Inspection and Test Plan For Cement Mortar Lining of Steel Pipes, Fittings, Bends and Welded Joints

KINGDOM OF SAUDI ARABIA Page 5 of 9
Saline Water Conversion Corporation

TAIF – TURUBAH / RANYAH / Al KHURMAH WTS
Inspection and Test Plan for Cement Mortar Lining of Steel Pipes, Spec. No. M03
Subject:
Fittings, Bends and Welded Joints ILF CONSULTING ENGINEERS
First Rev. A B 0 Document Number

Revision
Index
Issue Date 16.07.18 05.08.18 18-YA42-N-201
5 INSPECTION AND TEST PLAN

TAIF - TURUBAH / RANYAH / ALKHURMAH WATER TRANSMISSION SYSTEM
CONTRACTOR: MNG MAPA CONSTRUCTION
SUB-CONTRACTOR: RAYMOND INTERNATIONAL KSA Branch.
PARTICIPATION
QUALITY RELATED CHARACTERISTIC TESTING EQUIPMENT/ CALIBRATION REFERENCE DOCUMENTS
ACTIVITY FREQUENCY RAYMOND CML SWCC/ILF
ACTIVITY TO BE VERIFIED LOCATION TOOLS FREQUNECY ACCEPTANCE CRITERIA MAPA REP
REP. SPECIALIST REP.
1.0 Materials
Manufacturer Mill Monthly/per

1.1 Cement Supplier N /A N /A M03, ASTM C-150 Type 1 OPC TC/R/H R R R
Test Certificate Batch Delivery
Manufacturer Mill Per batch
2.0 Micro Silica Supplier N /A N /A M03, ASTM C-1240 TC/R/H R R R
Test Certificate Delivery
3.0 Sand
RSAL Test Report

3.1 Sand Gradation Daily Yard Sieve Mesh N/A M03, ASTM C-33, ASTM C-136 P/TC W/R R/W R
FM/QC/006 Rev.1
RSAL Test Repot M03, max.2%

3.2 Finer than 75 mic. Daily Yard Sieve Mesh N/A P/TC W/R R/W R
FM/QC/006 Rev.1 ASTM C-33, ASTM C-117
Clay Lumps and RSAL Test Report M03, max. 1%

3.3 Weekly Yard Sieve Mesh N/A P/TC W/R R/W R
Friable Particles FM/QC/018 Rev.1 ASTM C-142,
RSAL Test Report COLOR CHART M03, higher than standard

3.4 Organic Impurities Weekly Yard N/A P/TC W/R R/W R
FM/QC/018 Rev.1 (STANDARD) ASTM C-40
Independent Lab. TPI Lab Tools /

3.5 Soundness Weekly TPI Lab N/A M03, ASTM C-88 TC/R R R R
Test Report Equipment
LEGEND: P: PERFORM, A: ACTUAL INSPECTION, W: WITNESS INSPECTION, R: REVIEW DOCUMENTATION, TC: TEST REPORT/CERTIFICATE REQUIRED H: HOLD
Engineering Subcontractor Contractor Subcontractor
MAPA Construction and Trade Co. Inc. RAYMOND Intl. Co. Ltd.
Subject:

Revision
Index
Issue Date 16.07.18 05.08.18 12.09.18 18-YA42-N-201
PARTICIPATION
ACTIVITY FREQUENCY
ACTIVITY TO BE VERIFIED LOCATION TOOLS FREQUNECY ACCEPTANCE CRITERIA RAYMOND CML SWCC/ILF
MAPA REP
Independent Lab. TPI Lab Tools / M03, Max. 1.5%

3.6 Water absorption Monthly TPI Lab N/A TC/R R R R
Test Report Equipment ASTM C-128
Chloride Ion content Independent Lab. TPI Lab Tools / M03, Max. 0.05%
3.7 Monthly TPI Lab N/A TC/R R R R
(CI) Test Report Equipment BS 812 Part 117
Independent Lab. TPI Lab Tools / M03, Max. 0.40%

3.8 Sulphates SO3 Monthly TPI Lab N/A TC/R R R R
Test Report Equipment BS 812 Part 118
Potential Alkali Independent Lab. TPI Lab Tools /

3.9 Monthly TPI Lab N/A M03, ASTM C-289 TC/R R R R
Reactivity Test Report Equipment
Specific gravity and

3.10 Absorption of Fine Monthly TPI Lab N/A M03, ASTM C-128 TC/R R R R
aggregates

4.0 Water Monthly TPI Lab N/A M03, PH 7-8 TC/R R R R
Bonding Agent
Bonding agent MO3, Relevant Specification and
5.0 Master Cast 141 / Every repair Yard / Site Repair Tools N/A H H R R
workability Standards / Material Data Sheet
Rheomix 141
Manufacturer
Manufactu
6.0 Pozzolith 55-RA Admixture Once Lab Tools / N/A M03, BS-5075 Part 3 TC/R R R R
rer
Equipment
Hempel Epoxy Manufacturer Manufactu TPI Lab Tools /

7.0 Once N/A M03, Manufacturer Product Data TC/R R R R
Knifing Filler 355SA Certificate rer Equipment
Subject:

Revision
Index
Issue Date 16.07.18 05.08.18 18-YA42-N-201
PARTICIPATION
ACTIVITY FREQUENCY
MAPA REP
Once / Batch Plant / 3 months
8.0 Trial Mix Mix Design Yard MO3 and Applicable Standards P/H H H H
Every Project Testing Moulds (Batch Plant)
Visual /
Pipe Receiving / As per Pipe MTC /
9.0 Every Pipe Yard / Site Dimension N/ A M18 ; 78-YA42-F-206 P/TC R R R
Handling/ Shipping Delivery Note
Check
Once / Batch Plant / 3 months MO3 and Applicable Standards /
10.0 Mix Design Yard P/H H H H
Every Project Testing Moulds (Batch Plant) PQT Procedure
Compressive / M03, 28 Days Test
Compressive Test / 7, 14 & 28
10.1 Yard Flexural 6 months Compressive: 55 N/mm² min. P/TC W R W
PQT Bending Test days
Machine Bending: 6 N/mm² min.
M03,AASHTO T277,DIN 1048
Chloride Ion & Rapid Chloride
10.2 Monthly Yard 6 Months Water Perm.: below 4mm P/TC W W/R W/R
Water Penetration Machine
Chloride Perm.: 100-1000
Cement Mortar
11.0
Lining Process
Internal Pipe Surface Each pipe / Blasting
11.1 Visual Inspection Yard / Site N/A M03, ST-2 Finish, ISO 8501-1:2007 A A R A
Preparation Joint Equipment
Every Fittings
Reinforcement (Wire Wire Mesh Size
11.2 above 24 Yard / Site Wire mesh N/A M03, AWWA C205 / C602 TC/R R R R
Mesh) and Bonding Agent
inch
Approved mix
11.3a Mix Proportion (Yard)
design
Sand Sand Scale 3 months M03 W/TC/H W R W/R
Water Daily Yard Water Scale 3 months M03 W/TC/H W R W/R
Additives Measuring Cup N/A M03 W/TC/H W R W/R
Approved mix
11.3b Mix Proportion (Site)
design
Cement Weighing Scale 6 months M03 W/TC/H W R W/R
Sand Weighing Scale 6 months M03 W/TC/H W R W/R
Daily Site
Water Flow Meter 3 months M03 W/TC/H W R W/R
Additives Measuring Cup N/A M03 W/TC/H W R W/R
Subject:

Revision
Index
Issue Date 16.07.18 05.08.18 18-YA42-N-201
PARTICIPATION
ACTIVITY FREQUENCY RAYMOND CML SWCC/ILF
ACTIVITY TO BE VERIFIED LOCATION TOOLS FREQUNECY ACCEPTANCE CRITERIA MAPA REP
11.4 Slump Test Flow Table N/A M03, ASTM C-230, AWWA C-205, A/TC A R A/R
Wall “Ambient”
11.5 Ambient 6 months M03 A/TC A R A/R
Mortar Workability / Thermometer
Daily Site Needle
11.6 Mortar Temperatures Temperatures 6 months M03 - 32ºC max A/TC A R A/R
Thermometer
Surface
11.7 Pipe Temperatures 6 months M03 - 35ºC max A/TC A R A/R
Thermometer
Coating
11.8 Lining Thickness Mortar Thickness Each pipe Yard / Site Thickness 6 months M03 / AWWA C-205 A/TC A/W R A/W
Gauge
Mortar Surface Visual Inspection,
11.9 Condition after Pre- Lining cracks and Each Pipe Yard / Site N/A N /A M03 / AWWA C-205 A/TC/H A R A
Set Surface roughness
Visual, Cut Back

11.10 Pipe Ends Each Pipe Yard N/A N /A M03 / AWWA C-205 A/TC A R A
and end cover
12.0 Sampling Test

M03 :
Water- Cement & Weighing Scale, 6 Months /
12.1 Mortar Workability Daily Yard / Site W-C : 0.32 P/TC W W/R W/R
Sand Cement Ratio Sieve / Oven Yearly
S-C : 1.2
Compression & M03, 28 Days Test
Compressive and
12.2 Mortar Strength Weekly Yard Flexural 6 Months Compressive: 55 N/mm² min. P/TC W W/R W/R
Bending
Machine Bending: 6 N/mm² min.
M03, AASHTO T277,DIN 1048

Water and Chloride Chloride Ion & Rapid Chloride
12.3 Monthly Yard 6 Months Water Perm.: 4mm max. P/TC W W/R W/R
Permeability Water Penetration Machine
Chloride Perm.: 100-1000
RSAL Test Repot
12.4 Lining Structure Monthly Yard N/A N/A M03 TC A R A
FM/QC/025 Rev.0
12.5 Water Curing Visual inspection Each Pipe Yard / Site N/A N/A M03, AWWA C-205 A A R A
Subject:

Revision
Index
Issue Date 16.07.18 05.08.18 18-YA42-N-201
PARTICIPATION
ACTIVITY FREQUENCY
MAPA REP
Complete Release
Final Inspection and Report Each Pipe /
13.0 Yard / Site N/A N/A M03, AWWA C-205 W A/W W/R W/R
Release Recommendation Weekly
for Release
Visual and Video
14.0
Inspection
Video Inspection Each Pipeline

14.1 Site N/A N/A M03 A/W A R R
below 60 inch Section
Pipeline Section Visual Inspection
Each Pipeline Yard /
14.2 for 60 Inch and N/A N/A M03 A/W A R R
Section Site
Larger
Test Certificates,
Laboratory Test
Weekly / Yard / Relevant Specification and
15.0 Documentation Reports N/A N/A H H H R
Monthly Site Standards
Lining and
Inspection Reports

Inspection and Test Plan For Cement Mortar Lining of Steel Pipes, Fittings, Bends and Welded Joints

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KINGDOM OF SAUDI ARABIA Page 5 of 9

Saline Water Conversion Corporation

First Rev. A B 0  Document Number

Issue Date 16.07.18 05.08.18   18-YA42-N-201

5 INSPECTION AND TEST PLAN

Manufacturer Mill Monthly/per

RSAL Test Report

RSAL Test Repot M03, max.2%

Clay Lumps and RSAL Test Report M03, max. 1%

RSAL Test Report COLOR CHART M03, higher than standard

Independent Lab. TPI Lab Tools /

Engineering Subcontractor Contractor Subcontractor

First Rev. A B 0  Document Number

Issue Date 16.07.18 05.08.18 12.09.18  18-YA42-N-201

Independent Lab. TPI Lab Tools / M03, Max. 1.5%

Independent Lab. TPI Lab Tools / M03, Max. 0.40%

Potential Alkali Independent Lab. TPI Lab Tools /

Specific gravity and

Independent Lab. TPI Lab Tools /

Hempel Epoxy Manufacturer Manufactu TPI Lab Tools /

Engineering Subcontractor Contractor Subcontractor

First Rev. A B 0  Document Number

Issue Date 16.07.18 05.08.18   18-YA42-N-201

Engineering Subcontractor Contractor Subcontractor

First Rev. A B 0  Document Number

Issue Date 16.07.18 05.08.18   18-YA42-N-201

Visual, Cut Back

12.0 Sampling Test

M03, AASHTO T277,DIN 1048

Engineering Subcontractor Contractor Subcontractor

First Rev. A B 0  Document Number

Issue Date 16.07.18 05.08.18   18-YA42-N-201

Video Inspection Each Pipeline

Engineering Subcontractor Contractor Subcontractor

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