STANDARD NO, 1207

Standard
For
Supply of Precast Concrete Columns

SUNCOR ENERGY INC,

FORT MCMURRAY, ALBERTA
CANADA

Rev # Date Revision Notes By Chk'd App'd App'd APP"d

0 99.06.09 Issued for Comments MW
t Issued for Project Millenn ium MW
Implementation
2 Issued for General lmplementafion

~,
/,
3 Dec. 05 Issued for Voyageur Implementation
N~ 154
. ~ I!'fP
 STANDARD NO. 1207

Standard
For
Supply of Precast Concrete Columns

SUNCOR ENERGY INC.

FORT MCMURRAY , ALBERTA
CANADA

Rev # Date Revision Notes By Chk'd App'd App'd App'd

0 99.06.09 Issued for Comments MW
1 Issued for Project Millennium MW
Implementation
2 Issued for General Implementation
3 Dec. OS Issued for Voyageur Implementation
N~, ~ m
/I
PD
-rf; /

!
 Suncor Energy Supply o f Prec ast Rev. 3 Page 2 of 11
STD 1207 Conc rete Columns December, 2005

Index:

1.0 GEN ERAL ....................................................................................................................................................... 3

1.1 SCOPE ............. .. ...... . .... ... .............. 3
i2 D EFINITIONS ..................................................................................................... .. ........ .. . ............... ..... ... 3
1.3 CODES AN D STANDARDS ................................. . ...... ............ ....................... .............. .. ......... .. ..... 3
1.4 SlJFlMITTALS .. .4

2.0 !\1A T ERI AL..S .................................................................................................................................................. 5

2. 1 GENERAL ................................. ...... .... ........ ................................... . ... ... ...... 5
2.2 CONCRETE MATERIALS .......... ... .. .......... .. . . ................... .......... .. ........... .. ......... .. . .. 5
2.3 REINFORCEMENT M ATER JALS. .. ... ......... .. ........... ... .. . .... ................................. . .. .......... .. .... 6
2.4 E MBEDDED HARDWARE.. .......... ............ .. ....... . .... ........ ... ........... .. ................................ ... .... 6
2.5 MJSCELLANEOus M ATERIALS .. . ..... ......... .. .................. ....... ........ .. ......... .. . .. ....... . . .. ... 6

3.0 FA BRi CATION .............................................................................................................................................. 7

3.1 GE NERAL ....................................................... . ................................. .... ........................ 7
3.2 FORMS .. ... ....... ............. ... ... ..... . . . ................. ........ ........ ...................... 7
3.3 FINISH OF UNFORMED SURFACE ............. ... . .. .. .. ....... .... ........ ............. ... ..... .... ..... . 7
3.4 CURING AND P ROT ECTION OF CONCRETE .. ....... ... ............. . ..................... ... ..... . ........................ 7
3.5 REPAIR OF PRECAST CONCRETE .................... ....... .... ............. ........ ... .. ...... .. .. .... 8
3.6 PJ ECE MARKI NG OR T AGGlNG OF COLUMNS ...... ... ....... . .... ....... .. ...... .. ... ........ . ..... .. ......... ... ............ ..... . 9

4.0 HAN DL ING A.N D D ELIV ER Y ..................................................................................................................... 9

4.1 H ANDLING... .. .......... .... ....... ............ ....................... ..... ......... .. ......... . ..... ......... ........................ ... .. 9
4.2 D ELIVER y.. ..... .. .. . ... ..... ... ... . .. ..... .. .. .. .. .. ...... ........ .. ......... ..... . .... .. .. .......... ..... ...... .... ....... ... ....... . ... .. ...... 9

5.0 QUA LIT Y A SSURANC E............................................................................................................................... 9

5. 1 G ENERAL .... .... ... 9
5.2 T ESTING .. .......... .... ...... ..... . ................ ...................... .. ............................ .. .. 10
5.3 F ABRJCA nON T OLERANCES .... ...... .. ........................ .......... .......... ... . .... ............. 10
 Su ncor Energy Supply of Precast Rev. 3 Page 3 of 11
STD 1207 Conc rete Columns December, 2005

1.0 General

1.1 Scope
This standard covers the technica l requirements , in addition to the
requiremenl of Suncor Energy Inc. STD 1203, for malerials, fabrication and
delivery of precast concrete columns used to support the piperacks on the
Suncor Energy Inc. Oil Sands Group Site.
1.2 Definitions

(a) " Owner" means Suncor Energy Inc. or its designated

representative .
(b) "Owner's Engineer" - means a person responsible for the technical
integrity of the project.
(c) "Owner's Inspector" - means the person authorized by the Owner for
inspection.
(d) "Contractor" - means the entity, manufacturer, fabricator, vendor or
supplier that supplies the precast concrete columns , including all
subcontractors .
(e) " Local Authorities " • means the Governmental Regulatory Authority
controlling Laws , Codes, rules or regulations for the concrete materials
and construction in the Province of Alberta.
(I) " Testing Agency" • means an independent testing agency which will
perform the required laboratory andl or field testing on the materials,
components or the finished products of precast concrete items on
quality, workmanship and conformance wit h the Project standards and
specifications. Unless otherwise specified in Project documents, the
Testing Agency shall be retained by the Contractor, subject to approval
by the Owner.
1.3 Codes and Standards
1.3.1 The materials and fabrication of precast concrete columns shall conform
to all applicable industrial codes, standards, and specifications including
those listed below. Each publication shall be the latest revision and
addendum , including supplements if any.
Alberta Building Code (ABC)
American Society for Testing and Materials (ASTM)
ASTM A307 Standa rd Specification for Carbon Steel Bolts and
Studs; 60,000 psi Tensile Strength
Suncor Energy Supply of Precast Rev . 3 Page 4 of 11
STD 1207 Concrete Columns December, 2005

Canadian Standards Association (CSA)

CSA A23.1 Concrete Materials and Methods of Concrete
Construction
CSA A23.2 Methods of Test for Concrete
CSAA23.3 Design of Concrete Structures
CSA A23.4 Precast Concrete- Materials and Construction
CSA A251 Qualification Code for Manufacturers of Architectural
and Structural Precast Concrete
CSA A283 Qualification Code for Concrete Testing Laboratories
CSA G30.3 Cold Drawn Steel Wire for Concrete Reinforcement
CSA G30.5 Welded Steel Wire Fabric for Concrete
Reinforcement
CSA G30.18 Billet Steel Bars for Concrete Reinforcement
CSA G40.21 Structural Quality Steels
CSA S16.1 Limit States Design of Steel Structures
CSA S269.3 Concrete Formwork
CSAW47.1 Certification of Fusion Welding of Steel Structures
CSAW59 Welded Steel Construction
CSA W186 Welding of Reinforcing Bars in Reinforced Concrete
All references to the Alberta Building Code contained in this standard shall
also imply reference to the corresponding section of the National Building
Code of Canada, including supplemental sections, unless noted
otherwise.
1.3.2 The following Suncor Energy Inc. Standard s shall also be complied with:
STD 0302 Furnishing of Steel Structures
STD 1203 Cast-in-Place Concrete Materials and Construction
1.3 .3 Whenever a conflict exists among the referenced codes , standards and
specifications including this one, the more stringent shall apply unless
specifically noted otherwise in the project documents.

1.4 Submittals
1.4.1 All submittals shall be delivered to the Owner's Engineer or the Owner.
1.4.2 The following information or materials shall be submitted with the bid
documents:
(a) Copies of welding certification and qualification documents of steel
hardware and reinforcement welding per Suncor Energy Inc. STD
0302, Clause 1.5.2 , as well as per CSA W186.
 Suncor Energy Supply of Precast Rev. 3 Page 5 of 11
STD 1207 Concrete Columns December, 2005

(b) Copies of CSA A251 certification of the precast plant.

(c) List of the contractor's key personnel to be assigned to this project
and copies of their resumes .
(d) A complete written description of the Contractor's quality assurance
and control program for rebar and hardware fabrication , installation,
production , placing and curing of concrete, as we ll as delivery of
the co lumns.
1.4.3 Submittals Prior to and Dduring the Work'
(a) All the submittal items listed in Section 1.4 of Suncor Energy Inc.
STD 1203.
(b) Copies of mill certificates or manufacturer material certificate of
embedded items at the request of the Owner's Engineer.
(c) Materials and procedures for repairing any defects in the precast
concrete . However, the Owner's Engineer's written approval shall
be obtained prior to the start of any repair work.
(d) Concrete test results on a weekly basis. In case of any non-
conforming resu lts, the Owner's Engineer shall be notified
immediately.
,
Note:
The contractor shall develop a quality plan or inspection, and test
plan (ITP) that accurately depicts the quality and inspection
milestones. It shall be provided to the Owner's Inspector for review
and approval prior to start of construction. There the Owner's
Inspector shall indicate notification and hold points as needed.
Where hold points have been placed , the Contractor is responsible
to provide adequate notice to the Owner's Inspector such that the
work is not interrupted as a result of the need to complete the hold
point audit.

2.0 Materials

2.1 General
2.1.1 All materials, including all ingredients for making concrete , reinforcement ,
and embedded items shall conform, as a minimum, to the requirements of
Suncer Energy Inc. STD 1203. CSA A23.1 and A2 3.4.
2.1 .2 Any materials or items that are not clearly specified in the project
documents shall have the approval of Owner's Engineer prior to use.
2.2 Concrete Materials
2.2 .1 Ingredients or materials for concrete production and curing shall conform
to the requirements of CSA A23.1 and Suncer Energy Inc. STD 1203.
Suncor Energy Supply of Precast Rev. 3 Page 6 of 11
STD 1207 Concrete Columns Oecember, 2005

2.2.2 Unless otherwise specified in the project documents, the specified 28-day
compressive strength of the concrete shall be 35 MPa, and cement shall
be Type 50 or Type 20 (moderate sulphate resistant) . Maximum
aggregate size shall not exceed y." (20 mm).
2.2.3 Unless otherwise specified in the project documents, the precast concrete
shall be proportioned to meet the requirements of Class C-1 and S-2
exposures as per CSA A23.1.
2.3 Reinforcement Materials

2.3.1 All reinforcement shall be billet steel deformed bars conforming to the
requirements of CSA G30.18, Grade 400. It shall be new material, free from
loose rust, mill scales, oil , grease or any foreign substances that may impair
the bonding between the re inforcement and concrete .
2.3.2 Weldable re inforcing bars shall be used when reinforcing bars are to be
welded to each other or to hardware.

2.4 Embedded Hardware

2.4.1 All embedded steel hardware, including stee l shapes, plates, anchors, etc.,
shall conform to the req uirements of CAS G40.21 , weldable grade. The
minimum yield strength of steel hardware shall be 300 MPa , but higher
strength may be required in the design for some items, for example,
"Nelson" studs.
2.4.2 All hardware shall be new material, free from loose rust , mill scales, oil,
grease or any foreign substances that may impair the bonding between the
steel and concrete .
2.4.3 When coating is required , hardware shall be coated according to the project
specification and the coating material manufacturer's recommendations.

2.5 Miscellaneous Materials

2.5. 1 Supports, chairs and spacers for rebar and embedded items shall generally
be non-metallic type and shall be durable, strong and properly secured to
withstand the placing, compaction and consolidation of concrete. Metallic
supports, chairs and spacers that are placed inside the clear concrete cover
zone shall be galvanized or plastic coated.
2.5.2 Tie wire shall be soft annealed wire, minimum 16 gauge (1 .6 mm).
2.5.3 Curing com pound shall have the approval from the Owners Engineer
before use. It shall not discolor the finished concrete surface.
2.5.4 Other miscellaneous items used in the fabrication of precast columns shall
be as specified in the project documents or approved by the Owner's
Engineer.
 Suncor Energy Supply of Precast Rev. 3 Page 7 of 11
STO 1207 Concrete Columns December, 2005

3.0 Fabrication

3.1 General
3.1.1 As a minimum, the procedures and conditions used to fabricate the
precast columns shall conform to the requirements of Suncor Energy Inc.
STD 1203, CSA A23.1 and A23.4.
3.1 .2 Welding of steel hardware and reinforcement shall conform to the
requirements of CSA W47.1, W59 and W186.
3.2 Forms
3.2 .1 Forms for precast concrete columns shall be made from metal or treated
plywood (specially design for concrete forming) per CSA S269 .3 to
produce a uniform and smooth form finish , meeting the requirements
"Smooth-Form Finish" as per Clause 24.3.3 of CSA A23.1.
3.2.2 Form release agent sha ll not discolor the finished concrete surface.
3.2.3 Forms shall be water tight to prevent leaking , and rigid enough to
withstand the placing and consolidation of the concrete without
appreciable deformations, and to meet the dimensional tolerance
requirements of the finished columns.
3.2.4 Hardware and reinforcement shall be properly placed and secured in
position to prevent any distortion or dislocation during concrete place ment
and consolidation.

3.3 Finish of Unformed Surface

3.3.1 Unformed surfaces shall have a smooth trowel finish , producing
essentially the same finish as the formed surfaces. Care shall be taken as
not to over work the surface to damage the air void system.
3.3.2 Whenever possible, the unformed surface/side shall fa ce the inside of the
pipe rack when installed.

3.4 Curing and Protection of Concrete

3.4 .1 The concrete temperature at the time of placing shall be between 10 and
25°C.
3.4.2 Concrete shall be placed and cured under a protected environment that is
not exposed to rain , snow, direct sunlight or strong wind , and whose
ambient temperature shall be between 10 and 30° C. Care shall be taken
during placing , consolidating and finishing of concrete to prevent moisture
loss.
3.4.3 Immediately after finishing , any exposed concrete surfaces shall be tightly
covered with polyethylene sheets or other means to create a 100%
relative humidity environment for the concrete. Water and/or steam curing
may be applied after initial set, i.e., 4 to 5 hours after placement.
Suncor Energy Supply of Precast Rev. 3 Page 8 of 11
STD 1207 Concrete Columns December, 2005

3.4.4 Steam curing , if applied , shall not start until initial set, and shall not
exceed 20°C per hour of heating rate to the concrete , measured at a
location of 1 inch (25 mm) from the concrete surface. The Contractor
shall demonstrate, to the satisfaction of the Owner's Engineer, that the
timing , temperature rise rate and maximum temperature of the proposed
steam curing regime wi ll not jeopardize the specified 28-day compressive
strength of the concrete, using strength test results from cylinders cured
under exactly the same condition s.
3.4.5 The maximum concrete temperature during curing shall not exceed 65° C
under any ci rcumstances. W hen steam curing or external heating is used,
the Contractor shall monitor the temperature inside the concrete during
the curing period .
3.4.6 Unless otherwise approved by the Owner's Engineer, precast concrete
shall be cured (protected against moisture loss) under a minimum
temperature of 10° C for at least 7 days, or for the time necessary to
attain at least 70 % of it's specified 28-day compressive strength .
3.4.7 Forms shall not be stripped till concrete has reached at least 15 MPa of
compressive strength . If the forms are stripped prior to the specified
minimum curing duration as specified in Clause 3.4.6 has been reached ,
care shall be taken to prevent moisture loss during form stripping and
curing shall be resumed immediately after stripping.
3.5 Repair of Precast Concrete

3.5.1 The concrete surfaces shall be carefully examined immediately after form
stripping to identify any defects, such as honeycombs, larger voids,
excessive bug holes, segregation , discoloration, etc. The inspection
findings , including the nature/cause, dimension , location of the defects, if
any, shall be documented in the Q/e record.
3.5.2 Any repairs to defects shall be at the Contractor's own cost.
3.5.3 Material , application procedure and curing method for repa iring each type
of defect shall be approved by the Owne r's Engineer prior to use.
3.5.4 Any defects greater than 3/8" (10 mm) in depth or 1" (25 mm) in diameter
shall be repa ired .
3.5.5 Defects not exceeding 1" (2 5 mm) in depth or 3" (7 5 mm) in diameter shall
be considered as minor defects, and may be patched using approved dry
pack materials and procedures. The defect surfaces shall be cleaned prior
to patching to ensure bonding .
3.5.6 Defects greater than 1" (25 mm) in depth or 3" (75 mm) in diameter shall
be considered as major defects , and shall be reported the Owner's
Engineer immediately upon discovery. Depending on the nature, location
and extend of the defects, the Owner's Engineer may chose to reject the
affected piece or to accept it after being satisfactorily repaired . Repair
materials and procedures shall be established with the Owner's Eng ineer.
 Suncor Energy Supply of Precast Rev. 3 Page 9 of 11
STD 1207 Concrete Columns December, 2005

3.6 Piece Marking or Tagging of Columns

3.6. 1 Each column shall be piece marked or tagged according to the location
plan , using permanent ink or paint.
3.6.2 Th e marking letters shall be minimum 2" (50 mm) high and 1-1 /4 " (32 mm)
wide. The piece marking shall be pla ced on two opposite column faces
that are parallel to the pipe ra ck longitudinal direction , at a location of
approximately 7 ft (2.1 m) from the bottom of the column.

4.0 Handling and Delivery

4.1 Handling
4.1.1 The Contractor shall be responsible for providing holes for lifting the
precast columns in the fabrication yard and for erection. The holes shall
not exceed 1-112 " (40 mm) in diameter, and the location of the holes shall
requ ire prior approval from Owner's Engineer. The Contractor shall not be
permitted to include any embedded hooks, bolts, cab les or any device that
permanently protrudes through the co ncrete surface without the written
approval of the Owner's Engineer.
4.1.2 Care shall be taken during the ha nd ling and storing of the precast
concrete to preve nt any damages , cracking , discoloration or corrosion to
the finished concrete surface or the embedded items.
4.1.3 Finished co lumns shall be blocked off the ground and separated from
each other using wood blocks spaced at no more than 10 ft (3 m) .
4.2 Delivery
4.2. 1 The Contractor shall be responsible for loading , packing , transporting and
unloading the precast columns to deSignated location(s) at the Suncor
Energy Inc. Oil Sand Group Site.
4.2.2 The Contractor shall ensure proper supporting and protection of the
columns during handling and transportation to prevent damage to the
columns.
4.2.3 The columns shall not be moved or transported until they have reached at
least 75 % of the specified 28-day compressive strength.

5.0 Quality Assurance

5.1 General
5.1 .1 As a minimum, the materials, fabrication procedures, workmanship and
finished products of precast columns shall meet the requirements of
Suncor Energy Inc. STD 1203, CSA A23.1 , A23.4, A251 , W59 and W186 ,
in add ition to the requirements of this standard.
 Suncor Energy Supply of Precast Rev. 3 Page 10 of 11
STD 1207 Concrete Columns December, 2005

5.1.2 The Contractor shall be responsible for maintaining a complete QAJQC

record. The record shall include, but not to be limited to , concrete mix
design and trial test data, concrete test results during column production,
welding procedures, conditions and inspection results , ambient
temperature of the precast shop/yard , casting date and time, curing
method and duration, defects (if any) and repai r methods , etc. for each
column.
5.1.3 The Owner's Engineer and Inspector reserve the right to visit and inspect
the precast yard , related work sites and fin ished or unfinished products at
any time during the course of the work. The Contractor shall provide
unlimited access to his fabrication facility for such visit and in spection.
5.2 Testing
5.2.1 Unless otherwise specified in the project documents, the Contractor shall
be responsib le for retaining , at his own cost, a CSA certified independent
testing agency, subject to the approval of the Owner's Engineer, to
conduct all QAJQC testing .
5.2.2 Precast concrete shall be tested for both properties at the fresh state and
compressive strength at a frequen cy not less than 1 set of tests for every
10 columns made or for each day's work , whichever is more frequent.
5.2.3 The fresh concrete shall be tested for slump, air content, temperature and
density per CSA A23.2. If the concrete fails to meet the requirements , it
shall be rejected and removed from the site immediately. In such a case ,
each subsequent load/batch of concrete shall all be tested until 3
consecutive tests have yielded satisfactory results. Afte r that, the test
frequency can be reduced to that listed in 5.2.2.
5.2.4 At least a set of 4 cylinders shall be produced and cured, and tested for
compressive strength per CSA A23 .2. One cylinder shall be tested at 7
days , 2 at 28 days, and the remaining 1 kept as a spare. Addit ional
cylinders shall be made and tested for other purposes such as
determining the curing termination timing.
5.2.5 The Owner's Engineer and Inspector may request for any additional
testing of concrete or other materials, such as welding quality and
strength. If the test results meet the project requirements, the Owner shall
pay for the cost of these additional tests . Otherwise, the Contra ctor shall
be responsible for the cost of the tests as well as the cost of correcting
any deficiencies.

5.3 Fabrication Tolerances

5.3.1 As a minimum, the tolerances, when not specified in the project

document, shall meet the requ irements of Suncor Energy Inc. STD 1203
and CSA A23.1 and A23.4.
5.3.2 The embedded items designated to have the full plate or flange thickness
below the concrete surface shall not protrude through the co ncrete
Suncor Energy Supply of Precast Rev. 3 Page 11 of 11
STD 1207 Concrete Columns December, 2005

surface by more than 1/10 of the plate thickness or 3/32" (2.4 mm)
whichever is sma ller.
5.3 .3 The precast concrete columns shall meet the following tolerance
requirements after delivered to the Suncor Energ y Inc. site:
(a) Length : + - 3/8" (10 mm)
(b) Width and depth: + 1/2" (12 mm), -1/4" (6 mm)
(c) Cross section skew: + - 1/4 " (6 mm) (per diagonal length)
(d) Plum (from top or bottom): + - 1/4" (6 mm) per 10 It 3 m) , + - 1/2"
(12 mm) max
(e) Straightness : + - 1/8" (3 mm) per 10 It (3 m) straight
edge.
(I) Embedded item locations: + - 1/4 " (6 mm) in location ,
(g) Location of anchor bolt hole group: + - 1/16" (3 mm) off the
design center.