or steel framing and shall be lined with minimum 12mm thick new plywood with
smooth face or other equal for smooth fair finish.
11.8.5. Tolerances to formed surfaces shall be as follows:
Type of Structure Tolerance

Buried or unexposed concrete ± 15mm
Exposed concrete including floor slabs and paving ± 6mm
11.9. Concrete Production
11.9.1. Concrete production shall be carried out in a central batching plant and mixing equipment
conforming to ACI 304 and approved by the Company. Mixing or addition of water in
truck mixers shall not be permitted.
11.9.2. No concreting shall be carried out during heavy sandstorms, heavy rain or heavy fog or
when the ambient temperature in shade exceeds 37.7 deg. C.
11.10. Placing Concrete
11.10.1. Concrete shall not be dropped freely from a height of more than one (1) meter to avoid
segregation except in any special case approved by the Company.
11.10.2. Concrete shall be deposited in regular courses of thickness not exceeding 600mm and
shall be compacted in its final position within two hours from the time of introducing
cement into the aggregates.
11.10.3. Placing concrete against open excavations shall not be allowed as coating materials
cannot be applied afterwards on the concrete surfaces.
11.11. Bonding Concrete
11.11.1. Surface of joints between freshly mixed concrete and recently hardened concrete shall be
properly prepared to secure a high quality bond and water tightness.
11.11.2. The joints shall be dampened and than thoroughly covered with a coat of cement grout
10mm thick and before attaining its initial set, the fresh concrete shall be deposited
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11.12. Testing for Quality of Concrete
11.12.1. Testing samples shall be made at the time of placement at the rate of six (6) test
specimens per 20 m3 of concrete or concrete work per day, whichever is less. Three (3)
specimens shall be cured and tested for crushing strength at 7 days after casting and three
(3) at 28 days.
11.12.2. The test results for crushing strength after 28 days shall be deemed acceptable, provided
the following conditions are met:
11.12.2.1. The average strength of any group of four (4) consecutive test results exceeds
the characteristic strength by 3 N/sq.mm.
11.12.2.2. For none of the test results, the strength determined is less than the
characteristic strength minus 3N/sq.mm.
11.13. Concrete Joints
11.13.1. Construction joints shall generally be located at points of minimum shear and at right
angles to main reinforcing bars in the member.
11.13.2. Expansion and Contraction joints shall be designed and constructed in accordance with
ACI 504R.
11.13.3. Expansion joints shall be formed by using 20mm thick filler strip and 20mm deep
Company approved sealant as per ASTM D1751 and ASTM C920 or similar.
11.14. Curing
11.14.1. Curing shall start continuously after concrete is placed and finished and shall be
continuously moist for 24 hours.
11.14.2. Curing shall continue for at least 7 days except in case of high early strength concrete for
which the period shall be 3 days and for mass concrete for which the period shall be
minimum 10 days unless specified otherwise.
11.15. Protection to Concrete Surfaces
11.15.1. Concrete foundations shall be placed on minimum 50mm thick blinding concrete or mud-
mat (unless a higher minimum thickness is specified in the soil investigation report) cast
over an impervious layer of polyethylene membrane, 1000 gauge thick with minimum
150mm overlap and extending 150mm beyond the edges of foundations, floor slabs and
paving.
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A
ll concrete surfaces below ground level except blinding concrete in contact with soil shall
be protected by three (3) coats of cold applied modified bituminous paint of 1000 microns
overall thickness.
11.15.3. Prior to backfilling around foundations, all sides of concrete and column necks shall be
covered with impervious layer of polyethylene membrane, 1000 guage thick with
minimum 150mm overlap.
11.15.4. Exposed external concrete surfaces for a depth of 150mm below ground level and upto
300mm above ground level, or to the underside of base plates, whichever is lower, shall
primed with a low viscosity primer and coated with two (2) coats of light grey color
epoxy paint of approved quality with a minimum thickness of 125 microns DFT per coat.
The epoxy coat shall overlap with bituminous paint by 75mm. Paint brands shall be one
of the following or similar, approved by the Company:
11.15.4.1. Hempadur primer 0597 plus Hempadur HI Build 4523
11.15.4.2. Quickmast 173 primer plus Quickmast 40
11.15.5. Where chemical resistant epoxy paint is specified in the scope, the surface preparation,
number of coats, thicknesses and color of the paint shall be similar to the light grey color
epoxy paint described herein before. Contractor shall submit supplier catalogue for review
and approval of the Company.
11.15.6. All concrete pavements, floors, kerbs, walls, roofs likely to see spillage of chemicals or
designed to withhold loss of containment of chemicals shall be painted with approved
chemical resistant epoxy paint
12. GROUTING
12.1. General
The Contractor shall carry out Grouting of structural steel support base plates and
equipment bases in compliance with the requirements of KOC Standard for Grouting for
Bases – Materials & Workmanship (KOC-C-023)
12.2. Non-shrink Cementitious Grout
12.2.1. Light equipment, pipe supports and structure bases which are not subject to vibratory
loads shall be grouted with non-shrink cementitious grout.
12.2.2. Grout material shall be non-metallic, pre-mixed, factory packed as manufactured by

Masters Builders, Five Star, Fosroc or approved equal.
12.2.3. The compressive strength shall comply with minimum strength requirements as follows,
fc’ at 1 day = 14 N/Sq.mm., fc’ at 7 days = 35 N/Sq.mm., fc’ at 28 days = 49 N/Sq.mm.
12.3. Epoxy Grout
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12.3.1.
Grouting under machine base frames shall be done in compliance with Machine manufacturer’s
recommendations, or epoxy based grout shall be used for vibratory and / or heavier loads
or where chemical attack is possible.
12.3.2. Grout material shall be pre-mixed with epoxy based materials and factory packed as
manufactured by Masters Builders, Five Star, Fosroc or approved equal.
12.3.3. The compressive strength shall comply with minimum strength requirements as follows,
fc’ at 1 day = 35 N/Sq.mm., fc’ at 7 days = 56 N/Sq.mm., fc’ at 28 days = 77 N/Sq.mm.
12.4. Grout Thickness
12.4.1. Minimum grout thickness shall be based on approved construction drawings and
manufacturer requirements. However, minimum grout thickness underside steel bearing
plates shall be 25mm.
13. STRUCTURAL STEEL WORKS (MATERIALS, FABRICATION & ERECTION)
13.1. General
The Contractor shall carry out structural steel works for the Contract in compliance with
the requirements of KOC Standard for Structural Steel Work – Materials, Fabrication and
Erection (KOC-C-007).
13.2. Materials
13.2.1. All materials shall be new and free from dirt, grease, rust, scales and free from all defects.
Mill certificates covering chemical, physical and V-notch properties and heat treatment
data shall be submitted by Contractor for the Company approval prior to fabrication.
13.2.2. Rolled shapes and plates shall be in accordance of ASTM A36 or BS EN 10025 Grade
S275JR or equivalent.
13.2.3. High strength bolts shall conform to ASTM A325 or BS 3692 Grade 8.8. Nuts shall be as
per ASTM A563 or BS EN ISO 898. Washers as per ASTM F436.
13.2.4. Ordinary bolts shall conform to ASTM A307 or BS 4190 Grade 4.6 with nuts as per BS
EN ISO 898. Washers as per BS 4320 or ASME B18.22.1.
13.2.5. High strength friction grip bolts (HSFG) shall be as per ASTM A449 or BS 4395, Part 1,
General grade with ASTM A563 nuts and ASTM F436 washers.
13.2.6. Welding electrodes shall be E70XX as per AWS A5.1 for manual arc welding (SMAW)
and F7X EXXX as per AWS A5.17 for automatic or semi-automatic submerged arc
welding (SAW). All SMAW electrodes shall be low hydrogen with E70 filler metals.
13.3. Fabrication
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13.3.1.
Generally, structural steel work shall be fabricated in the shop. All shop connections shall be
welded. All field connections shall normally be bolted at site during erection.
13.3.2. All connections shall be made with minimum two (2) bolts with minimum bolt sizes as
follows:
13.3.2.1. For main connections: M20 high strength bolts.
13.3.2.2. For secondary connections: M16 ordinary bolts.
13.3.2.3. For ladder cages: M12 ordinary bolts.
13.3.3. All strength welds shall be continuous fillet welds of minimum six (6) mm size (leg
length).
13.3.4. Butt weld shall be full penetration.
13.3.5. Except for buildings, seal welds shall be provided for all faying surfaces not structurally
welded, to 3mm minimum size.
13.3.6. Gusset plates and stiffeners shall be minimum 10mm thick and welded end plates shall be
minimum 12mm thick.
13.3.7. Bolt holes shall be cut, drilled or punched and shall not be made or enlarged by burning.
For bolts upto 24mm diameter, hole diameter shall be maximum 2mm more and for bolts
over 24mm diameter, hole diameter shall be maximum 3mm more.
13.3.8. All beams with moving loads shall have a pair of 10mm thick stop angles bolted on the
flange at each end.
13.3.9. Where seated connections are used, beam set back shall not exceed 12mm.
13.3.10. Bracing shall be connected to both beams and columns at the intersection of beam,
columns and bracing.
13.3.11. Removable floor plates shall be fastened with M12 bolts.
13.4. Erection
13.4.1. Erection tolerances shall comply with BS 5950 Part 2 or AISC. For all safety
requirements ANSI A10.13 for steel erection shall be adhered to and all modern
techniques and lifting equipment shall be utilized.
13.4.2. The Contractor shall furnish an erection marking system identifying all members prior to
fabrication.
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13.4.3. All foundations including anchor bolts shall be checked for accuracy before commencing
erection. Setting out shall be carried out for all column bases and tops for accurately
positioning, plumbing, alignment and leveling of all other members of the structures.
13.4.4. Field holes shall be drilled and burning or punching shall not be allowed unless otherwise
authorized.
13.4.5. Field openings in gratings shall be banded.
13.5. Fabrication Drawings
13.5.1. The Contractor shall submit fabrication drawings to the Company for review. Fabrication
shall commence only after the Company has completed the review and informed the
Contractor in writing to proceed with work.
13.5.2. Bill of material in Standard format shall be the integral part of each fabrication drawings
listing all materials and weights of each member and actualizing into actual “weighing
up” of the member.
13.6. Welding
13.6.1. Welding procedure, inspection, testing and post weld heat treatment, if required, shall be
carried out in compliance with requirements specified in AWS D1.1.
13.6.2. The Contractor shall prepare and submit Welding Procedure Specifications (WPS) and
Procedure Qualification Records (PQR) as per AWS D1.1 for the Company approval at
least one month (1) before commencing fabrication works.
13.6.3. Welders shall be pre-qualified and approved by the Company through Welder
Qualification Tests as per AWS D1.1.
13.7. Acceptance of Welds
13.7.1. All welds shall be subject to random visual inspection as per Section 8.15 of AWS D1.1.
13.7.2. Non-destructive examinations (NDE) shall be carried out in random spots identified by
the Company.
13.7.3. Fillet welds shall be inspected by MP or DP tests as per Part A, Section 6 and shall be
accepted as per part D, Section 8 of AWS D1.1.
13.7.4. All full penetration welded corners and T-joints shall be inspected by Ultrasonic tests in
accordance with the following schedule:
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Thickness of thinnest section to be welded Weld length to be tested by UT (%)

Over 50mm 20
50mm to 25mm 5
Less than 25mm 0
13.7.5. All full penetration butt welds used in splicing shall be inspected by Ultrasonic or
Radiographic tests as follows:
13.7.5.1. Ultrasonic tests on the entire length including webs as per Part C, Section 6 of
AWS D1.1.
13.7.5.2. Radiography by one spot radiograph per 500mm of butt weld.

13.8. Miscellaneous Structural Works
13.8.1. Platforms shall be provided for operation, servicing and maintenance of equipment and
their appurtenances. Minimum width shall be 1000mm. Walkways connecting access
platforms shall be minimum 750mm wide.
13.8.2. Stairways shall be provided to Platforms requiring frequent attendance or rapid escape in
the event of an emergency. Minimum clear stairway width shall be 750mm, however,
main access and escape stairs shall have a minimum clear width between stringers of
1000mm and 1200mm respectively. Minimum length of landing shall be 1200mm.
13.8.3. Spiral stairways shall generally be provided to circular structures like vessels and tanks
for access to platforms with a minimum clear width of 1000mm.
13.8.4. Minimum headroom clearance for platforms and stairways shall not be less than 2150m.
13.8.5. Steel flooring shall be galvanized open grid type. However where chances of spillage
exists, galvanized checkered plate flooring shall be considered for safety.
13.8.6. Open grid flooring shall be serrated rectangular type with 30mm x 5mm load bearing bars
@ 30mm centers with 10mm twisted cross bars @ 100mm centers in transverse direction,
attached to supporting structure by clips. All treads at stairs and landings shall have full
width anti-skid checkered plate nosing.
13.8.7. Checkered floor plates shall have a raised pattern to provide non-slip surface and shall be
minimum 6mm thick excluding the pattern and shall be attached to supports with
countersunk bolts. Drainage holes of 12mm diameter shall be provided for every 1.5 sq.m
of floor plate with minimum one (1) hole per panel.
13.8.8. Fixed ladders shall be provided as a means of access and emergency escape and shall be
vertical. Side access ladders shall be preferred to front access and shall be provided with
safety bars at entrance to platforms.
13.8.9. Handrails made of steel sections or pipes shall be provided for all platforms which are
500mm or more above ground or any operating level.
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13.9. Metal Cladding
13.9.1. Materials
13.9.1.1. General: Typical roof and wall cladding shall consist of a color coated outer
Multi-layer profiled sheeting and an inner liner, each made of galvanized steel
substrate, 0.7mm thick with fiberglass insulation in between.
13.9.1.2. Cladding Materials: Base material for the cladding shall have a minimum
yield strength of 345 N/Sq.mm (50,000 psi) and shall conform to the physical
specifications of ASTM A653/A653M or BS EN 10143 or equivalent. The
zinc coating shall be by hot dip galvanization process conforming to ASTM
specification A-525 with a coating class of G-90 (0.90 oz/ft2 or 275 g/m2) or
its equivalent. The painting shall consist of a 5 micron epoxy primer, 70
micron heavy epoxy base coat and 50 micron high build weather coat of
urethane on the external face and 20 micron stoving polyester on the internal
face.
13.9.1.3. Insulation: The insulation shall be fiber-glass, blanket type with vinyl facing
and suitable for application to roofs and walls of industrial buildings. The
Standard insulation thickness shall be minimum 50mm supplied in rolls. The
overall roof and wall cladding construction shall be designed to give
maximum 'U' value of 0.6W/m2/oC. The fire resistance of the facing shall be
in accordance with the Underwriters’ Laboratories Test Method UL723, and
shall have a fire hazard classification for flame spread 15 and smoke
developed 105. The vinyl facing shall have a high vapor barrier efficiency
with a low perm rating to prevent condensation.
13.9.1.4. Translucent sheets: Translucent sheets shall be minimum 2mm thick

manufactured from high quality glass reinforced plastic and shall comply with
BS 4154, Parts 1 and 2.
13.9.1.5. Fasteners: Fasteners shall be stainless steel weathered drive screws fitted with
integral stainless steel and sealant neoprene washer.
13.9.1.6. Sealer: Sealer for sidelaps, endlaps shall be 6mm wide x 5mm thick, pressure
sensitive butyl tape. The sealer shall be non-asphaltic, non-shrinking, non-
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drying and non-toxic and shall have superior adhesion to metals, plastics and
painted surfaces at temperatures from -50C to +104C.
13.9.2. Installation of roof, wall panels and accessories
13.9.2.1. Roof and Wall panels: Roof panels shall be continuous from ridge to eave as
far as possible. Where endlaps are required, the same shall occur over a roof
purlin. Sidewall and endwall panels shall be continuous from the eave to
40mm below the column base plate, as far as possible or as indicated on
approved drawings. Where end laps are required the same shall occur over a
wall girt. Minimum lap joint shall be 150mm.
13.9.2.2. Flashing, Trim & Closures: Flashing, trims and closures made of 0.7mm
thick galvanized steel of the same specification as the roof and wall covering
material, shall be furnished at the rake, corners, eaves, framed openings, and
wherever necessary to provide weather tightness and finished appearance. A
formed peak panel matching the slope and profile of adjoining panels shall be
provided along the building ridge. Solid or closed cell, preformed E.T.P.
(Ethylene Polypropylene Terpolymer) closures matching the profile of the
panel shall be installed along the eave, rake and other required locations.
13.9.2.3. Eave Gutters and Down Spouts: Eave gutters shall be box shaped, color
coated, made of 0.7mm thick galvanized steel. The outside face of the gutters
shall be supported with color coated 0.7mm thick galvanized straps to the eave
member at a maximum spacing of 1.20m. Downspouts shall be rectangular
shaped, color coated, made of 0.7mm thick galvanized steel. Downspouts
shall have a 45 degree elbow at the bottom and shall be supported by
attachment to the wall covering at 3.0m maximum spacing. Alternatively
Down spouts can be of 100mm dia. UPVC drain pipes.
13.9.2.4. Color Finish: Unless specified otherwise, all wall and roof panels, flashing,
trim and other exposed galvanized steel surfaces shall be color coated off-
white.
13.10. Fencing
13.10.1. In general, the Contractor shall provide fencing for security around plant and facilities and
to restrict unauthorized access and for protection of equipment, facilities, concrete pits,
impounding basin, rain water pond etc. at isolated places and in remote and desert
locations. The term fencing should include gates and all other accessories.
13.10.2. The existing facility fencing and the high security fencing of the Gathering Centers
interfering with the facilities shall be dismantled and disposed-off along with its
foundations in accordance with Company’s HSEMS standards and/or as instructed by the
Company.
13.10.3. New facility fencing/gates and high security fencing/gates along with its foundations shall
be constructed, fabricated and installed to suit the new layout of the Gathering Centers.
Requirement of vehicular gates shall be decided based on detailed engineering.
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N
ecessary modification to the existing fencing shall be carried out to facilitate connection
to the new fencing.
13.10.5. Details of new facility fencing and gates shall conform to KOC standard drawings 55-02-
17 and 55-02-20.
13.10.6. Details of the new high security fencing and high security gates shall conform to KOC
standard drawings 55-02-34 (sheets 1 of 2 & 2 of 2) and 55-02-35.
13.10.7. All gates shall be provided with sign plates in accordance with KOC Standard drawing
55-02-21.
13.10.8. All works related to fencing shall comply with the requirements of KOC Standard KOC-
G-019 Part 2.
13.11. Painting and Galvanizing
13.11.1. Contractor shall carry out painting and galvanizing of all structural steel works included
in the scope of the Contract in accordance with KOC Standard # KOC-P-001 – “KOC
Standard for Painting and Coating of External Metal Surfaces”. All structural steel works
shall be painted unless specified for galvanizing in the Contract scope.
13.12. Surface Preparation
13.12.1. Surface preparation shall not be carried out when the high ambient temperature is greater
than 50 deg. C or when the relative humidity is 85% or higher or under adverse weather
conditions of rain, fog, sandstorm or high wind velocity 56 km/hr or higher.
13.12.2. Dry abrasive blast cleaning shall be used. Abrasive metal shall be industrial grade metal
angular grit or shot. Garnet, capable of producing required surface profile may also be
used. Abrasive material shall be dry and free from oil, grease, dust, salts and any other
impurities and contaminants. Sand, Copper Slag or Cadmium shall not be used for
abrasive blast cleaning.
13.12.3. Enclosures shall be provided all around the area where shot/ grit blasting will be carried
out.
13.13. Paint application
13.13.1. Paint application shall be in accordance of the paint manufacturer’s recommendations.
13.13.2. Paint application by airless spraying shall be the preferred paint application process. The
use of air spray method shall be subject to the Company approval.
13.14. Paint mixing and thinning
13.14.1. Paint mixing shall be in accordance of the paint manufacturer’s recommendations.
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M
ixing by high speed mechanical agitators or rotary mixers with flat blade and speed
control shall be used for containers larger than 5 litres. Hand mixing is permitted only for
containers up to 5 litres.
13.14.3. Thinners shall not be added to paint without the Company approval.
13.15. Restrictions on painting
13.15.1. Painting shall not be conducted in similar weather conditions as for abrasive blast
cleaning and also when the metal surface temperature is above 50 deg. C and under
adverse weather conditions of rain, fog, sandstorm or high wind velocity 56 km/hr or
higher or when such conditions are likely before painting/coating has become dry.
13.15.2. Painting shall not be conducted outside daylight hours on exterior locations, unless
permitted by the Company. Approved special lighting shall be arranged for night painting.
13.16. Surface preparation and Painting scheme
13.16.1. Surface preparation and painting scheme for non-galvanized onshore structural items shall
be as per the table below. Finish color shall be Aluminium.
Surface Intermediate
Item Primer Finish coat
Preparation coat
Structural steel Sa 2 ½ Zinc Rich Two pack high Two Pack
work not Surface Epoxy, DFT build MIO Acrylic
encased in Profile 35-50 70 micron. epoxy, DFT Polyurethane
concrete. micron 125 micron. based on
Aliphatic
Isocyanate
curing agent,
DFT 70
micron.
Structural steel Sa 2 ½ Two pack high
Zinc Rich
work encased Surface build MIO
Epoxy, DFT ---
in concrete. Profile 35-50 epoxy, DFT
70 micron.
micron 125 micron.
13.17. Galvanizing
13.17.1. All steel works such as open grid flooring, handrails, stair treads, ladders, cages, safety
guards, checkered plates and all steel work for valve pits and trenches including steel
beams and appurtenances shall be galvanized as per BS EN ISO 1461 and top coated. All
bolts, nuts and washers shall be galvanized.
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13.17.2.
S
urfaces to be galvanized shall be prepared to visual Standard Sa 2 ½. The minimum
coating weight shall be 610 gm/sq.m of surface area.
13.17.3. Top coating for galvanized surfaces for color coding purpose shall comprise of a two pack
high build epoxy of DFT 120 microns followed by 2 pack acrylic polyurethane finish
based on aliphatic isocyanate curing agent in required color of DFT 70 microns.
13.18. Materials
13.18.1. The fire proofing materials selected and approved for use shall be light weight vermiculite
concrete such as Fendolite MKII or equivalent.
13.18.2. Cement used shall be Portland cement conforming to ASTM C150. Light weight
aggregates such as vermiculite shall comply with grading and density requirements of
ASTM C332.
13.18.3. Vermiculite concrete shall be supplied as a proprietary mixture of dry pre-mixed factory
controlled materials such as treated vermiculite and Portland cement with additives,
having a density of 500-800 kg/cu. m.
13.18.4. Vermiculite concrete shall have a minimum cube strength of 2.0 N/sq.mm at 28 days
when spray applied and 1.0 N/ Sq.mm when manually applied.
13.18.5. Reinforcing fabric shall be galvanized wire mesh of 25mm x 25mm x 1.5mm size.
Expanded metal lath shall be galvanized. Steel pins of minimum 2.5mm diameter shall be
used to hold mesh reinforcement in place. Galvanized mild steel bands and buckles shall
not be less than 0.6mm thick x 13mm wide. Tie wires shall be soft iron wire of 1.6mm
diameter.
13.19. Workmanship
13.19.1. Abrasive blast cleaning with industrial grade metal grit or shot shall be carried out on all
surfaces to be fire proofed. All grease, oil, rust, scales, dust and other contaminants shall
be removed completely to a visual standard of Sa 2 ½
13.19.2. Steel pins / nelson studs shall be welded to steel sections at a maximum spacing of
400mm / 600mm respectively.
13.19.3. Reinforcing fabric shall be placed to allow a cover of not less than 25mm and not more
than 30mm from outside face of finished surface. Where the thickness of fire proofing
exceeds 40mm, the fabric shall be placed at midpoint, measured from the expanded metal
lath.
13.19.4. Mixing of vermiculite concrete shall be carried out in concrete mixers or paddle blade
mixer in accordance with manufacturer’s recommendations. No hand mixing shall be
allowed.
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Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022)13.19.5.
V
ermiculite concrete shall be applied by a spraying machine. Manual application is
acceptable only for members/sections less than 100mm in size subject to the Company
approval.
13.19.6. Where structural columns to be fire proofed are in close proximity of accessway,
vermiculite fire proofing shall be applied over 2.0m height of column. The lower 2.0m
shall be fire proofed with minimum 50mm thick in-situ dense concrete as per provisions
in Standard # KOC-C-027.
13.19.7. Unless otherwise specified, minimum finished thickness shall be 40mm with a tolerance
of -2mm/ +3mm. The material shall be built up in a series of minimum three coats with
10mm – 13mm per coat.
13.19.7.1. All angle and channels and other structural members upto 300mm size shall
be solid filled. All other larger size members shall be profiled.
13.19.7.2. Sealing compound in accordance with manufacturer’s instructions shall be

applied at all fire-proofing / steel interfaces in a rebate of size 15mm deep x
15mm wide.
13.19.7.3. A final finish or flash coat shall be applied for a final smooth finish. The final
coat shall be trowelled.
13.19.7.4. Curing shall be continued at least for a period of four (4) days after placing the
vermiculite concrete and shall be continued further if required depending on
the weather conditions.
14. ROADWAYS AND PAVING
14.1. General
14.1.1. Contractor shall carry out Design and Construction for Roadways, Paving and Hard
Standing in compliance with the requirements of KOC Standard KOC-C-024 Parts 1 &
Part 2 and KOC-S-001.
14.1.2. All main facility access and primary roads, plant roads, secondary roads, service roads
and plot perimeter roads should be of bituminous construction in compliance with KOC
Standard KOC-C-024 Part 1.
14.1.3. All paved areas subjected to contamination by spillage or leakage of hydrocarbons shall
be of concrete construction.
14.1.4. Access-ways and walkways inside the plants shall be of concrete construction.
14.1.5. Temporary roads shall be made of gatch in accordance with clause 14.0 of KOC Standard
KOC-C-024 Part 1.
14.2. Basic Engineering Information
EF/2092 Part-A
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49
14.2.1. Design life shall be not be less than 20 years as minimum.
14.2.2. Roadways shall be designed based on traffic intensities and traffic volume category as per
Table-1 of KOC Standard KOC-C-024 Part 1.
14.2.3. Road design shall meet the design requirements in clause 7.3 of KOC Standard KOC-C-
024 Part 1. Design of road construction layers shall be as per “AASHTO Guide for
Design of Pavement Structures”. Contractor shall submit design calculations of road
construction layers for review and approval of the Company. However, minimum
thicknesses of road construction layers provided in KOC Standard drawing 55-02-94 shall
be implemented in the Contract even if lesser thicknesses are found acceptable by
calculations.
14.3. Horizontal Clearances
14.3.1. At roads without raised kerbs, a horizontal clearance of 1000 mm shall be maintained
between the edge of the shoulder and any structure projecting above shoulder grade. The
minimum horizontal clearance for lighting poles, guardrails, and traffic signs shall be 600
mm. At roads with raised kerbs, the minimum horizontal clearance shall be 600 mm from
the face of the kerb.
14.4. Vertical Clearances
14.4.1. Minimum vertical clearance of vehicles over main facility access and primary roads, shall
be 5000 mm. Over other roads it shall be 4000 mm. Where access for heavy lift cranes is
required, the clearance height shall be 7000 mm. Traffic signs shall be erected with a
minimum clearance of 2100 mm from ground or footpath level to the underside of the
sign.
14.5. Material Requirements
14.5.1. Sub-grade material shall have good cementing properties and shall be clean with
maximum particle size of 50mm. Minimum properties of sub-grade material shall
conform to Table 2, clause 8.3.2 of KOC Standard KOC-C-024 Part-1.
14.5.2. Sub base material shall be Gatch of minimum properties as per Table 3, clause 8.4.2 of
KOC Standard KOC-C-024 Part-1.
14.5.3. Prime coat comprising of a thin layer of liquid asphalt (MC 70) shall be sprayed over sub-
base to receive the base course at the rate of 0.80 to 1.75 kg/sq.m.
14.5.4. Base course shall comprise of a rolled and compacted layer of Type 1 or Type II asphalt
concrete material, minimum 100mm thick.
14.5.5. Tack coat comprising of a thin layer of viscosity grade cationic or anionic emulsified
liquid asphalt of grade SS-1h or CSS-1h shall be applied over base course to receive the
wearing course at a rate of 0.25 to 0.75 kg/sq.m.
EF/2092 Part-A
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49
14.5.6. Wearing course shall comprise of a rolled and compacted layer of Type III or Type IV
asphalt concrete material, minimum 40mm thick.
14.6. Construction of Sub-Grade
14.6.1. All materials shall be excavated and removed down to 150mm below the top of required
level of sub-grade.
14.6.2. Where the soil at the specified sub-grade level is unsuitable, excavation shall continue
until a suitable foundation is encountered. The surface of acceptable ground shall be
scarified for a depth of 200mm and shall be leveled with approved batch of fill materials
in layers not exceeding 150mm and compacted to 95% of maximum dry density at
optimum moisture content.
14.6.3. Where existing ground is lower than required sub-grade levels, such areas shall be made
up with approved fill in layers not exceeding 150mm and thoroughly compacted to 95%
of maximum dry density at optimum moisture content. The surface of acceptable ground
shall be scarified for a depth of 200mm and compacted to 95% of maximum dry density
at optimum moisture content.
14.6.4. The sub-grade shall be finished to proper levels, falls and shape, shall be protected from
damage and necessary repairs shall be carried out prior to laying of sub-base.
14.7. Construction of Sub-Base
14.7.1. The material shall be placed in layers not exceeding 150mm compacted thicknesses to a
minimum of 95% of maximum dry density at optimum moisture content with minimum
30% CBR value over the finished surface.
14.7.2. Where more than one layer is required each layer shall be approximately of the same
thickness and the material shall be laid over the full width of the formation including the
shoulders.
14.8. Construction of Asphalt Concrete Courses
14.8.1. Prime coat shall be applied at a rate of 0.80 to 1.75 kg/sq.m. over full width of the sub-
base course.
14.8.2. Surfaces of kerbs, vertical faces of existing pavements and all structures in actual contact
with asphalt mixes shall be painted with a thin and complete coating of tack coat to
provide a closely bonded water tight joint. The application shall be at a rate of 0.25 to
0.75 kg/ sq.m. on the base course.
14.8.3. Design and construction of asphalt concrete base course and wearing course shall be in
accordance with clause 11.0 of KOC Standard KOC-C-024 Part-1.
EF/2092 Part-A
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49
14.9. Road Shoulders
14.9.1. Construction of Shoulders shall comply with the requirement of clause 12.0 of KOC
Standard KOC-C-024 Part-1.
14.10. Drainage of Roadways and Paving
14.10.1. Drainage facility shall be such that the surface run-off is removed by gravity as quickly as
possible, utilizing the natural ground slope as far as practicable.
14.10.2. Roadways except single carriageway roads shall be crowned to drain the surface water to
the adjoining grade for KOC access/field roads and then by percolation into the adjacent
ground where adjacent ground is below the grade level. Where adjacent ground is above
crown of the road, surface water shall be drained to run-off to open drainage system
consisting of lined swales/flumes or reinforced concrete channels/ditches. Bottom surface
of the open drains shall have a longitudinal gradient of 1 in 250. Where it is not feasible to
provide open drains, drainage should be provided via drain inlets and piped system.
14.10.3. Paved areas shall be divided into several catchments to contain water using gradients and
kerb/ bunds for efficient drainage. Slope shall be minimum 1 in 80 in large open areas and
minimum 1 in 60 in restricted areas. Maximum vertical fall across paving shall not exceed
250mm.
14.10.4. Drainage inlets wherever required shall generally be between 45m to 90m and each inlet
shall drain an area of about 200 to 250 sq.m. for a road width of approximately 4.6m. For
wider roads spacing of inlets shall be proportionately reduced.
14.10.5. Wherever storm water sewers or underground pipes are provided they shall be connected
to an existing drainage system. Manholes shall be provided for maintenance access to
pipes at about every 150m.
14.11. Testing
14.11.1. The density of any layer requiring compaction shall be determined in accordance with
AASHTO specifications at a rate of one (1) test per 100 meter run or 1000 sq.m.,
whichever is less.
14.11.2. Testing for asphalt courses shall be done at a rate of one (1) sample per 200 meter run or
2000 sq.m. whichever is less.
14.11.3. Tests shall be carried out in accordance with relevant provisions in KOC Standard KOC-
C-024 Part-1.
EF/2092 Part-A
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49
14.12. Crash Barriers, Protection Bollards and Guard Rails
14.12.1. Crash barriers and protection bollards shall be provided at locations where the horizontal
alignment of any type of road changes abruptly and at locations where potentially any out
of control vehicle could cause damage to pipework, cabling or other items of installation.
14.12.2. Crash barriers shall be provided for protection of fire hydrants with 6” diameter carbon
steel pipes.
14.12.3. Guard rails shall be provided for protection of process equipment / piping in close
proximity to edge of road-way. Guard rails shall be made of un-tensioned steel corrugated
profile beams on steel posts as per KOC Standard drawing # 55-02-87. All steel work
shall be hot dip galvanized as per BS EN ISO 1461.
14.13. Traffic Markings and Signs
14.13.1. Road / traffic marking shall be in accordance with KOC Standard KOC-C-024 Part-1.
14.13.2. Traffic signs shall be in accordance with KOC Standard KOC-C-024 Part-2.
15. DRAINAGE
15.1. General
15.1.1. Contractor shall carry out Design and Construction of the Drainage Systems for the
Contract in compliance with the requirements of KOC Recommended Practice # KOC-C-
025 unless more stringent requirements are noted hereunder.
15.1.2. Site should be thoroughly surveyed to establish its natural topography and shall be
assessed to provide a reliable, economical and simple to operate drainage system.
15.1.3. Actual ground conditions and subsurface data based on geotechnical investigations shall
be taken into consideration with regards to porosity, permeability, corrosivity, electrical
resistivity of the soil.
15.1.4. Natural ground slopes shall be utilized as far as possible to minimize the depths of sewer
or channels.
15.1.5. All drainages shall be collected and directed to one of the following dedicated systems
such as clean water, contaminated water, oily water, chemicals, sanitary and waste water.
EF/2092 Part-A
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49
15.2. Design Volumes
15.2.1. Systems draining paved / unpaved areas shall be designed for greater volume of either of
the following cases, a) Effluent volume + Rainwater volume. b) Effluent volume +
Firewater volume.
15.2.2. Effluent volumes shall be determined from process information whereas rainwater
volumes shall be derived from rainfall intensity using appropriate permeability factors for
paved and unpaved areas. Firewater volume shall be as per clause 9.4.2 of KOC Standard
KOC-C-025, usually an average value of 1360 cu.m/hr, 100% evenly distributed over the
whole process area or 70% evenly distributed over an area of 1000 sq.m. Located
anywhere within the process area, should be considered adequate.
15.3. Drainage Layout within Process Areas
15.3.1. Drainage layout within process areas shall conform to clause 10 of KOC Standard KOC-
C-025.
15.3.2. Main drain lines or drain trenches shall run along the edges of plant areas and roads.
15.3.3. Process plot area shall be provided with concrete paving divided into catchments and
directed towards drainage points with a gradient of 1 in 100. Bituminous paving,
wherever provided, shall have a gradient not less than 1 in 60. Around pumps and other
areas where leaks and spills are anticipated, minimum slope should be increased to 1 in
50.
15.3.4. Drains shall not pass below or through foundations.
15.4. Drainage Layout outside Process Areas
15.4.1. Drainage layout outside process areas shall conform to clause 11 of KOC Standard KOC-
C-025.
15.5. Storm/Surface Water Drainage System
15.5.1. Drainage of clean and uncontaminated storm/surface water shall conform to clause 12 of
15.6. Drainage from Buildings
15.6.1. Drainage from buildings and shelters/sheds shall conform to clause 13 of KOC Standard
KOC-C-025.
EF/2092 Part-A
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49
Upgrade of GCs Water Disposal Facilities and Other Water Mitigation Works (WI TFT-Year 2022) 15.7.
I
mpounding Basin
15.7.1. Impounding Basin shall be provided for the disposal of contaminated water (storm / fire)
mixed with hydrocarbons / oils through evaporation while protecting the quality of
ground water, surface water and lands, as per the provisions in clause 15.2 of KOC
Standard KOC-C-025.
15.8. Hydraulic Design
15.8.1. The hydraulic design of drainage system shall conform to clause 17 of KOC Standard
KOC-C-025.
15.8.2. Flow in pipes and open drains shall be evaluated using Standard design methods with due
allowance for roughness factors of piping and open drain bed materials and effects of pipe
joints on flow regime.
15.8.3. Drainage sewers shall be designed in open and / or closed gravity systems assuming a
maximum flow depth of 70% of pipe diameter and operating at or near to atmospheric
pressure. The minimum flow depth shall not be less than 30 mm for pipes likely to
transport solids.
15.8.4. Roughness factors used in calculating the flow rate shall conform to clause 17.2.11 of
15.8.5. Pipes shall be laid to minimum gradients such as, 1 in 80 for pipes less than 150mm
internal diameter, 1 in 250 for pipes between 150mm and 450mm internal diameter and 1
in 500 for pipes greater than 450mm internal diameter.
15.9. Design of Buried Pipe Work
15.9.1. Design of buried pipe works shall conform to clause 18 of KOC Standard KOC-C-025.
15.9.2. In paved areas, the top of pipes (rigid/ flexible) shall be minimum 600 mm below paving
level.
15.9.3. In unpaved areas, the top of pipes (rigid/ flexible) shall be minimum 1000 mm below the
natural ground level / well compacted grade level where traffic loads is expected.
However, in non-trafficable unpaved areas this cover to top of pipes may be reduced
subject to Company approval.
15.9.4. Drain lines around buildings, where the cover is less than 460 mm for carbon steel pipes
and 900 mm for all other materials shall be protected by a minimum 150 mm thick
concrete bed and surround.
15.9.5. Where pipes run in open cut trenches under roads, pipes and bedding should be designed
with a factor of safety of 1.5 on the expected loading.
EF/2092 Part-A
Page 49 of
49
A
ll drain lines under roads inclusive of gatch and track roads where the cover is less than
1200 mm shall be protected by providing an adequate load bearing sleeve or a reinforced
concrete slab over the pipe shall be provided for protection. Design and construction of
reinforced concrete slab protection shall be such that vehicular loads are transferred to the
soil directly without loading the drain lines.
15.10. Testing
15.11. Minimum one (1) compaction test on backfilling shall be carried out by the Contractor at
every manhole, sump.
15.12. Drains shall be tested after 48 hours from being jointed and before commencing any
concreting or backfilling other than that required for structural stability during test.
15.13. Manholes shall be tested for leaks by closing the pipes with stoppers and filling with
water to the underside of the cover slab. A minimum period of two (2) hours shall be
allowed for absorption after which water shall be added to restore the level to the
underside of the cover slab. The manhole shall be acceptable if the water level does not
drop further.
EF/2092 Part-A

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TECHNICAL SPECIFICATION PART-V (CIVIL)

KUWAIT OIL COMPANY (K.S.C.)

PROJECT REF. EF/2092 Part-A

UPGRADE OF GCs WATER DISPOSAL FACILITIES AND OTHER WATER

Scope of Civil and Structural Works

4.1. Design and Drawings

5. SPECIFICATIONS, CODES AND STANDARDS

6. BASIC DESIGN DATA

8.2. Field Investigations

11. CONCRETE WORKS – MATERIALS AND CONSTRUCTION

13. STRUCTURAL STEEL WORKS - MATERIALS, FABRICATION AND ERECTION

14. ROADWAYS AND PAVING

2.1.2.1. Re-routing of underground services;

2.1.2.2. Site levelling, grading, excavation, compaction etc.;

2.1.2.3. Drainage works around equipment and facilities of the project;

2.1.2.4. Foundations for above-ground pipe headers and piping;

2.1.2.5. Foundations for electrical and instrumentation equipment and materials;

2.1.2.6. Civil works associated with underground piping;

2.1.2.9. Removal of fencing to make space for erection of piping;

2.1.2.10. Miscellaneous works including equipment operating platforms and piping

2.1.4.2. Construction of road crossing ducts (open cut method) and

2.1.4.5. Construction of civil works of outdoor substations (EF/2092A) at the

2.1.4.5.1. Foundations and structures for electrical equipment

2.1.4.5.2. Installation of pre-engineered steel roof shelter (with partially

2.1.4.5.3. Chain link fencing around substation

2.1.4.7. Drainage works at EF/2092A substation area in EF/2093B facilities;

2.1.4.9. Civil works to support miscellaneous electric cabling works in EF/2093B

2.1.4.10. Miscellaneous civil works to support EF/2092A electrical works in EF/2093B

2.2.1. Design, engineering, construction, installation, fabrication, erection and testing of

2.3. Site Finished Grade Levels

2.4. Windblown Sand/Loose Soils

2.5. Equipment Foundations

Wherever required as per detailed engineering, necessary structural steel and/or

2.6. Pipe/Valve Supports, Operating/ Maintenance Platform/ Crossovers

2.7. Reinforced Concrete Drain Pits (Drain Sumps)

2.8. Drainage of HPS Pumps & Booster Pump Area

2.9. Soil Treatment

2.10. Temporary Works

2.10.5. Construction of Temporary Disposal Pit for Hydro test Water:

2.11. Miscellaneous Works

4.1. Design and Drawings

5. SPECIFICATIONS, CODES AND STANDARDS

Practices listed in Technical Specification. All international Standards, Codes and

6. BASIC DESIGN DATA

6.3. Wind / Seismic Data

6.4.1. Average total annual rainfall: 118mm.

6.4.2. Design Storm: 70mm/hour falling uniformly for 30 minutes.

6.5. Soil Parameters

6.5.2.1. 50 KN/sq.m at 1.0m from natural ground level; and

6.5.2.2. 125 KN/sq.m at 1.5m from natural ground level.

6.6. General Design Basis

6.7. Dynamic Equipment

6.8. Overhead Pipe Racks

6.9. Paving, Walkways and Access-ways

6.10. Pipe and Cable Crossings through Roads

6.11. Pipe Crossings through Structures

7.3. Reference Datum

7.4. Contractor’s Deliverables

8.2. Field Investigations

8.3. Laboratory Tests

8.4. Soil Investigation Report

9.2. Commencement Requirements

9.3. Relocation and Re-routing of existing Facilities